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Home >> Suzuki >> 2003 >> XL-7 Base, 4WD >> Repair and Diagnosis >> Engine Performance >> Remove, Overhaul & Install >> Removal & Installation >> Fuel System >> Fuel Tank >> Removal (Aerio)
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Removal (Aerio)

WARNING: Before starting the procedure, be sure to observe Precautions on Fuel System Service. See FUEL SYSTEM PRECAUTIONS  .
  1. Relieve fuel pressure in fuel feed line. See FUEL PRESSURE RELIEF  .
  2. Disconnect negative cable at battery.
  3. Remove fuel filler cap.
  4. Insert the hose of a hand operated pump into the fuel filler hose (1) and drain fuel in space "A." See Figure .
    CAUTION: Do not force pump hose into fuel tank, or pump hose may damage fuel tank inlet valve (2).
  5. Hoist vehicle.
  6. Remove muffler. See Figure .
  7. Remove propeller shaft No. 2. See Figure .
  8. Remove EVAP canister with its bracket (1) from vehicle. See Figure .
  9. Disconnect fuel filler hose (1) and breather hose (2) from filler neck (3). Then disconnect filter inlet hose (4) from canister air suction filter (5). See Figure .
  10. Due to absence of fuel tank drain plug, drain fuel tank by pumping fuel out through fuel tank filler. Use hand operated pump device to drain fuel tank.
    CAUTION: Do not force pump hose into fuel tank, or pump hose may damage fuel tank inlet valve. Never drain or store fuel in an open container due to possibility of fire or explosion.
    11. WARNING: A small amount of fuel may be released after the fuel hose is disconnected. In order to reduce the chance of personal injury, cover the hose and pipe to be disconnected with a shop cloth. Be sure to put that cloth in an approved container when disconnection is completed.
  11. Disconnect fuel pipe joints from fuel pipes. For quick joint, disconnect it as follows:
    • Remove mud, dust and/or foreign material between pipe and joint by blowing compressed air.
    • Unlock joint (1) lock by inserting special tool between pipe (2) and joint (1). Use special tool 09919-47020. See Figure .
    • Disconnect joint from pipe.
  12. Support fuel tank (1) with jack (2) and remove its mounting bolts. See Figure .
  13. Lower fuel tank a little to disconnect fuel pump connector (1), tank pressure and temperature sensor connector (2) and ground wire harness, then remove fuel tank. See Figure .
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