FUEL TANK REMOVAL/INSTALLATION [SKYACTIV-G (WITHOUT CYLINDER DEACTIVATION (E))]

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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.
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.

1.  Level the vehicle.

2.  Complete the “BEFORE SERVICE PRECAUTION”. (See BEFORE SERVICE PRECAUTION [SKYACTIV-G (WITHOUT CYLINDER DEACTIVATION (E))].)

3.  Drain the fuel. (See FUEL DRAINING PROCEDURE [SKYACTIV-G (WITHOUT CYLINDER DEACTIVATION (E))].)

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 pump unit connector
•  Quick release connector (See QUICK RELEASE CONNECTOR (FUEL SYSTEM) REMOVAL/INSTALLATION [SKYACTIV-G (WITHOUT CYLINDER DEACTIVATION (E))].)

7.  Remove the floor under cover No.1 (LH). (See FLOOR UNDER COVER REMOVAL/INSTALLATION.)

8.  Remove the floor under cover No.2. (See FLOOR UNDER COVER REMOVAL/INSTALLATION .)

9.  Remove the TWC and HO2S as a single unit. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G (WITHOUT CYLINDER DEACTIVATION (E))].)

10.  Remove the insulator (middle). (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G (WITHOUT CYLINDER DEACTIVATION (E))].)

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 (WITHOUT CYLINDER DEACTIVATION (E))].)

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1
Joint hose
(See Joint Hose Installation Note.)
2
Evaporative hose
(See Evaporative Hose Installation Note.)
3
Fuel tank insulator
4
Fuel tank strap
5
Fuel tank
(See Fuel Tank Removal Note.)
6
Breather hose
(See Breather Hose Installation Note.)
7
Fuel pump unit
(See FUEL PUMP UNIT REMOVAL/INSTALLATION [SKYACTIV-G (WITHOUT CYLINDER DEACTIVATION (E))].)
8
Cover


Fuel Tank Removal Note

1.  Disconnect the breather hose from the fuel-filler pipe side.

2.  Remove the following parts as single unit:

•  Breather hose
•  Fuel pump unit
•  Fuel tank
•  Cover

3.  Remove the fuel tank.


Evaporative Hose Installation Note

1.  Align the evaporative hose marking with the projection on the pipe as shown in the figure and assemble.

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Breather Hose Installation Note

1.  Align the breather hose marking with the projection on the pipe as shown in the figure and assemble.

Fuel tank side

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2.  Align the breather hose marking with the fuel-filler pipe marking as shown in the figure and assemble.

Fuel-filler pipe side

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Joint Hose Installation Note

1.  Align the joint hose marking with the pipe marking as shown in the figure and assemble.

Fuel tank side

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2.  Align the joint hose marking with the fuel-filler pipe marking as shown in the figure and assemble.

Fuel-filler pipe side

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