FUEL TANK REMOVAL/INSTALLATION AND INSPECTION [SKYACTIV-G]

FUEL TANK REMOVAL/INSTALLATION [SKYACTIV-G]

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 performing work on the fuel system, 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.
  1. Level the vehicle.
  2. Complete the “BEFORE SERVICE PRECAUTION”. (See BEFORE SERVICE PRECAUTION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)
  3. Drain the fuel. (See FUEL DRAINING PROCEDURE [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)
  4. Remove the rear seat cushion. (See REAR SEAT CUSHION REMOVAL/INSTALLATION.)
  5. Remove the service hole cover.

  1. Disconnect the following parts:
  • Fuel pump unit connector
  • Fuel gauge sender unit (AWD)
  • Quick release connector (See QUICK RELEASE CONNECTOR (FUEL SYSTEM) REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)
  1. Remove the floor under cover No.1 (LH). (See FLOOR UNDER COVER REMOVAL/INSTALLATION.)
  2. Remove the floor under cover No.2. (See FLOOR UNDER COVER REMOVAL/INSTALLATION.)
  3. Remove the TWC and HO2S as a single unit. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)
  4. Remove the propeller shaft. (AWD) (See PROPELLER SHAFT REMOVAL/INSTALLATION [(E)].)
  5. Remove the insulator (middle). (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)
  6. Remove in the order indicated in the table.
  7. Install in the reverse order of removal.
  8. Complete the “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)
    2WD

1Joint hose(See Joint Hose Installation Note.)
2Evaporative hose(See Evaporative Hose Installation Note.)
3Fuel tank insulator
4Fuel tank strap
5Fuel tank(See Fuel Tank Removal Note.)
6Breather hose(See Breather Hose Installation Note (2WD).)
7Fuel pump unit(See FUEL PUMP UNIT REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)
8Cover

AWD

1Joint hose(See Joint Hose Installation Note.)
2Evaporative hose(See Evaporative Hose Installation Note.)
3Fuel tank insulator
4Fuel tank strap
5Fuel tank(See Fuel Tank Removal Note.)
6Breather hose
7Quick release connector(See QUICK RELEASE CONNECTOR (FUEL SYSTEM) REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)
8Fuel pump unit(See FUEL PUMP UNIT REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)
9Fuel gauge sender unit(See FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION [(E)].)

Fuel Tank Removal Note

  1. Disconnect the breather hose from the fuel-filler pipe side.
  2. Remove the following parts as single unit:
  • Breather hose
  • Fuel pump unit
  • Fuel tank
  • Cover (2WD)
  • Quick release connector (AWD)
  • Fuel gauge sender unit (AWD)
  1. Remove the fuel tank.

Evaporative Hose Installation Note

1.  Align the evaporative hose marking with the projection on the pipe as shown in the figure and assemble.

Breather Hose Installation Note (2WD)

  1. Align the breather hose marking with the projection on the pipe as shown in the figure and assemble.
    Fuel tank side

2.  Align the breather hose marking with the fuel-filler pipe marking as shown in the figure and assemble.

Fuel-filler pipe side

Joint Hose Installation Note

  1. Align the joint hose marking with the pipe marking as shown in the figure and assemble.
    Fuel tank side

  1. Align the joint hose marking with the fuel-filler pipe marking as shown in the figure and assemble.
    Fuel-filler pipe side

FUEL TANK INSPECTION [SKYACTIV-G]

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 performing work on the fuel system, discharge static electricity by touching the vehicle body.
    Note
  • The rollover valve and the fuel shut-off valve (built into the fuel tank) and also fuel tank leakage are inspected in this inspection.

2WD

  1. Level the vehicle.
  2. Complete the “BEFORE SERVICE PRECAUTION”. (See BEFORE SERVICE PRECAUTION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)
  3. Drain the fuel. (See FUEL DRAINING PROCEDURE [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)
  4. Remove the fuel tank and fuel pump unit as a single unit. (See FUEL TANK REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))])
  5. Perform the following procedure to verify fuel tank airtightness.
    (1) Plug the fuel pump unit pipe, and ports B and C.

(2) Apply pressure of 5.9 kPa {44 mmHg, 1.7 inHg} to port A and wait for a while.
(3) Verify that there is no change in the pressure and no air leakage from the fuel tank.

  • If there is air leakage, replace the fuel tank. (See FUEL TANK REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)

6. Remove the port C plug

  1. Place the fuel tank in a level position.
  2. Close port A and apply 5.9 kPa {44 mmHg, 1.7 inHg} of pressure to port C, and leave it in this condition momentarily.
  3. Open port A and verify that the pressure decreases from 5.9 kPa {44 mmHg, 1.7 inHg}.
  • If it cannot be verified, replace the fuel tank. (See FUEL TANK REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)
  1. Close port A and apply -2.0 kPa {-15 mmHg, -0.59 inHg} vacuum to port C, and leave it in this condition momentarily.
  2. Open port A and verify that the -2.0 kPa {-15 mmHg, -0.59 inHg} negative pressure condition restores to near positive pressure.
  • If it cannot be verified, replace the fuel tank. (See FUEL TANK REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)
  1. Turn the fuel tank upside down.
  2. Apply pressure of 5.9 kPa {44 mmHg, 1.7 inHg} to port A and wait for a while.

  1. Verify that there is no change in the pressure and no air leakage from the port C.
  • If there is air leakage, replace the fuel tank. (See FUEL TANK REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)

AWD

  1. Level the vehicle.
  2. Complete the “BEFORE SERVICE PRECAUTION”. (See BEFORE SERVICE PRECAUTION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)
  3. Drain the fuel. (See FUEL DRAINING PROCEDURE [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)
  4. Remove the fuel tank and fuel pump unit and fuel gauge sender unit as a single unit. (See FUEL TANK REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))])
  5. Perform the following procedure to verify fuel tank airtightness.
    (1) Plug the fuel pump unit pipe, and ports B and C.

(2) Apply pressure of 5.9 kPa {44 mmHg, 1.7 inHg} to port A and wait for a while.
(3) Verify that there is no change in the pressure and no air leakage from the fuel tank.

  • If there is air leakage, replace the fuel tank. (See FUEL TANK REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)

6. Remove the port C plug

  1. Place the fuel tank in a level position.
  2. Close port A and apply 5.9 kPa {44 mmHg, 1.7 inHg} of pressure to port C, and leave it in this condition momentarily.
  3. Open port A and verify that the pressure decreases from 5.9 kPa {44 mmHg, 1.7 inHg}.
  • If it cannot be verified, replace the fuel tank. (See FUEL TANK REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)
  1. Close port A and apply -2.0 kPa {-15 mmHg, -0.59 inHg} vacuum to port C, and leave it in this condition momentarily.
  2. Open port A and verify that the -2.0 kPa {-15 mmHg, -0.59 inHg} negative pressure condition restores to near positive pressure.
  • If it cannot be verified, replace the fuel tank. (See FUEL TANK REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)
  1. Turn the fuel tank upside down.
  2. Apply pressure of 5.9 kPa {44 mmHg, 1.7 inHg} to port A and wait for a while.

  1. Verify that there is no change in the pressure and no air leakage from the port C.
  • If there is air leakage, replace the fuel tank. (See FUEL TANK REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)
FUEL SYSTEM SKYACTIV G