Fuel Tank Leak Test
Fuel Tank Leak CheckCAUTION: Refer to Fuel Tank Leak Check Caution in Service Precautions.
IMPORTANT: This check requires a fuel sender assembly, a fuel sender gasket, a fuel filler pipe and hose assembly, and a fuel filler cap to be installed in the fuel tank.
CAUTION: Refer to Battery Disconnect Caution in Service Precautions.
1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief Procedure. Fuel Pressure Release
3. Drain the fuel tank. Refer to Fuel Tank Draining Procedure (Pickup) or Fuel Tank Draining Procedure (Utility with Single Tank) or Fuel Tank Draining Procedure (Utility with Dual Tanks - Front Tank) or Fuel Tank Draining Procedure (Utility with Dual Tanks - Rear Tank). Fuel Tank
4. Remove the fuel tank.
5. Remove the fuel feed, return and EVAP pipes from the fuel sender and the fuel tank.
6. Install the fuel filler cap.
7. Cap the fuel feed pipe and the fuel return pipe on the fuel sender assembly.
8. Connect a piece of hose to the EVAP pipe on the fuel sender assembly.
9. Apply a soap solution to the outside of the fuel tank.
10. Apply 7-10 kPa (1-1.5 psi) air pressure to the piece of hose on the fuel tank vent pipe. Air bubbles appearing from the fuel tank indicate a leak.
11. Replace the fuel tank if it is leaking.