LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Suzuki >> 2007 >> XL7 Base, AWD >> Repair and Diagnosis >> Engine Performance >> Fuel Delivery >> Fuel System >> Repair Instructions >> Fuel Tank Replacement (AWD) >> Removal Procedure
April 5, 2026: LEMON Manuals is launched! Read the announcement.

Removal Procedure

WARNING:

Do not allow smoking or the use of open flames in the area where work on the fuel or EVAP system is taking place. Anytime work is being done on the fuel system, disconnect the negative battery cable, except for those tests where battery voltage is required.

WARNING:

Fuel supply lines will remain pressurized for long periods of time after the engine is shutdown. This pressure must be relieved before servicing the fuel system.

Fig 1: Identifying EVAP Canister & EVAP Canister Fresh Air Hose/Pipe
G04843417Courtesy of SUZUKI OF AMERICA CORP.
  1. Relieve the fuel system pressure. Refer to FUEL PRESSURE RELIEF (WITH J 34730-1A)  and FUEL PRESSURE RELIEF (WITHOUT J 34730-1A) .
  2. Ensure that the fuel level in the tank is less than 1/4 full. If necessary, drain the fuel tank to at least this level. Refer to FUEL TANK DRAINING .
  3. Disconnect the negative battery cable. Refer to REMOVAL PROCEDURE .
  4. Remove the muffler assembly. Refer to REMOVAL PROCEDURE .
  5. Remove the propeller shaft. Refer to REMOVAL PROCEDURE .
  6. Disconnect the evaporative emission (EVAP) canister fresh air hose/pipe from the fuel tank fresh air hose/pipe (2). Refer to PLASTIC COLLAR QUICK CONNECT FITTING SERVICE .
  7. Disconnect the EVAP canister vent hose/pipe from the EVAP canister (1). Refer to PLASTIC COLLAR QUICK CONNECT FITTING SERVICE .
    CAUTION:

    Clean all fuel pipe connections and surrounding areas before disconnecting the fuel pipes to avoid contamination of the fuel system.

    WARNING:

    Whenever fuel lines are removed, catch fuel in an approved container. Container opening must be a minimum of 300 mm (12 in) diameter to adequately catch the fluid.

  8. Disconnect the chassis fuel feed line quick connect fitting from the fuel tank. Refer to PLASTIC COLLAR QUICK CONNECT FITTING SERVICE .
    Fig 2: Identifying Fuel Fill Tube, EVAP Vent Hose & Fresh Air Hose From Fuel Tank
    G04843418Courtesy of SUZUKI OF AMERICA CORP.
  9. Disconnect the fuel fill tube, EVAP vent hose, and fresh air hose from the fuel tank.
  10. Disconnect the fuel tank electrical connector and remove the electrical connector retainer from the rear frame.
    Fig 3: Identifying Fuel Tank Strap Bolts & Fuel Tank Straps
    G04843419Courtesy of SUZUKI OF AMERICA CORP.
    CAUTION:

    Do not bend the fuel tank straps. Bending the fuel tank straps may cause damage to the straps.

  11. Support the fuel tank.
  12. Remove the fuel tank strap bolts and fuel tank straps.
  13. Lower the fuel tank and heat shield from the underbody of the vehicle.
  14. If replacing the fuel tank, remove the fuel tank module assemblies. Refer to REMOVAL PROCEDURE  and REMOVAL PROCEDURE .
scientia non olet · About LEMON Manuals