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Gas tank removal diagram needed

Tiny
TOYPACIFIC
  • MEMBER
  • 2004 SUZUKI GRAND VITARA
  • 6 CYL
  • 2WD
  • AUTOMATIC
  • 150,000 MILES
Good day gentlmen, may I request for a diagram as to removing fuel tank. I need to repair fuel pump. By looking at it, it doesnt seem so bad due to the fact its sitting right under the rear of the vehicle but I need some guidance on bolts and hoses I need to remove before bringing down.
just to add the car will not crank over so I couldn't release fuel pressure.
thank you in advance. Have a wonderful day.
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Monday, September 21st, 2020 AT 9:31 PM

5 Replies

Tiny
STEVE W.
  • MECHANIC
  • 13,452 POSTS
How did you determine the pump was the problem?
Removal isn't that hard but you need to drain the tank to a lower level before removal as the filler hose has to come off and it is lower than the full tank level. The first image is the common system components used.

Insert hose of a hand operated pump into fuel filler hose 1 and drain fuel in space A in the second image (drain fuel through it till fuel stops).
Do not force hose of a hand operated pump into fuel tank. Doing so can damage fuel tank inlet valve (2).

Third image - Next remove the fuel tank filler hose protector. Disconnect filler hose (3) from fuel tank (1) and breather hose (2) from fuel filler neck.
Remove fuel tank inlet valve (4). Use care not to damage inlet valve when removing.
Drain fuel tank by pumping fuel out through fuel tank filler.

Fourth image - Disconnect fuel filter inlet hose (3) from filter (1).

Fifth image - Disconnect fuel check valve hose (1), return hose (2) and vapor control outlet hose (3) from pipes.

Remove fuel tank protector from vehicle.

Sixth image - Lower fuel tank gradually while holding it horizontally and pull out each coupler from fuel pump (1) and fuel tank pressure sensor (2).
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Monday, September 21st, 2020 AT 11:11 PM
Tiny
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  • MEMBER
  • 159 POSTS
Thank you.

I'm guessing it is either the filter or fuel pump. The car was cranking over but would start up with starter fluid then just shut off. So I went ahead and ordered the pump and filter and going to give that a shot before moving forward. Hopefully that solves the issue.
Thank you for the diagram. By the way is there another way to release fuel pressure without starting the vehicle?
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Tuesday, September 22nd, 2020 AT 12:07 AM
Tiny
STEVE W.
  • MECHANIC
  • 13,452 POSTS
No easy way to release any pressure, but if the pump is bad there shouldn't be much if any pressure anyway. You could wrap a rag around the fuel fitting under the hood and loosen it to see if there is any pressure in the system. That fitting is also where you would tie in a pressure gauge to verify that the issue was the pump.
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Tuesday, September 22nd, 2020 AT 4:00 AM
Tiny
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  • 159 POSTS
Will do, thank you very much. Have a pleasant day or evening.

Stay safe
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Tuesday, September 22nd, 2020 AT 4:16 AM
Tiny
DANNY L
  • MECHANIC
  • 5,648 POSTS
Hello, I'm Danny.

Just to add my 2 cents. I've attached the fuel pressure specifications below as a reference. Once you complete the repair this can help if the problem persists. This specification is for the proper function of the fuel pump output. Hope this helps and let us know if you have any further questions in this issue. Thanks again for using 2CarPros.
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Thursday, September 24th, 2020 AT 5:12 PM

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