Fuel Tank Removal and Installation: Installation

CAUTION:

Failure to take proper precautions when reinstalling the fuel tank connections can result in fuel leakage or damage.

Clean the outside surface of the pipe where each quick joint is to be installed, push the pipe into the joint until the joint lock clicks, and then confirm that the pipe is connected securely.
Secure the fuel hoses and the wheel speed sensor harness (if equipped) so that they will not come in contact with each other.

If parts have been removed from fuel tank, install them before installing fuel tank to vehicle.
Raise fuel tank (1) with jack (2) and connect fuel pump connector (3), ground wire (4) and clamp wire harness.
Tightening torque

Ground wire bolt (a): 11 N.m (1.1 kg-m, 8.5 lbf-ft)
Install fuel tank to vehicle, and tighten new fuel tank bolts to specified torque.
Tightening torque

Fuel tank bolt (b): 45 N.m (4.6 kg-m, 33.5 lbf-ft)

Fig 1: Identifying Fuel Tank Hoses, Clamps And Bolts
Courtesy of SUZUKI OF AMERICA CORP.
Connect fuel filler hose (1), breather hose (3) and clamps (2) to fuel filler neck (3) as shown in figure, and clamp them securely.
Tightening torque

Fuel tank hose clamp (Non-EVAP-leak-check model) (a): 1.5 N.m (0.15 kg-m, 1.5 lbf-ft)

Fuel tank hose clamp (EVAP leak check model) (b): 3.5 N.m (0.36 kg-m, 2.5 lbf-ft)

Fig 2: Connecting Fuel Filler Hose Breather Hose And Clamps To Fuel Filler Neck
Courtesy of SUZUKI OF AMERICA CORP.
Connect quick joints (1) to each pipe (2) as shown in figure.

Fig 3: Connecting Quick Joints To Each Pipe
Courtesy of SUZUKI OF AMERICA CORP.
Install exhaust center pipe. See EXHAUST PIPE AND MUFFLER REMOVAL AND INSTALLATION
Install propeller shaft (4WD model). See PROPELLER SHAFT ASSEMBLY REMOVAL AND INSTALLATION
Install EVAP canister. See EVAP CANISTER REMOVAL AND INSTALLATION
Connect negative (-) cable at battery.
With engine stationary, turn ignition switch to ON position and check for fuel leaks. See FUEL LEAKAGE CHECK PROCEDURE .