Fuel Injector Inspection

Reference: FUEL INJECTOR REMOVAL AND INSTALLATION 

1. Remove fuel injector(s). See Fuel Injector Removal and Installation 
2. Set special tools as follows.

   Special Tool 

   1. 09912-58421 
   2. 09912-57610 
   3. 09930-86310 
   1. Fit washer (1) (inside diameter 13.5 - 14.5 mm (0.532 - 0.570 in.)) to injector (2), and then install injector to special tool (A).
   2. Connect special tool (C) to injector.
   3. Install special tool (B) to special tool (A).
   4. Connect fuel feed hose to special tool (A).
      Fig 1: Connecting Fuel Feed Hose To Special Tool

      Courtesy of SUZUKI OF AMERICA CORP.
3. Install suitable vinyl tube (1) onto injector nozzle to prevent fuel from splashing out when injecting.
4. Put graduated cylinder (2) under injector.
5. Connect one terminal of special tool (C) to battery positive (+) terminal.
   WARNING: There is an increased risk of personal injury and fire if the following procedure is performed without taking proper precautions. Put injectors as far away from the battery as possible when connecting / disconnecting the test lead to / from the battery.
   Fig 2: Connecting One Terminal Of Special Tool To Battery Positive (+) Terminal

   Courtesy of SUZUKI OF AMERICA CORP.
6. Operate fuel pump and apply fuel pressure to injector as follows:
   1. When using scan tool:
      1. Connect scan tool to DLC (1) with ignition switch OFF.
      2. Turn ignition switch to ON position, clear DTC and select "Active Test" mode on scan tool.
      3. Turn fuel pump ON by using scan tool.

         Special Tool 

         (A): SUZUKI scan tool (SUZUKI-SDT) 

         Fig 3: Connecting Scan Tool To DLC

         Courtesy of SUZUKI OF AMERICA CORP.
   2. When not using scan tool:
      1. Remove fuel pump relay from connector.
      2. Connect two terminals of relay connector using service wire (1) as shown in figure.
         CAUTION: Check that connection is made between correct terminals. Wrong connection can cause damage to ECM, wire harness, etc.
         Fig 4: Connecting Terminals Of Relay Connector Using Service Wire

         Courtesy of SUZUKI OF AMERICA CORP.
      3. Turn ignition switch to ON position.
7. Apply battery voltage to injector (1) for 15 seconds and measure injected fuel volume with graduated cylinder. Test each injector two or three times. If injected volume is out of reference value greatly, replace injector.

   Reference injected fuel volume 

   Approx. 72 - 74 cc/15 sec. (2.20/2.29 US/Imp oz/15 sec.) 

   Fig 5: Applying Battery Voltage To Injector

   Courtesy of SUZUKI OF AMERICA CORP.
8. Check fuel leakage from injector nozzle. Do not operate injector for this check (but fuel pump should be at work). If fuel leaks (1) more than the following specifications, replace.

   Fuel leakage 

   Less than 1 drop/min.

   Fig 6: Checking Fuel Leakage

   Courtesy of SUZUKI OF AMERICA CORP.
9. Remove injector from special tool (A) and disconnect special tool (C) from injector.
   WARNING: As the fuel feed line is still under high fuel pressure, there is a risk of fuel spraying out if the injector is removed without first releasing the fuel pressure. This can cause a fire and/or personal injury. Before removing the injector, be sure to release the fuel pressure by performing the following steps in sequence.

   1. Stop operation of fuel pump.
   2. Put graduated cylinder under injector.
   3. Apply battery voltage to injector until no fuel is injected from injector.
10. Carry out Steps  2) through  9) on each injector to obtain four readings.
11. After checking, remove special tools from fuel injector and fuel feed hose.
12. Connect fuel feed hose to fuel delivery pipe.
13. Install fuel injectors to cylinder head. See Fuel Injector Removal and Installation 
14. Check for fuel leaks. See Fuel Leakage Check Procedure