Component Tests and General Diagnostics

Fuel odor may be caused by a leaking fuel tank, filler neck or filler cap. Loose mounting straps or foreign material in the tank may be the cause of a rattle at the fuel tank.

Leak Check Procedure

CAUTION: Place a dry chemical (Class B) fire extinguisher near the area before performing a Fuel Tank Leak Check. Before removing the fuel tank for a suspected leak, make sure that the fuel pipes or the tubes are not leaking onto the tank. Once removed, make sure that the fuel is not leaking around the fuel sender O-ring. Failure to follow these precautions may result in personal injury.

1. Verify that the fuel sender and O-ring are installed.

CAUTION: Refer to Battery Disconnect Caution in Service Precautions.

2. Disconnect the battery cables.
3. Drain the fuel tank. Refer to Fuel Tank Draining Procedure. Fuel Delivery and Air Induction
4. Remove the fuel tank. Refer to Fuel Tank Replacement (Passenger/Cargo) or Fuel Tank Replacement (Commercial/RV).
5. Cap the fuel feed tube and the fuel return tube on the fuel sender.
6. Connect a piece of hose to the filler tube nipple and plug the opposite end.
7. Submerge the tank in water or apply a soap solution to the outside of the tank.
8. Apply 35 kPa (5 psi) air pressure to the vent hose of the fuel tank. A leak will show up as bubbles.