Fuel Injector Inspection

Reference: FUEL INJECTOR REMOVAL AND INSTALLATION 

1. Remove fuel injector (5), see FUEL INJECTOR REMOVAL AND INSTALLATION .
2. Set special tools to injector as follows.

   Special Tool 

   1. 09912-58421 
   2. 09912-57610 
   3. 09930-86310 
   4. 09919-45710 
   1. Fit washer (1) (inside diameter 13.5 - 14.5 mm (0.531 - 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) and special tool (D) to special tool (A).
   4. Connect fuel feed pipe to special tool (D).
      Fig 1: Identifying Fuel Injector And Special Tools

      Courtesy of SUZUKI OF AMERICA CORP.
3. Install suitable vinyl tube (1) onto injector nozzle to prevent spout of fuel when performing test.
4. Put graduated cylinder (2) under injector.
5. Connect one of 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 Special Tool To Battery Positive Terminal

   Courtesy of SUZUKI OF AMERICA CORP.
6. Operate fuel pump and apply fuel pressure to injector as follows:

   When using scan tool:

   1. Connect scan tool to DLC (1) with ignition mode of keyless push start system in "OFF".

      Special Tool 

      1. SUZUKI scan tool (SUZUKI-SDT) 
      Fig 3: Connecting Scan Tool To DLC

      Courtesy of SUZUKI OF AMERICA CORP.
   2. Push engine switch to change ignition mode to "ON", clear DTC and select "ACTIVE TEST" mode on scan tool, see DTC CLEARANCE .
   3. Turn ON fuel pump using scan tool.

   When not using scan tool:

   1. Remove fuel pump relay (1) from connector.
   2. Connect two terminals of relay connector (2) using service wire (3) as shown in figure.
      CAUTION: If the service wire is connected between the wrong terminals, the ECM, wire harness, etc. may be damaged. Be sure to connect the service wire to the correct terminals.
      Fig 4: Identifying Fuel Pump Relay And Relay Connector

      Courtesy of SUZUKI OF AMERICA CORP.
   3. Push engine switch to change ignition mode to "ON".
7. Apply battery voltage to injector for 15 seconds and measure injected fuel volume with graduated cylinder.
8. Test each injector two or three times. If injected volume is out of reference value range to a large degree, replace injector.

   Reference injected fuel volume 

   90 - 92 cm ³  /15 sec. (0.19/0.158 - 0.194/0.162 US/lmp pt/15 sec.) 

   Fig 5: Applying Battery Voltage To Injector

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

   Fuel leakage 

   Less than 1 drop/min  .

   Fig 6: Checking Fuel Leakage From Injector Nozzle

   Courtesy of SUZUKI OF AMERICA CORP.
10. Remove injector from special tool (A) and disconnect special tool (C) from injector.
    WARNING: As fuel feed line is still under high fuel pressure even after inspection, removing injector directly may cause hazardous spout of fuel. Before removing injector, make sure to relieve fuel pressure as follows.

    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.
11. Carry out Steps  2) through  10) on each injector to obtain four readings.
12. After checking, remove special tools from fuel injector and fuel feed pipe.
13. Install fuel injector to cylinder head, see FUEL INJECTOR REMOVAL AND INSTALLATION .
14. Connect fuel feed pipe to fuel delivery pipe, see FUEL HOSE DISCONNECTING AND RECONNECTING .
15. Check for fuel leaks, see FUEL LEAKAGE CHECK PROCEDURE .