Fuel Tank: Testing and Inspection

Fuel Tank Leak Test

The diagnosis of fuel odor may be a condition of a leaking fuel tank, filler neck or filler cap. A defective filler cap, a plugged or pinched vent pipe can cause a collapsed fuel tank. Loose mounting straps or foreign material in tank may be the cause of a rattle at the fuel tank.

Leak Check Procedure

Warning

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.

This check requires the fuel sender and the O-ring to be installed.

Warning

Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Disconnect the battery cables.
2. Drain the fuel tank. Refer to Fuel Tank Draining (without L59) (Service and Repair)Fuel Tank Draining (with L59) (Service and Repair).
3. Remove the fuel tank. Refer to Fuel Tank Replacement (Service and Repair).
4. Cap the fuel feed tube and the fuel return tube on the fuel sender.
5. Connect a piece of hose to the filler tube nipple and plug the opposite end.
6. Submerge the tank in water or apply a soap solution to the outside of the tank.
7. Apply 35 kPa (5 psi) of air pressure to the vent hose of the fuel tank. A leak will show up as bubbles.