1998-2003 Suzuki Alto 4 Door Engine Fuel -> On-Vehicle Service User Manual
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Engine Fuel -> On-Vehicle Service for Your Suzuki Alto 4 Door Fifth Generation (1998-2003)

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
2
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

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