FUEL TANK REMOVAL/INSTALLATION [SKYACTIV-D 1.5]

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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 a vehicle.

Fuel Tank Type A

1.  Level the vehicle.

2.  Complete the “BEFORE SERVICE PRECAUTION”. (See BEFORE SERVICE PRECAUTION [SKYACTIV-D 1.5].)

3.  Drain the fuel. (See FUEL DRAINING PROCEDURE [SKYACTIV-D 1.5].)

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 connector

•  Fuel hose (main side) (See Fuel hose installation note.)

•  Fuel hose (return side) (See Fuel hose installation note.)

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

8.  Remove the middle pipe. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 1.5].)

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 1.5].)

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1	Joint hose (See Joint hose installation note.)
2	Breather hose (fuel-filler pipe side) (See Breather hose installation note.)
3	Fuel tank strap
4	Fuel tank (See Fuel tank removal note.)
5	Fuel tank insulator (See Fuel tank insulator removal note.)
6	Breather hose (fuel tank side) (See Breather hose installation note.)
7	Evaporative hose (See Evaporative hose installation note.)
8	Fuel gauge sender unit (See FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION.)

Fuel tank 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 insulator

•  Fuel tank

3.  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.  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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Fuel hose installation note

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

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Fuel Tank Type B

1.  Level the vehicle.

2.  Complete the “BEFORE SERVICE PRECAUTION”. (See BEFORE SERVICE PRECAUTION [SKYACTIV-D 1.5].)

3.  Drain the fuel. (See FUEL DRAINING PROCEDURE [SKYACTIV-D 1.5].)

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 connector

•  Fuel hose (main side) (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [SKYACTIV-D 1.5].)

•  Fuel hose (return side) (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [SKYACTIV-D 1.5].)

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

8.  Remove the middle pipe. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 1.5].)

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 1.5].)

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1	Joint hose (See Joint hose installation note.)
2	Breather hose (fuel-filler pipe side) (See Breather hose installation note.)
3	Fuel tank insulator
4	Clip
5	Fuel tank strap
6	Fuel tank (See Fuel tank removal note.)
7	Evaporative hose (See QUICK RELEASE CONNECTOR (EMISSION SYSTEM) REMOVAL/INSTALLATION [SKYACTIV-D 1.5].)
8	Fuel gauge sender unit (See FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION.)

Fuel tank removal note

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

2.  Remove the following parts as a single unit:

•  Evaporative hose

•  Fuel gauge sender unit

•  Fuel tank

3.  Remove the fuel tank.

Breather hose installation note

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

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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