Fuel System Leak Test

PROCEDURE
1. Verify fuel system pressure is at least 10,343 kPa (1500 psi) by connecting Rotunda Fuel Filter Neck Venting Kit 134-00117 or equivalent to receptacle and opening manual back flow valve on the fill valve and monitoring vent tool gauge.
2. If pressure is below 10,343 kPa (1500 psi), vent pressure in fuel lines through bleed valve on venting kit.
3. Close manual back flow valve. Tighten jackscrew to 7-9 Nm (60-80 lb in).
4. Pressurize fuel system as shown in Post-Service procedures. Service and Repair
5. Using Rotunda Combustible Gas Detector 134-00049 or equivalent, inspect any fuel fitting by holding the detector extension within 5 mm (0.20 in) above the joint for at least 30 seconds. Verify leak with Snoop.
6. If leak is detected, verify fitting is tightened properly.
7. If fitting tightened properly, vent fuel lines and disconnect fitting.
8. Inspect O-ring, O-ring land and sealing surface for any damage, distortion or contamination.
9. Replace parts as necessary.
10. Repeat Steps 4 through 8 on all fittings, braze joints and crimp joints. Inspect upper fuel tank assembly by placing detect wand at the outlet of the flexible tube located under the vehicle.
11. If leak is detected at upper fuel tank assembly, remove upper tank rack assembly, remove vent box cover, reinstall upper tank rack assembly and activate solenoid valves to pressurize system. Repeat Steps 4 through 9.

NOTE: If leak is detected at a braze joint or crimp joint, entire fuel line must be replaced.

12. If no leaks are detected at high pressure, disconnect battery ground cable. Vent fuel lines until fuel pressure is 690-2069 kPa (100-300 psi) by monitoring Rotunda Fuel Filter Neck Venting Kit 134-00117.

NOTE: When the battery has been disconnected or reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy.

13. Repeat Steps 4 through 10.
14. Close manual back flow valve. Tighten to 7-9 Nm (60-80 lb in). Remove Rotunda Fuel Filter Neck Venting Kit 134-00117 or equivalent.
15. Install vent box.