SB-10054501-6779

XL7

Technical Bulletin
Division: Automotive
Category: Technical
SUBJECT:
MODEL(S):
YEAR:
VIN RANGE:

Section Title: Engine
TSB No. TS 27 07313

SPECIAL COVERAGE EXTENSION - CAMPAIGN “ZC”; FUEL ODOR OR
SPOTTING ON THE GROUND.
XL7 (JC636)
2007 ~ 2009
2S3DB217676101940 – 2S3DA717876113877

CONDITION:

The customer may notice a fuel odor while the vehicle is being driven or after it
is parked. In more extreme cases, fuel may be observed dripping onto the
ground in the area of the fuel tank at the rear of the vehicle. Vehicle
performance may be affected.

CAUSE:

Some vehicles have a condition in which the plastic supply or return port on the
Fuel Pump Module may crack, and could cause a fuel leak.

CORRECTION: Suzuki dealers are required to confirm vehicle eligibility for Special Coverage
Extension through the Vehicle Master Inquiry on Suzuki Connect, prior to
inspection, or any required repairs. This special Coverage Extension is
limited by VIN application with unlimited time and mileage.
WARNING
Handling a fuel tank with too much fuel can be hazardous and is not advised.
Advise each customer when scheduling this campaign to be sure the vehicle arrives at
the dealer with ¼ or less of fuel in the fuel tank.
NOTE:
Vehicles not listed in the above affected VIN range may also exhibit this condition. If you have a
vehicle exhibiting the condition described in this Technical Service Bulletin, and the vehicle is not
listed within the affected VIN range, please see the Safety Recall Campaign bulletin, TS 26
03073 and SC-64 for potential coverage.
Technical Service Department
Dealership Circulation – Initial and file:
Service Manager

Parts Manager

Service Advisor

Technicians

Suzuki bulletins are intended for use by professional technicians, NOT a “do-it-yourselfer.” They are written to inform these technicians of
conditions that may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained
technicians have the equipment, tools, safety instructions, and know-how to do a job properly and safely. If a condition is described, DO NOT
assume that the bulletin applies to your vehicle, or that your vehicle will have that condition. See your authorized Suzuki dealer for information on
whether your vehicle may benefit from the information. Suzuki reserves the right to change technical specifications at any time without prior notice.
Page 1 of 20

Model: XL7

Section: Engine

TS 27 07313

PART(S) INFORMATION
Description

Year

Part
Number

Qty.

Fuel Pump Kit

2007

15100-78J31

1

Fuel Pump Kit

2008 ~ 2009

15100-78J50

1

Notes
To remove the primary fuel tank
module, the secondary module must
also be removed. This kit includes a
second fuel tank module seal for the
secondary module.

WARRANTY INFORMATION
Campaign
Code

Operation
Code

Complaint
Code

Defect Code

Labor Time

Please refer to the Service Campaign Bulletin SC-66 for claim submission instructions and
labor times.

NOTICE
Fuel system components become very dirty over time. Allowing dirt to enter the system
while servicing the fuel system can cause damage.
Clean all fuel pipe/hose connections, caps and their surrounding areas before
disassembling to avoid possible contamination of the fuel system.

NOTE:
NEW fuel tank module seals are necessary
each time the fuel tank module is serviced.
Obtain NEW seals for both the primary and
secondary modules any time they are removed.

Page 2 of 20

Model: XL7

Section: Engine

Page 3 of 20

TS 27 07313

Model: XL7

Section: Engine

TS 27 07313

INSPECTION
NOTE:
During the inspection process, battery discharge may
occur. It is recommended to connect a secondary
power supply to the battery.
1. Connect the Tech2 along with the CANdi Module, to
the vehicle Data Link Connector (DLC) and turn the
power on. Select ENTER to proceed to the Main
Menu screen.
2. Select function F0: Diagnostics, to proceed to the
Vehicle Identification screens.
3. Select model year for the vehicle being worked on.
4. Select “LD Trk, MPV, Incomplete” to proceed to the
Diagnostics screen.
5. Select function F0: Powertrain, to proceed to the
Vehicle Identification screens.
6. Select the engine type “3.6L V6 LY7”.
7. Select the “With” or “Without” AWD option to proceed to the Powertrain Screen.
8. Select function F0: Engine Control Module, to proceed to the Engine Control Module Screen.
9. Select function F2: Special Functions, to proceed to the Special Functions screens.
10. Select function F0: Output Control, to proceed to the Output Control screen.
11. Select function F4: Fuel Pump, to proceed to the Fuel Pump screen.
12. Select function F0: Fuel Pump Relay, and ensure
that all fuel lines are connected. Select ENTER to
proceed to the Fuel Pump Relay screen.
13. Highlight “Fuel Pump Relay Command OFF” then
select ON to actuate the fuel pump. Repeat this
step no more than 5 times. Stop if a leak is noted.
a. The fuel pump will run for 3 seconds.
b. Inspect the bottom and each side of the fuel tank
for any fuel stain or run-off from the top of the
tank. Inspect the general area of the fuel tank for
fuel spray or the presence of fuel odor.
c. If a fuel leak is noted, diagnose the cause.
Continue to Removal Procedure, page 5, step #1
to complete this campaign if it applies. If the cause
does not apply, or no leak is found then this
Special Coverage Extension does not apply.

Inspect tank surfaces and
general area around the tank.

Page 4 of 20

Model: XL7

Section: Engine

TS 27 07313

REMOVAL PROCEDURE
1. Remove the engine cover.
2. Ensure that the fuel level in the fuel tank is
less than 1/4 full. If necessary, drain the fuel
level to no more than ¼ full.
3. Relieve the fuel system pressure at the fuel
rail service port with the following procedure.
a. Loosen the fuel fill cap in order to relieve
the fuel tank vapor pressure.
b. Remove the fuel rail service port cap.
c. Wrap a shop towel around the fuel rail
service port and using a small flat bladed
tool, depress (open) the fuel rail test port
valve, catching the fluid in the towel.
d. Remove the shop towel from around the
fuel rail service port, and place in an
approved gasoline container.
e. Install the fuel rail service port cap.
f. Tighten the fuel fill cap.

Service Port

WARNING
Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition
source is present.
Do not allow smoking, the use of open flames or any ignition source in the area where
work on the fuel or EVAP system is taking place. Anytime work is being done on the
fuel system, disconnect the negative battery cable, except for those tests where battery
voltage is required and have a dry chemical (Class B) fire extinguisher nearby.
WARNING
Fuel supply lines will remain pressurized for long periods of time after the engine is
shut down. Fuel could spray out under pressure when you loosen or remove fuel lines.
Opening a fuel system while it is under pressure may allow fuel to come in contact with
an ignition source or with you causing personal injury.
Remove the fuel tank cap and relieve the fuel system pressure before servicing the
fuel system.
NOTE:
Fuel will remain in the system after pressure is relieved. Whenever fuel line fittings are loosened
or removed, wrap a shop cloth around the fitting and have an approved container available to
collect any fuel. Container opening must be a minimum of 300 mm (12 in) diameter to adequately
catch the fluid. Never store fuel in an open container, due to the possibility of fire or explosion.
Have a dry chemical (Class B) fire extinguisher nearby. Dispose of or store fuel soaked rags in
accordance with local regulations.

Page 5 of 20

Model: XL7

Section: Engine

4. Record the radio presets and disconnect the
negative battery cable.
5. Remove the muffler assembly.
a. Loosen the 2 exhaust pipe muffler clamps.
b. Disconnect the 5 rubber isolators from the
exhaust pipe hangers.
c. Slide the muffler assembly from the
exhaust pipes, removing it from the
vehicle.

TS 27 07313

2 Clamps

5 Rubber Isolators

AWD Vehicles Proceed with step #6.
FWD vehicles continue to step #7.
6. Remove the propeller shaft.
a. Place the transmission in neutral (N).
b. Mark the relationship of the propeller shaft
to the rear differential drive flange and the
transfer case flange.
c. Support the propeller shaft at the rear
differential.
d. Remove the 4 mounting bolts for the
propeller shaft at the rear differential drive
flange.
e. Support propeller shaft at the transfer
case.
f. Remove the 6 mounting bolts for the
propeller shaft at the transfer case flange.
g. Support the propeller shaft at the center
support bearing.
h. Remove the 2 mounting bolts for the
center support bearing.
i. Remove the propeller shaft from the
vehicle.

4 Bolts

Alignment Marks

2 Bolts

6 Bolts
Page 6 of 20

Alignment Marks

Model: XL7

Section: Engine

TS 27 07313

Disconnect

7. Disconnect the evaporative emission (EVAP)
canister lines:
a. Fresh air hose.
b. Vent hose.
c. Chassis fuel feed line.
d. Electrical connector.

8. Disconnect connections at the fuel tank:
a. Fuel fill tube.
b. EVAP vent hose.
c. Fresh air hose.
.
Disconnect

d. Fuel tank electrical connector.
NOTE:
If present, remove the electrical connector
retainer from the rear frame to allow
disconnection of the electrical connector.
Disconnect

Page 7 of 20

Model: XL7

Section: Engine

TS 27 07313
Remove 4

9. Support the fuel tank and remove the 4 fuel
tank strap bolts (2 each strap), and the 2 fuel
tank straps.

NOTICE
The fuel tank straps can be easily bent.
Be careful not to damage the straps so
that proper installation of the fuel tank
can be completed.

10. With the help of an assistant if needed, lower
the fuel tank and heat shield from the
underbody of the vehicle. Relocate it to an
area that will allow proper ventilation and
cleanliness for the primary and secondary fuel
tank module removal and replacement.

Page 8 of 20

Model: XL7

Section: Engine

TS 27 07313

Vent Line

11. Remove the secondary fuel pump module.
a. Disconnect the EVAP vent line at the quick
connect.
b. Using service tool J 39765-A
(Secondary Fuel Sender Lock Ring
Tool) or equivalent, remove the
secondary fuel pump module lock ring.
NOTE:
Certain Driving Conditions will allow debris
and dirt to accumulate on the Top of the Fuel
Tank. Clean the area around the Primary and
Secondary Fuel Pump Modules prior to
removal)