Symptom Related Diagnostic Procedures
WARNING:When conducting inspections below, be sure to observe the following:
- Put a "CAUTION: INFLAMMABLE" sign in workshop.
- Do not smoke while servicing fuel system. Keep open flames and sparks away from work area.
- Be sure to furnish the workshop with a CO2 fire extinguisher.
CAUTION:
- Before removing fuel line parts, carry out the following procedures:
a. Put drained fuel in an explosion-proof container and put lid on securely.
b. Release fuel pressure from fuel line. Refer to "Fuel Pressure Release".
c. Disconnect battery ground cable.
- Always replace O-ring when the fuel gauge retainer is removed.
- Do not kink or twist hose and tube when they are installed.
- Do not tighten hose and clamps excessively to avoid damaging hoses.
- After installation, run engine and check for fuel leaks at connection.
DIAGNOSTIC PROCEDURE
SYMPTOM:
Fuel odor from EVAP canister is strong.
SYMPTOM:
Cannot refuel/Fuel odor from the fuel filler opening is strong while refueling.
COMPONENT INSPECTION
Refueling Control Valve
Check refueling control valve as follows:
1. Remove fuel filler cap.
2. Check air continuity between hose ends (A) and(B).
Blow air into the hose end (B). Air should flow freely into the fuel tank.
3. Blow air into hose end (A) and check there is no leakage.
4. Apply pressure to both hose ends (A) and (B) [20 kPa (150 mmHg, 5.91 inHg)] using a pressure pump and a suitable 3-way connector. And check there is no leakage.
If NG, replace refueling control valve with fuel tank.
Refueling EVAP Vapor Cut Valve
With CONSULT
1. Remove fuel tank. Drain fuel from the tank as follows:
a. Remove fuel feed hose located on the fuel gauge retainer.
b. Connect a spare fuel hose, one side to fuel gauge retainer where the hose was removed and the other side to a fuel container.
c. Drain fuel using "FUEL PUMP RELAY" in "ACTIVE TEST" mode with CONSULT.
OR
Without CONSULT
a. Remove fuel gauge retainer.
b. Drain fuel from the tank using a hand pump into a fuel container.
2. Check refueling EVAP vapor cut valve for stuck to close as follows.
Blow air into the refueling EVAP vapor cut valve (from hose end (B)) and check that the air flows freely into the tank.
3. Check EVAP vapor cut valve for stuck to open as following.
a. Connect vacuum pump to hose ends (A) and (B) using a suitable 3-way connector.
b. Remove fuel gauge retainer with fuel gauge unit.
After removing filler tube
Always replace O-ring with new one.
c. Put fuel tank upside down.
d. Apply vacuum pressure to both hose ends (A) and (B) [-13.3 kPa (-100 mmHg, -3.94 inHg)] with fuel gauge retainer remaining open and check that the pressure is applicable. If NG, replace refueling EVAP vapor cut valve with fuel tank.
One-way Fuel Valve
1. Drain fuel from the tank.
2. Remove fuel filler tube and hose.
3. Check one-way fuel valve for operation.
When a stick is inserted, the valve should open; when removing stick, it should close.
CAUTION: Do not drop any material into the tank.
If NG, replace one-way fuel valve with fuel tank.