FUEL TANK REMOVAL/INSTALLATION [SKYACTIV-G 2.0, SKYACTIV-G 2.5]

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Warning

• Fuel is very flammable liquid. If fuel spills or leaks from the pressurized fuel system, it will cause serious injury or death and facility breakage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line Safety Procedure”, while referring to the “BEFORE SERVICE PRECAUTION”.

• 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.

2WD

1. Level the vehicle.

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

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

4. Using the following procedure:

6:4 split type

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

4:2:4 split type

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 pump unit connector

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

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

9. Disconnect the HO2S connector.

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

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 [SKYACTIV-G 2.0, SKYACTIV-G 2.5].)

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1

Joint hose

(See Joint hose installation note.)

2

Fuel tank strap

3

Fuel tank insulator

(See Fuel tank insulator removal note.)

4

Fuel tank

(See Fuel tank removal note.)

5

Evaporative hose

(See Evaporative hose installation note.)

6

Breather hose

(See Breather hose installation note.)

7

Fuel pump unit

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

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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4WD

1. Level the vehicle.

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

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

4. Using the following procedure:

6:4 split type

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

4:2:4 split type

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 pump unit connector

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

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.

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

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

12. Remove in the order indicated in the table.

13. Install in the reverse order of removal.

14. Complete the “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION [SKYACTIV-G 2.0, SKYACTIV-G 2.5].)

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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 gauge sender unit (sub)

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