Fuel Tank: Testing and Inspection

Fuel Tank Leak Check

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.

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 pressure.
3. Drain the fuel tank.
4. Remove the fuel tank.
5. Remove the fuel feed, return and EVAP pipes from the fuel sender.
6. Reinstall the fuel tank filler pipe and hose.
7. Install the fuel filler cap.
8. Cap the fuel feed pipe, the fuel return pipe and the roll over valves.
9. Connect a piece of hose to the EVAP pipe on the fuel sender assembly.
10. Apply a soap solution to the outside of the fuel tank.
11. Apply 7 - 10 kPa (1 - 11/2 psi) air pressure to the piece of hose on the EVAP pipe. Air bubbles appearing from the fuel tank indicate a leak.
12. Replace the fuel tank if it is leaking.