Suggested Tools:

• Standard Screwdriver • Ratchet• Socket: 12mm• Extension: 9”• Long Needle Nose pliers• Assembly Lube (or Motor Oil)• Gasket Scraper• Ratcheting Torque Wrench

CAUTION: Safety glasses should be worn at all times when working with vehicles and related tools and equipment.

1986-1989 Suzuki Samurai Mechanical Fuel Pump Carbureted Model 1.3L G13A Engine (SKU# SER-FPM)

Installation Instructions

For additional copies of these and other instructions go to:www.lowrangeoffroad and click on the “Instructions” tab.

Instructions Created by an:

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.

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Step 2Disconnect the negative battery cable.

Step 1Remove the fuel cap to relieve any pressure that may exist in the fuel system. Reinstall the cap.

Step 3Disconnect 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 4Disconnect the fuel pump outlet hose.

Step 5Remove the front mounting nut using a 12 mm socket, 9” extension and a ratchet.

Step 6Remove the rear mounting nut.

Step 7Remove 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 8Remove 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.

Step 9Clean off any old gasket or sealer that may be stuck to the head using a gasket scraper, putty knife or razor blade.

Caution: Do not gouge the aluminum. Damaging this machined surface can prevent the gasket from sealing causing an oil leak.

Step 10Apply some engine assembly lube or motor oil to the push rod.

Step 11Reinstall the push rod in the same orientation as it was when removed.

Note: If you are reusing the original push rod, the black or dirty section should extend outward.

Figure B

Step 12Install the supplied gasket on the mounting studs with it oriented as shown here.

Note: The small loop goes up.

Tech Tip 12This shows the gasket properly installed.

Step 13Install the new fuel pump on the studs.

Small Loop

Step 15Reconnect the Inlet and return hoses and tighten the clamps.

Note: If these hoses are cracked, brittle or bulging they should be replaced.

Step 14Install 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 t ighten 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 16Reconnect the outlet hose and tighten the clamp.

Note: Replace this hose if it is showing signs of wear.

Step 17Reconnect the negative battery cable.

Congratulations!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) be t te r, p lease ema i l us a t : sales@lowrangeoffroad.com

Step 18Start the engine and check for fuel leaks at the (3) hoses and for oil leaks at the fuel pump gasket.

Tech Tip 18After a fuel pump has been replaced a little longer cranking time may be required before the engine starts up the first time.

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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