FUEL TANK INSPECTION [SKYACTIV-D 2.2]

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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 draining fuel, make sure to discharge static electricity by touching the vehicle body.

Note

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

2WD

1.  Park the vehicle on a level surface.

2.  Perform the “Fuel Line Safety Procedure” referring to 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.  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 gauge sender unit connector

•  Fuel hose (main side)

•  Fuel hose (return side)

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

8.  Remove the middle pipe. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

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

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

(1)  Plug the fuel gauge sender 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 [SKYACTIV-D 2.2].)

11.  Remove the port C plug

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12.  Place the fuel tank in a level position.

13.  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.

14.  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].)

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

16.  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].)

17.  Turn the fuel tank upside down.

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

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19.  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].)

4WD

1.  Park the vehicle on a level surface.

2.  Perform the “Fuel Line Safety Procedure” referring to 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.  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 gauge sender unit (main) connector

•  Fuel hose (main side)

•  Fuel hose (return side)

Sub side

•  Fuel gauge sender unit (sub) connector

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

8.  Remove the middle pipe. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

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

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

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

(1)  Plug the fuel gauge sender 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 [SKYACTIV-D 2.2].)

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 [SKYACTIV-D 2.2].)

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 [SKYACTIV-D 2.2].)

18.  Turn the fuel tank upside down.

19.  Apply pressure of 5.9 kPa {44 mmHg, 1.7 inHg} to port C 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 fuel tank.

•  If there is air leakage, replace the fuel tank. (See FUEL TANK REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)