FUEL TANK INSPECTION [MZR-CD 2.2]

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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 two rollover valves built into the fuel tank and check valves (two-way) also 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-CD 2.2].)

2.  Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZR-CD 2.2].)

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

4.  Disconnect the fuel gauge sender unit connector. (See FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION.)

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

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

(1)  Plug the fuel gauge sender 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 leakage from the fuel tank.

•  If there is airflow, replace the fuel tank. (See FUEL TANK REMOVAL/INSTALLATION [MZR-CD 2.2].)

7.  Plug the fuel gauge sender unit pipe and port B.

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8.  Level the fuel tank.

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

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

•  If there is no airflow, replace the fuel tank. (See FUEL TANK REMOVAL/INSTALLATION [MZR-CD 2.2].)

11.  Apply a pressure of –0.5 kPa {–3.7 mmHg, –0.1 inHg} to port A and wait for a while.

12.  With the pressure still applied, verify that there is airflow from port C and the pressure is –0.5—0 kPa {–3.7—0 mmHg, 0—–0.1 inHg}.

•  If there is no airflow, replace the fuel tank. (See FUEL TANK REMOVAL/INSTALLATION [MZR-CD 2.2].)

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

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

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14.  With the pressure still applied, verify that there is no airflow from port C.

•  If there is airflow, replace the fuel tank. (See FUEL TANK REMOVAL/INSTALLATION [MZR-CD 2.2].)