Suzuki Vitara, Grand Vitara, XL7 2000-06

Fuel Pump

Print

Removal & Installation



  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Fuel filler hose and vent hose
     
    Fuel tank inlet valve and drain the fuel tank
     
    Fuel filter inlet hose
     
    Evaporative Emissions (EVAP) vapor hose
     
    Fuel return line
     
    Fuel tank skidplate
     
    Fuel pump connector
     
    Fuel tank pressure sensor connector
     
    Fuel tank
     
    Fuel pump module
     

  6.  

To install:

  1. Install or connect the following:

    Fuel pump module with a new seal. Tighten the bolts to 44 inch lbs. (5 Nm).
     
    Fuel tank. Tighten the strap bolts to 37 ft. lbs. (50 Nm).
     
    Fuel tank pressure sensor connector
     
    Fuel pump connector
     
    Fuel tank skidplate
     
    Fuel return line
     
    EVAP vapor hose
     
    Fuel filter inlet hose
     
    Fuel tank inlet valve and drain the fuel tank
     
    Fuel filler hose and vent hose
     
    Negative battery cable
     

  2.  
  3. Fill the fuel tank.
  4.  
  5. Start the engine and check for leaks.
  6.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Fuel filler hose and vent hose
     
    Fuel tank inlet valve and drain the fuel tank
     
    Fuel filter inlet hose
     
    Evaporative Emissions (EVAP) vapor hose
     
    Fuel return line
     
    Fuel tank skidplate
     
    Fuel pump connector
     
    Fuel tank pressure sensor connector
     
    Fuel tank
     
    Fuel pump module
     

  6.  

To install:

  1. Install or connect the following:

    Fuel pump module with a new seal. Tighten the bolts to 44 inch lbs. (5 Nm).
     
    Fuel tank. Tighten the strap bolts to 37 ft. lbs. (50 Nm).
     
    Fuel tank pressure sensor connector
     
    Fuel pump connector
     
    Fuel tank skidplate
     
    Fuel return line
     
    EVAP vapor hose
     
    Fuel filter inlet hose
     
    Fuel tank inlet valve and drain the fuel tank
     
    Fuel filler hose and vent hose
     
    Negative battery cable
     

  2.  
  3. Fill the fuel tank.
  4.  
  5. Start the engine and check for leaks.
  6.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. 1)Relieve fuel pressure in fuel feed line.
  6.  
  7. Disconnect negative (-) cable at battery.
  8.  
  9. Hoist vehicle.
  10.  
  11. Remove exhaust center pipe.
  12.  
  13. Remove rear propeller shaft.
  14.  
  15. With cable connected, detach parking brake cable clamp from fuel tank cover.
  16.  
  17. Disconnect fuel filler hose and breather hose from filler neck.
  18.  
  19. Disconnect fuel pump connector.
  20.  
  21. Due to absence of fuel tank drain plug, drain fuel tank by pumping fuel out through fuel tank filler.
  22.  
  23. Use hand operated pump device to drain fuel tank.
  24.  
  25. Disconnect fuel hoses and EVAP canister hose from each pipe.
  26.  
  27. Support fuel tank with jack and remove fuel tank.
  28.  
  29. Remove fuel pump assembly.
  30.  

To install:

  1. Install fuel pump assembly.
  2.  
  3. Raise fuel tank with jack, and connect connectors of fuel pump and sub fuel level gauge and clamp wire harness.
  4.  
  5. Install fuel tank to vehicle.
  6.  
  7. Tighten fuel tank mounting bolts to 36 ft. lbs (50 Nm).
  8.  
  9. Connect fuel filler hose and breather hose to filler neck, and clamp them securely.
  10.  
  11. Connect fuel pump connector.
  12.  
  13. Connect fuel hoses and EVAP canister hose to each pipe, and clamp them securely.
  14.  
  15. Install parking brake cable clamp to fuel tank cover.
  16.  
  17. Install rear propeller shaft. Install exhaust center pipe
  18.  
  19. Connect the negative battery cable.
  20.  
  21. With engine OFF, turn ignition switch to ON position and check for fuel leaks.
  22.  

 
label.common.footer.alt.autozoneLogo