Fuel Tank: Installation

If parts have been removed from fuel tank, install them before installing fuel tank to vehicle.
Raise fuel tank (1) with jack and connect fuel pump connector, tank pressure and temperature sensor connector and ground wire harness, then clamp wire harness. See Fig 7 .
Install fuel tank to vehicle. See Fig 7 and TORQUE SPECIFICATIONS .
Connect fuel filler hose (1), breather hose (2) and filter inlet hose (4) as shown in Fig 5 . Clamp them securely. See TORQUE SPECIFICATIONS .
Connect fuel feed pipe (1), fuel return pipe (3) and purge pipe (2) to each pipe as shown in Fig 9 . Clamp them securely.
CAUTION: When connecting joint, clean outside surfaces of pipe where joint is to be inserted, push joint into pipe till joint lock clicks and check to ensure that pipes are connected securely, or fuel leak may occur. Never let the fuel hoses touch the ABS sensor harness (if equipped).
Install EVAP canister with its bracket (1) to vehicle. SeeFig 4 .
Install propeller shaft No. 2. See Fig 10 .
Install muffler. See Fig 2 .
Connect negative cable at battery. With engine OFF, turn ignition switch to ON position and check for fuel leaks.

Fig 1: Locating Fuel Filler Hose & Fuel Tank Inlet Valve (Aerio)

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Fig 2: Identifying Exhaust System Components (Aerio)

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Fig 3: Removing Propeller Shaft (Aerio)

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Fig 4: Locating EVAP Canister Bracket (Aerio)

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Fig 5: Locating Fuel Tank Hoses (Aerio)

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Fig 6: Identifying Fuel Pipe Joints (Aerio)

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Fig 7: Locating Fuel Tank Mounting Bolts (Aerio)

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Fig 8: Removing Fuel Tank (Aerio)

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Fig 9: Connecting Fuel Pipe Joints (Aerio)

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Fig 10: Installing Propeller Shaft (Aerio)

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Install fuel pump assembly and fuel cut valve to fuel tank. Refer to FUEL PRESSURE RELIEF .
Connect fuel hoses to fuel tank, fuel cut valve, vapor control valve, check valve and fuel pump assembly. After connecting, clamp hoses securely.
Install inlet valve to fuel tank. If deformed or damaged in any other way, replace with a new one.
Install fuel tank by using fuel tank belts and then install protector to vehicle. See Fig 6 & TORQUE SPECIFICATIONS .
Connect fuel filler hose to fuel tank and breather hose to fuel filler neck. Clamp them securely. See Fig 6 & TORQUE SPECIFICATIONS .
Install fuel filler hose protector.
Connect check valve hose (1), return hose (2), vapor control valve outlet hose (3) to fuel pipe. And lamp them securely. See Fig 3 .
Connect fuel filter inlet hose (3) to fuel filter (1). See Fig 3 .
Connect coupler to fuel pump assembly and tank pressure sensor respectively.
Connect negative cable to battery.
Upon completion of installation, check fuel system for leakage.

Fig 1: Draining Fuel Tank (Grand Vitara, Vitara & XL-7)

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Fig 2: Removing Recirculation Hose & Filler Hose From Fuel Tank (Grand Vitara, Vitara & XL-7)

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Fig 3: Disconnecting/Connecting Fuel Filter Inlet Hose (Grand Vitara, Vitara & XL-7)

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Fig 4: Disconnecting/Connecting Fuel Check Valve Hose, Return Hose & Vapor Control Outlet Hose (Grand Vitara, Vitara & XL-7)

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Fig 5: Lowering Fuel Tank (Grand Vitara, Vitara & XL-7)

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Fig 6: Installing Fuel Tank (Grand Vitara, Vitara & XL-7)

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