Get Engine and Emission Control System -> Fuel Delivery System Guide for Suzuki Alto 4 Door Fifth Generation (1998-2003)

FUEL DELIVERY SYSTEM

FUEL PRESSURE INSPECTION

1) Relieve fuel pressure in fuel feed line referring to FUEL PRES-

SURE RELIEF PROCEDURE in SECTION 6.

2) Disconnect fuel feed hose from fuel delivery pipe.

3) Connect special tools and hose between fuel delivery pipe and

fuel feed hose (1) as shown in figure, and clamp hoses securely

to ensure no leaks occur during checking.

Special Tool

(A): 09912-58441

(B): 09912-58431

(C): 09912-58490

4) Check that battery voltage is above 11V.

WARNING:

Be sure to perform work in a well-ventilated area and

away from any open flames, or there is a risk of a fire

breaking out.

CAUTION:

A small amount of fuel may be released when fuel

hose is disconnected. Place container under the joint

with a shop cloth so that released fuel is caught in

container or absorbed in cloth. Place that cloth in an

approved container.

5) Turn ignition switch ON to operate fuel pump and after 2 se-

conds turn it OFF. Repeat this 3 or 4 times and then check fuel

pressure.

6) Start engine and warm it up to normal operating temperature.

7) Measure fuel pressure at idling.

If measured pressure doesn’t satisfy specification, refer to B-3

FUEL PRESSURE CHECK in this section and check each

possibly defective part. Replace if found defective.

At specified

idle speed

200 – 240 kPa

2.0 – 2.4 kg/cm

28.4 – 34.1 psi

With 1 min. after

engine (fuel pump) stop

(Pressure reduces as

time passes)

over 200 kPa

2.0 kg/cm

28.4 psi

CONDITION FUEL PRESSURE

With fuel pump

operating and

engine stopped

270 – 310 kPa

2.7 – 3.1 kg/cm

38.4 – 44.0 psi

8) After checking fuel pressure, remove fuel pressure gauge.

CAUTION:

As fuel feed line is still under high fuel pressure, make

sure to release fuel pressure according to following

procedures.

D Place fuel container under joint.

D Cover joint with rag and loosen joint nut slowly to

release fuel pressure gradually.

ENGIINE AND EMISSION CONTROL SYSTEM 6E1-55

9) Remove special tools from fuel delivery pipe.

10) Connect fuel feed hose to fuel delivery pipe and clamp it se-

curely.

11) With engine “OFF” and ignition switch “ON”, check for fuel

leaks.

FUEL PUMP

ON-VEHICLE INSPECTION

CAUTION:

When fuel filler cap is removed in any procedure, work

must be done in a well-ventilated area, keep away from

any open flames and without smoking.

1) Remove filler cap and turn ON ignition switch. Then fuel pump

operating sound should be heard from fuel filler for about 2 se-

conds and stop. Be sure to reinstall fuel filler cap after checking.

If above check result is not satisfactory, advance to DIAGNOS-

TIC FLOW TABLE B-1.

1. Fuel filler

2. Ignition switch

2) Fuel pressure should be felt at fuel return hose for 2 seconds

after ignition switch ON.

If fuel pressure is not felt, advance to DIAGNOSTIC FLOW

TABLE B-3.

REMOVAL

1) Remove fuel tank from body according to procedure described

in Section 6C and remove fuel pump from fuel tank.

INSPECTION

Check fuel pump filter for evidence of dirt and contamination. If

present, clean and check for presence of dirt in fuel tank.

INSTALLATION

Install fuel pump to fuel tank and then install fuel tank to body ac-

cording procedure described in Section 6C.

6E1-56 ENGIINE AND EMISSION CONTROL SYSTEM

FUEL PRESSURE REGULATOR

ON-VEHICLE INSPECTION

Perform fuel pressure inspection according to procedure de-

scribed in FUEL PRESSURE INSPECTION in this section.

REMOVAL

1) Relieve fuel pressure according to procedure described in Sec-

tion 6.

2) Disconnect battery negative cable at battery.

3) Remove air cleaner outlet hose referring to Section 6A.

4) Remove air cleaner case by removing its fastening bolts.

5) Disconnect vacuum hose (1) from fuel pressure regulator (2).

6) Disconnect fuel return hose (3) from fuel pressure regulator.

7) Remove fuel pressure regulator from fuel delivery pipe (4).

CAUTION:

A small amount of fuel may be released when hose is

disconnected. Cover hose to be disconnected with a

shop cloth.

CAUTION:

A small amount of fuel may be released when it is

from delivery pipe.

Place a shop cloth under delivery pipe so that re-

leased fuel is absorbed in it.

INSTALLATION

For installation, reverse removal procedure and note following pre-

cautions.

D Use new O-ring.

D Apply thin coat of spindle oil or gasoline to O-ring to facilitate

installation.

D With engine “OFF” and ignition switch “ON”, check for fuel leaks

around fuel line connection.

ENGIINE AND EMISSION CONTROL SYSTEM 6E1-57

FUEL INJECTOR

ON-VEHICLE INSPECTION

1) Using sound scope or such, check operating sound of injector

when engine is running or cranking.

Cycle of operating sound should vary according to engine

speed.

If no sound or an unusual sound is heard, preform B-2 FUEL IN-

JECTOR AND ITS CIRCUIT CHECK in this section.

1. Sound scope

2. Injector

2) Disconnect coupler from injector, connect ohmmeter between

terminals of injector and check resistance.

Resistance of injector : 10 – 15 W

If resistance is out of specification, replace.

3) Connect coupler to injector securely.

REMOVAL

1) Relieve fuel pressure according to procedure described in Sec-

tion 6.

2) Disconnect battery negative cable at battery.

3) Remove air cleaner outlet hose referring to Section 6A.

4) Remove intake manifold stiffener.

5) Disconnect fuel injector couplers.

6) Remove fuel delivery pipe bolts.

7) Remove fuel injector(s).

CAUTION:

A small amount of fuel may come out after removal of

fuel injectors, cover them with shop cloth.

1. Fuel delivery pipe

2. Fuel injector

3. Grommet

4. O-ring

5. Cushion

INSPECTION

WARNING:

As fuel is injected in this inspection, perform in a well

ventilated area and away from open flames.

Use special care to prevent sparking when connecting

and disconnecting test lead to and from battery.

6E1-58 ENGIINE AND EMISSION CONTROL SYSTEM

1) Install injector (1) and fuel pressure regulator (2) to special tool

(injector checking tool).

Special Tool

(A): 09912-58421

2) Connect special tools (hoses and attachment) to pipes of ve-

hicle.

Special Tool

(B): 09912-58431

3) Connect special tool (test lead) to injector.

Special Tool

(C): 09930-88530

4) Install suitable vinyl tube onto injector nozzle to prevent fuel

from splashing out when injecting.

5) Put graduated cylinder under injector as shown.

6) Remove fuel pump relay.

7) To operate fuel pump and apply fuel pressure to injector, con-

nect two terminals of disconnected connecter (1) by using ser-

vice wire (2) as shown in figure.

CAUTION:

Check to make sure that connections made between

correct terminals. Wrong connection can cause dam-

age to ECM, wire harness, etc.

8) Apply battery voltage to injector for 15 seconds and measure in-

jected fuel volume with graduated cylinder.

Test each injector two or three times.

If not within specification, replace injector.

Injected fuel volume:

35 – 37 cc/15 sec. (1.18/1.23 – 1.25/1.30 US/Imp.

oz/15 sec.) ... F8B

38.3 – 40.7 cc/15 sec. (1.29/1.35 – 1.37/1.43 US/Imp.

oz/15 sec.) ... F8D

1. Injector

2. Battery

3. Keep as far apart as possible

4. Fuel pump relay coupler

5. Service wire

ENGIINE AND EMISSION CONTROL SYSTEM 6E1-59

9) Check fuel leakage from injector nozzle. Do not operate injector

for this check (but fuel pump should be at work). If fuel leaks

more than following specification, replace.

Fuel leakage: Less than 1 drop/min.

1. Injector

2. Vinyl tube

3. Less than one fuel

drop/min.

4. Graduated cylinder

INSTALLATION

For installation, reverse removal procedure and note following pre-

cautions.

D Replace injector O-ring with new one using care not to damage

it.

D Check if cushion is scored or damaged. If it is, replace with new

one.

D Apply thin coat of fuel to O-rings and then install injectors into de-

livery pipe and intake manifold.

Make sure that injectors rotate smoothly. If not, probable cause

is incorrect installation of O-ring. Replace O-ring with new one.

D Tighten delivery pipe bolts and make sure that injectors rotate

smoothly.

D With engine “OFF” and ignition switch “ON”, check for fuel leaks

around fuel line connection.

1. Grommet

2. O-ring

3. Cushion

1. O-ring

2. Grommet

6E1-60 ENGIINE AND EMISSION CONTROL SYSTEM

Engine and Emission Control System -> Fuel Delivery System for Your Suzuki Alto 4 Door Fifth Generation (1998-2003)

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