FUEL TANK INSPECTION [SKYACTIV-G 2.0, SKYACTIV-G 2.5]

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Warning

•  Fuel is very flammable liquid. If fuel spills or leaks from the pressurized fuel system, it will cause serious injury or death and facility breakage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line Safety Procedure”, while referring to the “BEFORE SERVICE PRECAUTION”.

•  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 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 [SKYACTIV-G 2.0, SKYACTIV-G 2.5].)

3.  Drain the fuel. (See FUEL DRAINING PROCEDURE [SKYACTIV-G 2.0, SKYACTIV-G 2.5].)

4.  Using the following procedure:

6:4 split type

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

4:2:4 split type

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

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5.  Partially peel back the floor mat 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 pump unit connector

•  Quick release connector (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [SKYACTIV-G 2.0, SKYACTIV-G 2.5])

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

9.  Disconnect the HO2S connector.

10.  Remove the TWC and HO2S as a single unit. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.0, SKYACTIV-G 2.5])

11.  Remove the fuel tank and fuel pump unit as a single unit. (See FUEL TANK REMOVAL/INSTALLATION [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, ports B and C.

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(2)  Apply a pressure of 3 kPa {23 mmHg, 0.9 inHg} to port A and wait for a while.

(3)  Verify that there is no air flow leakage from the fuel tank.

•  If there is air flow, replace the fuel tank. (See FUEL TANK REMOVAL/INSTALLATION [SKYACTIV-G 2.0, SKYACTIV-G 2.5].)

13.  Plug the fuel pump unit pipe and port B.

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14.  Level the fuel tank.

15.  Apply a pressure of 3 kPa {23 mmHg, 0.9 inHg} to port A and wait for a while.

16.  With the pressure still applied, verify that there is air flow from port C and the pressure is 0—3 kPa {0—23 mmHg, 0—0.9 inHg}.

•  If there is no air flow, replace the fuel tank. (See FUEL TANK REMOVAL/INSTALLATION [SKYACTIV-G 2.0, SKYACTIV-G 2.5].)

17.  Apply a pressure of -0.5 kPa {-3.8 mmHg, -0.1 inHg} to port A and wait for a while.

18.  With the pressure still applied, verify that there is air flow from port C and the pressure is -0.5—0 kPa {-3.8—0 mmHg, -0.1—0 inHg}.

•  If there is no air flow, replace the fuel tank. (See FUEL TANK REMOVAL/INSTALLATION [SKYACTIV-G 2.0, SKYACTIV-G 2.5].)

•  If there is air flow, place the fuel tank upside down.

19.  Apply a pressure to port A and wait for a while.

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20.  With the pressure still applied, verify that there is no air flow from port C.

•  If there is air flow, replace the fuel tank. (See FUEL TANK REMOVAL/INSTALLATION [SKYACTIV-G 2.0, SKYACTIV-G 2.5].)

4WD

1.  Level the vehicle.

2.  Complete the “BEFORE SERVICE PRECAUTION”. (See BEFORE SERVICE PRECAUTION [SKYACTIV-G 2.0, SKYACTIV-G 2.5].)

3.  Drain the fuel. (See FUEL DRAINING PROCEDURE [SKYACTIV-G 2.0, SKYACTIV-G 2.5].)

4.  Using the following procedure:

6:4 split type

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

4:2:4 split type

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.  Partially peel back the floor mat 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 pump unit connector

•  Quick release connector (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [SKYACTIV-G 2.0, SKYACTIV-G 2.5])

Sub side

•  Fuel gauge sender unit (sub) connector

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

9.  Disconnect the HO2S connector.

10.  Remove the TWC and HO2S as a single unit. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.0, SKYACTIV-G 2.5])

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

12.  Remove the fuel tank, fuel pump unit and fuel gauge sender unit (sub) as a single unit. (See FUEL TANK REMOVAL/INSTALLATION [SKYACTIV-G 2.0, SKYACTIV-G 2.5])

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

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

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(2)  Apply a pressure of 3 kPa {23 mmHg, 0.9 inHg} to port A and wait for a while.

(3)  Verify that there is no air flow leakage from the fuel tank.

•  If there is air flow, replace the fuel tank. (See FUEL TANK REMOVAL/INSTALLATION [SKYACTIV-G 2.0, SKYACTIV-G 2.5].)

14.  Plug the fuel pump unit pipe and port B.

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15.  Level the fuel tank.

16.  Apply a pressure of 3 kPa {23 mmHg, 0.9 inHg} to port A and wait for a while.

17.  With the pressure still applied, verify that there is air flow from port C and the pressure is 0—3 kPa {0—23 mmHg, 0—0.9 inHg}.

•  If there is no air flow, replace the fuel tank. (See FUEL TANK REMOVAL/INSTALLATION [SKYACTIV-G 2.0, SKYACTIV-G 2.5].)

18.  Apply a pressure of -0.5 kPa {-3.8 mmHg, -0.1 inHg} to port A and wait for a while.

19.  With the pressure still applied, verify that there is air flow from port C and the pressure is -0.5—0 kPa {-3.8—0 mmHg, -0.1—0 inHg}.

•  If there is no air flow, replace the fuel tank. (See FUEL TANK REMOVAL/INSTALLATION [SKYACTIV-G 2.0, SKYACTIV-G 2.5].)

•  If there is air flow, place the fuel tank upside down.

20.  Apply a pressure to port A and wait for a while.

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21.  With the pressure still applied, verify that there is no air flow from port C.

•  If there is air flow, replace the fuel tank. (See FUEL TANK REMOVAL/INSTALLATION [SKYACTIV-G 2.0, SKYACTIV-G 2.5].)