FUEL TANK INSPECTION [WITHOUT CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5)]

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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 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 [WITHOUT CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5)].)

3.  Drain the fuel. (See FUEL DRAINING PROCEDURE [WITHOUT CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5)].)

4.  Remove the rear seat cushion. (See REAR SEAT CUSHION REMOVAL/INSTALLATION.)

5.  Remove the service hole cover.

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6.  Disconnect the following parts:

•  Fuel pump unit connector

•  Quick release connector (See QUICK RELEASE CONNECTOR (FUEL SYSTEM) REMOVAL/INSTALLATION [WITHOUT CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5)])

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

8.  Disconnect the HO2S connector.

9.  Remove the TWC and HO2S as a single unit. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [WITHOUT CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5)])

10.  Remove the fuel tank and fuel pump unit as a single unit. (See FUEL TANK REMOVAL/INSTALLATION [WITHOUT CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5)])

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

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

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(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 [WITHOUT CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5)])

12.  Remove the port C plug.

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13.  Place the fuel tank in a level position.

14.  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.

15.  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 [WITHOUT CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5)])

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

17.  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 [WITHOUT CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5)])

18.  Turn the fuel tank upside down.

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

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20.  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 [WITHOUT CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5)])

4WD

1.  Level the vehicle.

2.  Complete the “BEFORE SERVICE PRECAUTION”. (See BEFORE SERVICE PRECAUTION [WITHOUT CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5)].)

3.  Drain the fuel. (See FUEL DRAINING PROCEDURE [WITHOUT CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5)].)

4.  Remove the rear seat cushion. (See REAR SEAT CUSHION REMOVAL/INSTALLATION.)

5.  Remove the service hole cover.

Main side

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Sub side

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6.  Disconnect the following parts:

Main side

•  Fuel pump unit connector

•  Quick release connector (See QUICK RELEASE CONNECTOR (FUEL SYSTEM) REMOVAL/INSTALLATION [WITHOUT CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5)])

Sub side

•  Fuel gauge sender unit (sub) connector

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

8.  Disconnect the HO2S connector.

9.  Remove the TWC and HO2S as a single unit. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [WITHOUT CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5)])

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

11.  Remove the fuel tank, fuel pump unit and fuel gauge sender unit (sub) as a single unit. (See FUEL TANK REMOVAL/INSTALLATION [WITHOUT CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5)])

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

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

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(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 [WITHOUT CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5)].)

13.  Remove the port C plug.

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14.  Place the fuel tank in a level position.

15.  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.

16.  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 [WITHOUT CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5)])

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

18.  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 [WITHOUT CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5)])

19.  Turn the fuel tank upside down.

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

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21.  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 [WITHOUT CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5)])