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FUEL TANK REMOVAL/INSTALLATION [SKYACTIV-X 2.0]

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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 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-X 2.0].)

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

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-X 2.0].)

•  Fuel gauge sender unit (AWD) (See FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION [(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.  Disconnect the NOx sensor connector. (With exhaust shutter valve) (See NOx SENSOR REMOVAL/INSTALLATION [SKYACTIV-X 2.0])

10.  Remove the middle pipe and NOx sensor as a single unit. (With exhaust shutter valve) (See MIDDLE PIPE REMOVAL/INSTALLATION [SKYACTIV-X 2.0])

11.  Remove the middle pipe. (With exhaust shutter valve) (See MIDDLE PIPE REMOVAL/INSTALLATION [SKYACTIV-X 2.0])

12.  Remove the propeller shaft. (AWD) (See PROPELLER SHAFT REMOVAL/INSTALLATION [(E)])

13.  Remove the insulator (middle). (See EXHAUST SYSTEM INSULATOR REMOVAL/INSTALLATION [SKYACTIV-X 2.0])

14.  Remove in the order indicated in the table.

15.  Install in the reverse order of removal.

16.  Complete the “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION [SKYACTIV-X 2.0].)

2WD (Except Chinese specs.)

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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 (2WD))
7	Fuel pump unit (See FUEL PUMP UNIT REMOVAL/INSTALLATION [SKYACTIV-X 2.0])
8	Cover

2WD (Chinese specs.)

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1	Joint hose (See Joint Hose Installation Note)
2	Quick release connector (See QUICK RELEASE CONNECTOR (FUEL SYSTEM) REMOVAL/INSTALLATION [SKYACTIV-X 2.0].)
3	Fuel tank insulator
4	Fuel tank strap
5	Fuel tank (See Fuel Tank Removal Note)
6	Fuel pump unit (See FUEL PUMP UNIT REMOVAL/INSTALLATION [SKYACTIV-X 2.0])

AWD

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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
7	Quick release connector (See QUICK RELEASE CONNECTOR (FUEL SYSTEM) REMOVAL/INSTALLATION [SKYACTIV-X 2.0])
8	Fuel pump unit (See FUEL PUMP UNIT REMOVAL/INSTALLATION [SKYACTIV-X 2.0])
9	Fuel gauge sender unit (See FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION [(E)])

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 (2WD)

•  Quick release connector (AWD)

•  Fuel gauge sender unit (AWD)

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 (2WD)

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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