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Fuel Tank Inspection: AWD

  1. Level the vehicle.
  2. Complete the "BEFORE SERVICE PRECAUTION". (See BEFORE SERVICE PRECAUTION .)
  3. Drain the fuel. (See FUEL DRAINING PROCEDURE .)
  4. Remove the fuel tank, fuel pump unit and fuel gauge sender unit (sub) as a single unit. (See FUEL TANK REMOVAL/INSTALLATION )
  5. 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 specs. 

      Fig 1: Identifying Fuel Tank Ports B And C (U.S.A. And Canada Specs)
      G10968852Courtesy of MAZDA MOTORS CORP.

      Except U.S.A. and CANADA specs. 

      Fig 2: Identifying Fuel Tank Ports B And C (Except U.S.A. And Canada Specs)
      G10968853Courtesy of MAZDA MOTORS CORP.
    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.
  6. Remove the port C plug.

    U.S.A. and CANADA specs. 

    Fig 3: Identifying Fuel Tank Ports B And C (U.S.A. And Canada Specs)
    G10968854Courtesy of MAZDA MOTORS CORP.

    Except U.S.A. and CANADA specs. 

    Fig 4: Identifying Fuel Tank Ports B And C (Except U.S.A. And Canada Specs)
    G10968855Courtesy of MAZDA MOTORS CORP.
  7. Place the fuel tank in a level position.
  8. 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.
  9. Open port A and verify that the pressure decreases from 5.9 kPa {44 mmHg, 1.7 inHg}  .
  10. Close port A and apply -2.0 kPa {-15 mmHg, -0.59 inHg}  vacuum to port C, and leave it in this condition momentarily.
  11. Open port A and verify that the -2.0 kPa {-15 mmHg, -0.59 inHg}  negative pressure condition restores to near positive pressure.
  12. Turn the fuel tank upside down.
  13. Apply pressure of 5.9 kPa {44 mmHg, 1.7 inHg}  to port A and wait for a while.

    U.S.A. and CANADA specs. 

    Fig 5: Identifying Fuel Tank Ports B And C (U.S.A. And Canada Specs)
    G10968856Courtesy of MAZDA MOTORS CORP.

    Except U.S.A. and CANADA specs. 

    Fig 6: Identifying Fuel Tank Ports B And C (Except U.S.A. And Canada Specs)
    G10968857Courtesy of MAZDA MOTORS CORP.
  14. Verify that there is no change in the pressure and no air leakage from the port C.
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