Fuel Tank Removal and Installation: Installation

Reference: FUEL TANK PURGING PROCEDURE 

Reference: FUEL TANK INSPECTION 

1. Install fuel pump assembly (2) and fuel cut valve (15) to fuel tank (1). Refer to FUEL PUMP REMOVAL AND INSTALLATION .
2. 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.

3. Install inlet valve (14) to fuel tank (1). If deformed or damaged in any other way, replace with a new one.
4. Install fuel tank (1) by using fuel tank belts (10) and then install protector (9) to vehicle.

   Tightening torque 

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

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

5. 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: Identifying Fuel Tank Components

   Courtesy of SUZUKI OF AMERICA CORP.
6. Install fuel filler hose protector.
7. 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, refer to FUEL PIPE REMOVAL AND INSTALLATION .

   Fig 2: Identifying Valve Hose, Return Hose And Vapor Control Valve Outlet Hose

   Courtesy of SUZUKI OF AMERICA CORP.
8. Connect fuel filter inlet hose (3) to fuel filter (1) referring to FUEL FILTER REMOVAL AND INSTALLATION .
   Fig 3: Identifying Fuel Filter Inlet Hose, Fuel Filter Outlet Hose & Fuel Filter

   Courtesy of SUZUKI OF AMERICA CORP.
9. Connect negative (-) cable to battery.
10. Upon completion of installation, check fuel system for leakage.