Fuel Tank Inspection

NOTE:

The three rollover valves and the fuel-shut off valve built into the fuel tank and fuel tank leakage are inspected in this inspection.

Follow "BEFORE SERVICE PRECAUTION" before performing any work operations to prevent fuel from spilling from the fuel system. (See BEFORE SERVICE PRECAUTION .)
Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION .)
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.
Disconnect the quick release connector and the fuel pump unit connector. (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION .)
Disconnect the joint hose. (See FUEL TANK INSPECTION .)
Disconnect the evaporative hose. (See FUEL TANK REMOVAL/INSTALLATION .)
Remove the fuel tank with the fuel pump unit. (See FUEL TANK REMOVAL/INSTALLATION .)
Perform the following procedure to verify the fuel tank airtightness.
1. Plug the fuel pump unit pipe and port B.
  2WD
  
  Fig 1: Inspecting Fuel Tank - 2WD
  Courtesy of MAZDA MOTORS CORP.
  
  AWD
  
  Fig 2: Inspecting Fuel Tank - AWD
  Courtesy of MAZDA MOTORS CORP.
2. Apply a pressure of 3 kPa {0.03 kgf/cm ₂ , 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 .)
Level the fuel tank.
Remove the plug of the port B.
Apply a pressure of 3 kPa {0.03 kgf/cm ₂ , 0.4 psi} to port B and wait for a while.
With the pressure still applied, verify that there is airflow from port A and the pressure is 0-3 kPa {0.03 kgf/cm ₂ , 0.4 psi}
- If malfunction, replace the fuel tank. (See FUEL TANK REMOVAL/INSTALLATION .)
Apply a pressure of -0.5 kPa {-3.8 mmHg, -0.1 inHg} to port B and wait for a while.
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 .)
- If there is airflow, place the fuel tank upside down.
Apply a pressure of 3 kPa {0.03 kgf/cm ₂ , 0.4 psi} to port B and wait for a while.
2WD

Fig 3: Inspecting Fuel Tank - 2WD
Courtesy of MAZDA MOTORS CORP.

AWD

Fig 4: Inspecting Fuel Tank - AWD
Courtesy of MAZDA MOTORS CORP.
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 .)