Part 3 – DIY Gas Tank Lift for Offroad Clearance on Vitara Tracker


In this article we finish the plumbing and relocate the fuel filler neck. I took a rather large diversion of adding a partial roll cage during my fuel tank relocation project but now I am back to working on the fuel tank itself.

In the DIY Gas Tank Lift part 2 post, we left off with the support built for the tank and most of the plumbing done. The internal roll cage is covered in my other posts: Part 1 and Part 2 of building an internal roll cage in case you missed it.

Some of these posts are pretty detailed, but I like to go overkill in case the information is helpful to somebody. I would rather you have to scroll through a couple of extra pics than waste a bunch of time trying to figure out how I did something.

DIY Gas Tank Lift Relocation- Vitara Tracker without Body Lift
First up, we start getting the plumbing laid out. Make sure you use the correct hoses. The line going to the fuel filter that has pressure on it needs to be ‘fuel injection rated’ which is available online or at your auto parts store.

I ordered two boxes of hose clamps from Amazon for this project, each one with various sizes of two different styles of hose clamps. The spring type clamps are for EVAP lines and the hose clamp style are better for lines that will have pressure.

DIY Gas Tank Lift Relocation- Vitara Tracker without Body Lift
There were two wires going to the EVAP system for the solenoid that I had to extend to reach its new location at the rear. I took some bulk speaker wire and extended the wires. I just cut the connector off but left ~6″ pig tails so I could connect it to the end of the extension. I always use heat shrink butt connectors to keep water out and Lady Liberty to seal the deal. ‘Merica!
DIY Gas Tank Lift Relocation- Vitara Tracker without Body Lift
There was also one hose connected to the EVAP system that I had to extend to the rear. Here you can see the hose and the two wires that I put in convoluted tubing.

I bought three different sizes of convoluted tubing from Amazon for general stock in the garage. It is so cheap and easy to get from Amazon, I don’t even look for stuff like this at the auto parts store unless it is an emergency.

DIY Gas Tank Lift Relocation- Vitara Tracker without Body Lift
Got it plumbed enough for a test drive! Ratchet strap for safety 😀

The fuel tank fits so tight within the roll bar it touches the front and both sides. I will work on securing it more once I build the enclosure.

DIY Gas Tank Lift Relocation- Vitara Tracker without Body Lift
Finally out in the sun for a minute!
DIY Gas Tank Lift Relocation- Vitara Tracker without Body Lift
Now to address the fuel filler neck. It obviously can’t go in the old fuel filler hole on the outside anymore.
DIY Gas Tank Lift Relocation- Vitara Tracker without Body Lift
Test fitting my cheapo Amazon fuel door (I’ll keep it a secret that I bought Jeep parts for my Suzuki)

How does that saying go? Made for a Jeep but strong enough for a Suzuki 😆

DIY Gas Tank Lift Relocation- Vitara Tracker without Body Lift
The first hole always hurts the most 😮
DIY Gas Tank Lift Relocation- Vitara Tracker without Body Lift
Measure twice and cut once people. I cut the hole but put the hinge on the wrong side. I wanted the hinge to be at the front to keep the fuel door from flying open but once I started assembling it I couldn’t due to the angle of the dangle on the inner fuel door frame. You can see here I had to mark and cut the backside also.
DIY Gas Tank Lift Relocation- Vitara Tracker without Body Lift
Of course 3 out of 4 bolts broke off when removing the old fuel filler neck so I got to drill those out.
DIY Gas Tank Lift Relocation- Vitara Tracker without Body Lift
You can see here, the top center and now covered bottom center bolts are fake. I just used the four initial holes I drilled. Not like this thing is load bearing and actually needs 6 bolts. Here I put on some adhesive weatherstrip to fill the gap and seal between the body and the fuel door.
DIY Gas Tank Lift Relocation- Vitara Tracker without Body Lift
More adjusting angles of dangles. I put a washer on the top to keep from kinking the tube, it just needed a little more angle. For more info on my Press Brake go here: DIY Home Made Press Brake
DIY Gas Tank Lift Relocation- Vitara Tracker without Body Lift
Here is a tip for getting off stuck on hoses. There is a tool called a ‘Hose Remover Hook’ that makes this easy. You just hook it under the hose and work it all the way around to break the seal.
DIY Gas Tank Lift Relocation- Vitara Tracker without Body Lift
Here is the inner part bolted together and ready to install.
DIY Gas Tank Lift Relocation- Vitara Tracker without Body Lift
In some fit of magic I happened to have an extra foam ring for a 6.5″ speaker laying around that fit this perfectly. It weirds me out when things just work.
DIY Gas Tank Lift Relocation- Vitara Tracker without Body Lift
Here is the fuel door installed. You can see where the foam fills the gap where the body line goes through.
DIY Gas Tank Lift Relocation- Vitara Tracker without Body Lift
Done! Used a little bit of black silicone to seal around the cut edge and stop it from rusting
DIY Gas Tank Lift Relocation- Vitara Tracker without Body Lift
Here is a view of the filler hose connection on the inside. I did eventually test this at the gas station and I can still fill it at full speed!
DIY Gas Tank Lift Relocation- Vitara Tracker without Body Lift
Boom! Looks like it was supposed to be there.

I will eventually fill the lower hole with something. This isn’t a Ferarri and I’m really not concerned about it.

But if somebody has a silver fuel door that would fit on hand send me a message or post in the comments below!

DIY Gas Tank Lift Relocation- Vitara Tracker without Body Lift
That finishes up the functional part of the install.

In part 4 we will build a sheetmetal enclosure around the tank on the inside that will have a storage shelf on top kind of like a roof rack.

Until then… YOU, get outside and work on something!

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