Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
1990 Suzuki SamuraiFACTORY OEM SERVICE PROCEDURE
Fuel System Pressure Release
WARNING:
ALWAYS relieve fuel pressure before disconnecting any fuel injection-related component. DO NOT
allow fuel to contact engine or electrical components.
- Place transmission in Neutral or Park and set parking brake. Loosen fuel tank filler cap to relieve tank vapor pressure. Remove harness connector from fuel pump relay which is located under extreme right side of dash, mounted at the top front of ECM. See the FUEL PUMP RELAY LOCATION table.
- Start engine and let idle until engine dies. Crank engine 2-3 times to ensure fuel pressure is dissipated from system. Turn ignition off and remove key. Fuel system may now be opened safely. When loosening fuel line, hose or fitting, cover it with shop towel to absorb leaking fuel. When repair is completed, reconnect relay.
FUEL PUMP RELAY LOCATION
| Model | Location |
|---|---|
| Samurai | Under Far Right Side Dash, Above ECM |
Factory Service Tools
Use the Manual With the Right Hardware
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.
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