Fuel Tank Removal and Installation: Removal

WARNING: Before starting the following procedure, be sure to observe Precautions on Fuel System Service .

Relieve fuel pressure in fuel feed line according to Fuel Pressure Relief Procedure .
Disconnect negative cable at battery.
Remove fuel filler cap.
Insert hose of a hand operated pump into fuel filler hose (1) and drain fuel in space "A" in the figure.
CAUTION: Do not force pump hose into fuel tank, or pump hose may damage fuel tank inlet valve (2).

Fig 1: Inserting Hose Of A Hand Operated Pump Into Fuel Filler Hose
Courtesy of SUZUKI OF AMERICA CORP.
Hoist vehicle.
Remove muffler. .
Remove propeller shaft No. 2 referring to PROPELLER SHAFT REMOVAL AND INSTALLATION .
Remove EVAP canister with its bracket (1) from vehicle referring to EVAP CANISTER REMOVAL AND INSTALLATION .

Fig 2: Removing EVAP Canister With Its Bracket
Courtesy of SUZUKI OF AMERICA CORP.
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).

Fig 3: Disconnecting Fuel Filler Hose & Breather Hose From Filler Neck
Courtesy of SUZUKI OF AMERICA CORP.
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.
Disconnect fuel pipe joints from fuel pipes.
For quick joint, disconnect it as follows:
1. Remove mud, dust and/or foreign material between pipe and joint by blowing compressed air.
2. Unlock joint (1) lock by inserting special tool between pipe (2) and joint (1).
  Special tool
  
  (A): 09919-47020
3. Disconnect joint from pipe.
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.

Fig 4: Disconnecting Fuel Pipe Joints From Fuel Pipes
Courtesy of SUZUKI OF AMERICA CORP.
Support fuel tank (1) with jack (2) and remove its mounting bolts.

Fig 5: Removing Fuel Tank Mounting Bolts
Courtesy of SUZUKI OF AMERICA CORP.
Lower fuel tank a little to disconnect fuel pump connector (1), tank pressure and temp. sensor connector (2) and ground wire harness, then remove fuel tank.

Fig 6: Disconnecting Fuel Pump Connector, Tank Pressure & Temp. Sensor Connector

Courtesy of SUZUKI OF AMERICA CORP.