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Project Cappuccino: Upgrading the Fuel System

  • Dave Zipf

A few months ago we found that we were starting to lose power and boost at higher RPM in our 1992 Suzuki Cappucino.  We weren’t 100% sure what the issue was, but we were concerned that fuel flow was insufficient.  We decided to be proactive and refurbish our entire fuel system.  Not only will this ensure plenty of fuel flow, but it will also guarantee that our three decade old fuel system is safe and leak free.

Suzuki Cappuccino parcel shelf where the fuel tank access is located
The access panel for the fuel pump is under the center panel of the parcel shelf. Unfortunately, removing this piece of trim also requires removing the center console. Follow these steps and come back here when the console is clear. We also removed the harness bar which is secured by the factory shoulder belt bolts.
Cappuccino parcel shelf center piece removed
Once the console is out remove the two screws the center console was obscuring. Then carefully pop the snap fasteners that hold the trim panel down. I say carefully because this panel has been exposed to 25+ years of sun and weather. It’s going to be brittle and easy to break.
Cappuccino fuel tank access panel in the body
Under the trim panel is the access panel for the fuel pump. Remove this to expose the top of the fuel tank.
Fuel tank access panel removed, the access panels for the fuel pump and fuel level sender are exposed
You will notice two different access hatches. The smaller one is for the fuel level sender. This is a nice arrangement as we don’t have to wrestle with (and potentially break) the fuel level sender. The larger hatch is for the pump. Find and unplug the connector for the fuel pump (it will be somewhere under the parcel shelf). Next, remove the gas cap to vent the pressure inside the tank. Then you can remove the feed and return lines and unscrew the fuel pump hanger. Those screws have been in there for a long time so you will want to use the right technique to loosen those screws without damaging the heads. Round the heads and there is a good chance you’re going to have to remove the gas tank to get the pump out.
Cappuccino fuel pump & hanger on the workbench
With the hanger freed, we can work on removing the fuel pump. After inspecting the hanger, it appears that this is the first time the pump has been out of the car since Suzuki installed it in 1992. That’s pretty damn good! More importantly there is no rust staining on the pump body or any signs of rust flakes on the filter sock. Rusty fuel tanks are a common issue with Cappuccinos. Our pump looks remarkably clean.

Related

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Related Topics
  • Fuel Pump
  • AEM
  • Suzuki
  • Cappuccino
  • Suzuki Cappuccino
  • Project Cappuccino
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3 comments
  1. James says:
    July 16, 2025 at 10:58 am

    This is a cool project. Getting all the power back is a huge deal at such low numbers lol. I have really considered picking up an AZ-1. Didn’t you make a comparison article where you decided between the Cappucino, AZ-1, and the Beat?

    Reply
    1. Dave Zipf says:
      July 21, 2025 at 5:48 am

      Hey James,

      We have not done a full comparison of the ABC cars. I’ve test driven a couple of Beats and ridden in an AZ-1. In our Project intro for the Cappuccino I discussed my reasoning for picking a Cappuccino over a Beat or AZ-1. I think I would quickly summarize them thusly:

      AZ-1: Most expensive of the 3 due to its rarity (about double the price of a Cappuccino). Very cramped. No trunk or frunk. But man are they cool. It really is a mini DeLorean: awesome to look at and you’ll get a ton of questions but not the best day to day car. Also the cabin is a glass bubble so they get very hot in the summer.

      Beat: Usually the cheapest of the three. Super fun to drive, and they’re great with the top down. But slow as hell. Naturally aspirated 660cc engine just has no torque. Great engines once they’re wound up a bit. Great cruiser especially if you live somewhere you can have the roof down all the time. Great interior too. IIRC, the roomiest of the 3. The trunk is pretty small but the interior has lots of storage. Beware of leaky roofs. I’ve heard they’re not too hard or expensive to replace though.

      Cappuccino: Probably the best all rounder. Has a real trunk. Has a decent interior. 3-piece roof is great. Definitely the best for performance and the fastest of the 3 (that’s not saying much though). Lots of aftermarket support even today. I’ve had mine for 7 years now and still love it.

      For any of them there are a few things to keep in mind. Not sure where you’re from, but if you’re in the US, you will need to either be a good DIY mechanic, or line up a shop that is willing to work on your car. A lot of shops won’t work on them. The Cappuccino has an English service manual, not sure if the AZ-1 or Beat do. Make sure you inspect your car thoroughly. DIY maintenance on all of these cars is tough. Everything is small and cramped so you have to get creative working on them. All of these cars have a tendency to rust and sometimes it is not obvious. The cheapest route is the DIY import route but it’s the riskiest. Rust will be hard to spot in the port photos and you won’t be able to drive the car until it’s already yours. I’ve heard a number of horror stories from DIY importing. A car that’s already imported, either by a dealer or privately, saves a lot of time and hassle and you can actually drive and inspect the car you want to buy. Finally, remember that these are hard cars to live with. They’re impractical, hard to maintain, and old. But any of the ABC cars is a blast to drive and people ask about them all the time. I highly recommend getting an ABC kei car, just be prepared for what you’re getting into.

      Reply
  2. Khiem Dinh says:
    July 21, 2025 at 7:28 am

    That fuel pump was plenty for Project S2000 with the turbo added, so you’ll have all the headroom you need for more power 🙂 While the fuel system wasn’t the root cause of your issue, it was good to upgrade everything on a car that old!

    Reply

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