SER-FPM_1986-1989 Suzuki Samurai Mechanical Fuel Pump

Instructions Created by an:
1986-1989 Suzuki Samurai Mechanical Fuel Pump
Carbureted Model 1.3L G13A Engine
(SKU# SER-FPM)
Installation Instructions
Notice: It is recommended
that you replace the fuel filter
when replacing the pump.
Many fuel pumps fail because
the fuel filter allows rust or
other debris to pass through
damaging the pump.
To see the fuel filtered offer by
Low Range, Click HERE.
Suggested Tools:
CAUTION: Safety glasses should be
worn at all times when working with
vehicles and related tools and
equipment.
For additional copies of these
and other instructions go to:
www.lowrangeoffroad and click on the
“Instructions” tab.
•
•
•
•
•
•
•
•
Standard Screwdriver
Ratchet
Socket: 12mm
Extension: 9”
Long Needle Nose pliers
Assembly Lube (or Motor Oil)
Gasket Scraper
Ratcheting Torque Wrench
Step 1
Step 2
Remove the fuel cap to relieve any
pressure that may exist in the fuel
system. Reinstall the cap.
Disconnect the negative battery cable.
Step 3
Disconnect the inlet and return hoses
(See Figure A) using a screwdriver or
pliers depending on the type of hose
clamps being used.
Figure A
Step 4
Disconnect the fuel pump outlet hose.
Step 6
Remove the rear mounting nut.
Step 5
Remove the front mounting nut using a
12 mm socket, 9” extension and a
ratchet.
Step 7
Remove the fuel pump.
Note: You may need to wiggle it a bit to
brake the pump away from the head.
Caution: Do not wedge a screwdriver
between the pump and the cylinder
head. Both parts are cast aluminum
which is easily damaged.
Step 8
Step 9
Remove and inspect the fuel pump push
rod. It should be smooth and straight
with no scoring on the shaft or
mushrooming on the ends. Replace this
part if needed.
Clean off any old gasket or sealer that
may be stuck to the head using a gasket
scraper, putty knife or razor blade.
Step 10
Step 11
Apply some engine assembly lube or
motor oil to the push rod.
Reinstall the push rod in the same
orientation as it was when removed.
Caution: Do not gouge the aluminum.
Damaging this machined surface can
prevent the gasket from sealing causing
an oil leak.
Note: If you are reusing the original
push rod, the black or dirty section
should extend outward.
Small
Loop
Step 12
Figure B
Install the supplied gasket on the
mounting studs with it oriented as
shown here.
Note: The small loop goes up.
Tech Tip 12
Step 13
This shows the gasket properly
installed.
Install the new fuel pump on the studs.
Step 14
Install the mounting nuts. It works well
to place some grease inside the 12 mm
socket to keep the nut from falling out
during installation. Then place the nut in
the socket on a 9” extension. Work the
nut back through all the hoses and on to
the stud. Repeat the same procedure
on the second mounting nut. Attach a
ratcheting torque wrench to the
extension and tighten the nuts,
alternating back and forth between the
two nuts, a little at a time until 8 ft. lbs
(Suzuki Spec is 7-11.5ft. lbs.) is
reached. Do not over tighten. The fuel
pump and the cylinder head are cast
aluminum and are easily damaged.
Step 15
Reconnect the Inlet and return hoses
and tighten the clamps.
Note: If these hoses are cracked, brittle
or bulging they should be replaced.
Step 16
Reconnect the outlet hose and tighten
the clamp.
Note: Replace this hose if it is showing
signs of wear.
Step 17
Reconnect the negative battery cable.
Step 18
Start the engine and check for fuel leaks
at the (3) hoses and for oil leaks at the
fuel pump gasket.
Congratulations!
Tech Tip 18
After a fuel pump has been replaced a
little longer cranking time may be
required before the engine starts up the
first time.
You have successfully installed fuel
pump. We hope these instructions
have been helpful.
If you have
suggestions on how to make these
instructions (or any of our products)
b e t t e r, p l e a s e e m a i l u s a t :
[email protected]
As always, If you experience any difficulty during the installation of this product
please contact Low Range Off-Road Technical Support at 801-805-6644 M-F
during regular store hours. Thank you for purchasing from Low Range Off-Road.
These instructions are designed as a general installation guide. Installation of many Low Range
Off-Road products require specialized skills such as metal fabrication, welding and mechanical
trouble shooting. If you have any questions or are unsure about how to proceed, please contact
our shop at 801-805-6644 or seek help from a competent fabricator. Using fabrication tools such
as welders, torches and grinders can cause serious bodily harm and death. Please operate
equipment carefully and observe proper safety procedures.
Rock crawling and off-road driving are inherently dangerous activities. Some modifications will
adversely affect the on-road handling characteristics of your vehicle. All products sold by Low
Range Off-Road are sold for off road use only. Any other use or application is the responsibility
of the purchaser and/or user. Some modifications and installation of certain aftermarket parts may
under certain circumstances void your original dealer warranty. Modification of your vehicle may
create dangerous conditions, which could cause roll-overs resulting in serious bodily injury or
death. Buyers and users of these products hereby expressly assume all risks associated with any
such modifications and use.
Revised 11/13/14©
Copyright 2014 Low Range Off-Road, LC All Rights Reserved