Test 9: Injector Sealing Check
Certain faults make it impossible to carry out this test - deal with these first.
Watch out for any objects (tool or others) on the sides of the engine room.
It is useless and dangerous to engage the starter for more than 5 seconds.
Tooling Required
Special Tool
: 09912–96540
Step Action YES NO
Check the injector return volume following procedure:
Ensure that the engine coolant temperature is above 60 °C.
Turn ignition switch OFF.
Disconnect the return pipes from the four injectors.
Cap the pump venturi tube to prevent the low pressure circuit from contamination.
Connect the four transparent tubes (09912-96540) in place of the return pipes.
Put the other ends of the four pipes into four graduated measuring cylinders (09912-96540).
Having carried out these preparations, start the engine and let it idle for 2 minutes.
Carry out “Leak detection test” by using SUZUKI scan tool.
Once the cycle is complete, carry out “Leak detection test” again to obtain a correct reading of the return volume of each injector.
Is the return volume of one of the injectors above 35 ml?
Replace faulty injector(s).
Go to Step 2.
Carry out the following test to confirm the repair:
Disconnect the 4 transparent pipes and reconnect the injector return circuit.
With the ignition off, disconnect connector from fuel flow actuator and connect the test adapter in special tool (09912-96540).
Disconnect the 4 electrical connectors from all injectors.
Connect SUZUKI scan tool and display “Data list” on scan tool.
Run the starter for 5 seconds, read the “Fuel Rail Pressure” maximum value during the test on the SUZUKI scan tool.
Is the rail pressure greater than 1050 bar?
End of test.
Carry out test 7.
After Repair
Turn ignition switch OFF, and reconnect the four injectors electrically.
Disconnect the test adapter and reconnect the fuel flow actuator connector.
Turn ignition switch ON, and clear the injection faults using SUZUKI scan tool.