Removal Procedure

NOTE:

A NEW fuel tank module seal is necessary each time the fuel tank module is serviced. Obtain a NEW seal prior to beginning this service procedure.

WARNING:

Whenever fuel line fittings are loosened or removed, wrap a shop cloth around the fitting and have an approved container available to collect any fuel.

CAUTION:

Clean all fuel pipe and hose connections and surrounding areas before disassembling to avoid possible contamination of the fuel system. Spray the fuel pump module cam-lock ring tang with penetrating oil prior to attempting removal.

Remove the fuel tank. Refer to REMOVAL PROCEDURE and REMOVAL PROCEDURE .
Disconnect the EVAP vent line quick connect. Refer to PLASTIC COLLAR QUICK CONNECT FITTING SERVICE .

Fig 1: Identifying Secondary Fuel Pump Module & Retaining Ring
Courtesy of SUZUKI OF AMERICA CORP.

CAUTION:
To prevent retainer damage, do not attempt to remove the retainer with a 12 in. or shorter ratchet/breaker bar.
Use the J39765-A and remove the secondary fuel pump module (2) retaining ring.

Fig 2: Identifying Secondary Level Sensor Electrical Connector Tab
Courtesy of SUZUKI OF AMERICA CORP.
Disconnect the secondary level sensor electrical connector.
Disconnect the suction port attaching tube by pressing down on the tab (1).
CAUTION:
To prevent bending of the sending unit float arm during removal, lift the pump module up slightly to disengage the orientation tabs in the tank and rotate the module 45 degrees.
Remove the secondary fuel pump module.
NOTE:
Always replace the fuel pump module-to-tank seal, O-ring, when the fuel pump module is removed.
Discard the fuel pump module-to-tank seal.
If the fuel level sending unit is being replaced as well, remove the fuel level sender. Refer to REMOVAL PROCEDURE .