FUEL TANK REMOVAL/INSTALLATION [SKYACTIV-D 1.5]

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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 1.5].)

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 fuel tank side cover.(See FUEL TANK SIDE COVER REMOVAL/INSTALLATION.)

8.  Remove the parking brake cable bracket (RH) nuts shown in the figure and set the parking brake cable bracket aside in a location that does not interfere with the servicing.

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

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 1.5].)

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1
Joint hose
(See Joint Hose Installation Note.)
2
Breather hose No.1
(See Breather Hose No.1 Installation Note.)
3
Fuel tank insulator
4
Fuel tank strap
5
Fuel tank
(See Fuel Tank Removal Note.)
(See Fuel Tank Installation Note.)
6
Breather hose No.2
(See Breather Hose No.2 Installation Note.)
7
Joint pipe
8
Fuel gauge sender unit
(See FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION.)


Fuel Tank Removal Note

1.  Remove the following parts as a single unit:

•  Breather hose No.2
•  Joint pipe
•  Fuel gauge sender unit
•  Fuel tank

2.  Remove the fuel tank.


Breather Hose No.2 Installation Note

1.  Install the breather hose No.2 as shown in the figure.

Fuel tank side

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Joint pipe side

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Fuel Tank Installation Note

1.  Install the following parts as a single unit:

•  Fuel tank
•  Fuel gauge sender unit
•  Joint pipe
•  Breather hose No.2


Breather Hose No.1 Installation Note

1.  Install the breather hose No.1 as shown in the figure.

Joint pipe 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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