Removal & Installation (Grand Vitara,Vitara & XL-7)
- Relieve fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE
. Disconnect negative battery cable. Go to next step.
- Removing fuel from fuel tank, DO NOT put siphon hose through filler neck at fuel filler cap. Disconnect fuel filler hose and breather hose(s) from fuel filler neck (car body side). See Fig 2
. Insert hose of a hand operated fuel siphon pump into rubber hose, but not into tank. Do not force hose into fuel tank. Siphon fuel into a fuel certified container, from section "A", see Figure
. Remove siphon hose.
- Remove rubber hose from gas tank neck. Remove fuel tank inlet valve from gas tank neck. See Figure
. Insert hose of a hand operated fuel siphon pump into fuel tank neck and siphon fuel into a fuel certified container. Some fuel will remain in tank, proceed with caution. Go to next step.
- Hoist vehicle, remove muffler if necessary. Disconnect EVAP canister hoses and vapor hoses, follow fuel lines and disconnect fuel hoses, where quick disconnect fittings are supplied, use Quick Disconnect Tool (09919-47020). Disconnect components as necessary. Support fuel tank on jack, slowly lower tank away from vehicle. Be careful that fuel lines and/or wires do not get hung up on vehicle while lowering tank. When clearance permits reach up and disconnect wiring harness connectors from fuel pump and fuel tank pressure sensor (FTPS). Continue to lower tank. Clean off tank with compressed air before removing fuel pump assembly. Remove fuel pump assembly from fuel tank. See Fig 1
. To install, reverse removal procedure. See TORQUE SPECIFICATIONS
table. To install fuel pump assembly, Install in same position as before removed. Torque fuel pump assembly bolts to 3.5 Ft.Lbs. (5 Nm).
- After repairs, check for fuel leaks. With engine off, turn ignition to ON position for 2-3 seconds to activate fuel pump. Repeat until pressure can be felt in fuel hose. Check for fuel leaks around connections. Repair fuel leaks if necessary.
Courtesy of SUZUKI OF AMERICA CORP.
Courtesy of SUZUKI OF AMERICA CORP.