Fuel Cap Seal - Testing
Section2
Group
23
No.
0038
Year
99
Month
07
S80
1999-
Reference: This Service Bulletin replaces the previous SB 23-0038 from June 1999, which should be discarded.
Fuel cap, test equipment
Background:
This service bulletin describes how to test function of the fuel cap
Special tool:
Fuel cap, test equipment 1 9-95757
Fuel cap, test equipment
Special tools: 999 5757
1
Checking fuel cap sealing ring
The temperature of the filler cap should be 20°C +/- 10°C (68°F +/- 18°F).
Tool 999 5757 must be used for the leakage test. Check seal for any damage. Replace cap if necessary.
Check seating surface for the seal on the fuel cap so that no cuts or nicks are present. Replace fuel cap if necessary.
Check seating surface for seal on the filler neck so that no cuts or nicks are present.
2
Checking hose to the vacuum pump and fuel cap adapter
Check so that hose on the vacuum pump and the fuel cap adapter is correctly installed.
3
Checking seal vacuum pump
Check vacuum pump seal by blocking the hole in the adapter with i.e. your finger and pump out the air. There must be no increase in pressure.
4
Installing the fuel cap
Fit the fuel cap on the adapter. Turn until you hear a click / ratcheting.
5
Leakage test, vacuum
Move the selector knob to the VACUUM position. Slowly pump out the air to negative (-) 3 kPa (0.4 psi). Wait until the vacuum has stabilized. A pressure increase of 1 kPa (0.2 psi) every 30 seconds is permissible.
If fuel cap fails the test it must be replaced.
6
Testing vacuum relief valve
Pump Out the air until the tow Pressure valve Opens. This Should Occur between negative (-) 4kPa (0.6 psi) and negative (-) 12 kPa (1.7 psi).
7
Leakage test, pressure
Move the selector knob to the PRESSURE Position.
Slowly Pump in the air to Positive Pressure of (+) 3 kPa (0.4 psi). Wait until the Pressure has stabilized. A pressure decrease of 1 kPa (0.2 psi) every 30 seconds is permissible.
If fuel cap fails the test it must be replaced.
8
Testing the relief valve
Pump in air until the pressure relief valve opens. This should Occur between Positive Pressure of (+) 14 kPa (2.0 Psi) and positive Pressure of (+) 30 kPa (4.0 psi).
WARRANTY STATEMENT: Claims may be submitted under the New Car Warranty when there is a documented customer complaint, using claim type 01.
Operation No. Labor description Time allowance
23925-2 Fuel cap function check 0.2 hr