This steps are for ,
working the fuel pump,filter, fuel pump regulator,
pulling gas tank or lines, or pulling engine , pulling injectors or
fuel RAIL. DE-PRESSURIZE THE FUEL LINES ! and all other warnings , regardless if engine runs or not!!! Gasoline is very flammable, please take every precaution. Rule 1: The tank is pressurized and so are the fuel lines, running and not running ! UP TO 60 PSI (pounds!) Ask for professional help, if unsure or confused, about this system! (it can be tricky) If system is already leaking , do not run car and see if gas cap put ON, helps or makes the leak worse? Most cars will slow the leak with gas cap on , but if the gas warms, or is warming, the leak will get worse. Park any leaking cars at the curb, not near any valuable property, and DRAIN THE TANK NOW! NEVER DO !:
Do not allow someone (anyone) to have keys to this car , allowing them unwittingly,to try to start a car with a open fuel system.! ( do that, by pulling the battery negative lead when done de-pressurizing). Use fuel proof gloves, fuel is toxic (Google ;Benzene toxicity) If engine is dead, use rags to catch fuel , take the rags far from home . (hang them down wind from a tree?) The fuel will spurt and hit your eyes, wear GOGGLES PLEASE! If engine is dead?, read all rules above, first and my dead motor method below. NO OPEN Flames or any heaters allowed near car. Avoid confined spaces, by any means ! Delay, find a safer place to work , ask for help. If possible: Work out doors, call your insurance company and activate full coverage now. and full life insurance. No kidding. Gas fumes are toxic and very very flammable. Have a plan in you mind, before a flame starts (all it takes is spark , from metal to metal tools) I even keep a blanket near by, and never water. THE FAST way to bleed off pressure, on all SIDEKICKS and TRACKERs is :
The remainder of this page explaining the 10 years of FSM ways. Use MY way above and safe huge time and efforts. One more way, person said, "my exhaust manifold is missing" (or whole exhaust ,etc) and I dont want to make a racket. at 6am.
Rumor: Pulling fuses does this?, false, the fuses kill the Main relay and pump and ECU and kills the injectors dead, defeating the whole purpose here. Many cars have a dedicated fuel pump fuse, sadly, not Suzuki. FSM ways: (a summary) All modern EFI fuel injection system have large residual fuel pressures when the car is parked sitting ,and not running. It can be as high as 65 PSI or more ! IT MUST BE BLED off first, before working on the EFI fuel systems. or gas will be all over the place ! LOTS ! Errata: 1996 Geo Tracker FSM , Vol:1, page 6C6 figure 6C7 is dead wrong , shows Fuel Pump relay location for 95 and older. See 96 link below. Some manuals (OEM too) are wrong on some facts, so use the pink wire colors, to find the relay. There are many ways to do this job. 1: dead motor , no start and motor runs. 2 if the motor starts then by all means , pull the fuel pump power running, This is best done at the left rear tail light. 3: if motor dont run then , be out doors, and use lots of rags and eye protection and bleed off the pressure at the filter test port (10mm screw). Keep these rags out doors and away from people and belongings until fully dry. ( I use a nail on a tree and hang them high , from pets and kids) This procedure is different that simply killing injections. Pulling the relay allows you to RUN off the fuel pressure. For doing a compression test we have 3 choices. There are 3 ways to kill Fuel pressure and delivery ( flooding and fire safety) Choices: 1 Pull the pink wired connector at the Left Rear tail light housing ( usually wrapped in gray plastic wrap) while running 2: Pull the fuel PUMP relay. (easy on 8v cars) while running. 3: find another fuel pump feed wire connector. (The FSM shows this path clear) while running. Pulling the ECU power , kills the spark and fuel injection defeating this purpose. Step 1, find the fuel pump relay: ( I never do it this way, but show how, for completeness) 1989 to 1995 Early Relay location drawing. 1996 to 1998 location. (glove box removed) can be real hard to pull this relay 1999 Vitara 2.0L Grand Vitara's typ. 2.5L And here too and 04'. On 96+ year cars , I recommend Pulling the pink wired connector at the Left Rear tail light housing ( usually wrapped in gray plastic warp) MOTOR RUNNING. Preconditions, if possible: I'd wait until tank is low to 3/4, not full. To reduce the chance, of siphoning.(if possible) If you leave the gas cap on , siphoning will happen. How to purge the gas from the Gas lines: { MUST BE DONE BEFORE WORKING ON THE FUEL PRESSURE SYSTEM }
1991 Real Photo: 91-95 FP Relay in the hand: My 96 FP Relay pulled (top-one) (behind glove box) Before touching Air bags and associated devices defeat those bags, see yellow connectors and wire sheaths?, "DANGER" Q/A's: The obvious, but not a stated fact in the FSM is that a car that will not start, can not be bled , by the above procedure. oop's. How do you relieve this pressure with out starting car? or with no starter or battery in car.? If you have spark and car will crank , you could crank the pressure down. But that will take along time, and floods the motor (not good). That is a good question.? Answer: Put a vacuum pump (MityVac or hand pump) to the Fuel Pressure Regulator (FPreg) nipple and pump it up and the valve will open and will bleed the pressure back to the fuel tank. Use rags to and goggles and catch the remainder so it does not hit you , in any way. Wrench on, rag on wrench end , turn. Do not be tempted to hot wire the injector , you will burn it to a crisp. If you have no spark, the Injectors will not bleed down the rail pressure. (ECU safety feature in software (ROM)) The key on prime pulse (up to10x times) may bleed it down?, but is not a guaranteed, the prime pulse is for air purging only. (FSM quote) Lots of questions , I get here , on this subject. Keep them coming. Happy Trails The above report is what I read in the FSM for from other mechanics, I do not recommend that YOU be working on your fuel system. Hire a Professional ! I do NOT guarantee my accuracy nor my source (FSM) as being accurate, but I am sure spilled gasoline is unsafe, at all times. Keep all fuels leaks , far from people , children , pets , homes/ buildings and valuables to you and to others. Have 2 Fire Extinguishers close by, but not TOO CLOSE. 5 big steps or so... (one might fail) Never ever use water to put out a fuel fire. Have a friend attend you with Extinguisher at hand, rated for fuels. In a panic use a blanket. Get and find expert training ,before working near fuel or air bags. Do not guess. I replaced my fuel filter , including supplied new copper washers (WIX). The rear banjo than weeped, very slowly. I had to take 1500 grit wet and dry sand paper wrapped to a small steel plate and honed the banjo face. This proved easier than dropping the tank and replacing the hose. V2: Jargon list. FP = Fuel pump |