FUEL TANK REMOVAL/INSTALLATION [SKYACTIV-D 2.2]

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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.

2WD

1. Level the vehicle.

2. Complete the “BEFORE SERVICE PRECAUTION”. (See BEFORE SERVICE PRECAUTION [SKYACTIV-D 2.2].)

3. Drain the fuel. (See FUEL DRAINING PROCEDURE [SKYACTIV-D 2.2].)

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 hose (main side)

• Fuel hose (return side)

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

8. Remove the middle pipe. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

9. Remove in the order shown in the figure.

10. Install in the reverse order of removal.

11. Complete the “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION [SKYACTIV-D 2.2].)

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1

Joint hose

(See Joint hose installation note.)

2

Fuel tank strap

3

Fuel tank insulator

(See Fuel tank insulator removal note.)

4

Breather hose

(See Breather hose removal note.)

(See Breather hose installation note.)

5

Evaporative hose

(See Evaporative hose installation note.)

6

Fuel gauge sender unit

(See FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION [2WD].)

(See FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION [4WD].)

7

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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Breather hose removal note

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

2. Remove the following parts as a single unit:

• Evaporative hose

• Breather hose

• Fuel gauge sender unit

• Fuel tank

3. Remove the breather hose.

Evaporative hose installation note

1. Align the marking and install the evaporative hose as shown in the figure.

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Breather hose installation note

1. Align the marking and 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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4WD

1. Level the vehicle.

2. Complete the “BEFORE SERVICE PRECAUTION”. (See BEFORE SERVICE PRECAUTION [SKYACTIV-D 2.2].)

3. Drain the fuel. (See FUEL DRAINING PROCEDURE [SKYACTIV-D 2.2].)

4. Remove the rear seat cushion. (See REAR SEAT CUSHION REMOVAL/INSTALLATION.)

5. Remove the service hole cover.

Main side

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Sub side

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6. Disconnect the following parts:

Main side

• Fuel gauge sender unit (main) connector

• Fuel hose (main side)

• Fuel hose (return side)

Sub side

• Fuel gauge sender unit (Sub) connector

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

8. Remove the middle pipe. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

9. Remove the propeller shaft (See PROPELLER SHAFT REMOVAL/INSTALLATION.)

10. Remove in the order shown in the figure.

11. Install in the reverse order of removal.

12. Complete the “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION [SKYACTIV-D 2.2].)

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1

Joint hose

(See Joint hose installation note.)

2

Fuel tank strap

3

Fuel tank insulator

(See Fuel tank insulator removal note.)

4

Breather hose

(See Breather hose removal note.)

(See Breather hose installation note.)

5

Evaporative hose

(See Evaporative hose installation note.)

6

Fuel gauge sender unit (main)

(See FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION [4WD].)

7

Fuel gauge sender unit (sub)

(See FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION [2WD].)

(See FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION [4WD].)

8

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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Breather hose removal note

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

2. Remove the following parts as a single unit:

• Evaporative hose

• Breather hose

• Fuel gauge sender unit

• Fuel tank

3. Remove the breather hose.

Evaporative hose installation note

1. Align the marking and install the evaporative hose as shown in the figure.

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Breather hose installation note

1. Align the marking and 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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1	Joint hose (See Joint hose installation note.)
2	Fuel tank strap
3	Fuel tank insulator (See Fuel tank insulator removal note.)
4	Breather hose (See Breather hose removal note.) (See Breather hose installation note.)
5	Evaporative hose (See Evaporative hose installation note.)
6	Fuel gauge sender unit (See FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION [2WD].) (See FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION [4WD].)
7	Fuel tank