Fuel Tank: Testing and Inspection

Exploded View:

NOTE: To perform a complete inspection as listed below it is necessary to remove the fuel tank. For these procedures refer to "COMPONENT REPLACEMENT AND REPAIR PROCEDURES".

1. Check the hoses and the pipes for cracks or damage.
2. Check the fuel tank cap for proper fit and seal.
3. Check the fuel tank for deformation, corrosion or cracking.
4. Check the inside fuel of the tank for dirt, rust or foreign material.
5. Check the in-tank fuel filter for damage or restriction.
6. Test the two-way valve for proper operation.
7. To check the two-way valve, lightly breathe into the inlet and outlet. If air passes through after slight resistance, then the valve is GOOD. If the valve flows air freely with no resistance or is clogged and flows no air at all, replace the two-way valve and retest.

FUEL TANK LEAK TEST:

NOTE: Perform this test only after the fuel tank has been removed and cleaned.

1. Plug all outlets as follows:
a. Install the filler neck and hoses, including upper neck assembly and filler cap.
b. Install the fuel level sending unit assembly with the seal and plug the fuel supply and return line outlets.
c. Install a short piece of fuel line on the vent tube outlet of the fuel level sending unit.
2. Slowly apply air pressure inside the tank through the fuel line installed on the vent tube outlet. As soon as air can be heard escaping from the filler cap, at approximately;

1.0 - 1.5 psi (7.0 - 10.0 kPa),

stop the applied air pressure and pinch the fuel line installed on vent tube outlet to retain pressure inside the tank.

CAUTION: Permanent and unrepairable damage will result if pressure inside the tank exceeds:

1.5 psi (10.0 kpa)

3. Test suspect area for leaks with a soap solution or by submersion. If a leak is detected, repair or replace the tank or leaking component.

WARNING: DO NOT attempt to weld on the fuel tank. Even after purging, the fuel tank presents a potentially fatal explosion hazard.