FUEL TANK REMOVAL/INSTALLATION [SKYACTIV-D 2.2]

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Warning

• Fuel is highly flammable and dangerous. Fuel line spills and leakage can cause serious injury or death, and damage to equipment. If fuel comes into contact with the skin and eyes it will cause irritation. To prevent this, always perform the “Fuel Line Safety Procedure” referring to the “BEFORE REPAIR PROCEDURE”.

• 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 a vehicle.

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. Perform the following procedure:

6:4 split seat

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

4:2:4 split seat

1. Set the rear seat aside as shown in the figure. (See REAR SEAT REMOVAL/INSTALLATION.)

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5. Partially peel back the floor mat as shown in the figure.

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6. Remove the service hole cover.

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7. Disconnect the following parts:

• Fuel gauge sender unit (main) connector

• Fuel hose (main side)

• Fuel hose (return side)

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

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

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.)

2

Fuel tank strap

3

Evaporative hose

(See Evaporative Hose Removal Note.)

4

Breather hose

(See Breather Hose Installation Note.)

5

Fuel gauge sender unit

(See FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION [2WD].)

6

Fuel tank

Evaporative Hose Removal Note

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.

Breather Hose Installation Note

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

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. Perform the following procedure:

6:4 split seat

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

4:2:4 split seat

1. Set the rear seat aside as shown in the figure. (See REAR SEAT REMOVAL/INSTALLATION.)

Main side

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Sub side

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5. Partially peel back the floor mat as shown in the figure.

Main side

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Sub side

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6. Remove the service hole cover.

Main side

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Sub side

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7. 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

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

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

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

11. Remove in the order shown in the figure.

12. Install in the reverse order of removal.

13. 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.)

2

Fuel tank strap

3

Evaporative hose

(See Evaporative Hose Removal Note.)

4

Breather hose

(See Breather Hose Installation Note.)

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

Evaporative Hose Removal Note

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.

Breather Hose Installation Note

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

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.)
2	Fuel tank strap
3	Evaporative hose (See Evaporative Hose Removal Note.)
4	Breather hose (See Breather Hose Installation Note.)
5	Fuel gauge sender unit (See FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION [2WD].)
6	Fuel tank