FUEL TANK INSPECTION [MZR 2.0, MZR 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 check valve (two-way) built into the fuel tank and fuel tank leakage are inspected in this inspection.

1.  Complete the “BEFORE SERVICE PRECAUTION”. (See BEFORE SERVICE PRECAUTION [MZR 2.0, MZR 2.5].)

2.  Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [MZR 2.0, MZR 2.5].)

3.  Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZR 2.0, MZR 2.5].)

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

5.  Disconnect the fuel pump unit connector. (See FUEL PUMP UNIT REMOVAL/INSTALLATION [MZR 2.0, MZR 2.5].)

6.  Remove the fuel tank and the fuel pump unit as a single unit. (See FUEL TANK REMOVAL/INSTALLATION [MZR 2.0, MZR 2.5].)

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

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

MZR 2.0 (Fuel filter (high-pressure) is a built-in type in fuel pump unit)

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MZR 2.0 (Fuel filter (high-pressure) is not a built-in type in fuel pump unit)

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MZR 2.5 (Fuel filter (high-pressure) is a built-in type in fuel pump unit)

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MZR 2.5 (Fuel filter (high-pressure) is not a built-in type in fuel pump unit)

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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 [MZR 2.0, MZR 2.5].)

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

MZR 2.0 (Fuel filter (high-pressure) is a built-in type in fuel pump unit)

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MZR 2.0 (Fuel filter (high-pressure) is not a built-in type in fuel pump unit)

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MZR 2.5 (Fuel filter (high-pressure) is a built-in type in fuel pump unit)

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MZR 2.5 (Fuel filter (high-pressure) is not a built-in type in fuel pump unit)

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9.  Level the fuel tank.

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

11.  With the pressure still applied, verify that there is air flow 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 [MZR 2.0, MZR 2.5].)

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

13.  With the pressure still applied, verify that there is air flow 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 [MZR 2.0, MZR 2.5].)

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

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

MZR 2.0 (Fuel filter (high-pressure) is a built-in type in fuel pump unit)

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MZR 2.0 (Fuel filter (high-pressure) is not a built-in type in fuel pump unit)

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MZR 2.5 (Fuel filter (high-pressure) is a built-in type in fuel pump unit)

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MZR 2.5 (Fuel filter (high-pressure) is not a built-in type in fuel pump unit)

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15.  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 [MZR 2.0, MZR 2.5].)