FUEL TANK INSPECTION [SKYACTIV-D 2.2]

id0114z7803200

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.

Note

•  The rollover valve built into the fuel tank, and fuel tank leakage are inspected in this inspection.

2WD

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.  Install the fuel gauge sender unit. (See FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION [2WD].)

5.  Remove the fuel tank and the fuel gauge sender unit as a single unit. (See FUEL TANK REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

6.  Perform the following procedure to verify fuel tank airtightness.

(1)  Plug the fuel gauge sender unit pipe, and ports B and C.

am6zzw00014546

(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-D 2.2].)

7.  Remove the port C plug

am6zzw00014547

8.  Place the fuel tank in a level position.

9.  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.

10.  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-D 2.2].)

11.  Close port A and apply -2.0 kPa {-15 mmHg, -0.59 inHg} vacuum to port C, and leave it in this condition momentarily.

12.  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-D 2.2].)

13.  Turn the fuel tank upside down.

14.  Apply pressure of 5.9 kPa {44 mmHg, 1.7 inHg} to port A and wait for a while.

am6zzw00014548

15.  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-D 2.2].)

4WD

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.  Install the fuel gauge sender unit. (See FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION [4WD].)

5.  Remove the fuel tank and the fuel gauge sender unit as a single unit. (See FUEL TANK REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

6.  Perform the following procedure to verify fuel tank airtightness.

(1)  Plug the fuel gauge sender unit pipe, and ports B and C.

am6zzw00013108

(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-D 2.2].)

7.  Remove the port C plug

am6zzw00013109

8.  Place the fuel tank in a level position.

9.  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.

10.  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-D 2.2].)

11.  Close port A and apply -2.0 kPa {-15 mmHg, -0.59 inHg} vacuum to port C, and leave it in this condition momentarily.

12.  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-D 2.2].)

13.  Turn the fuel tank upside down.

14.  Apply pressure of 5.9 kPa {44 mmHg, 1.7 inHg} to port A and wait for a while.

am6zzw00013110

15.  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-D 2.2].)