Fuel Tank Removal and Installation: Installation

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 wheel speed sensor harness (if equipped).

If parts have been removed from fuel tank, install them before installing fuel tank to vehicle.
Raise fuel tank (1) with jack (2) and connect fuel pump connector (3), ground wire (4) and clamp wire harness.
Tightening torque

Ground wire bolt a: 11 N.m (1.1 kg-m, 8.0 lb-ft)
Install fuel tank to vehicle, and tighten new fuel tank bolts to specified torque.
Tightening torque

Fuel tank bolt b: 45 N.m (4.5 kg-m, 33.0 lb-ft)

Fig 1: Identifying Fuel Tank With Jack, Fuel Pump Connector And Ground Wire
Courtesy of SUZUKI OF AMERICA CORP.
Connect fuel filler hose (1) and breather hose (2) to filler neck (3) as shown in figure, and clamp them securely.
Tightening torque

Fuel tank hose clamp (EVAP leak check model) a: 1.5 N.m (0.15 kg-m, 1.0 lb-ft)

Fuel tank hose clamp (Non-EVAP-leak-check model) b: 3.5 N.m (0.35 kg-m, 2.5 lb-ft)

Fig 2: Identifying Fuel Filler Hose And Breather Hose
Courtesy of SUZUKI OF AMERICA CORP.
Connect fuel feed hose (1) and vapor hose (2) to each pipe as shown in figure, and clamp them securely.

Fig 3: Identifying Fuel Feed Hose And Vapor Hose
Courtesy of SUZUKI OF AMERICA CORP.
Install exhaust center pipe referring to EXHAUST PIPE AND MUFFLER REMOVAL AND INSTALLATION .
Install propeller shaft (4WD model) referring to PROPELLER SHAFT ASSEMBLY REMOVAL AND INSTALLATION .
Install EVAP canister referring to EVAP CANISTER REMOVAL AND INSTALLATION .
Connect negative (-) cable at battery.
With engine OFF, turn ignition switch to ON position and check for fuel leaks.