FUEL TANK INSPECTION [MZI-3.7]

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  Note
  • The rollover valve and the check valve (two-way) built into the tank and fuel tank leakage are inspected in this inspection.

1. Complete the “BEFORE SERVICE PRECAUTION”. (See BEFORE SERVICE PRECAUTION [MZI-3.7].)

2. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZI-3.7].)

3. To disconnect the fuel pump unit connector, remove the following parts:

  (1) Second-row seat (LH) (See SECOND-ROW SEAT REMOVAL/INSTALLATION.)

  (2) Edge cover (See LONG SLIDER REMOVAL/INSTALLATION.)

  (3) Long slider cover (See LONG SLIDER REMOVAL/INSTALLATION.)

  (4) Rear heat duct No.3 (See REAR HEAT DUCT COMPONENT REMOVAL/INSTALLATION.)

  (5) Disconnect the fuel pump unit connector.

4. Disconnect the quick release connector and the fuel pump unit connector. (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [MZI-3.7].)

5. Disconnect the joint hose. (See FUEL TANK INSPECTION [MZI-3.7].)

6. Disconnect the evaporative hose. (See FUEL TANK REMOVAL/INSTALLATION [MZI-3.7].)

7. Remove the fuel tank with the fuel pump unit. (See FUEL TANK REMOVAL/INSTALLATION [MZI-3.7].)

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

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

  2WD

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  4WD

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  (2) Apply a pressure of 3 kPa {0.03 kgf/cm2, 0.4 psi} to port A and wait for a while.

  (3) Verify that there is no air leakage from the fuel tank.
    • If there is airflow, replace the fuel tank. (See FUEL TANK REMOVAL/INSTALLATION [MZI-3.7].)

9. Level the fuel tank.

10. Remove the plug of the port B.

11. Apply a pressure of 3 kPa {0.03 kgf/cm2, 0.4 psi} to port B and wait for a while.

12. With the pressure still applied, verify that there is airflow from port A and the pressure is 0—3 kPa {0—0.03 kgf/cm2, 0—0.4 psi}.

  • If malfunction, replace the fuel tank. (See FUEL TANK REMOVAL/INSTALLATION [MZI-3.7].)

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

14. With the pressure still applied, verify that there is airflow from port A and the pressure is -0.5—0 kPa {-3.8—0 mmHg, -0.2—0 inHg}.

  • If malfunction, replace the fuel tank. (See FUEL TANK REMOVAL/INSTALLATION [MZI-3.7].)
  • If there is airflow, place the fuel tank upside down.

15. Apply a pressure of 3 kPa {0.03 kgf/cm2, 0.4 psi} to port B and wait for a while.

2WD

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4WD

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16. With the pressure still applied, verify that there is no airflow from port A.

  • If there is airflow, replace the fuel tank. (See FUEL TANK REMOVAL/INSTALLATION [MZI-3.7].)