Suzuki Grand Vitara JB627. Manual - part 108

1G-15 Fuel System: 

Fuel Tank Removal and Installation

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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

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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

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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

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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 

Removal and Installation”.

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 

Removal and Installation”.

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