Suzuki Aerio, Verona 2002-06

Fuel Pump

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Removal & Installation



  1. Disconnect the battery negative terminal.
    WARNING
    The use of a fresh air mask is recommended.

  2.  
  3. Insert the heavy duty hose 1.3 meters into the fuel filler pipe, measured from the edge of the opening of the filler pipe.
  4.  
  5. Pump until air comes out.
  6.  
  7. Remove the outer rear seats.
  8.  
  9. Remove the center rear seat.
  10.  
  11. Fold the carpet back.
  12.  
  13. Remove the ventilation pipe
  14.  
  15. Remove the insulation block
  16.  
  17. Remove the insulation block
  18.  
  19. Remove the 6 seat frame bolts
  20.  
  21. Remove the 2 seat frame bolts
  22.  
  23. Raise the rear edge of the seat frame approximately 1 inch (25mm). Position a block between the frame and the transaxle tunnel.
  24.  
  25. Cover the area around the cover and between the doors with absorbent material.
    CAUTION
    Ensure that there is no risk of dirt getting into the tank.



    Click image to see an enlarged view

    Fig. Accessing the level sensors

  26.  
  27. Remove the covers (1 and 2) over the fuel tank units.
  28.  
  29. Disconnect the level sensor connector (3).
  30.  
  31. Remove the hoses from the right-hand level sensor.
  32.  
  33. Clean the area around the fuel tank unit thoroughly. Open the right-hand level sensor. Insert the heavy duty hose and suck out the remains from the bottom of the right-hand side of the fuel tank.
  34.  
  35. Connect hose 999 5721 to the heavy duty hose. Suck out the remains from the bottom of the level sensor reservoir.
  36.  
  37. Carefully remove the overflow pipe from the reservoir.
  38.  
  39. Remove the thin hose 999 5721 from the heavy duty hose. Connect the thin hose to the overflow pipe. Use a hose clamp.
  40.  
  41. Pump until a lot of air comes out.
  42.  
  43. Open the left-hand level sensor. Insert the heavy duty hose and suck out the remains from the bottom of the left-hand side of the fuel tank.
  44.  

To install:

Click image to see an enlarged view

Fig. Left side sensor installation



Click image to see an enlarged view

Fig. Right side sensor installation

  1. Place the overflow pipe approximately half a centimeter to the left-hand side.
  2.  
  3. Grip around the right level sensor reservoir. Pinch the level sensor reservoir so that the float is held in its lowest position.
  4.  
  5. Lower the reservoir carefully while rotating it backwards around the front-rear shaft on the float.
  6.  
  7. Install the overflow pipe on the reservoir.
  8.  
  9. On the left-hand level sensor:
    1. Install a new O-ring.
    2.  
    3. Press the left level sensor down so that the row of protruding cables runs along the car. Check that the O-ring is not trapped.
    4.  
    5. Tighten the bolt. Tighten to 44 ft. lbs. (60 Nm).
    6.  
    7. Position the wiring in the cut-out in the rubber ring
      NOTE
      Check that the arrow on the cover is between the markings on the tank. If the arrow is outside the markings the fuel gauge sensor will give an incorrect value and the float may catch against the inner wall of the tank. If not: Slacken off the bolt and adjust the position of the sensor. Tighten as above.

    8.  

  10.  
  11. On the right-hand level sensor:
    1. Install a new O-ring.
    2.  
    3. Press the right-hand level sensor down so that the fuel line connections are pointing forwards and to the right.
    4.  
    5. Check that the O-ring is not trapped.
    6.  
    7. Tighten the bolt. Tighten to 44 ft. lbs. (60 Nm).
    8.  
    9. Install the hoses on the level sensor.
    10.  
    11. Position the wiring in the cut-out in the rubber ring.
      NOTE
      Check that the arrow on the cover is between the markings on the tank. If the arrow is outside the markings the fuel gauge sensor will give an incorrect value and the float may catch against the inner wall of the tank. If not: Slacken off the bolt and adjust the position of the sensor. Tighten as above.

    12.  

  12.  
  13. Install the covers over the level sensors. Tighten the bolts.
  14.  
  15. Connect the wiring and the connectors.
  16.  
  17. Remove the block from under the seat frame
  18.  
  19. Install the 8 seat frame bolts. Tighten to 37 ft. lbs. (50 Nm).
  20.  
  21. Install the 2 seat frame bolts. Tighten to 18 ft. lbs. (24 Nm).
  22.  
  23. Fold the carpet down
  24.  
  25. Install the center rear seat.
  26.  
  27. Install the outer rear seat.
  28.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the pressure from the fuel system.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Drain the fuel from the tank by pumping the fuel out through the fuel tank filler.
    CAUTION
    Use a gasoline safe hand operated pump device to drain the fuel tank.

  8.  
  9. Remove or disconnect the following:

    Fuel filler cap
     

  10.  
  11. Raise and safely support the vehicle.

    Muffler
     
    Propeller shaft No. 2
     
    EVAP canister and bracket
     
    Fuel filler hose and breather hose
     
    Filter inlet hose from canister air suction filter
     

  12.  
  13. 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 drain or store fuel in an open container due to possibility of fire or explosion.

  14.  
  15. Disconnect fuel pipe joints from fuel pipes. For quick joint, disconnect it as follows:
    1. Remove mud, dust and/or foreign material between pipe and joint by blowing compressed air.
    2.  
    3. Unlock joint lock by inserting special tool 09919-47020 between pipe and joint.
    4.  
    5. Disconnect joint from pipe.
      CAUTION
      A small amount of fuel may be released after the fuel hose is disconnected. In order to reduce the chance of personal injury, cover the hose and pipe to be disconnected with a shop cloth. Be sure to put that cloth in an approved container when disconnection is completed.

    6.  

  16.  
  17. Support the fuel tank using a transmission jack.

    Two bands that secure the fuel tank
     

  18.  
  19. Slowly and carefully lower the fuel tank enough to disconnect the fuel pump connector, tank pressure and temperature sensor connector and ground wire harness.

    Fuel tank from vehicle
     
    Fuel cut valve hose, fuel feed line and fuel return pipe from fuel pump assembly
     
    Fuel pump assembly from fuel tank

    Click image to see an enlarged view

    Fig. Fuel pump assembly components-Aerio

     

  20.  

To install:

  1. Clean mating surfaces of fuel pump assembly and fuel tank.
  2.  
  3. Put plate on fuel pump assembly by matching the protrusion of fuel pump assembly to plate hole.
  4.  
  5. Install new gasket and fuel pump assembly with plate to fuel tank and tighten the assembly bolts to 7.5 ft. lbs. (10 Nm).
  6.  
  7. Install or connect the following:
    NOTE
    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.



    Fuel cut valve hose, fuel feed line and fuel return pipe to the fuel pump assembly
     

  8.  
  9. Raise fuel tank with jack and connect fuel pump connector, tank pressure and temperature sensor connector and ground wire harness and then clamp wire harness.
    NOTE
    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.



    Fuel tank to the vehicle. Tighten the fuel tank strap bolts to 36.5 ft. lbs. (50 Nm).
     
    Fuel filler hose, breather hose and filter inlet hose. Clamp them securely and tighten to 2.5 ft. lbs. (3.5 Nm).
     
    Fuel feed pipe, fuel return pipe and purge pipe and clamp securely
     



    EVAP canister and bracket
     
    Propeller shaft No. 2
     
    Muffler
     
    Lower the vehicle
     
    Fuel filler cap
     
    Negative battery cable
     

  10.  
  11. Fill the fuel tank enough to check for fuel leaks.
  12.  
  13. Turn the ignition switch to the ON position, but leave the engine OFF and check for fuel leaks.
  14.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the pressure from the fuel system.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Drain the fuel from the tank by pumping the fuel out through the fuel tank filler.
    CAUTION
    Use a gasoline safe hand operated pump device to drain the fuel tank.

  8.  
  9. Remove or disconnect the following:

    Exhaust front muffler
     
    Fuel tank shield
     

  10.  
  11. Support the fuel tank using a transmission jack.

    Two bands that secure the fuel tank
     

  12.  
  13. Slowly and carefully lower the fuel tank until enough space for the fuel tank filler tube removal is achieved.
  14.  
  15. Pull the fuel tank filler tube release fully backward and disconnect the fuel tank filler tube.
    CAUTION
    A small amount of fuel may be released after the fuel hose is disconnected. Cover the hose and pipe to be disconnected with a shop cloth.



    Fuel inlet line
     
    Fuel return line
     



    EVAP vent hose
     
    Fuel pump harness connectors
     
    Fuel tank
     
    Fuel pump and sending unit from fuel tank
     

  16.  

To install:

  1. Install or connect the following:
    NOTE
    Always install a new fuel pump strainer when replacing the fuel pump.



    Fuel strainer on the fuel pump
     



    Fuel pump and sending unit into the fuel tank
     
    Electrical connectors to the fuel pump
     
    Remaining components in the reverse order of removal
     
    Negative battery cable
     

  2.  
  3. Fill the fuel tank enough to check for fuel leaks.
  4.  
  5. Turn the ignition switch to the ON position, but leave the engine OFF and check for fuel leaks.
  6.  

 
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