FUEL TANK REMOVAL/INSTALLATION [WITH CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5)]

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Warning

• Highly pressurized fuel may spray out if the fuel line is cut. Due to the following dangers occurring with a fuel spray, always complete the “Fuel Line Safety Procedure” to prevent the fuel from spraying.

― Fuel may cause irritation if it comes in contact with skin and eyes.

― If fuel ignites and causes a fire, it may lead to serious injury or death, and damage to property and facilities.

• A person charged with static electricity could cause a fire or explosion, resulting in death or serious injury. Before performing work on the fuel system, discharge static electricity by touching the vehicle body.

Caution

• Disconnecting/connecting the quick release connector without cleaning it may cause damage to the fuel pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting using a cloth or soft brush, and make sure that it is free of foreign material.

2WD

1. Level the vehicle.

2. Complete the “BEFORE SERVICE PRECAUTION”. (See BEFORE SERVICE PRECAUTION [WITH CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5)].)

3. Drain the fuel. (See FUEL DRAINING PROCEDURE [WITH CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5)].)

4. Remove the rear seat cushion. (See REAR SEAT CUSHION REMOVAL/INSTALLATION.)

5. Remove the service hole cover.

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6. Disconnect the following parts:

• Fuel pump unit connector

• Quick release connector (See QUICK RELEASE CONNECTOR (FUEL SYSTEM) REMOVAL/INSTALLATION [WITH CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5)].)

7. Remove the floor under cover. (See FLOOR UNDER COVER REMOVAL/INSTALLATION.)

8. Disconnect the HO2S connector.

9. Remove the TWC and HO2S as a single unit. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [WITH CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5)].)

10. Remove in the order indicated in the table.

11. Install in the reverse order of removal.

12. Complete the “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION [WITH CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5)].)

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1

Joint hose

(See Joint hose installation note (2WD).)

2

Fuel tank strap

3

Breather hose

(See Breather hose installation note (2WD).)

4

Evaporative hose

(See Evaporative hose installation note (2WD).)

5

Fuel pump unit

(See FUEL PUMP UNIT REMOVAL/INSTALLATION [WITH CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5)].)

6

Fuel tank

(See Fuel tank removal note (2WD).)

7

Fuel tank insulator

(See Fuel tank insulator removal note (2WD).)

Fuel tank insulator removal note (2WD)

Note

• The fuel tank insulator are installed using rivets.

1. Push out the mandrel using a hammer and punch (2—2.8 mm {0.08—0.11 in} diameter).

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2. Remove the flange using a drill (5 mm {0.20 in} drill bit).

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Fuel tank removal note (2WD)

1. Disconnect the breather hose from the fuel-filler pipe.

2. Disconnect the evaporative hose from the check valve.

3. Remove the following parts as single unit.

• Breather hose

• Evaporative hose

• Fuel pump unit

• Fuel tank

4. Remove the fuel tank.

Evaporative hose installation note (2WD)

1. Install the evaporative hose as shown in the figure.

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Breather hose installation note (2WD)

1. Install the breather hose as shown in the figure.

Fuel tank side

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Fuel-filler pipe side

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Joint hose installation note (2WD)

1. Install the joint hose as shown in the figure.

Fuel tank side

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Fuel-filler pipe side

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4WD

1. Level the vehicle.

2. Complete the “BEFORE SERVICE PRECAUTION”. (See BEFORE SERVICE PRECAUTION [WITH CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5)].)

3. Drain the fuel. (See FUEL DRAINING PROCEDURE [WITH CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5)].)

4. Remove the rear seat cushion. (See REAR SEAT CUSHION REMOVAL/INSTALLATION.)

5. Remove the service hole cover.

Main side

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Sub side

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6. Disconnect the following parts:

Main side

• Fuel pump unit connector

• Quick release connector (See QUICK RELEASE CONNECTOR (FUEL SYSTEM) REMOVAL/INSTALLATION [WITH CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5)].)

Sub side

• Fuel gauge sender unit (sub) connector

7. Remove the floor under cover. (See FLOOR UNDER COVER REMOVAL/INSTALLATION.)

8. Disconnect the HO2S connector.

9. Remove the TWC and HO2S as a single unit. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [WITH CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5)].)

10. Remove the propeller shaft. (See PROPELLER SHAFT REMOVAL/INSTALLATION.)

11. Remove in the order indicated in the table.

12. Install in the reverse order of removal.

13. Complete the “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION [WITH CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5)].)

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1

Joint hose

(See Joint hose installation note (4WD).)

2

Fuel tank strap

3

Breather hose

(See Breather hose installation note (4WD).)

4

Evaporative hose

(See Evaporative hose installation note (4WD).)

5

Fuel pump unit

(See FUEL PUMP UNIT REMOVAL/INSTALLATION [WITH CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5)].)

6

Fuel gauge sender unit (sub)

(See FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION [4WD].)

7

Fuel tank

(See Fuel tank removal note (4WD).)

8

Fuel tank insulator

(See Fuel tank insulator removal note (4WD).)

Fuel tank insulator removal note (4WD)

Note

• The fuel tank insulator are installed using rivets.

1. Push out the mandrel using a hammer and punch (2—2.8 mm {0.08—0.11 in} diameter).

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2. Remove the flange using a drill (5 mm {0.20 in} drill bit).

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Fuel tank removal note (4WD)

1. Disconnect the breather hose from the fuel-filler pipe.

2. Disconnect the evaporative hose from the check valve.

3. Remove the following parts as single unit.

• Breather hose

• Evaporative hose

• Fuel pump unit

• Fuel tank

4. Remove the fuel tank.

Evaporative hose installation note (4WD)

1. Install the evaporative hose as shown in the figure.

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Breather hose installation note (4WD)

1. Install the breather hose as shown in the figure.

Fuel tank side

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Fuel-filler pipe side

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Joint hose installation note (4WD)

1. Install the joint hose as shown in the figure.

Fuel tank side

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Fuel-filler pipe side

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1	Joint hose (See Joint hose installation note (2WD).)
2	Fuel tank strap
3	Breather hose (See Breather hose installation note (2WD).)
4	Evaporative hose (See Evaporative hose installation note (2WD).)
5	Fuel pump unit (See FUEL PUMP UNIT REMOVAL/INSTALLATION [WITH CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5)].)
6	Fuel tank (See Fuel tank removal note (2WD).)
7	Fuel tank insulator (See Fuel tank insulator removal note (2WD).)