WARNING:
Fuel is very flammable liquid. If fuel spills or leaks from the pressurized fuel system, it will cause serious injury or death and facility breakage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line Safety Procedure”, while referring to the “BEFORE SERVICE PRECAUTION”.
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 possibly cause damage to the fuel pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting using cloth or soft brush, and make sure that it is free of foreign material.
1. Complete the “BEFORE SERVICE PRECAUTION”. (See BEFORE SERVICE PRECAUTION [SKYACTIV-G 2.5].)
2. Disconnect the quick release connector as shown in the figure. (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [SKYACTIV-G 2.5].)
3. Connect a long hose to the disconnected quick release connector and drain the fuel into a container used for collecting gasoline.
4. Drain the fuel from the fuel tank using the following procedure:CAUTION:
The fuel pump could be damaged if it is operated while there is no fuel in the fuel tank. Verify the amount of fuel being discharged from the hose and stop operation of the fuel pump when essentially no fuel is being discharged.
Using M-MDS
Connect the M-MDS to the DLC-2.
Using the simulation function “FP”, start the fuel pump. (See ON-BOARD DIAGNOSTIC TEST [SKYACTIV-G 2.5].)
If the fuel pump cannot be operated, remove the fuel using the procedure in the reference. (See Fuel Siphoning Procedure Not Using Fuel Pump.)
Without using M-MDS
Disconnect the negative battery cable. (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [SKYACTIV-G 2.5].)
Remove the fuel pump relay.
CAUTION:
Short the specified terminals because shorting the wrong terminal of the relay and fuse block may cause malfunctions.
Using a jumper wire, short fuel pump relay terminals C and D in the relay and fuse block.
Connect the negative battery cable and operate the fuel pump. (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [SKYACTIV-G 2.5].)
If the fuel pump cannot be operated, remove the fuel using the procedure in the reference. (See Fuel Siphoning Procedure Not Using Fuel Pump.)
5. Stop the fuel pump using the following procedure.Using M-MDS
Using the simulation function “FP”, stop the fuel pump. (See ON-BOARD DIAGNOSTIC TEST [SKYACTIV-G 2.5].)
Disconnect the negative battery cable. (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [SKYACTIV-G 2.5].)
Without using M-MDS
Remove the jumper wire to stop the fuel pump.
Disconnect the negative battery cable. (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [SKYACTIV-G 2.5].)
1. Complete the “BEFORE SERVICE PRECAUTION”. (See BEFORE SERVICE PRECAUTION [SKYACTIV-G 2.5].)
2. Perform the following procedure (1) to (3) if the fuel gauge value is 3/4 or more. If the fuel gauge value is 3/4 or less, go to Step 3.
CAUTION:
If an excessive length of hose is inserted into the fuel-filler pipe, the hose will push the non-return valve and the hose may enter the fuel tank. If the hose enters the fuel tank, the hose may get stuck on the non-return valve when the hose is pulled and the non-return valve could be damaged. Do not insert the hose more than the specified length.
When removing the hose from the fuel-filler opening, use a rag to prevent fuel spatter.
NOTE:
Cut the tip of the hose diagonally so that it can be inserted into the fuel-filler pipe smoothly.
When inserting the hose into the fuel-filler pipe, the hose may get stuck. In such cases, rotate the hose so that the hose can be inserted easily.
The pump siphons all the fuel that leaked out of the non-return valve and was trapped in the joint hose, then it suctions the air. After siphoning the fuel, wait several seconds until the air is suctioned out, then resume siphoning.
Cut the tip of the hose diagonally and place a mark at the position of the specified hose insertion length.
Hose insertion length (specified value)
1090 mm {42.91 in}
Hose type (reference)
Oil-resistant plastic hose of 10 mm {0.39 in} outer diam. × 6 mm {0.2 in} inner diam. or equivalent
Insert the hose from the fuel-filler opening by rotating it to the marked position.
Using a pump, siphon the fuel until the fuel gauge value reaches 3/4 or less.
3. Remove the fuel pump unit. (See FUEL PUMP UNIT REMOVAL/INSTALLATION [SKYACTIV-G 2.5].)
4. Drain the fuel.
5. Remove the hose using a rag.