FUEL TANK REMOVAL/INSTALLATION [SKYACTIV-D 2.2]

id0114z7801600

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.

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.

am3zzw00016403

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].)

am3zzw00013796

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).

am3zzw00016404

2.  Remove the flange using a drill (5 mm {0.20 in} drill bit).

am3zzw00016405


Evaporative Hose Installation Note

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

am3zzw00016406


Breather Hose Installation Note

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

Fuel tank side

am3zzw00016407

Fuel-filler pipe side

am3zzw00016408


Joint Hose Installation Note

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

Fuel tank side

am3zzw00016409

Fuel-filler pipe side

am3zzw00016410