Fuel Injector Inspection
Fuel Injector InspectionWARNING: Put injector and battery as far away as possible to reduce risk of fire and personal injury when connecting/disconnecting test harness to/from battery.
1. Remove fuel injector (5).
2. Set special tools to injector as follows.
Special Tool
(A): 09912-58421
(B): 09912-57610
(C): 09930-86310
(D): 09919-45710
a. 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).
b. Connect special tool (C) to injector.
c. Install special tool (B) and special tool (D) to special tool (A).
d. Connect fuel feed pipe to special tool (D).
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.
6. Operate fuel pump and apply fuel pressure to injector as follows:
When using scan tool:
a. Connect scan tool to DLC (1) with ignition mode of keyless push start system in "OFF".
Special Tool
(A): SUZUKI scan tool (SUZUKI-SDT)
b. Push engine switch to change ignition mode to "ON", clear DTC and select "ACTIVE TEST" mode on scan tool.
c. Turn ON fuel pump using scan tool.
When not using scan tool:
a. Remove fuel pump relay (1) from connector.
b. Connect two terminals of relay connector (2) using service wire (3) as shown in figure.
CAUTION: Be sure to connect to correct terminals. Connecting to an incorrect terminal could cause damage to ECM, wire harness, etc.
c. 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 cm3/15 sec. (0.19/0.158 - 0.194/0.162 US/Imp pt/15 sec.)
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.
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.
14. Connect fuel feed pipe to fuel delivery pipe.
15. Check for fuel leaks.