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FUEL TANK REMOVAL/INSTALLATION [SKYACTIV-D 1.8]

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Warning

•  Fuel is highly flammable and dangerous. Fuel line spills and leakage can cause serious injury or death, and damage to equipment. If fuel comes into contact with the skin and eyes it will cause irritation. To prevent this, always perform the “Fuel Line Safety Procedure” referring to the “BEFORE REPAIR PROCEDURE”.

•  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 a vehicle.

1.  Level the vehicle.

2.  Complete the “BEFORE SERVICE PRECAUTION”. (See BEFORE SERVICE PRECAUTION [SKYACTIV-D 1.8].)

3.  Drain the fuel. (See FUEL DRAINING PROCEDURE [SKYACTIV-D 1.8].)

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 gauge sender unit (main) connector

•  Fuel gauge sender unit (sub) connector (AWD)

•  Fuel hose (main side) (See QUICK RELEASE CONNECTOR (FUEL SYSTEM) REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

•  Fuel hose (return side) (See QUICK RELEASE CONNECTOR (FUEL SYSTEM) REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

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 ammonia slip catalyst component. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

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

11.  Remove the insulator (middle). (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

12.  Remove in the order shown in the figure.

13.  Install in the reverse order of removal.

14.  Complete the “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION [SKYACTIV-D 1.8].)

2WD

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1	Joint hose (See Joint Hose Installation Note.)
2	Fuel tank insulator
3	Fuel tank strap
4	Fuel tank (See Fuel Tank Removal Note (2WD).) (See Fuel Tank Installation Note (2WD).)
5	Breather hose (See Breather Hose Installation Note (2WD).)
6	Fuel gauge sender unit (See FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION [(E)].)
7	Cover
8	Evaporative chamber (See EVAPORATIVE CHAMBER REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

AWD

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1	Joint hose (See Joint Hose Installation Note.)
2	Fuel tank insulator
3	Fuel tank strap
4	Fuel tank (See Fuel Tank Removal Note (AWD).) (See Fuel Tank Installation Note (AWD).)
5	Breather hose
6	Fuel gauge sender unit (main) (See FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION [(E)].)
7	Quick release connector (See QUICK RELEASE CONNECTOR (FUEL SYSTEM) REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)
8	Evaporative chamber (See EVAPORATIVE CHAMBER REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)
9	Fuel gauge sender unit (sub) (See FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION [(E)].)

Fuel Tank Removal Note (2WD)

1.  Remove the following parts as a single unit:

•  Breather hose

•  Joint hose

•  Fuel gauge sender unit

•  Fuel tank

•  Cover

•  Evaporative chamber

2.  Remove the fuel tank.

Fuel Tank Removal Note (AWD)

1.  Disconnect the breather hose from the clip.

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2.  Remove the following parts as a single unit:

•  Breather hose

•  Joint hose

•  Fuel gauge sender unit (main)

•  Fuel gauge sender unit (sub)

•  Fuel tank

•  Evaporative chamber

3.  Remove the fuel tank.

Breather Hose Installation Note (2WD)

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

Fuel tank side

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Joint pipe side

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Fuel Tank Installation Note (2WD)

1.  Install the following parts as a single unit:

•  Fuel tank

•  Fuel gauge sender unit

•  Joint hose

•  Breather hose

•  Cover

•  Evaporative chamber

Fuel Tank Installation Note (AWD)

1.  Install the following parts as a single unit:

•  Fuel tank

•  Fuel gauge sender unit (sub)

•  Fuel gauge sender unit (main)

•  Joint hose

•  Breather hose

•  Evaporative chamber

2.  Connect the breather hose to the clip.

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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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