fuel cap SUZUKI SWIFT 2000 1.G RG413 Service User Guide

6C-2 ENGINE FUEL
ON-VEHICLE SERVICE
COMPONENTS
1. Fuel tank 7. Fuel vapor line 13. Fuel filler hose clamp screw 19. Fuel pressure regulator
2. Fuel pump assembly 8. EVAP canister 14. Tank cover 20. Fuel pump
3. Breather hose 9. Delivery pipe 15. Fuel filler bracket screw 21. Fuel filter assembly
4. Fuel filler cap 10. Fuel/vapor separator 16. Fuel filler bracket nut 22. Fuel level gauge (Fuel sender gauge)
5. Fuel feed line 11. Fuel pump bolt (6 pcs.) 17. Gasket Do not reuse.
6. Wire harness for fuel pump 12. Fuel tank bolt (4 pcs.) 18. O-ring Tightening torque

ENGINE FUEL 6C-3
PRECAUTIONS
WARNING:
Before attempting service of any type on fuel system, the
followings should be always observed in order to reduce
the risk or fire and personal injury.
Disconnect negative cable at battery.
Do not smoke, and place no smoking signs near work
area.
Be sure to have CO
2 fire extinguisher handy.
Be sure to perform work in a well-ventilated area and
away from any open flames (such as gas hot heater).
Wear safety glasses.
To relieve fuel vapor pressure in fuel tank, remove fuel
filler cap from fuel filler neck and then reinstall it.
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 “FUEL PRESSURE
RELIEF PROCEDURE” in Section 6.
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
approved container when disconnection is completed.
Note that fuel hose connection varies with each type of
pipe. Be sure to connect and clamp each hose cor-
rectly referring to the figure.
[A] : With short pipe, fit hose as far as it reaches pipe joint as shown.
[B] : With the following type pipe, fit hose as far as its peripheral projection as shown.
[C] : With bent pipe, fit hose as far as its bent part as shown or till depth “b”.
[D] : With straight pipe, fit hose till depth “b”.
[E] : With red marked pipe, fit hose end reaches red mark on pipe.
1. Pipe
2. Hose
3. Clamp
4. Ped mark
“a” : Clamp securely at a position 3 to 7 mm (0.12 – 0.27 in.) from hose end.
“b” : 20 to 30 mm (0.79 – 1.18 in.)
“c” : 0 to 5 mm (0 – 0.19 in.)

ENGINE FUEL 6C-5
4) Mark the location of clamps (1) on fuel pipes (2), so that the
clamps can be reinstalled to where they were.
5) Remove pipes (2) with clamp (1) from vehicle.
6) Remove clamp (1) from pipes (2).
INSTALLATION
1) Install clamps to marked location on pipes. If clamp is
deformed or its claw is bent or broken, replace it with new
one.
2) Install pipes with pipe clamps to vehicle.
3) Connect fuel hoses and pipes to each pipe.
4) With engine OFF, turn ignition switch to ON position and
check for fuel leaks.
FUEL FILLER CAP
INSPECTION
Remove cap (1), and check gasket for even filler neck imprint,
and deterioration or any damage. If gasket (2) is in malcondition,
replace cap.
2
1
CAUTION:
When connecting joint, clean outside surfaces of pipe
where joint is to be inserted, push joint into pipe till joint
lock clicks and check to ensure that pipes are connected
securely, or fuel leak may occur.
NOTE:
If cap requires replacement, only a cap with the same fea-
tures should be used. Failure to use correct cap can
result in critical malfunction of system.

6C-6 ENGINE FUEL
FUEL TANK INLET VALVE
REMOVAL
1) Remove fuel filler cap.
2) Insert hose of a hand operated pump into fuel filler hose (1)
and drain fuel in space “A” in the figure.
3) Hoist vehicle and remove clamp (2) and fuel filler hose (1)
from fuel tank.
4) Remove fuel tank inlet valve (1) using flat-bladed screw-
driver.
INSPECTION
Check fuel tank inlet valve for the followings.
Damage
Smooth opening and closing
If any damage or malfunction is found, replace.WARNING:
Refer to the WARNING at the beginning of ON-VEHICLE
SERVICE in this section.
CAUTION:
Do not force pump hose into fuel tank, or pump hose
may damage fuel tank inlet valve (2).
1
2
CAUTION:
Be careful not to damage fuel tank inlet valve (1) with flat-
bladed screwdriver.

ENGINE FUEL 6C-7
INSTALLATION
1) Install fuel tank inlet valve (1) to fuel tank.
2) Install fuel filler hose (1) to fuel tank and secure it with clamp
(2).
For proper installation, refer to “COMPONENTS” under “ON-
VEHICLE SERVICE”.
3) Lower vehicle and install fuel filler cap.
FUEL TANK
REMOVAL
1) Relieve fuel pressure in fuel feed line according to “FUEL
PRESSURE RELIEF PROCEDURE” in Section 6.
2) Disconnect negative cable at battery.
3) Hoist vehicle.
4) Disconnect fuel filler hose (1) and breather hose (2) from
filler neck (3).
5) Due to absence of fuel tank drain plug, drain fuel tank by
pumping fuel out through fuel tank filler.
Use hand operated pump device to drain fuel tank.
1
2
WARNING:
Before starting the following procedure, be sure to
observe “PRECAUTIONS”.
CAUTION:
Never disconnect fuel filler hose (1) from fuel tank inlet. If
half or more of fuel is remaining to fuel tank, fuel over
flows in this case and come out.
CAUTION:
Do not force pump hose into fuel tank, or pump hose
may damage fuel tank inlet valve.
Never drain or store fuel in an open container due to
possibility of fire or explosion.
2
1
3

6E1-22 ENGINE AND EMISSION CONTROL SYSTEM
6) Start engine and warm it up to normal operating tempera-
ture.
7) Measure fuel pressure at idling.
If measured pressure does not satisfy specification, refer to
“Diagnostic Flow Table B-3” in “Engine Diagnosis” section
and check each possibly defective part. Replace if found
defective.
8) After checking fuel pressure, remove fuel pressure gauge.
9) Remove special tools from fuel delivery pipe.
10) Connect fuel feed hose to fuel delivery pipe and clamp it
securely.
11) With engine “OFF” and ignition switch “ON”, check for fuel
leaks.
FUEL PUMP WITH PRESSURE REGULATOR
ON-VEHICLE INSPECTION
1) Remove filler cap and turn ON ignition switch. Then fuel
pump operating sound should be heard from fuel filler for
about 2 seconds and stop. Be sure to reinstall fuel filler cap
after checking.
If above check result is not satisfactory, advance to “Diag-
nostic Flow Table B-2”. CAUTION:
As fuel feed line is still under high fuel pressure, make
sure to release fuel pressure according to following pro-
cedures.
Place fuel container under joint.
Cover joint with rag and loosen joint nut slowly to
release fuel pressure gradually.
CAUTION:
When fuel filler cap is removed in any procedure, work
must be done in a well-ventilated area, keep away from
any open flames and without smoking.
NOTE:
The fuel pressure regulator is the one body with the fuel
pump assembly so individual inspection of it is impossi-
ble.
1. Fuel filler
2. Ignition switch