Get Engine Fuel Guide for Suzuki Alto 4 Door Fifth Generation (1998-2003)

ENGINE FUEL 6C-1

SECTION 6C

ENGINE FUEL

CONTENTS

GENERAL DESCRIPTION 6C- 1. . . . . . . . . . . . . . . .

Fuel System 6C- 1. . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Tank 6C- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Pump Refer to SECTION 6E1. . . . . . . . . . . .

Fuel Filter 6C- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Filler Cap 6C- 2. . . . . . . . . . . . . . . . . . . . . . . . .

ON-VEHICLE SERVICE 6C- 3. . . . . . . . . . . . . . . . . .

Fuel Lines 6C- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Pipe 6C- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Filler Cap 6C- 4. . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Filter 6C- 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Tank 6C- 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Pump 6C- 8. . . . . . . . . . . . . . . . . . . . . . . . . . . .

CAUTION:

THE ENGINE OF THIS VEHICLE REQUIRES THE USE OF UNLEADED FUEL ONLY. USE OF LEADED

AND/OR LOW LEAD FUEL CAN RESULT IN ENGINE DAMAGE AND REDUCE THE EFFECTIVENESS

OF THE EMISSION CONTROL SYSTEM.

GENERAL DESCRIPTION

FUEL SYSTEM

The main components of the fuel system are fuel tank, fuel pump, fuel filter and fuel level gauge and it includes

three lines; fuel feed line, fuel return line and fuel vapor line.

For the details of fuel flow and fuel vapor flow, refer to ENGINE AND EMISSION CONTROL SYSTEM section.

1. Fuel tank

2. Fuel pump

3. Fuel level gauge

4. Fuel feed line

5. Fuel return line

6. Fuel filter

F8D engine

F8B engine

FUEL TANK

The fuel tank is located under the rear of the vehicle. The fuel pump

and fuel level gauge are installed on the upper part of fuel tank.

Whenever servicing the fuel level gauge or the fuel pump, the fuel

tank must be removed from the body.

FUEL FILTER

The fuel filter is located in front of fuel tank as shown in figure and

filters the fuel sent under pressure from the fuel pump.

As it can’t be disassembled, it must be replaced as an assembly.

FUEL FILLER CAP

A ratchet tightening device on the threaded fuel filler cap reduces

the chances of incorrect installation, which would prevent sealing

fuel vapors.

After the gasket (2) on fuel filler cap and the filler neck flange con-

tact, the ratchet produces a loud clicking noise, indicating the seal

has been set.

This cap has a vacuum relief valve (1) inside.

The vacuum relief valve opens to relieve the vacuum created in the

fuel tank (supplies air (3) into tank).

6C-2 ENGINE FUEL

ON-VEHICLE SERVICE

Clamp securely at a position 3 to 7 mm

(0.12 – 0.27 in.) from hose end.

With following type pipe, fit hose as far as its peripheral

projection as shown.

With short pipe, fit hose as far as it reaches pipe joint

as shown.

Clamp securely at a position

3 to 7 mm (0.12 – 0.27 in.)

from hose end.

Clamp

Pipe

Hose

Clamp securely at a position

3 to 7 mm (0.12 – 0.27 in.)

from hose end.

With bent pipe, fit hose as far its bent part as shown

or till pipe is about 20 to 30 mm (0.79 – 1.18 in.) into

the hose.

Clamp securely at a position

3 to 7 mm (0.12 – 0.27 in.)

from hose end.

With straight pipe, fit hose till pipe is about 20 to 30 mm

(0.79 – 1.18 in.) in the hose.

Clamp

Hose

20 to 30 mm

(0.79 – 1.18 in.)

WARNING:

Before attempting service of any type on fuel system, fol-

lowing cautions should be always observed.

D Disconnect negative cable at battery.

D DO NOT smoke, and place “NO SMOKING” signs near

work area.

D Be sure to have CO

fire extinguisher handy.

D Be sure to perform work in a well-ventilated area and

away from any open flames (such as gas hot heater).

D Wear safety glasses.

D To relieve fuel vapor pressure in fuel tank, remove fuel

filler cap from fuel filler neck and then reinstall it.

D As fuel feed line is still under high fuel pressure even

after engine was stopped, loosening or disconnecting

fuel feed line directly may cause dangerous spout of

fuel to occur where loosened or disconnected. Before

loosening or disconnecting fuel feed line, make sure

to relieve fuel pressure according to procedure de-

scribed on p. 6-4.

D A small amount of fuel may be released after the fuel

line is disconnected. In order to reduce the chance of

personal injury, cover the fitting to be disconnected

with a shop cloth. Be sure to put that cloth in an ap-

proved container when disconnection is completed.

D Note that fuel hose connection varies with each type

of pipe. Be sure to connect and clamp each hose cor-

rectly referring to the left figure.

FUEL LINES

Due to the fact that fuel feed line is under high pressure, use special

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.

ENGINE FUEL 6C-3

FUEL PIPE

REMOVAL

1) Relieve fuel pressure in fuel feed line according to procedure on

p. 6-4.

2) Disconnect negative cable at battery.

3) Disconnect fuel hose from fuel pipe at the front and rear of each

fuel pipe.

4) Remove pipe cover from body.

5) Put clamp position mark on pipes so that clamps can be

installed on original position.

6) Remove pipes with clamp from body.

7) Remove clamp from pipes.

WARNING:

A small amount of fuel may be released after fuel hose is

disconnected. In order to reduce the chance of personal

injury, cover hose and pipe to be disconnected with a

shop cloth. Be sure to put that cloth in an approved con-

tainer when disconnection is completed.

INSTALLATION

1) Install clamps to marked position on pipes referring to the figure

in p.6C-2. If clamp is deformed or its claw is bent or broken, re-

place it with new one.

2) Install pipes with pipe clamp to body.

3) Install pipe cover to body. Be sure to use new nuts.

4) Connect fuel hoses to fuel pipes.

5) With engine “OFF” and ignition switch “ON”, check for fuel

leaks.

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, re-

place cap.

NOTE:

If cap requires replacement, only a cap with the same features

should be used. Failure to use correct cap can result in critical

malfunction of system.

6C-4 ENGINE FUEL

FUEL FILTER

REMOVAL

1) Relieve fuel pressure in fuel feed line according to procedure

described on p. 6-4.

2) Disconnect negative cable at battery.

3) Place fuel container under fuel filter.

4) Disconnect inlet and outlet hoses from fuel filter.

5) Remove fuel filter with bracket.

WARNING:

A small amount of fuel may be released after fuel hose is

disconnected. In order to reduce the chance of personal

injury, cover hose and pipe to be disconnected with a

shop cloth. Be sure to put that cloth in an approved con-

tainer when disconnection is completed.

INSTALLATION

1) Install filter.

2) Connect outlet and inlet hoses.

Clamp hoses securely.

3) Connect negative cable to battery.

4) With engine “OFF” and ignition switch “ON”, check for fuel

leaks.

FUEL TANK

REMOVAL

1) Relieve fuel pressure in fuel feed line according to procedure

described on p. 6-4.

2) Disconnect negative cable at battery.

3) Hoist vehicle.

WARNING:

D Refer to the WARNING at the beginning of ON-VE-

HICLE SERVICE in this section.

D A small amount of fuel may be released after the fuel

hose is disconnected. In order to reduce the chance of

personal injury, cover the hose and pipe to be discon-

nected with a shop cloth. Be sure to put that cloth in an

approved container when disconnection is com-

pleted.

ENGINE FUEL 6C-5

4) Disconnect fuel filler hose (1) and breather hose (2) from filler

neck.

5) As fuel tank has no drain plug, drain fuel tank by pumping fuel

through fuel tank filler.

Use hand operated pump device to drain fuel tank.

CAUTION:

Never drain or store fuel in an open container to avoid

possibility of fire or explosion.

6) Disconnect fuel hoses (1).

7) Support fuel tank with jack and lower fuel tank gradually until

connector of fuel pump and terminal of fuel level gauge can be

disconnected. Then disconnect wire harness at connector and

terminal.

8) Remove fuel tank from vehicle.

INSPECTION

After removing fuel tank, check hoses and pipes connected to fuel

tank for leaks, loose connections, deterioration or damage. Also

check fuel pump, level gauge and fuel cut valve gaskets for leaks,

visually inspect fuel tank for leaks and damage.

Replace any damaged or malconditioned parts.

6C-6 ENGINE FUEL

FUEL TANK PURGING PROCEDURE

Following procedure is used for purging fuel tank.

1) After removing fuel tank, remove all hoses, pipes, fuel cut

valves, fuel pump and fuel level gauge 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.

WARNING:

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.

INSTALLATION

1) Install fuel pump (1) and fuel level gauge (2) to fuel tank.

Use new gaskets.

2) Connect fuel hoses and pipes to fuel tank as shown.

Clamp hoses and wire harness securely.

3) Connect fuel breather hose to fuel tank.

4) Install fuel tank to vehicle after connecting connecter and termi-

nal.

5) Connect fuel filler hose (2) to tank and breather hose (3) to filler

neck as shown in figure and clamp them securely.

6) Connect fuel and return hoses to pipes and clamp them secure-

ly.

7) Connect negative cable at battery.

8) With engine “OFF” and ignition switch “ON”, check for fuel

leaks.

9) Start engine and check each joint of exhaust system for leak-

age.

ENGINE FUEL 6C-7

FUEL PUMP

REMOVAL

1) Remove fuel tank from vehicle. Refer to FUEL TANK RE-

MOVAL in this section.

WARNING:

Refer to the WARNING at the beginning of ON-VEHICLE

SERVICE in this section.

2) Remove fuel pump assembly (1) from fuel tank.

INSPECTION

Check fuel pump assembly for damage.

For inspection of fuel pump itself, refer to Section 6E1 of this manu-

al.

INSTALLATION

1) Clean mating surfaces of fuel pump assembly (1) and fuel tank.

2) Install new gasket (2) to fuel pump assembly then install fuel

pump assembly to fuel tank.

3) Install fuel tank to vehicle. Refer to FUEL TANK INSTALLATION

in this section.

6C-8 ENGINE FUEL

Engine Fuel for Your Suzuki Alto 4 Door Fifth Generation (1998-2003)

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