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Home >> Suzuki >> 2007 >> XL7 Base, AWD >> Repair and Diagnosis >> Engine Performance >> Fuel Delivery >> Fuel System >> Repair Instructions >> Fuel Tank Replacement (AWD) >> Installation Procedure
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Installation Procedure

  1. If previously removed, install the fuel tank module assemblies. Refer to INSTALLATION PROCEDURE  and INSTALLATION PROCEDURE .
    Fig 1: Identifying Fuel Tank Straps & Fuel Tank Strap-To-Body Bolts
    G04843420Courtesy of SUZUKI OF AMERICA CORP.
  2. Install the fuel tank heat shield and fuel tank assembly to the vehicle.
    CAUTION:

    Refer to FASTENER NOTICE .

  3. Install the fuel tank straps and the fuel tank strap-to-body bolts.

    Tightening torque 

    Tighten the bolts to 25 N.m (18 lb ft). 

    Fig 2: Identifying EVAP Vent & Fresh Air Hoses To Fuel Tank
    G04843421Courtesy of SUZUKI OF AMERICA CORP.
  4. Connect the fuel tank electrical connector and install the electrical connector retainer to the rear frame.
  5. Connect the EVAP vent, and fresh air hoses to the fuel tank.
  6. Connect the fuel fill tube to the fuel tank.

    Tightening torque 

    Tighten the clamp to 5 N.m (44 lb in). 

    Fig 3: Identifying EVAP Canister & EVAP Canister Fresh Air Hose/Pipe
    G04843422Courtesy of SUZUKI OF AMERICA CORP.
  7. Connect the chassis fuel feed line quick connect fitting to the fuel tank. Refer to PLASTIC COLLAR QUICK CONNECT FITTING SERVICE .
  8. Connect the EVAP canister fresh air hose/pipe to the fuel tank fresh air hose/pipe (2). Refer to PLASTIC COLLAR QUICK CONNECT FITTING SERVICE .
  9. Connect the EVAP canister vent hose/pipe to the EVAP canister (1). Refer to PLASTIC COLLAR QUICK CONNECT FITTING SERVICE .
  10. Install the propeller shaft. Refer to INSTALLATION PROCEDURE .
  11. Install the muffler assembly. Refer to INSTALLATION PROCEDURE .
  12. Lower the vehicle.
  13. Fill the fuel tank with gasoline.
  14. Connect the negative battery cable. Refer to INSTALLATION PROCEDURE .
  15. Tighten the fuel fill cap.
  16. Prime the fuel system:
    1. Cycle the ignition ON for 5 seconds and then OFF for 10 seconds.
    2. Repeat the previous step twice.
    3. Crank the engine until it starts. The maximum starter motor cranking time is 20 seconds.
    4. If the engine does not start, repeat steps  a- 16.
  17. Install the fuel injector sight shield. Refer to INSTALLATION PROCEDURE .
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