Installation Procedure
1. Check the primary and secondary lock rings for flatness.
a. Place the lock ring on a flat surface. Measure the clearance between to lock ring and the flat surface using a feeler gage at 7 points.
b. If the warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement. If the warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced.
NOTE:
^ Some lock rings were manufactured with DO NOT REUSE stamped into them. These lock rings may be reused if they are not damaged or warped.
^ Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring.
^ Check the lock ring for flatness.
2. Position the new primary and secondary module seals in place.
NOTE:
Always replace the fuel tank module seal when installing the assembly.
3. Route the suction tube through the correct routing previously noted, being careful not to damage it.
CAUTION
^ If you handle the Fuel Pump Module by the fuel pipes, the amount of leverage generated could damage the joints.
^ Do Not handle the Fuel Pump Module by the fuel pipes.
4. Insert the new primary fuel pump module assembly with the level sender.
5. Use the required tool J 45722 or equivalent (Primary Fuel Sender Lock Ring Tool), in order to install the fuel tank module lock ring. Turn the fuel sender lock ring in a clockwise direction.
NOTE:
Do not apply any type of lubrication in the seal groove. Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction.
6. Connect the wiring harness to the primary fuel pump module and fuel tank pressure sensor.
7. Position the new secondary seal in place.
NOTE:
Always replace the fuel tank module seal when installing the fuel sender assembly.
8. Connect the suction tube securing it with the clip.
9. Connect the wire harness.
10. Insert the secondary fuel pump module.
11. Use the J39765-A or equivalent (Secondary Fuel Sender Lock Ring Tool), to install the secondary fuel tank module lock ring.
12. Connect the EVAP line quick connect.
13. Be sure to secure the external fuel tank lines to their connections.
14. With the help of an assistant if needed, install the fuel tank heat shield and fuel tank assembly to the vehicle.
NOTICE
Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
15. Install the 2 fuel tank straps and the 4 (2 each strap) fuel tank strap-to-body bolts.
a. Tighten the bolts to 25 N.m (18 lb ft).
16. Connect the Electrical connector, EVAP vent, and fresh air hoses to the fuel tank.
17. Connect the fuel fill tube to the fuel tank.
a. Tighten the clamp to 5 N.m (44 lb in).
18. Connect the chassis fuel feed line quick connect fitting to the fuel tank.
19. Connect the EVAP canister fresh air hose/pipe to the fuel tank fresh air hose/pipe.
20. Connect the EVAP canister vent hose/pipe to the EVAP canister.
21. Connect the electrical connector.
PROPELLER SHAFT INSTALLATION
22. Thoroughly clean the mounting bolts for the center bearing and the front and rear propeller shaft flanges. Apply thread lock, Suzuki part number 99000-32020 or equivalent.
23. With the aid of an assistant, position the propeller shaft on supports.
24. Align the reference marks on the front and rear of the propeller shaft to the transfer case and rear differential.
25. Position the propeller shaft on the transfer case output flange.
26. Finger tighten the 6 mounting bolts for the propeller shaft at the transfer case output flange.
27. Position the center support bearing of the propeller shaft on the vehicle.
28. Finger tighten the 2 mounting bolts for the center support bearing.
29. Position the propeller shaft on the rear differential drive flange.
30. Finger tighten the 4 rear mounting bolts for the propeller shaft.
31. Tighten the propeller shaft to transfer case output flange mounting bolts.
a. Tighten to 25 N.m (18 lb ft).
32. Tighten the center support bearing mounting bolts.
a. Tighten to 25 N.m (18 lb ft)
33. Tighten the propeller shaft to differential drive flange mounting bolts.
a. Tighten to 50 N.m (37 lb ft).
34. Remove the supports.
35. Slide the exhaust assembly onto the exhaust pipes.
NOTE:
Be sure the muffler slides onto the exhaust pipes up to the stop.
36. Install the 5 rubber isolators of the exhaust pipe hangers.
37. Tighten the 2 exhaust muffler clamps.
a. Tighten to 5 N.m (44 lb in).
38. Replace the fuel that was drained out and tighten the fuel cap.
39. Connect the negative battery cable.
40. Prime the fuel system.
a. Cycle the ignition ON for 5 seconds and then OFF for 10 seconds.
b. Repeat the previous step twice.
c. Crank the engine until it starts. The maximum continuous starter motor cranking time is 20 seconds.
d. If the engine does not start, repeat steps a thru c. If the vehicle will not prime and start, contact Suzuki Techline if necessary.
41. Install the engine cover.
42. Connect the battery and reset the radio presets.
43. Road test the vehicle.
44. Apply the proper campaign label to the upper radiator support in an area where it will be easily seen and identified, and write your dealer code in the white portion of the label.