Fuel Tank Inspection

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 also fuel tank leakage are inspected in this inspection.

Level the vehicle.
Complete the "BEFORE SERVICE PRECAUTION". (See BEFORE SERVICE PRECAUTION .)
Drain the fuel. (See FUEL DRAINING PROCEDURE .)
Remove the fuel tank and fuel pump unit as a single unit. (See FUEL TANK REMOVAL/INSTALLATION )
Perform the following procedure to verify fuel tank airtightness.
1. Plug the fuel pump unit pipe, and ports B and C.
  U.S.A. and CANADA
  
  Fig 1: Identifying Fuel Pump Unit Pipe And Port (U.S.A. And CANADA)
  Courtesy of MAZDA MOTORS CORP.
  
  Except U.S.A. and CANADA
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 .)
Remove the port C plug

Fig 2: Identifying Fuel Pump Unit Pipe And Port (Except U.S.A. And CANADA)
Courtesy of MAZDA MOTORS CORP.

U.S.A. and CANADA

Fig 3: Identifying Fuel Pump Unit Pipe And Port (U.S.A. And CANADA)
Courtesy of MAZDA MOTORS CORP.

Except U.S.A. and CANADA
Place the fuel tank in a level position.
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.
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 .)
Close port A and apply -2.0 kPa {-15 mmHg, -0.59 inHg} vacuum to port C, and leave it in this condition momentarily.
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 .)
Turn the fuel tank upside down.
Apply pressure of 5.9 kPa {44 mmHg, 1.7 inHg} to port A and wait for a while.

Fig 4: Identifying Fuel Pump Unit Pipe And Port (Except U.S.A. And CANADA)
Courtesy of MAZDA MOTORS CORP.

U.S.A. and CANADA

Fig 5: Identifying Fuel Pump Unit Pipe And Port (U.S.A. And CANADA)
Courtesy of MAZDA MOTORS CORP.

Except U.S.A. and CANADA
Verify that there is no change in the pressure and no air leakage from the port C.
- If there is air leakage, replace the fuel tank. (See FUEL TANK REMOVAL/INSTALLATION .)
  
  Fig 6: Identifying Fuel Pump Unit Pipe And Port (Except U.S.A. And CANADA)
  Courtesy of MAZDA MOTORS CORP.