FUEL TANK REMOVAL/INSTALLATION [SKYACTIV-D 2.2]

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Warning
•  Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
•  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.

2WD

1.  Park the vehicle on a level surface.

2.  Perform the “Fuel Line Safety Procedure” referring to the “BEFORE SERVICE PRECAUTION”. (See BEFORE SERVICE PRECAUTION [SKYACTIV-D 2.2].)

3.  Drain the fuel. (See FUEL DRAINING PROCEDURE [SKYACTIV-D 2.2].)

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 gauge sender unit (main) connector
•  Fuel hose (main side)
•  Fuel hose (return side)

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

8.  Remove the middle pipe. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

9.  Remove in the order shown in the figure.

10.  Install in the reverse order of removal.

11.  Perform the fuel leakage inspection referring to “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION [SKYACTIV-D 2.2].)

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1
Joint hose
(See Joint hose installation note (2WD).)
2
Fuel tank strap
3
Evaporative hose
(See Evaporative hose removal note (2WD).)
4
Breather hose
(See Breather hose installation note (2WD).)
5
Fuel gauge sender unit
(See FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION [2WD].)
6
Fuel tank
7
Fuel tank insulator
(See Fuel tank insulator removal note (2WD).)


Evaporative hose removal note (2WD)

1.  Disconnect the evaporative hose on the fuel-filler pipe side.

2.  Remove the following parts as a single unit:

•  Evaporative hose
•  Breather hose
•  Fuel gauge sender unit
•  Fuel tank

3.  Remove the evaporative hose from the fuel tank.


Fuel tank insulator removal note (2WD)

Note
•  The insulator is 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 {0.2 in} drill bit).

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Breather hose installation note (2WD)

1.  Align the marking and 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.  Park the vehicle on a level surface.

2.  Perform the “Fuel Line Safety Procedure” referring to the “BEFORE SERVICE PRECAUTION”. (See BEFORE SERVICE PRECAUTION [SKYACTIV-D 2.2].)

3.  Drain the fuel. (See FUEL DRAINING PROCEDURE [SKYACTIV-D 2.2].)

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 gauge sender unit (main) connector
•  Fuel hose (main side)
•  Fuel hose (return side)
Sub side
•  Fuel gauge sender unit (sub) connector

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

8.  Remove the middle pipe. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

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

10.  Remove in the order shown in the figure.

11.  Install in the reverse order of removal.

12.  Perform the fuel leakage inspection referring to “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION [SKYACTIV-D 2.2].)

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1
Joint hose
(See Joint hose installation note (4WD).)
2
Fuel tank strap
3
Evaporative hose
(See Evaporative hose removal note (4WD).)
4
Breather hose
(See Breather hose installation note (4WD).)
5
Fuel gauge sender unit (main)
(See FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION [4WD].)
6
Fuel gauge sender unit (sub)
(See FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION [4WD].)
7
Fuel tank
8
Fuel tank insulator
(See Fuel tank insulator removal note (4WD).)


Evaporative hose removal note (4WD)

1.  Disconnect the evaporative hose on the fuel-filler pipe side.

2.  Remove the following parts as a single unit:

•  Evaporative hose
•  Breather hose
•  Fuel gauge sender unit (main)
•  Fuel gauge sender unit (sub)
•  Fuel tank

3.  Remove the evaporative hose from the fuel tank.


Fuel tank insulator removal note (4WD)

Note
•  The insulator is 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 {0.2 in} drill bit).

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Breather hose installation note (4WD)

1.  Align the marking and 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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