FUEL TANK REMOVAL/INSTALLATION [SKYACTIV-G 2.5T]

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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 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.

1.  Level the vehicle.

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

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

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 2.5T].)

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

8.  Disconnect the HO2S connector.

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

10.  Remove in the order indicated in the table.

11.  Install in the reverse order of removal.

12.  Complete the “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION [SKYACTIV-G 2.5T].)

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1	Joint hose (See Joint Hose Installation Note.)
2	Fuel tank strap
3	Fuel tank (See Fuel Tank Removal Note.)
4	Fuel tank insulator (See Fuel Tank Insulator Removal Note.)
5	Breather hose (See Breather Hose Installation Note.)
6	Evaporative hose (See Evaporative Hose Installation Note.)
7	Fuel pump unit (See FUEL PUMP UNIT REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)

Fuel Tank Removal Note

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

2.  Disconnect the evaporative hose (between charcoal canister and check valve) from the check valve side.

3.  Remove the following parts as single unit:

•  Breather hose

•  Evaporative hose

•  Fuel pump unit

•  Fuel tank insulator

•  Fuel tank

4.  Remove the fuel tank.

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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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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