FUEL TANK REMOVAL/INSTALLATION [SKYACTIV-G 2.5]

id0114za801600

Replacement Part

Rivet
 
Quantity: 4
 
Location of use: Fuel tank insulator

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 [SKYACTIV-G 2.5].)

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

4.  Remove the second-row seat. (See SECOND-ROW SEAT REMOVAL/INSTALLATION.)

5.  Cut the floor covering along the dotted lines shown in the figure and partially peel it back.

Note
•  Cut the floor covering to use the service hole.
ac8wzw00003783

6.  Remove the service hole cover.

ac8wzw00003784

7.  Disconnect the following parts:

•  Fuel pump unit connector
•  Quick release connector (See QUICK RELEASE CONNECTOR (FUEL SYSTEM) REMOVAL/INSTALLATION [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 2.5].)

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 2.5].)

ac8wzw00003785

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 2.5].)
6
Fuel tank
(See Fuel tank removal note.)
7
Fuel tank insulator
(See Fuel tank insulator removal note.)


4WD

1.  Level the vehicle.

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

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

4.  Remove the second-row seat. (See SECOND-ROW SEAT REMOVAL/INSTALLATION.)

5.  Cut the floor covering along the dotted lines shown in the figure and partially peel it back.

Note
•  Cut the floor covering to use the service hole.

main side

ac8wzw00003783

sub side

ac8wzw00003786

6.  Remove the service hole cover.

Main side

ac8wzw00003784

Sub side

ac8wzw00003787

7.  Disconnect the following parts:

Main side
•  Fuel pump unit connector
•  Quick release connector (See QUICK RELEASE CONNECTOR (FUEL SYSTEM) REMOVAL/INSTALLATION [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 2.5].)

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 2.5].)

ac8wzw00003788

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 2.5].)
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).

ac5wzw00002710

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

ar8uuw00001479


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.

ac8wzw00003789


Breather hose installation note

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

Fuel tank side

ac8wzw00003790

Fuel-filler pipe side

ac8wzw00003791


Joint hose installation note

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

Fuel tank side

ac5uuw00000398

Fuel-filler pipe side

ac5wzw00013082