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I need fuel line diagram for Suzuki 2002 GSX-R 1000 motorcycle.

I removed the in tank fuel pump, installed in-line fuel pump. on the tank is one fuel outlet i connected to the pump then pump to the inlet for the fuel injectors there are two more connections on the tank. one is connected to the canister the other is a hose just hanging open is that how it should be?

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Marvin

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I don';t have that diagram but I did find a free service manual at thelink below.
http://www.kpematop.com/gsxr1000/Suzuki%20GSX-R1000%20K1%20K2%20Service%20Manual%202001%20-%202002.pdf

Posted on Jan 25, 2017

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Steps replacing a 1985 grand marquis fuel pump for first time alone thanks


See Figure 1
Two different electric fuel pump configurations were used on fuel injected models. One consists of a low pressure in-tank boost pump in conjunction with an external, frame-mounted high pressure pump. The low pressure pump is used to provide pressurized fuel to the inlet of the high pressure pump and helps prevent noise and heating problems. System pressure is controlled by a pressure regulator mounted on the engine.
The other configuration consists of an in-tank high pressure pump which does not utilize a boost pump.


0900c15280053dd7.jpg enlarge_icon.gifenlarge_tooltip.gif

Fig. Fig. 1: Disassembled electric fuel pump


REMOVAL & INSTALLATION

In-Tank Pump
See Figures 2, 3 and 4

  1. Disconnect the negative battery cable.
  2. Depressurize the system and drain as much gas from the tank by pumping out through the filler neck.
  3. Raise and support the rear end on jackstands.
  4. Disconnect the fuel supply, return and vent lines at the right and left side of the frame.
  5. Disconnect the wiring to the fuel pump.



0900c15280053dd8.jpg enlarge_icon.gifenlarge_tooltip.gif

Fig. Fig. 2: Low pressure in-tank electric fuel pump


0900c15280053dd9.jpg enlarge_icon.gifenlarge_tooltip.gif

Fig. Fig. 3: High pressure in-tank fuel pump


0900c15280053dda.jpg enlarge_icon.gifenlarge_tooltip.gif

Fig. Fig. 4: Removal of electric fuel pump

  1. Support the gas tank, loosen and remove the mounting straps. Remove the gas tank.
  2. Disconnect the lines and harness at the pump flange.
  3. Clean the outside of the mounting flange and retaining ring. Turn the fuel pump lock ring counterclockwise and remove.
  4. Remove the fuel pump.

To install:
  1. Clean the mounting surfaces. Put a light coat of grease on the mounting surfaces and on the new sealing ring. Install the new fuel pump.
  2. Installation is in the reverse order of removal. Start the vehicle and check electric fuel pump operation. Check for fuel leaks.

High Pressure External Pump
See Figure 5
  1. Disconnect the negative battery cable.
  2. Depressurize the fuel system.
  3. Raise and support the rear of the vehicle on jackstands.
  4. Disconnect the inlet and outlet fuel lines.
  5. Detach the electrical harness connection.
  6. Bend down the retaining tab and remove the pump from the mounting bracket ring.
  7. Install in reverse order. Make sure the pump is indexed correctly in the mounting bracket insulator. Start the vehicle and check electric fuel pump operation. Check for fuel leaks.



0900c15280053ddb.jpg enlarge_icon.gifenlarge_tooltip.gif

Fig. Fig. 5: High pressure external fuel pump

Feb 12, 2011 | 1985 Mercury Grand Marquis

2 Answers

Fuel pump replacement


Fuel Pump - Multi-Port Fuel Injection models REMOVAL & INSTALLATION 1984-95 Models Fig. 1: Loosen the hose clamps and tag the fuel hoses before disconnecting them . . . 91075p07.jpg
Fig. 2: . . . then detach the hoses from the fuel pump module/sending unit 91075p06.jpg
Fig. 3: Disengage the fuel pump module/sending unit wiring harness connector 91075p05.jpg
  1. Disconnect the negative battery cable.
  2. Remove the fuel tank filler cap.
  3. Relieve the fuel system pressure as outlined in this section.
  4. Drain the fuel from the fuel tank.
  5. Raise and support the rear end on jackstands.
  6. Remove the fuel inlet and outlet hoses from the sending unit. Be ready to catch any spilled fuel.
  7. Disengage the sending unit wires. Fig. 4: The fuel pump module/sending unit retaining ring must be rotated counterclockwise for removal 91075p01.jpg

  8. Using a brass punch and hammer, remove the sending unit retaining lockring by tapping it counterclockwise. Fig. 5: Carefully pull the fuel pump module/sending unit out of the fuel tank - step shown with the fuel tank mounted on the vehicle 91075p03.jpg
    Fig. 6: Remove and discard the fuel pump module O-ring gasket 91075p02.jpg

  9. Remove the sending unit, which incorporates the electric fuel pump, along with the O-ring seal from the fuel tank. Discard the O-ring.
  10. Remove and discard the pump inlet filter.
  11. Disengage the fuel pump terminal wires.
  12. Remove the pump outlet hose and clamp.
  13. Unfasten the pump top mounting bracket nut and remove the pump. To install:
  14. Install a new inlet filter on the pump. Fig. 7: This is the proper positioning of the fuel pump module assembly inside the fuel tank 86745g55.gif

  15. Assemble the pump and bracket. Connect the hose and wiring.
  16. Install the unit and new O-ring in the tank. The rubber stopper on the end of the fuel return tube must be inserted into the cup in the fuel tank reservoir.
  17. Install the lockring. Carefully tap it into place until it seats against the stop on the tank.
  18. Connect the hoses.
  19. Engage the wiring.
  20. Lower the vehicle, fill the tank, run the engine and check for leaks.
1996-98 Models Fig. 8: Fuel pump module location - 1996 model shown 86745g52.gif
  1. Drain and remove the fuel tank as outlined in this section.
  2. Using tool 6856 or its equivalent, remove the module locknut which is threaded onto the fuel tank. The module will spring up when the nut is removed.
  3. Remove the module. To install:
  4. Install a new gasket and place the module into the opening in the fuel tank.
  5. Position a new locknut on top of the module and tighten the nut using tool 6856 or its equivalent to 40 ft. lbs. (54 Nm).
  6. Install the fuel tank as outlined in this section. Fig. 9: Locknut removal using tool 6856 or its equivalent 86745g56.gif
    Fig. 10: Install a new gasket on the fuel tank opening 86745g57.gif
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Jan 19, 2011 | 1993 Jeep Grand Cherokee

1 Answer

I need to replace a thermostat in a 2000 Chevy 2500 6.0 liter pickup


4.8L, 5.3L and 6.0L Engines To Remove:
CAUTION
The thermostat is not serviceable separately. The thermostat housing (water pump inlet) and thermostat must be replaced as an assembly.
  1. Remove the radiator outlet hose. chevy_aval15_02-04_inlet.gif

  2. Remove the bolts from water pump inlet.
  3. Remove the water pump inlet from the water pump.
To Install:
  1. Install the water pump inlet to the water pump.
  2. Install the water pump inlet bolts.
    • Torque to: 11 ft-lbs. (15 Nm)
  3. Install the radiator outlet hose.
6.6L Engine To Remove:
  1. Before servicing the vehicle refer to the precautions at the beginning of this section.
  2. Drain the engine coolant.
  3. Remove or disconnect the following:
    • Water outlet 6.6L Thermostat housing removal gm_trk_sil25_02-04_66_therm_hous_rem.gif

    • Bolt for the fuel line bracket
    • Thermostat housing cover bolts
    • Thermostats and seals
To Install:
6.6L Thermostats and seals gm_trk_sil25_02-04_66_therm_seal.gif

  1. Install or connect the following:
    • Thermostats and seals to the thermostat housing NOTE: The rear thermostat (D) has 2 vent valves. Install with the vent valves towards the rear of engine.
    • Thermostat housing cover with a NEW gasket
    • Thermostat housing cover bolts and tighten the bolts
      1. Torque to: 15 ft. lbs. (21 Nm)
    • Fuel line bracket bolt and tighten the bolt
      1. Torque to: 15 ft. lbs. (21 Nm)
    • Water outlet
  2. Fill the engine with coolant.
  3. Test drive the vehicle to confirm the repairs.
8.1L Engine To Remove:
  1. Before servicing the vehicle refer to the precautions at the beginning of this section.
  2. Drain the cooling system.
  3. Remove or disconnect the following:
    • Inlet hose from the water outlet Water outlet and thermostat removal chevy_sub25_02-04_60_thermost_rem.gif

    • Water outlet bolts (B)
    • Water outlet (A)
    • Thermostat (C)
To Install:
  1. Install or connect the following:
    • Thermostat
    • Water outlet
    • Water outlet bolts and tighten the bolts.
      1. Torque to: 22 ft-lbs (30 Nm)
    • Inlet hose to the water outlet
  2. Fill the cooling system.
  3. Test drive the vehicle to confirm the repairs.
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Jan 12, 2011 | 2000 Chevrolet 2500

1 Answer

Access panel for fuel pump


There is none:

Fuel Tank & Fuel Pump Module Assembly Removal & Installation To Remove:
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2. Shift the vehicle into NEUTRAL and position it on a hoist.
  3. Release the fuel pressure.
  4. Disconnect the negative battery cable.
  5. Remove the fuel tank filler cap.
  6. Drain as much fuel from the tank as possible.
  7. Using suitable hose pinching pliers, clamp the fuel tank filler hose. Clamp the fuel tank filler hose in the location shown ford-05-00-396.gif

  8. Disconnect the three quick connect couplings from the fuel tank tubes at the tank.
  9. Disconnect the fuel pump electrical connector.
  10. Disconnect the fuel filter inlet tube from the filter.
  11. Position a suitable lifting device under the fuel tank.
  12. Remove the two fuel tank support strap bolts.
  13. Lower the fuel tank to access the fuel pump module while swinging the fuel tank support straps away from the tank.
  14. Clean the area around the fuel pump mounting flange.
  15. Disconnect the fuel pump module electrical connector and the fuel pump module fuel outlet tube.
  16. Using the special tool, turn the fuel pump module retaining ring counterclockwise and remove it. CAUTION
    The fuel pump module must be handled carefully to avoid damage to the float arm, filter and convolute hoses.
  17. Turn the fuel pump module counterclockwise and the fuel pump module will release from the locking tabs. Remove the fuel pump module from the fuel tank.
To Install:
  1. Install the fuel pump module in the fuel tank.
  2. Connect the fuel pump module electrical connector and the fuel pump module fuel outlet tube.
  3. Raise the tank into position and install the mounting strap bolts. Tighten the bolts to 26 ft-lbs (35 Nm).
  4. Connect the fuel lines and electrical connectors at the fuel tank.
  5. Lower the vehicle and refill the tank.
  6. Connect the negative battery cable.
  7. Turn the ignition key to the ON position to pressurize the fuel system.
  8. Visually inspect the fuel system for leaks.
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Oct 05, 2010 | 2000 Ford Taurus

2 Answers

Where is the fuel pump on a 1995 Nissan PU


see instructions from AutoZone:
The fuel pump assembly is located in the fuel tank. Refer to the fuel tank assembly illustrations in this section. On most applications, the fuel tank must be lowered to remove the fuel pump assembly. The fuel pump assembly is cooled by the fuel in the tank.

REMOVAL & INSTALLATION


See Figure 1
  1. Before disconnecting the fuel lines or any of the fuel system components, release the fuel system pressure as described previously in this section. Releasing system pressure is a very important step for the correct removal of the electric fuel pump.




0900c1528018d240.jpg enlarge_icon.gifenlarge_tooltip.gif Fig. Fig. 1: Internal view of the electric fuel pump
  1. Disconnect the negative battery cable. Unfasten the fuel pump assembly electrical connector and remove the fuel tank inspection cover.

If the truck has no fuel tank inspection cover, the fuel tank must be lowered or removed to gain access to the in-tank fuel pump.
  1. Disconnect the fuel outlet and return hoses. Remove the fuel tank assembly, if necessary.
  2. Remove the ring retaining bolts and the O-ring, then lift the fuel pump assembly from the fuel tank. Plug the opening with a clean rag to prevent dirt from entering the system.

When removing or installing the fuel pump assembly, be careful not to damage or deform it. Always install a new O-ring.
To install:
  1. Install the fuel pump assembly in the fuel tank with a new O-ring. Install the ring retaining bolts. Install the fuel tank if removed.
  2. Reconnect the fuel lines and fasten the electrical connection.
  3. Connect the battery cable, then start the engine and check for fuel leaks.

The "Check Engine Light'' may stay on after installation is completed. If so, the trouble code in the control unit's memory must be erased. To erase the code, disconnect the battery cable for 10 seconds, then reconnect it a verify that the light is extinguished.

TESTING


See Figures 2 and 3
  1. Relieve the fuel system pressure, as described previously in this section.
  2. Disconnect the fuel inlet hose at the electro injection unit.




0900c1528018d241.jpg enlarge_icon.gifenlarge_tooltip.gif Fig. Fig. 2: Make sure that the fuel line hose clamps are installed properly



0900c1528018d242.jpg enlarge_icon.gifenlarge_tooltip.gif Fig. Fig. 3: Testing fuel system pressure using a gauge and a "T'' fitting
  1. Install a fuel pressure gauge.
  2. Start the engine and check the fuel line for leakage.
  3. Read the pressure on the pressure gauge. The gauge should read approximately 36.3 psi (250 kPa).
  4. Relieve the fuel system pressure again.
  5. Remove the pressure gauge from the fuel line and reconnect the fuel inlet hose.

Aug 25, 2010 | 1995 Nissan Pickup

3 Answers

How do u get the fuel pump on


Removal & Installation To Remove:
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2. Shift the vehicle into NEUTRAL and position it on a hoist.
  3. Release the fuel pressure.
  4. Disconnect the negative battery cable.
  5. Remove the fuel tank filler cap.
  6. Drain as much fuel from the tank as possible.
  7. Using suitable hose pinching pliers, clamp the fuel tank filler hose. Clamp the fuel tank filler hose in the location shown ford-05-00-396.gif

  8. Disconnect the three quick connect couplings from the fuel tank tubes at the tank.
  9. Disconnect the fuel pump electrical connector.
  10. Disconnect the fuel filter inlet tube from the filter.
  11. Position a suitable lifting device under the fuel tank.
  12. Remove the two fuel tank support strap bolts.
  13. Lower the fuel tank to access the fuel pump module while swinging the fuel tank support straps away from the tank.
  14. Clean the area around the fuel pump mounting flange.
  15. Disconnect the fuel pump module electrical connector and the fuel pump module fuel outlet tube.
  16. Using the special tool, turn the fuel pump module retaining ring counterclockwise and remove it. CAUTION
    The fuel pump module must be handled carefully to avoid damage to the float arm, filter and convolute hoses.
  17. Turn the fuel pump module counterclockwise and the fuel pump module will release from the locking tabs. Remove the fuel pump module from the fuel tank.
To Install:
  1. Install the fuel pump module in the fuel tank.
  2. Connect the fuel pump module electrical connector and the fuel pump module fuel outlet tube.
  3. Raise the tank into position and install the mounting strap bolts. Tighten the bolts to 26 ft-lbs (35 Nm).
  4. Connect the fuel lines and electrical connectors at the fuel tank.
  5. Lower the vehicle and refill the tank.
  6. Connect the negative battery cable.
  7. Turn the ignition key to the ON position to pressurize the fuel system.
  8. Visually inspect the fuel system for leaks.
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Aug 19, 2010 | 2001 Ford Taurus

1 Answer

How to change a fuel pump on a 2005 Nissan


Nissan Car Altima & Sentra 1999-06 Repair Guide
Fuel Pump - Removal & Installation
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Relieve the pressure from the fuel system.
  3. Remove or disconnect the following:
    NOTE When the fuel sending unit needs to be removed, pull the tab upwards. The tab is located on the sending unit, opposite the end of the float. After the tab is pulled, the sending unit will lift straight out of the tank bracket.
    Negative battery cable Rear seat and the access cover Fuel pump electrical connector Fuel lines from the fuel pump assembly Locking ring Fuel gauge assembly Fuel tube and connector from the fuel gauge
    Fuel pump by pinching the 2 locking tabs together. Lift the fuel pump assembly straight upward and out of fuel tank. O-ring and discard
  4. Place a clean rag in the hole to keep out dirt.
To install:
  1. Remove the rag
  2. Install or connect the following:
    NOTE Verify that the mark on the fuel tank and the components are aligned when installing the pump and fuel gauge sending unit.
    New O-ring and fuel pump Electrical connection and fuel tube to the fuel gauge sending unit Fuel sending unit into the tank
  3. If equipped with a threaded lock ring torque the ring to 22-26 ft. lbs. (30-35 Nm). If equipped with a lock ring held by six retaining screws, torque the screws to 18-22 inch lbs. (2-2.5 Nm).
    Fuel lines and fuel pump electrical connector. Always install new clamps on the fuel lines. Negative battery cable
  4. Start the engine, check for leaks and repair if necessary.
    Fuel pump access cover Rear seat

The fuel pump is located in the fuel tank on all vehicles. In-tank fuel pumps are accessible by lifting up the rear seat to gain access to the inspection cover.
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Relieve the fuel system pressure.
  3. Remove or disconnect the following:
    Negative battery cable Rear seat from the vehicle Inspection cover that is located under the rear seat Inlet and outlet fuel lines from the fuel pump assembly Fuel pump and gauge wiring connections 6 mounting bolts that secure the fuel pump assembly to the top of the fuel tank
  4. Raise up the fuel pump assembly and detach the fuel tubes and connector.
    Fuel gauge assembly Fuel pump with the fuel chamber
  5. Pull up the front of the fuel pump chamber and slide the chamber forward.
    Fuel pump from the chamber O-ring seal or gasket
To install:
  1. Install or connect the following:
    Fuel pump to the fuel pump chamber and slide chamber rearward Fuel pump with the fuel pump chamber Fuel gauge assembly using a new O-ring Fuel tubes and connector. Use new hoses and clamps. 6 mounting bolts to the top of the fuel gauge unit and torque the bolts to 18-22 inch lbs. (2-2.5 Nm) Fuel pump and gauge wiring connections New inlet and outlet fuel lines to the fuel pump assembly Negative battery cable
  2. Start the vehicle, check for leaks and repair if necessary. Inspection cover and the rear seat

Hope helps (remember comment and rates this).

Jul 07, 2010 | 2005 Nissan Sentra

1 Answer

I need to change my fuel filter in my 98 Dodge Intrepid. I know I need to drop the gas tank, but I'll be honest I've never did this before. I would like to have pictures to see what it looks like.


300M, Concorde, Intrepid, LHS, 1998-2004 - Fuel Filter Removal & Installation The fuel filter mounts to the frame rail in front of the fuel tank. The inlet and outlet ends of the filter are marked for installation purposes. Install the fuel filter making certain that it is properly orientated.

NOTE The fuel filter is part of the fuel pressure regulator mounted on the fuel pump module.
  1. Before servicing the vehicle, refer to the Precautions section.
  2. Properly relieve the fuel system pressure.
  3. Lower the fuel tank.
  4. Remove or disconnect the following:
    Negative battery cable Purge and vent lines Fuel line from the pressure regulator Filter/regulator by pushing in the locking tab, turning the regulator to unlock it and pulling the it straight up
To install:


7c8fc38.jpg

Fig. Cut away view of the fuel filter/pressure regulator
  1. Push the fuel filter/regulator into the fuel pump module and turn to lock it into position.
  2. Connect the fuel lines and install the tank.
  3. Start the engine, check for leaks and repair if necessary.


Fuel Pump - Removal & Installation
The in-tank fuel pump module contains the fuel pump and pressure regulator which adjusts fuel system pressure. Fuel pump voltage is supplied through the fuel pump relay.

The fuel pump is serviced as part of the fuel pump module. The fuel pump module is installed in the top of the fuel tank and contains the electric fuel pump, fuel pump reservoir, inlet strainer fuel gauge sending unit, fuel supply and return line connections and the pressure regulator. The inlet strainer, fuel pressure regulator and level sensor are the only serviceable items. If the fuel pump requires service, replace the fuel pump module.
  1. Before servicing the vehicle, refer to the Precautions section.
  2. Properly relieve the fuel system pressure.
  3. Remove or disconnect the following:
    Negative battery cable Fuel tank
  4. Clean the top of the tank to remove any loose dirt.
    Fuel lines from the fuel pump module by squeezing the quick-connect fitting with thumb and forefinger

    4edc7fc.jpg


    Fig. Using special tool 6856, remove the fuel pump module locknut
    Fuel pump module electrical connector from the top of the fuel pump module
  5. Using special tool 6856, remove the fuel pump locknut by turning it counterclockwise.
    CAUTION The fuel reservoir of the fuel pump module does not empty out when the tank is drained. The fuel in the reservoir may spill out when the module is removed.
  6. Remove the fuel pump and O-ring from the tank and discard the O-ring.
To install:
  1. Thoroughly clean all parts. Wipe the seal area of the tank clean. Place a new O-ring on the ledge between the tank threads and the pump module opening.
  2. Position the fuel pump module in the tank. Be sure the alignment tab on the underside of the pump module flange sits in the corresponding notch in the fuel tank.
  3. While holding the fuel pump module in place install the locking ring and torque to 40 inch lbs. (5 Nm) using special tool 6856 or a spanner-type tool.
  4. Install or connect the following:
    Fuel tank Fuel pump module electrical connector Negative battery cable
  5. Fill the fuel tank with fuel. Install the fuel filler cap. Turn the ignition switch to the ON position to pressurize the system. Check the fuel system for leaks.
Hope this helped.

May 11, 2010 | 1998 Dodge Intrepid

2 Answers

How do I replace the fuel pump on a 1997 Isuzu Rodeo


The 1997 Isuzu pump is electronic and in the tank.
This method will not get it.

Anyone else done it?

My guess. Disconnect the battery,
disconnect the leads to the pump mounted on top of the fuel tank,
Disconnect the outlet and return lines from the pump,
Remove all mounting nuts on the top plate and lift the pump out of the tank.
Replace gasket and reverse the order to replace.

Apr 06, 2010 | 1997 Isuzu Rodeo

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