The 1988 Suzuki Samurai was equipped with a mechanical fuel pump installed underneath the hood on the side of the cylinder head. Within the fuel pump are a number of seals that create the suction necessary to pull the gasoline from the fuel tank to the engine. Over time, these seals tend to harden and crack. The Samurai's fuel pump is a sealed unit, meaning that it cannot be repaired, but replacing a defective fuel pump requires only a few minutes and no specialized tools.
Tools Used: Wrench, Masking tape, Marker, Screwdriver, Fluid catch pan, Engine degreaser, Fuel pump gasket, Gasket sealant
Fuel Pump Replacement
Unfasten the negative battery cable with a wrench.
Remove the gas tank's cap to release any residual pressure inside the tank.
Wrap a piece of masking tape around each of the fuel pump's three hoses. Label each piece of tape with a marker to avoid confusing the position of each hose.
Loosen the clamp on the end of each of the three fuel lines with a screwdriver. Slide the clamps away from the fuel pump.
Position a fluid catch pan underneath the fuel pump. Pull each of the three fuel lines off the pump and allow them to drain into the pan.
Remove the fuel pump's securing bolts with a wrench and pull the pump off the cylinder head.
Remove and discard the old fuel pump gasket.
Clean the fuel pump's mating surface on the cylinder head with engine degreaser.
Apply gasket sealant to each side of a new fuel pump gasket. Position the gasket onto the pump's mating surface on the cylinder head.
Press the fuel pump against the cylinder head. Tighten the pump's securing bolts with a wrench.
Slide the pump's three fuel lines onto their respective positions on the fuel pump. Slide each hose clamp to the end of the hoses and tighten the clamps with a screwdriver.
Fasten the negative battery cable to the battery with a wrench.
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