VISUAL INSPECTION
Visually inspect all electrical wiring, looking for chafed, stretched, cut or pinched wiring. Ensure electrical connectors fit tightly and are not corroded. Ensure vacuum hoses are properly routed and are not pinched or cut. See the M - VACUUM DIAGRAMS article to verify routing and connections (if necessary). Inspect air induction system for vacuum leaks.
Fuel Pressure Test (Samurai & Sidekick)
- Start engine. Warm it to normal operating temperature. Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-25802-S11496748372001010500000). Attach Pressure Gauge (09912-58441), Hose (09912-58431) and Coupling (09919-46010) at fuel delivery tube. (Scheme 1)and (Scheme 2). Start engine, and ensure no leakage exists at pressure gauge connection. Turn engine off.
- Turn ignition on to operate fuel pump for 3 seconds. Turn ignition off. Repeat this 3-4 times, and then check fuel pressure. See «FUEL PUMP PERFORMANCE»(ref-25802-S24393441612001010500000) table. Start engine. Measure fuel pressure at idle. Turn ignition off.
- If pressures are not within specification, check for defective fuel pump, pressure regulator or restriction in fuel system. Repair as required. Remove fuel pressure gauge, and start engine to ensure no fuel leakage exists.
Scheme 1
Scheme 2
Scheme 3
Scheme 3: Fuel Pressure Test (Swift)
Scheme 4
- Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-25802-S11496748372001010500000). On SOHC, remove air cleaner from throttle body. Disconnect fuel hose from throttle body. On DOHC, remove ISC solenoid valve and EGR modulator bracket (if equipped). see scheme 1and see scheme 2.
- On all models, install fuel pressure gauge and 3-way connector between fuel feed hose and fuel return hose. (Scheme 3)and (Scheme 4). On SOHC, install air cleaner. On all models, verify battery voltage is at least 11 volts.
- Remove fuel pump relay from fuse/relay box with harness connector installed. Fuse relay box is located in engine compartment, behind battery. Using jumper wire, connect Pink wire terminal to White/Blue wire terminal.
- Turn ignition on. Observe and record fuel pressure. See «FUEL PUMP PERFORMANCE»(ref-25802-S24393441612001010500000) table. Turn ignition off. Recheck pressure after one minute. Remove jumper wire. Install IAC valve on DOHC models. On all models, start engine and warm it to normal operating temperature. Note fuel pressure with engine idling.
- If pressure is not within specification, check for defective fuel pump, pressure regulator or restriction in fuel system. Repair as required. Release fuel pressure, and remove fuel pressure gauge. Reconnect fuel hoses, and check for leaks.
| Application | @ Idle: psi (kg/cm 2 ) | Engine Off: psi (kg/cm 2 ) |
|---|
| Samurai | (1) 24.2-30.0 (1.7-2.1) | 34.1-39.8 (2.4-2.8) |
| Sidekick | (2) 29.8-37.0 (2.1-2.6) | 35.6-42.7 (2.5-3.0) |
| Swift |
| DOHC | (2) 25.6-30.0 (1.8-2.1) | 35.5-38.4 (2.5-2.7) |
| SOHC | (3) 12.8-20.0 (0.9-1.4) | 22.7-30.0 (1.6-2.1) |
| (1) Pressure should maintain at least 21.3 psi (1.5 kg/cm 2 ) for one minute after fuel pump is turned off. (2) Pressure should maintain at least 25.6 psi (1.8 kg/cm 2 ) for one minute after fuel pump is turned off. (3) Pressure should maintain at least 12.8 psi (0.9 kg/cm 2 ) for one minute after fuel pump is turned off. |
| (1) | Pressure should maintain at least 21.3 psi (1.5 kg/cm 2 ) for one minute after fuel pump is turned off. |
| (2) | Pressure should maintain at least 25.6 psi (1.8 kg/cm 2 ) for one minute after fuel pump is turned off. |
| (3) | Pressure should maintain at least 12.8 psi (0.9 kg/cm 2 ) for one minute after fuel pump is turned off. |
SPARK TEST
Note. On Swift DOHC, disconnect injector connector at wiring harness near engine oil dipstick before cranking engine.
- Remove coil wire from distributor cap. Have a helper depress clutch pedal (if required). Using a high output spark tester or holding coil wire terminal end 5/16" from an engine ground with an insulated holder, crank engine. Check for strong Blue spark from coil wire. If spark does not exist, continue with ignition checks.
- If spark exists at coil wire, check for spark from each spark plug wire. Remove spark plugs and connect them to spark plug wires. Ground spark plugs. If spark exists on one or more spark plug, check plug wire resistance. Using ohmmeter, ensure resistance of each plug wire is 3000-6700 ohms per foot. Replace any plug wire that does not test as specified.
