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FUEL TANK INSPECTION [SKYACTIV-G (WITHOUT CYLINDER DEACTIVATION (E))]

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Warning

•  Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.

•  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 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 (WITHOUT CYLINDER DEACTIVATION (E))].)

3.  Drain the fuel. (See FUEL DRAINING PROCEDURE [SKYACTIV-G (WITHOUT CYLINDER DEACTIVATION (E))].)

4.  Remove the fuel tank and fuel pump unit as a single unit. (See FUEL TANK REMOVAL/INSTALLATION [SKYACTIV-G (WITHOUT 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.

Except Chinese specs.

ac30zw00002230

Chinese specs.

ac30zw00004248

(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 (WITHOUT CYLINDER DEACTIVATION (E))].)

6.  Remove the port C plug

Except Chinese specs.

ac30zw00002231

Chinese specs.

ac30zw00004249

7.  Place the fuel tank in a level position.

8.  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.

9.  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 (WITHOUT CYLINDER DEACTIVATION (E))].)

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

11.  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 (WITHOUT CYLINDER DEACTIVATION (E))].)

12.  Turn the fuel tank upside down.

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

Except Chinese specs.

ac30zw00002232

Chinese specs.

ac30zw00004250

14.  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 (WITHOUT CYLINDER DEACTIVATION (E))].)

AWD

1.  Level the vehicle.

2.  Complete the “BEFORE SERVICE PRECAUTION”. (See BEFORE SERVICE PRECAUTION [SKYACTIV-G (WITHOUT CYLINDER DEACTIVATION (E))].)

3.  Drain the fuel. (See FUEL DRAINING PROCEDURE [SKYACTIV-G (WITHOUT CYLINDER DEACTIVATION (E))].)

4.  Remove the fuel tank and fuel pump unit as a single unit. (See FUEL TANK REMOVAL/INSTALLATION [SKYACTIV-G (WITHOUT 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.

ac30zw00003555

(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 (WITHOUT CYLINDER DEACTIVATION (E))].)

6.  Remove the port C plug

ac30zw00002234

7.  Place the fuel tank in a level position.

8.  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.

9.  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 (WITHOUT CYLINDER DEACTIVATION (E))].)

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

11.  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 (WITHOUT CYLINDER DEACTIVATION (E))].)

12.  Turn the fuel tank upside down.

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

ac30zw00002235

14.  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 (WITHOUT CYLINDER DEACTIVATION (E))].)