User Manual Q&AAnswer
Feb 27, 2025 - 05:36 AM
To remove and install the fuel tank on a 2008 Suzuki SX4 4WD L4-2.0L, follow these steps:
1. Before starting, make sure to observe the precautions mentioned in the manual to reduce the risk of fire and personal injury.
2. Relieve the fuel pressure in the fuel feed line according to the Fuel Pressure Relief Procedure.
3. Disconnect the negative cable at the battery.
4. Remove the fuel filler cap.
5. Insert the hose of a hand-operated pump into the fuel filler hose and drain the fuel in space A as shown in the figure. Be cautious not to force the pump hose into the fuel tank.
6. Hoist the vehicle and remove the clamp, fuel filler hose, and breather hose from the fuel filler neck.
7. Remove the EVAP canister by referring to the EVAP Canister Removal and Installation section in the manual.
8. Remove the exhaust center pipe by referring to the Exhaust Pipe and Muffler Removal and Installation section.
9. If it is a 4WD model, remove the propeller shaft by referring to the Propeller Shaft Assembly Removal and Installation section.
10. Since there is no fuel tank drain plug, drain the fuel tank by pumping the fuel out through the fuel tank filler using a hand-operated pump device. Again, do not force the pump hose into the fuel tank, and never store fuel in an open container due to the risk of fire or explosion.
11. Disconnect the quick joint from the fuel pipes by referring to the Fuel Hose Disconnecting and Reconnecting section.
12. Support the fuel tank with a jack and remove its mounting bolts.
13. Lower the fuel tank slightly to disconnect the wire harness at the connector and the ground wire, then remove the fuel tank.
To install the fuel tank:
1. Before connecting the joint, clean the outside surfaces of the pipe where the joint is to be inserted. Push the joint into the pipe until it locks securely, and ensure that the pipes are connected securely to avoid fuel leaks.
2. Make sure the fuel hoses do not touch the wheel speed sensor harness (if equipped).
3. If any parts have been removed from the fuel tank, install them before installing the fuel tank back into the vehicle.
4. Raise the fuel tank with a jack and connect the fuel pump connector, ground wire, and clamp wire harness. Tighten the ground wire bolt to a torque of 11 Nm (1.1 kgf-m, 8.0 ft. lbs.).
5. Install the fuel tank to the vehicle and tighten the new fuel tank bolts to a torque of 45 Nm (4.5 kgf-m, 33.0 ft. lbs.).
6. Connect the fuel filler hose and breather hose to the filler neck and securely clamp them. The tightening torque for the fuel tank hose clamp is 1.5 Nm (0.15 kgf-m, 1.0 ft. lbs.) for EVAP leak check models and 3.5 Nm (0.35 kgf-m, 2.5 ft. lbs.) for non-EVAP-leak-check models.
7. Connect the fuel feed hose and vapor hose to each pipe and securely clamp them.
8. Install the exhaust center pipe by referring to the Exhaust Pipe and Muffler Removal and Installation section, and install the propeller shaft for 4WD models.
9. Install the EVAP canister by referring to the EVAP Canister Removal and Installation section.
10. Connect the negative (-) cable at the battery.
11. With the engine off, turn the ignition switch to the ON position and check for any fuel leaks.
Please note that the information provided is based on the ALLDATA 2008 Suzuki SX4 4WD L4-2.0L Fuel Tank Instruction Manual. It is always recommended to refer to the specific vehicle's manual for accurate and detailed instructions.
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