Fuel Tank Removal & Installation: Installation

NOTE: H27 engine refers to XL-7.

Install fuel pump assembly (2) and fuel cut valve (15) to fuel tank (1). Refer to FUEL PUMP REMOVAL & INSTALLATION .
Connect fuel hoses to fuel tank (1), fuel cut valve (15), vapor control valve (18), check valve and fuel pump assembly (2).
After connecting, clamp hoses securely.
Install inlet valve (14) to fuel tank (1). If deformed or damaged in any other way, replace with a new one.
Install fuel tank (1) by using fuel tank belts (10) and then install protector (9) to vehicle.
Tightening torque: 50 N.m (5.0 kg-m, 36.5 lb-ft)

Fuel tank bolt (a):

Fuel tank protector bolt (b): 50 N.m (5.0 kg-m, 36.5 lb-ft)
Connect fuel filler hose (13) to fuel tank (1), and recirculation hose to fuel filler neck (11). Clamp them securely.
Tightening torque:

Fuel filler hose clamp (c): 4 N.m (0.4 kg-m, 3.0 lb-ft)

Fig 1: Installing Fuel Tank
Courtesy of SUZUKI OF AMERICA CORP.
Install fuel filler hose protector.
Connect check valve hose (1), return hose (2) and vapor control valve outlet hose (3) to fuel pipe. And clamp them securely.
For quick joint (H27 engine only), refer to FUEL PIPE REMOVAL & INSTALLATION .

Fig 2: Connecting Hoses
Courtesy of SUZUKI OF AMERICA CORP.
Connect fuel filter inlet hose (3) to fuel filter (1) referring to FUEL FILTER REMOVAL & INSTALLATION .

Fig 3: Connecting Fuel Filter Inlet Hose To Fuel Filter
Courtesy of SUZUKI OF AMERICA CORP.
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.