Fuel Tank Removal and Installation: Removal

WARNING: This page is about a different car, the 2004 Suzuki Vitara. However, it is still accessible from the selected car via links, so may be relevant.

Relieve fuel pressure in fuel feed line. Refer to "FUEL PRESSURE RELIEF PROCEDURE: ".
CAUTION: This work must not be done when engine is hot. If done so, it may cause adverse effect to catalyst.
Disconnect negative cable at battery.
Insert hose of a hand operated pump into fuel filler hose (1) and drain fuel in space "A" in the figure (drain fuel through it till fuel stops).
CAUTION: Do not force hose of a hand operated pump into fuel tank. Doing so can damage fuel tank inlet (check) valve (2).

Fig 1: Inserting Hose Of Hand Operated Pump Into Fuel Filler Hose And Draining Fuel
Courtesy of SUZUKI OF AMERICA CORP.
Remove fuel tank filler hose protector. Disconnect filler hose (3) from fuel tank (1) and breather hose (2) from fuel filler neck.
Remove fuel tank inlet valve (4). Use care not to damage inlet valve when removing.

Fig 2: Removing Fuel Tank Inlet Valve
Courtesy of SUZUKI OF AMERICA CORP.
Drain fuel tank by pumping fuel out through fuel tank filler. Use hand operated pump device to drain fuel tank.
CAUTION: Never drain or store fuel in an open container due to possibility of fire or explosion.
Disconnect fuel filter inlet hose (3) from filter (1).

Fig 3: Disconnecting Fuel Filter Inlet Hose From Filter
Courtesy of SUZUKI OF AMERICA CORP.
Disconnect fuel check valve hose (1), return hose (2) and vapor control outlet hose (3) from pipes.

Fig 4: Disconnecting Fuel Check Valve Hose, Return Hose And Vapor Control Outlet Hose From Pipes
Courtesy of SUZUKI OF AMERICA CORP.
Remove fuel tank protector from vehicle.
Lower fuel tank gradually while holding it horizontally and pull out each coupler from fuel pump (1) and fuel tank pressure (and temp.) sensor (2).

Fig 5: Pulling Out Coupler From Fuel Pump And Fuel Tank Pressure Sensor
Courtesy of SUZUKI OF AMERICA CORP.