FUEL TANK REMOVAL/INSTALLATION [SKYACTIV-G 1.5, SKYACTIV-G 2.0]
id0114zg801600
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Warning
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• 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.
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― 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.
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Caution
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• 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 1.5, SKYACTIV-G 2.0].)
3. Drain the fuel. (See FUEL DRAINING PROCEDURE [SKYACTIV-G 1.5, SKYACTIV-G 2.0].)
4. Remove the following parts:
- (1) Trunk end trim (See TRUNK END TRIM REMOVAL/INSTALLATION)
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- (2) Trunk covering (See TRUNK COVERING REMOVAL/INSTALLATION)
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- (3) Partition board (See PARTITION BOARD REMOVAL/INSTALLATION)
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- (4) Trunk side trim (LH) (See TRUNK SIDE TRIM REMOVAL/INSTALLATION)
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- (5) Trunk side trim (RH) (See TRUNK SIDE TRIM REMOVAL/INSTALLATION)
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5. Remove the breather hose, joint hose.
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1
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Breather hose
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2
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Joint hose
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6. Using the retractable hardtop switch, keep the retractable hardtop half-open. (with retractable hardtop)
7. Disconnect the negative battery cable. (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION.)
8. Remove the following parts:
- (1) Seat (LH) (See SEAT REMOVAL/INSTALLATION.)
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- (2) Selector lever knob (AT) (See AUTOMATIC TRANSMISSION SHIFT MECHANISM REMOVAL/INSTALLATION.)
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- (3) Shift lever knob (MT) (See TRANSMISSION REMOVAL/INSTALLATION [M66M-D].)
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- (4) Shift panel compartment (See SHIFT PANEL REMOVAL/INSTALLATION.)
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- (5) Upper panel (See UPPER PANEL REMOVAL/INSTALLATION.)
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- (6) Parking brake lever boot panel (See PARKING BRAKE LEVER BOOT PANEL REMOVAL/INSTALLATION.)
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- (7) Rear console (See REAR CONSOLE REMOVAL/INSTALLATION.)
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- (8) Scuff plate (See SCUFF PLATE REMOVAL/INSTALLATION.)
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- (9) Tire house trim (See TIRE HOUSE TRIM REMOVAL/INSTALLATION.)
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- (10) Seat back bar garnish (See SEAT BACK BAR GARNISH REMOVAL/INSTALLATION.)
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- (11) Quarter trim (See QUARTER TRIM REMOVAL/INSTALLATION.)
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- (12) Wind blocker (See WIND BLOCKER REMOVAL/INSTALLATION.)
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- (13) Roof hook lever (See ROOF HOOK REMOVAL/INSTALLATION.)
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- (14) Back trim (See BACK TRIM REMOVAL/INSTALLATION.)
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- (15) Retractable hardtop control module (with retractable hardtop) (See RETRACTABLE HARDTOP CONTROL MODULE REMOVAL/INSTALLATION)
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- (16) CD player, CD player bracket (with CD player) (See CD PLAYER REMOVAL/INSTALLATION.)
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- (17) DVD/CD player, DVD/CD player bracket (with DVD/CD player) (See DVD/CD PLAYER REMOVAL/INSTALLATION.)
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- (18) Side shelf (LH) (See SIDE SHELF REMOVAL/INSTALLATION.)
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- (19) Rear package trim (See REAR PACKAGE TRIM REMOVAL/INSTALLATION.)
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9. Remove the service hole cover.
10. Disconnect the following parts:
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• Fuel pump unit connector
11. Remove the following parts:
- (1) Protector (See FUEL-FILLER PIPE REMOVAL/INSTALLATION [SKYACTIV-G 1.5, SKYACTIV-G 2.0].)
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- (2) TWC (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 1.5, SKYACTIV-G 2.0].)
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- (3) Propeller shaft (See PROPELLER SHAFT REMOVAL/INSTALLATION.)
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- (4) Power plant frame (See POWER PLANT FRAME REMOVAL/INSTALLATION [SJ6A-EL].) (See POWER PLANT FRAME REMOVAL [M66M-D].) (See POWER PLANT FRAME INSTALLATION [M66M-D].)
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- (5) Floor under cover (See FLOOR UNDER COVER REMOVAL/INSTALLATION.)
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- (6) Rear crossmember component (See REAR CROSSMEMBER REMOVAL/INSTALLATION.)
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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 1.5, SKYACTIV-G 2.0].)
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1
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Evaporative hose No.3
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2
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Evaporative hose No.1
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3
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Evaporative hose No.2 (check valve side)
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4
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Bracket
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5
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Charcoal canister component
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6
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Fuel tank
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7
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Evaporative hose No.2 (fuel tank side)
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8
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Insulator
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9
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Fuel pump unit
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Fuel Tank Removal Note
1. Remove the following parts as single unit:
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• Evaporative hose No.3
• Fuel pump unit
• Insulator
• Fuel tank
2. Remove the fuel tank.
Insulator Removal Note
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Note
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• 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).
2. Remove the flange using a drill (5 mm {0.2 in} drill bit).
Evaporative Hose No.2 (Fuel Tank Side) Installation Note
1. Install the evaporative hose No.2 (fuel tank side) as shown in the figure.
Fuel Tank Installation Note
1. Install the following parts as a single unit:
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• Fuel tank
• Insulator
• Fuel pump unit
• Evaporative hose No.2
2. Temporarily tighten the bolt as shown in the figure.
3. Tighten the bolt as shown in the figure.
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Tightening torque
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22—30 N·m {2.3—3.0 kgf·m, 17—22 ft·lbf}
4. Tighten the bolt as shown in the figure.
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Tightening torque
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22—30 N·m {2.3—3.0 kgf·m, 17—22 ft·lbf}
Joint hose installation note
1. Install the joint hose as shown in the figure.
Fuel tank side
Fuel-filler pipe side
Breather hose installation note
1. Install the breather hose as shown in the figure.
Fuel tank side
Fuel-filler pipe side
