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, 8.5 lbf-ft)
Install fuel tank to vehicle, and tighten new fuel tank bolts to specified torque.
Tightening torque

Fuel tank bolt (b): 45 N.m (4.6 kg-m, 33.5 lbf-ft)

Fig 1: Identifying Fuel Tank Hoses, Clamps And Bolts
Courtesy of SUZUKI OF AMERICA CORP.
Connect fuel filler hose (1), breather hose (3) and clamps (2) to fuel filler neck (3) as shown in figure, and clamp them securely.
Tightening torque

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

Fuel tank hose clamp (EVAP leak check model) (b): 3.5 N.m (0.36 kg-m, 2.5 lbf-ft)

Fig 2: Connecting Fuel Filler Hose Breather Hose And Clamps To Fuel Filler Neck
Courtesy of SUZUKI OF AMERICA CORP.
Connect quick joints (1) to each pipe (2) as shown in figure.

Fig 3: Connecting Quick Joints To Each Pipe
Courtesy of SUZUKI OF AMERICA CORP.
Install exhaust center pipe. See EXHAUST PIPE AND MUFFLER REMOVAL AND INSTALLATION
Install propeller shaft (4WD model). See PROPELLER SHAFT ASSEMBLY REMOVAL AND INSTALLATION
Install EVAP canister. See EVAP CANISTER REMOVAL AND INSTALLATION
Connect negative (-) cable at battery.
With engine stationary, turn ignition switch to ON position and check for fuel leaks.