Suzuki Grand Vitara JB627. Manual — part 108
1G-15 Fuel System:
Fuel Tank Removal and Installation
S6JB0B1706015
WARNING
!
Before starting the following procedure, be
sure to observe “Precautions on Fuel System
Service” in order to reduce the risk or fire
and personal injury.
Removal
1) Relieve fuel pressure in fuel feed line according to
“Fuel Pressure Relief Procedure”.
2) Disconnect negative (–) cable at battery.
3) Hoist vehicle.
4) Remove exhaust center pipe.
5) Remove rear propeller shaft referring to “Propeller
Shaft Removal and Installation in Section 3D”.
6) With cable connected, detach parking brake cable
clamp from fuel tank cover referring to “Parking
Brake Cable Location in Section 4D”.
7) Remove fuel filler cap.
8) Insert hose of a hand operated pump into fuel filler
hose (1) and drain fuel in space “A” as shown in
figure.
CAUTION
!
Do not force pump hose into fuel tank, or
pump hose may damage to fuel tank inlet
valve (2).
9) Disconnect fuel filler hose (2) and breather hose
from filler neck.
10) Disconnect fuel pump connector (1).
11) Due to absence of fuel tank drain plug, drain fuel
tank by pumping fuel out through fuel tank filler.
Use hand operated pump device to drain fuel tank.
CAUTION
!
• Do not force pump hose into fuel tank, or
pump hose may damage fuel tank inlet
valve.
• Never store fuel in an open container due
to possibility of fire or explosion.
12) Disconnect fuel hoses (2) and EVAP canister hose
(1) from each pipe referring to “Fuel Hose
Disconnecting and Reconnecting”.
13) Support fuel tank (1) with jack (2) and remove fuel
tank.
14) Remove fuel tank inlet valve (if equipped) from fuel
tank if necessary.
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Fuel System: 1G-16
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).
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 connectors
of fuel pump and sub fuel level gauge and clamp
wire harness.
3) Install fuel tank to vehicle tighten new fuel tank bolts
to specified torque.
Tightening torque
Fuel tank bolt (a): 45 N·m (4.5 kgf-m, 32.5 lb-ft)
4) Connect fuel filler hose (1) and breather hose to filler
neck as shown in figure, and clamp them securely.
For proper installation, refer to “Fuel Hose
Disconnecting and Reconnecting”.
Tightening torque
Fuel filler hose clamp (a): 4 N·m (0.4 kgf-m, 3.0
lb-ft)
5) Connect fuel pump connector (2).
6) Connect fuel hoses (1) and EVAP canister hose (2)
to each pipe as shown in figure, and clamp them
securely referring to “Fuel Hose Disconnecting and
Reconnecting”.
7) Install parking brake cable clamp to fuel tank cover
referring to “Parking Brake Cable Location in Section
4D”.
8) Install rear propeller shaft referring to “Propeller
Shaft Removal and Installation in Section 3D”.
9) Install exhaust center pipe referring to “Exhaust
System Components in Section 1K”.
10) Connect negative (–) cable at battery.
11) With engine OFF, turn ignition switch to ON position
and check for fuel leaks.
Fuel Tank Inspection
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After removing fuel tank, check hoses and pipes
connected to fuel tank for leaks, loose connections,
deterioration or damage. Also check fuel pump
assembly gaskets for leaks, visually inspect fuel tank for
leaks and damage.
Replace any damaged or malconditioned parts.
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1G-17 Fuel System:
Fuel Tank Purging Procedure
S6JB0B1706017
WARNING
!
• Before starting the following procedure, be
sure to observe “Precautions on Fuel
System Service” in order to reduce the risk
or fire and personal injury.
• This purging procedure will not remove all
fuel vapor.
Do not attempt any repair on tank using
heat of flame as an explosion resulting in
personal injury could occur.
CAUTION
!
Never remain water in fuel tank after washing,
or fuel tank inside will get corrosion.
The following procedure are used for purging fuel tank.
1) After removing fuel tank, remove all hoses, pipes,
sub fuel level gauge and fuel pump assembly from
fuel tank.
2) Drain all remaining fuel from tank.
3) Place fuel tank to flushing area.
4) Fill tank with warm water or tap water, and agitate
vigorously and drain. Repeat this washing until
inside of tank is clean. Replace tank if its inside is
rusty.
5) Completely flush out remaining water after washing.
Fuel Pump On-Vehicle Inspection
S6JB0B1706018
WARNING
!
Before starting the following procedure, be
sure to observe “Precautions on Fuel System
Service” in order to reduce the risk or fire
and personal injury.
1) Remove filler cap and turn ON ignition switch (2).
Then fuel pump operating sound should be heard
from fuel filler (1) for about 2 seconds and stop. Be
sure to reinstall fuel filler cap after checking.
If the check result is not satisfactory, go to “Fuel
Pump and Its Circuit Check in Section 1A”.
2) Turn OFF ignition switch and leave over 10 minutes
as it is.
3) Fuel pressure should be felt at fuel feed hose (1) for
about 2 seconds after ignition switch ON.
If fuel pressure is not felt, go to “Fuel Pressure
Check in Section 1A”.
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Fuel System: 1G-18
Fuel Pump Assembly Removal and Installation
S6JB0B1706019
WARNING
!
Before starting the following procedure, be
sure to observe “Precautions on Fuel System
Service” in order to reduce the risk or fire
and personal injury.
Removal
1) Remove fuel tank from vehicle. Refer to “Fuel Tank
2) Disconnect fuel feed pipe (1) and fuel return pipe (3)
from fuel pump assembly (2) referring to “Fuel Hose
Disconnecting and Reconnecting”.
3) Disconnect fuel suction hose (2) referring to “Fuel
Hose Disconnecting and Reconnecting”.
4) Remove fuel pump assembly (1) from fuel tank.
Installation
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.
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.
3) Install new gasket (2) and fuel pump assembly (1)
with plate (3) to fuel tank (4).
Tightening torque
Fuel pump assembly nut (a): 11 N·m (1.1 kgf-m,
8.0 lb-ft)
4) Connect fuel feed pipe (1) (pipe joint) and fuel return
pipe (3) (pipe joint) to fuel pump assembly (2).
5) Install fuel tank to vehicle. Refer to “Fuel Tank
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(a)
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