FUEL TANK REMOVAL/INSTALLATION [SKYACTIV-G 2.5T]

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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 the vehicle body.

Caution

• Disconnecting/connecting the quick release connector without cleaning it may cause damage to the fuel pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting using a cloth or soft brush, and make sure that it is free of foreign material.

2WD

1. Level the vehicle.

2. Complete the “BEFORE SERVICE PRECAUTION”. (See BEFORE SERVICE PRECAUTION [SKYACTIV-G 2.5T].)

3. Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.)

4. Drain the fuel. (See FUEL DRAINING PROCEDURE [SKYACTIV-G 2.5T].)

5. Disconnect the following parts:

• Fuel pump unit connector (See FUEL PUMP UNIT REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)

• Quick release connector (See FUEL PUMP UNIT REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)

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

7. Disconnect the HO2S connector. (See HEATED OXYGEN SENSOR (HO2S) REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)

8. Remove the HO2S clip from the body. (See HEATED OXYGEN SENSOR (HO2S) REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)

9. Remove the TWC and HO2S as a single unit. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)

10. Remove in the order indicated in the table.

11. Install in the reverse order of removal.

12. Complete the “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION [SKYACTIV-G 2.5T].)

Taiwan

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1	Fuel tank insulator (See Fuel tank insulator removal note (2WD).)
2	Joint hose
3	Fuel tank (See Fuel tank removal note (2WD).)
4	Fuel tank strap
5	Quick release connector (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)
6	Breather hose
7	Fuel pump unit (See FUEL PUMP UNIT REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)

Except Taiwan

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1	Fuel tank insulator (See Fuel tank insulator removal note (2WD).)
2	Joint hose
3	Fuel tank (See Fuel tank removal note (2WD).)
4	Fuel tank strap
5	Evaporative hose
6	Breather hose
7	Fuel pump unit (See FUEL PUMP UNIT REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)

Fuel tank insulator removal note (2WD)

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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Fuel tank removal note (2WD)

1. Disconnect the evaporative hose from the check valve.

2. Disconnect the breather hose from the fuel-filler pipe.

3. Remove the fuel tank.

4WD

1. Level the vehicle.

2. Complete the “BEFORE SERVICE PRECAUTION”. (See BEFORE SERVICE PRECAUTION [SKYACTIV-G 2.5T].)

3. Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.)

4. Drain the fuel. (See FUEL DRAINING PROCEDURE [SKYACTIV-G 2.5T].)

5. Disconnect the following parts:

Main side

• Fuel pump unit connector (See FUEL PUMP UNIT REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)

• Quick release connector (See FUEL PUMP UNIT REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)

Sub side

• Fuel gauge sender unit (sub) connector (See FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION [4WD].)

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

7. Disconnect the HO2S connector. (See HEATED OXYGEN SENSOR (HO2S) REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)

8. Remove the HO2S clip from the body. (See HEATED OXYGEN SENSOR (HO2S) REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)

9. Remove the TWC and HO2S as a single unit. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)

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

11. Remove in the order indicated in the table.

12. Install in the reverse order of removal.

13. Complete the “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION [SKYACTIV-G 2.5T].)