2005 SUZUKI JIMNY fuel tank

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On-Vehicle Service
Before work, refer to “Precaution on Fuel System Service” in Sec-
tion 6.
Fuel Lines
Due to the fact that fuel feed line is under high pressure, use spe-
cial care when servicing it.
INSPECTION
Visually inspect fuel lines for evidence of fuel leakage, hose crack
and deterioration, or damage. Make sure all clamps are secure.
Replace parts as needed.
Fuel Filler Cap
Remove cap (1) and check gasket (2) for even filler neck imprint
and deterioration or any damage. If gasket is in malcondition,
replace cap.
Fuel Tank
REMOVAL
1) Relieve fuel pressure in fuel feed line referring to “Fuel Pres-
sure Relief Procedure” in Section 6.
2) Disconnect negative cable at battery.
3) Remove fuel filler cap.
NOTE:
If cap requires replacement, only a cap with the same fea-
tures should be used. Failure to use correct cap can
result in critical malfunction of system.
WARNING:
Before starting the following procedure, be sure to
observe “Precaution on Fuel System Service” in Sec-
tion 6.
Keep fuel tank horizontally and stably when removing
it. Fuel may come out if tank is tilted. Also, fuel tank
may drop and cause personal injury.

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4) Insert hose of a hand operated pump into fuel filler hose (1)
and drain fuel in space “A” in the figure (drain fuel through it
till fuel stops).
5) Hoist vehicle.
6) Remove exhaust center pipe referring to “Components” in
Section 6K and rear propeller shaft referring to “Propeller
Shafts” in Section 4B.
7) Disconnect coupler (1) for fuel pump assembly.
The coupler is close by left rear suspension coil spring (3).
8) Remove fuel tank filler hose protector.
Disconnect filler hose and breather hose from fuel filler neck.
9) Disconnect fuel vapor hose from pipe.
10) With fuel tank supported on a jack, remove fuel tank bolts.
11) Lower fuel tank a little and hold it. Unclamp fuel hoses and
disconnect them from fuel pump assembly (1).
When disconnecting joints of fuel feed line and return line
from pipe, unlock joint by inserting special tool between pipe
(3) and joint lock first.
Special tool
(A) : 09919-47020 CAUTION:
Do not force hose of a hand operated pump into fuel
tank. Doing so can damage inlet valve (2).
2. Fuel tank
2. Quick joint 5. Disconnect joint
4. Insert special tool

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12) Remove fuel tank (1) from vehicle. Remove fuel tank protec-
tor (3) and inlet valve (2) as necessary.
FUEL TANK PURGING PROCEDURE
The following procedure is used for purging the fuel tank.
1) After removing fuel tank, remove all hoses and fuel pump
assembly from fuel tank.
2) Drain all remaining fuel from tank.
3) Move tank to flushing area.
4) Fill tank with warm water or tap water, and agitate vigorously
and drain. Repeat this washing until inside of tank is clean.
Replace tank if its inside is rusty.
5) Completely flush out remaining water after washing.
CAUTION:
This purging procedure will not remove all fuel vapor. Do
not attempt any repair on tank where heat or flame is
required, as an explosion resulting in personal injury
could occur.

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INSTALLATION
1) Install fuel pump (1) assembly to fuel tank. Refer to “Fuel
Pump Assembly” in this section. Install protector to fuel tank.
2) Install inlet valve to fuel tank.
If deformed or damaged in any other way, replace with a new
one.
3) Connect fuel filler and breather hoses to fuel tank and vapor
hose to fuel pump assembly. Clamp them securely.
4) Lift up fuel tank on jack.
Connect fuel feed hose (4) and return hose (3) to pipes as
shown in figure and clamp them securely.
5) Install fuel tank to vehicle and connect wire harness coupler.
6) Connect fuel filler hose and breather hose to fuel filler neck.
Connect fuel vapor hose to pipe. Clamp them securely.
7) Install fuel filler hose protector.
Fuel Pump Assembly
REMOVAL
1) Remove fuel tank from vehicle. Refer to “Fuel Tank” in this
section.
2) Disconnect wire harness coupler and fuel vapor hose from
fuel pump assembly.
3) Remove fuel pump assembly from fuel tank by removing
bolts. CAUTION:
When connecting joint, clean outside surfaces of pipe
where joint is to be inserted, push joint into pipe till joint
lock clicks and check to ensure that pipes are connected
securely, or fuel leak may occur.
2. Quick joint
WARNING:
Before starting the following procedure, be sure to
observe “Precaution on Fuel System Service” in Section
6.

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INSPECTION
Check fuel pump assembly for damage.
Check fuel suction filter (1) for evidence of dirt and contamination.
If present, replace or clean and check for presence of dirt in fuel
tank.
For inspection of fuel pump itself, refer to “Table B – 3 Fuel Pres-
sure Check” in Section 6.
For inspection of fuel level gauge, refer to “Fuel Meter / Fuel
Gauge Unit” in Section 8.
DISASSEMBLY / REASSEMBLY
2. Fuel filter & bracket assembly
3. Fuel pump motor & level gauge assembly
“A” : Apply oil 4. Housing 8. Cushion
1. Bracket sub assembly (including fuel filter) 5. Lead wire 9. Bracket
2. Grommet 6. Fuel level gauge 10. Spacer
3. Tube 7. Fuel pump

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INSTALLATION
1) Clean mating surfaces of fuel pump assembly and fuel tank.
2) Install new gasket (2) and plate (3) to fuel pump assembly
(1) then install fuel pump assembly to fuel tank.
Tightening torque
Fuel pump assembly bolts (a) : 10 N·m (1.0 kg-m, 7.5 lb-ft)
3) Connect wire harness coupler (2) and fuel vapor hose (3) to
fuel pump assembly (1).
4) Install fuel tank to vehicle. Refer to “Fuel Tank” in this sec-
tion. CAUTION:
While removing fuel level gauge, do not contact resis-
tor plate (2) or deform arm (3). It may cause fuel level
gauge to fail.
When removing grommet from fuel tube or bracket sub
assembly, be very careful not to cause damage to
grommet installed section (sealed section in bore).
Should it be damaged, replace it with new one, or fuel
will leak from that part.
NOTE:
When removing fuel level gauge, press snap-fit part (1)
and slide it in the arrow direction as shown in figure.
When installing fuel level gauge to housing, fit protru-
sion (4) of fuel level gauge in groove (5) in housing and
slide it up till lug (6) fits in window (7) securely. Refer to
figure shown.
[A] : Removal
[B] : Installation

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Air Intake System
The main components of the air intake system are air cleaner (1), air cleaner outlet hose (2), throttle body (3),
idle air control valve (4) and intake manifold (5).
The air (by the amount corresponding to the throttle valve (6) opening and engine speed) is filtered by the air
cleaner (1), passes through the throttle body (3), is distributed by the intake manifold (5) and finally drawn into
each combustion chamber.
When the idle air control valve (4) is opened according to the signal from ECM, the air (7) bypasses the throttle
valve (6) through bypass passage and is finally drawn into the intake manifold (5).
1. Air Cleaner 17. Knock sensor 31-2. Test switch terminal
(vehicle w/o immobilizer indicator lamp)
2. EVAP canister purge valve 18. ECT sensor 31-3. Duty output terminal
(vehicle w/o immobilizer indicator lamp)
3. IAT sensor 19. CMP sensor 32. Immobilizer indicator lamp (if equipped)
4. TP sensor 20. CKP sensor 33. Stop lamp switch
5. IAC valve 21. VSS 34. ECM
6. MAP sensor 22. A/C condenser fan (if equipped) 35. Barometric pressure sensor
(vehicle with immobilizer indicator lamp)
7. EGR valve (if equipped) 23. Malfunction indicator lamp in combination meter 36. Battery
8. EVAP canister 24. Park/Neutral position switch in TR switch (A/T) 37. Immobilizer control module (if equipped)
9. Tank pressure control valve (built-in fuel pump) 25. Ignition switch 38. ABS control module (if equipped)
10. Fuel pump 26. Starter magnetic switch 39. CO adjusting resistor (if equipped)
11. Fuel level sensor 27. TCM (A/T) 40. Power steering pressure switch
(if equipped)
12. Ignition coil assembly 28. Transmission range switch (A/T) 41. A/C compressor clutch (if equipped)
13. Fuel injector 29. DLC 42. A/C EVAP TEMP. sensor (if equipped)
14. Heated Oxygen Sensor (HO2S)-1 (if equipped) 30. Electric load 43. A/C switch (if equipped)
15. Heated Oxygen Sensor (HO2S)-2 (if equipped) 31. Monitor connector (if equipped)
16. Three way catalytic convertor (if equipped) 31-1. Diagnosis switch terminal
(vehicle w/o immobilizer indicator lamp)

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Fuel Delivery System
The fuel delivery system consists of the fuel tank (1), fuel pump (2), fuel filter (3), fuel pressure regulator (11),
delivery pipe (9) and fuel injectors (10).
The fuel in the fuel tank is pumped up by the fuel pump, filtered by the fuel filter and fed under pressure to each
injector through the delivery pipe.
As the fuel pressure applied to the injector (the fuel pressure in the fuel feed line) is always kept a certain
amount higher than the pressure in the intake manifold by the fuel pressure regulator, the fuel is injected into the
intake port of the cylinder head when the injector open according to the injection signal from ECM.
The fuel relieved by the fuel pressure regulator returns through the fuel return line (8) to the fuel tank.
Fuel pump
An in-tank type electric pump has been adopted for the fuel pump
(1). Incorporated in the pump assembly are;
Tank pressure control valve (2) which keeps the pressure in
the fuel tank constant, and prevents the fuel from spouting
and tank itself from being deformed.
Relief valve (3) which prevents the pressure in tank from ris-
ing excessively.
Fuel cut valve (4) which closes as the float rises so that the
fuel will not enter the canister when the fuel level in the tank
rises high depending on the fuel level in the tank and the
vehicle tilt angle.
Also, a fuel filter (5) is included and a fuel level gauge (6) is
attached.
4. Fuel cut valve 6. To EVAP canister 12. To intake manifold (vacuum passage)
5. Fuel tank pressure control valve 7. Fuel feed line