Fuel Tank Removal and Installation: Installation

Reference: FUEL TANK INSPECTION 

Reference: FUEL TANK PURGING PROCEDURE 

1. If parts have been removed from fuel tank, install them before installing fuel tank to vehicle.
2. Raise fuel tank (1) with jack and connect fuel pump connector and ground wire harness, and then clamp wire harness.
3. Install fuel tank to vehicle.

   Tightening torque 

   Fuel tank bolt a: 50 N.m (5.0 kg-m, 36.5 lb-ft) 

   Fig 1: Raising Fuel Tank With Jack And Connecting Fuel Pump Connector And Ground Wire Harness

   Courtesy of SUZUKI OF AMERICA CORP.
4. Connect fuel filler hose (1), breather hose (2) and filter inlet hose (3) as shown in figure and clamp them securely.

   Tightening torque 

   Fuel filler hose for vehicle with ORVR system a: 3.5 N.m (0.35 kg-m, 2.5 lb-ft) 

   Fuel filler hose clamp for vehicle without ORVR system a: 1.5 N.m (1.5 kg-m, 1.0 lb-ft) 

   Fig 2: Connecting Fuel Filler Hose Breather Hose And Filter Inlet Hose

   Courtesy of SUZUKI OF AMERICA CORP.
5. Connect fuel feed pipe (1), fuel return pipe (3) and purge pipe (2) to each pipe as shown in figure and clamp them securely.
   CAUTION:

   • When connecting joint, clean outside surfaces 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.
   • Never let the fuel hoses touch the ABS sensor harness (if equipped).
     Fig 3: Connecting Fuel Feed Pipe Fuel Return Pipe And Purge Pipe

     Courtesy of SUZUKI OF AMERICA CORP.
6. Install EVAP canister to vehicle referring to EVAP CANISTER REMOVAL AND INSTALLATION .
7. Install propeller shaft No. 2 referring to PROPELLER SHAFT REMOVAL AND INSTALLATION .
8. Install muffler referring to EXHAUST PIPE REMOVAL AND INSTALLATION .
9. Connect negative cable at battery. With engine OFF, turn ignition switch to ON position and check for fuel leaks.