Suzuki Esteem, Swift 1994-02

Removal & Installation

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  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. Remove rear seat cushion.
  8.  
  9. Disconnect connectors of fuel tank wire harness.
  10.  
  11. Hoist vehicle.

    Click image to see an enlarged view

    Fig. Fuel filler neck (1), fuel filler hose (2), breather hose or pressure control valve hose (3), air suction outlet hose (if equipped) (4)-Swift

  12.  
  13. Disconnect fuel tank filler hose and breather hose from filler neck.
  14.  
  15. As fuel tank has no drain plug, drain fuel tank by pumping fuel out through fuel tank filler or fuel tank inlet. Use hand operated pump to drain fuel tank.
    WARNING
    Never drain or store fuel in an open container to avoid possibility of fire or explosion.

  16.  
  17. Disconnect fuel pipe joints and fuel hose from 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 (part No. 09919-47020) between pipe and joint.
    4.  
    5. Disconnect joint from pipe.
    6.  

  18.  
  19. Remove fuel tank from vehicle.
  20.  

To install:

  1. If parts have been removed from top of fuel tank, install them according to the following procedure.


    1. Install fuel pump assembly.
    2.  
    3. Install tank pressure sensor, refuel vapor control valve, tank pressure control solenoid valve, EVAP canister and canister air valve to fuel tank, if equipped.
    4.  
    5. Install fuel pipes, hoses and tank pressure control valves. Clamp hoses and wire harness securely.
    6.  
    7. Install fuel tank inlet valve to fuel tank inlet, if equipped.
    8.  

  2.  
  3. Install fuel tank and tank protector to vehicle.
  4.  
  5. Connect fuel filler hose and breather hose or pressure control valve hose to filler neck, and air suction outlet hose to its pipe if equipped.
  6.  
  7. Connect fuel hose and pipes to each pipe. Install muffler mounting bolts and joint nuts if removed.
    CAUTION
    When connecting joint, clean outside surfaces of pipe inserted to joint, push joint into pipe till joint lock clicks and check to ensure that pipes are connected securely, or fuel leak may occur.

  8.  
  9. Connect connectors of fuel tank wire harness. Fix wire harness with tape.
  10.  
  11. Install rear seat cushion.
  12.  
  13. Connect negative cable to battery.
  14.  
  15. With engine -OFF- and ignition switch -ON-, check for fuel leaks.
  16.  

  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. Remove rear seat cushion, rear right seat back, right side sill scuff, right front partition trim and right rear door opening trim.
  8.  
  9. Disconnect connectors of fuel tank wire harness.
  10.  
  11. Remove parking brake cover and console box (if equipped with the 1.6L engine).
  12.  
  13. Disconnect connector of heated oxygen sensor-2.
  14.  
  15. Hoist vehicle.
  16.  
  17. Remove muffler.
    WARNING
    To avoid the danger of being burned, do not touch the exhaust system when the system is hot. Any service on the exhaust system should be performed when the system has cooled down.

  18.  
  19. Disconnect connector from EVAP canister vent valve.
  20.  
  21. Disconnect hoses from EVAP canister. For quick joint, disconnect it as follows:


    1. Remove mud or dust around joint by blowing compressed air, and push joint fully in arrow direction.
    2.  
    3. Disconnect hose joint while joint lock is unlocked by pushing both sides of joint.
    4.  

  22.  
  23. Disconnect fuel filler hose and pressure control valve hose from filler neck.
  24.  
  25. As fuel tank has no drain plug, drain fuel tank by pumping fuel out through fuel tank filler. Use hand operated pump to drain fuel tank.
    WARNING
    Never drain or store fuel in an open container to avoid possibility of fire or explosion. Do not force hose of a hand operated pump into or out of fuel tank. Doing so can damage inlet valve.

  26.  
  27. Disconnect fuel pipe joints from 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 (3) between pipe and joint.
    4.  
    5. Disconnect joint from pipe.
      WARNING
      A small amount of fuel may be released after fuel hose is disconnected. In order to reduce the chance of personal injury, cover 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.  

  28.  
  29. Support fuel tank with jack.
  30.  
  31. Remove fuel tank from vehicle.
  32.  

To install:

  1. If parts have been removed from top of fuel tank, install
  2.  
  3. Install fuel tank and tank protector to vehicle.
  4.  
  5. Connect fuel filler hose and breather hose to filler neck.
  6.  
  7. Connect pipe joints to each pipe.
    CAUTION
    When connecting joint, clean outside surfaces of pipe inserted to joint, push joint into pipe till joint lock clicks and check to ensure that pipes are connected securely, or fuel leak may occur.



    Click image to see an enlarged view

    Fig. Fuel pipes (1), joint locks (2), push joint until lock clicks (3)-Esteem

  8.  
  9. Connect connector to EVAP canister vent valve.
  10.  
  11. Connect refuel vapor control valve hose and purge hose to EVAP canister. For quick joint, push joint into pipe till joint lock clicks.
  12.  
  13. Install muffler and tighten muffler nuts to 37 ft. lbs. (50 Nm).
  14.  
  15. Connect connector of heated oxygen sensor-2.
  16.  
  17. Install console box and parking brake cover (if removed).
  18.  
  19. Connect connectors of fuel tank wire harness.
  20.  
  21. Install right rear door opening trim, right front partition trim, right side sill scuff, rear seat back and rear seat cushion.
  22.  
  23. Connect negative cable at battery.
  24.  
  25. With engine -OFF- and ignition switch -ON-, check for fuel leaks.
  26.  
  27. Start engine and check each joint of exhaust system for leakage.
  28.  

 
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