FUEL TANK INSPECTION [SKYACTIV-D 2.2]

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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.  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.  Perform the following procedure:

6:4 split seat

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

4:2:4 split seat

1.  Set the rear seat aside as shown in the figure. (See REAR SEAT REMOVAL/INSTALLATION.)

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5.  Set the floor mat aside as shown in the figure.

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6.  Remove the service hole cover.

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7.  Disconnect the following parts:

•  Fuel gauge sender unit connector

•  Fuel hose (main side)

•  Fuel hose (return side)

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

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

10.  Remove the fuel tank and the fuel gauge sender unit 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].)

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.  Perform the following procedure:

6:4 split seat

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

4:2:4 split seat

1.  Set the rear seat aside as shown in the figure. (See REAR SEAT REMOVAL/INSTALLATION.)

Main side

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Sub side

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5.  Set the floor mat aside as shown in the figure.

Main side

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Sub side

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6.  Remove the service hole cover.

Main side

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Sub side

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7.  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

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

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

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

11.  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].)

12.  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].)

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 [SKYACTIV-D 2.2].)

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 [SKYACTIV-D 2.2].)

19.  Turn the fuel tank upside down.

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

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