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Discussion Starter #1
Just bought an old jimny (10+ years), and the fuel injection fuse keeps blowing (changed the fuse 3 times in two months). Now mechanic says i need a new fuel injection pump, though pump was replaced last year. I've been told I have to keep fuel tank at least half full to avoid pump from overheating and will try that, but what else can I check to fix in the elec. system to avoid having to change pump now? appreciate help!
 

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Suzuki used the Jimny name on many different vehicles over the years - when you say an old (10+ years) Jimny, we still don't have a clue as to what you're driving.

First - let me deal with a pet peeve - I don't buy that "keep the tank half full" crap, which manufacturer would equip a vehicle with a 20 gallon fuel tank that could only be used for 10 gallons - where's the sense in that?

As far as I'm concerned as long as there's fuel in the tank to run the engine, there is enough fuel in the tank to cool the pump, it's not the fuel surrounding the pump that cools it, it's the fuel flowing through the pump.

There are three vehicles in my signature, all of them have the original in tank fuel pumps, my son drives the Swift, and I swear he has figured out a way to get it to run on fumes - I've seen him drive for days with the needle on or below E - if there was any truth to that tale, that pump would have long burned up - the other two vehicles I drive, and I don't fill them until the needle is down to E.

Now - onto your problem - the FI fuse feeds the entire EFI system, not just the fuel pump, but also the injectors, ignition, heated O2 sensors (if fitted), EGR (if fitted) - any one of those can cause the fuse to blow.

If the vehicle has multi port injection (one injector per cylinder) take a close look at the injector harness, some vehicles are known to have chafing issues which can wear through the insulation and cause shorts.
 

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Thank you fordem,
It's a 1999 jimny 1.300 cc and I agree completely with you about the advice I keep getting about having to keep the tank at least half full...What's frustrating is, I am at the mercy of the mechanics here for the most part, but am going to try to check all that I can myself first....which means I will figure out where the injector harness is (assuming it has multi port injection and I know where to find that!) and check thru all the wiring for any chafing and/or rusting there and anywhere in general.
[I have no idea if this is relevant or not to the FI fuse problem, but I mainly use the car for slowly going up a mountain dirt road in 4x4.]

If there is anything you can add, I'd appreciate it!
thanks again!
 

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Which country are you in? Can you PM me the chassis number? Let's try to narrow it down some.
 

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That chassis number comes back as a European market SN413 with a G13BB engine (1.3 litre 16v engine) and a 5 speed manual transmission.

It is multi-point injection, the four injectors will be on the right side (to your left if you're standing in front of the car facing it) of the engine just about where the intake manifold meets the head - check the wiring harness connect to them, make sure it's not rubbing on anything.
 

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4 Fordem

just updating - after ur advice of checking all connections-esp. harness- we couldn't find any 'bad connections' but a friend electrician checked n basically did sth to the pump connection under the car. I don't know specifics as there's no way I could stick my face down under the car to check on what he did...there's a bit of 'if you don't trust me, go away' thing going on...n we do trust this guy...all he explained was that he 'fixed' the connection there- I assume he soldered sth by what I saw him do....and altho I think the 'keep gas tank filled' theory is strange, he explained that pumps, as well as everything else, can burn out quickly on the island here because of the sea air, which corrodes everything. He just thinks keeping the tank on the red light constantly is asking for trouble, and having at least a bit of fuel helps in general....n so far..all good!
Thank you very much for your help!!! I really appreciate it and am encouraged to learn more about my car myself!
Thanks again!
 

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Just so you're aware, Guyana, although on the South American continent, is considered Caribbean, we're a part of Caricom, I live within a mile of the sea and drive on the beach - I know only too well the corrosive effects of salt water, and how far the sea air can carry the salt spray.

Having said that, the sea air and salt water can cause corrosion issues especially down where the fuel tank is, but there is no "sea air" in the tank, it's a sealed system (listen for the "woosh" the next time you open the tank).

The fuel pump gets it's power from the EFI system so a chafed wire causing a short circuit down there will blow the fuse.
 
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