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.
1991 Suzuki Samurai JSFACTORY OEM SERVICE PROCEDURE
Fuel System Pressure Release
- Place transmission in Neutral (M/T) or Park (A/T). Set parking brake and block drive wheels. Disconnect fuel pump relay connector. Fuel pump relay is located on right kick panel, above ECM. See Fig 1.
- Remove fuel filler cap to release fuel vapor pressure in fuel tank.
- Reinstall fuel filler cap. Start engine and run until engine runs out of fuel. After engine runs out of fuel, crank engine 2-3 times for about 3 seconds to dissipate fuel pressure in lines. Reconnect fuel pump relay connector (Samurai).
Factory Service Tools
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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.