2006 SUZUKI SX4 Fuel filler

Downloaded from www.Manualslib.com manuals search engine 1G-13 Fuel System:
Fuel Tank Removal and InstallationS6RW0D1706011
WARNING!
Before starting the following procedure, be
sure to observe “Precautions on Fuel System
Service” in order to reduce the risk of fire and
personal injury.

Removal
1) Relieve fuel pressure in fuel feed line according to
“Fuel Pressure Relief Procedure”.
2) Disconnect negative cable at battery.
3) Remove fuel filler cap.
4) Insert hose of a hand operated pump into fuel filler
hose (1) and drain fuel in space “A” as shown in
figure.
CAUTION!
Do not force pump hose into fuel tank.

5) Hoist vehicle, and remove clamp (2), fuel filler hose
(1) and breather hose (3) from fuel filler neck.6) Remove exhaust center pipe referring to “Exhaust
Pipe and Muffler Removal and Installation in Section
1K”.
7) Remove propeller shaft (For 4WD model) referring to
“Propeller Shaft Assembly Removal and Installation
in Section 3D”.
8) Due to absence of fuel tank drain plug, drain fuel
tank by pumping fuel out through fuel tank filler.
Use hand operated pump device to drain fuel tank.
CAUTION!
• Do not force pump hose into fuel tank.
• Never store fuel in an open container due
to possibility of fire or explosion.

9) Disconnect quick joint (fuel pipe) (1) from fuel pipes
(2) referring to “Fuel Hose Disconnecting and
Reconnecting”.
10) Support fuel tank (1) with jack (2) and remove its
mounting bolts (3).
11) Lower fuel tank a little as to disconnect wire harness
at connector (1)and ground wire (2), then remove
fuel tank.
2. Inlet check valve
I4RS0B170022-01
1 23
I5RW0A170012-01
2
1
I5RW0A170014-02
1
2
33
I5RW0A170013-01
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I7RW01170009-01

Downloaded from www.Manualslib.com manuals search engine Fuel System: 1G-14
Installation
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.
• Never let the fuel hoses touch the ABS
sensor harness (if equipped).

1) If parts have been removed from fuel tank, install
them before installing fuel tank to vehicle.
2) 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 kgf-m, 8.0 lb-ft)
3) Install fuel tank to vehicle.
Tightening torque
Fuel tank bolt (b): 45 N·m (4.5 kgf-m, 33.0 lb-ft)4) Connect fuel filler hose (1) and breather hose (2) to
filler neck (3) as shown in figure, and clamp them
securely.
Tightening torque
Fuel filler hose clamp (a): 1.5 N·m (0.15 kgf-m,
1.0 lb-ft)
5) Connect fuel feed hose (1) and vapor hose (2) to
each pipe as shown in figure, and clamp them
securely.
6) Install exhaust center pipe referring to “Exhaust Pipe
and Muffler Removal and Installation in Section 1K”.
7) Install propeller shaft (For 4WD model) referring to
“Propeller Shaft Assembly Removal and Installation
in Section 3D”.
8) Connect negative cable at battery.
9) With engine OFF, turn ignition switch to ON position
and check for fuel leaks.
Fuel Tank InspectionS6RW0D1706012
After removing fuel tank, check hoses and pipes
connected to fuel tank for leaks, loose connections,
deterioration or damage. Also check fuel pump
assembly gaskets for leaks, visually inspect fuel tank for
leaks and damage.
Replace any damaged or malconditioned parts.
(b)(b)
1
2
3
4
(a)
I7RW01170010-01
1(a)2
3
I5RW0A170017-01
1
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I5RW0A170018-01

Downloaded from www.Manualslib.com manuals search engine 1G-15 Fuel System:
Fuel Tank Purging ProcedureS6RW0D1706013
WARNING!
• Before starting the following procedure, be
sure to observe “Precautions on Fuel
System Service” in order to reduce the risk
of fire and personal injury.
• This purging procedure will not remove all
fuel vapor.
Do not attempt any repair on tank using
heat of flame as an explosion resulting in
personal injury could occur.

CAUTION!
Never remain water in fuel tank after washing,
or fuel tank inside will get corrosion.

The following procedure are used for purging fuel tank.
1) After removing fuel tank, remove all hoses, pipes
and fuel pump assembly from fuel tank.
2) Drain all remaining fuel from tank.
3) Place fuel 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.
6) Be sure to dry fuel tank assembly thoroughly out of
direct sunlight after washing.
Fuel Pump On-Vehicle InspectionS6RW0D1706014
WARNING!
Before starting the following procedure, be
sure to observe “Precautions on Fuel System
Service” in order to reduce the risk of fire and
personal injury.

NOTE
The fuel pressure regulator is incorporated
with the fuel pump assembly so individual
inspection of it is impossible.

1) Remove filler cap and turn ON ignition switch (2).
Then fuel pump operating sound should be heard
from fuel filler (1) for about 2 seconds and stop. Be
sure to reinstall fuel filler cap after checking.
If the check result is not satisfactory, go to “Fuel
Pump and Its Circuit Check in Section 1A”.2) Turn OFF ignition switch and leave over 10 minutes
as it is.
3) Fuel pressure should be felt at fuel feed hose (1) for
about 2 seconds after ignition switch ON.
If fuel pressure is not felt, go to “Fuel Pressure
Check in Section 1A”.
Fuel Pump Assembly Removal and InstallationS6RW0D1706015
WARNING!
Before starting the following procedure, be
sure to observe “Precautions on Fuel System
Service” in order to reduce the risk of fire and
personal injury.

Removal
1) Remove fuel tank from vehicle referring to “Fuel
Tank Removal and Installation”.
2) Disconnect fuel pipe (1) from fuel pump assembly (2)
referring to “Fuel Hose Disconnecting and
Reconnecting”.
3) Remove fuel pump assembly and earth bracket from
fuel tank.
IVSY01170013-01
1I5RW0A170019-01
1
2
I7RW01170011-01

Downloaded from www.Manualslib.com manuals search engine 1G-17 Fuel System:
Fuel Pump InspectionS6RW0D1706016
• Check fuel pump assembly for damage.
• Check fuel suction filter for evidence of dirt and
contamination.
If present, replace or clean and check for presence of
dirt in fuel tank.
• For electrical circuit, refer to “Fuel Pump and Its
Circuit Check in Section 1A”.
• For inspection of fuel level gauge (1), refer to “Fuel
Level Sensor Inspection in Section 9C”.
Specifications
Tightening Torque SpecificationsS6RW0D1707001
NOTE
The specified tightening torque is also described in the following.
“Fuel System Components”
“Fuel Hose Disconnecting and Reconnecting”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
1
I5JB0A171027-01
Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
Fuel delivery pipe bolt 25 2.5 18.0)
Ground wire bolt 11 1.1 8.0)
Fuel tank bolt 45 4.5 33.0)
Fuel filler hose clamp 1.5 0.15 1.0)
Fuel pump assembly bolt 11 1.1 8.0)