FUEL TANK REMOVAL/INSTALLATION [SKYACTIV-G 2.5T]

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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 draining fuel, make sure to 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.

1.  Level the vehicle.

2.  Complete the “BEFORE SERVICE PRECAUTION”. (See BEFORE SERVICE PRECAUTION [SKYACTIV-G 2.5T].)

3.  Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.)

4.  Drain the fuel. (See FUEL DRAINING PROCEDURE [SKYACTIV-G 2.5T].)

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

6.  Remove the service hole cover.

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7.  Disconnect the following parts:

Main side
•  Fuel pump unit connector (See FUEL PUMP UNIT REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)
•  Quick release connector (See FUEL PUMP UNIT REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)
Sub side
•  Fuel gauge sender unit (sub) connector

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

9.  Disconnect the HO2S connector. (See HEATED OXYGEN SENSOR (HO2S) REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)

10.  Remove the HO2S clip from the body. (See HEATED OXYGEN SENSOR (HO2S) REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)

11.  Remove the TWC and HO2S as a single unit. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)

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

13.  Remove in the order indicated in the table.

14.  Install in the reverse order of removal.

15.  Complete the “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION [SKYACTIV-G 2.5T].)

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1
Joint hose
(See Joint Hose Installation Note.)
2
Fuel tank strap
3
Breather hose
(See Breather Hose Installation Note.)
4
Evaporative hose
(See Evaporative Hose Installation Note.)
5
Fuel pump unit
(See FUEL PUMP UNIT REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)
6
Fuel gauge sender unit (sub)
(See FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION [4WD].)
7
Fuel tank
(See Fuel Tank Removal Note.)
8
Fuel tank insulator
(See Fuel Tank Insulator Removal Note.)


Fuel Tank Insulator Removal Note

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

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

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

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Breather Hose Installation Note

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

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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