Fuel Rail - Revised Design

90suzuki01
Division: Automotive

Category: Technical
TSB No. TS 4-09 03150

Section Title: Engine



SUBJECT: GT FUEL LINE KNOCK
MODEL: GT

YEAR: 1989 - 1990


EFFECTIVE VIN: JS2AA34S_L5110040

Beginning with the VIN/production dates listed above, a new injector fuel rail has been installed by the factory to reduce the fuel line knocking noise.

SYMPTOMS:

- Knocking noise heard more clearly from inside the vehicle.

- Appears to be louder when engine is cold.

- Perceived by driver or passenger to be coming from the firewall area or front floor tunnel area.

DIAGNOSIS:

While the noise is occuring, temporarily remove the fuel pump relay connector. If the noise goes away when the relay is disconnected, the noise is coming from the fuel line.

REPAIR PROCEDURE:

! CAUTION: Observe all normal safety procedures relating to fuel and fuel system repairs.

1. Remove the fuel cap.

2. Disconnect the connector to the fuel pump relay. Start and run the engine until it dies, Continue cranking engine 2-3 times for about 3 seconds each time to dissipate fuel line pressure.
3. Disconnect Battery negative cables.

4. Remove the old fuel rail and fuel hoses.



5. When installing the new type fuel delivery pipe in place of old type, be sure to cut the fuel return hose 20 mm shorter in length. This will reduce the length from 220 mm to 200 mm.



All fuel return hoses supplied as spare parts have been cut at the factory to 300 mm (11.8 in.) long. Therefore, when replacing the fuel return hose only, cut the fuel return hose to the length as illustrated.



6. Install the new fuel rail.

NOTE: Make sure all injector "O" rings are in place. "O" rings should be lubricated lightly with liquid silicon when the rail is installed.


7. Make sure the injector can be turned easily by hand when the rail is bolted securely in place.

8. Install hoses and vacuum line.

9. Reconnect fuel pump relay.

10. Reconnect battery negative cables.

11. Cycle the ignition switch on and off several time without cranking or starting engine.

12. Check for fuel leaks.

13. Start engine and drive the vehicle until it is warm.

14. Recheck all connections.