LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Suzuki >> 2005 >> Aerio SX, AWD >> Repair and Diagnosis >> Engine Performance >> Fuel Delivery >> Fuel System >> Repair Instructions >> Fuel Pump Assembly Removal and Installation >> Installation
April 5, 2026: LEMON Manuals is launched! Read the announcement.

Fuel Pump Assembly Removal and Installation: Installation

  1. Clean mating surfaces of fuel pump assembly (1) and fuel tank.
  2. Put plate (2) on fuel pump assembly (1) by matching the protrusion of fuel pump assembly (3) to plate hole (4) as shown.
    Fig 1: Putting Plate On Fuel Pump Assembly
    G04014269Courtesy of SUZUKI OF AMERICA CORP.
  3. Install new gasket (2) and fuel pump assembly (1) with plate (3) to fuel tank.

    Tightening torque 

    Fuel pump assembly bolts (a): 10 N.m (1.0 kg-m, 7.5 lb-ft) 

    Fig 2: Tightening Fuel Pump Assembly Bolts
    G04014270Courtesy of SUZUKI OF AMERICA CORP.
  4. Connect fuel cut valve hose (1), fuel return pipe (2) (pipe joint) and fuel feed line (3) (pipe joint) to fuel pump assembly.
    CAUTION: When connecting joint, clean outside surface 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.
    Fig 3: Connecting Fuel Cut Valve Hose, Fuel Return Pipe And Fuel Feed Line To Fuel Pump Assembly
    G04014271Courtesy of SUZUKI OF AMERICA CORP.
  5. Install fuel tank to vehicle. Refer to "FUEL TANK REMOVAL AND INSTALLATION :".