Yep, the fuel pump's toast. This has got to be the single biggest "no-brainer" Samurai repair you can make. A new pump is around $55.00 US and can be had from any number of sources. (See the aftermarket parts page for one source and part number). Many of the aftermarket pumps come with a lifetime warranty. Here's how to get it done: Tools and parts required
ProcedureTurn off the engine and disconnect the battery cables. Allow the engine to cool down. There will be some spilled fuel here and you don't want to play "human torch." Open the fuel filler cap to release any pressure from the system. This is to prevent fuel from spraying out of the lines when you disconnect them. Replace and tighten the cap, so you don't forget later. Depending on the type of clamps on your lines, use either pliers (for "squeeze-type") or a flat-blade screwdriver (for screw-type) to loosen the hose clamps for the fuel lines on the pump. There are three. One going forward along the valve cover to the carb and two coming off the passenger side. Of the side two, one is the line from the tank, the other is a return line to the tank. Disconnect the fuel lines from the fuel pump. Use your socket wrench, extensions, universal (whatever it takes to get in there, in other words) and 12mm socket to remove the two nuts holding the pump to the cylinder head. Pick up the nut you dropped. Remove the pump from the studs and place it outside somewhere to dry out. Remove the old gasket. The Suzuki manual says to remove the pump push-rod and oil it lightly with engine oil, then replace it. Depending on the position of the cam when you pull the pump, you may not be able get hold of it to pull it out. I just put a little oil on both the end of the rod and the new pump mechanism before I installed it. Place the new gasket over the studs. Place the new pump over the studs. Place the nuts on the studs (pick up the one you dropped and try again) and tighten securely (there's no torque spec. given in the Suzuki manual for these nuts). Reconnect the three fuel lines at the pump and retighten the clamps. Clean up any spilled fuel and oil. Reconnect the battery cables. Start the truck and check for oil leaks from the pump mount, as well as fuel leaks from the lines and line ends. Follow us on Twitter at www.twitter.com/OffRoadDotCom
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