Fuel Tank: Testing and Inspection

Fuel Tank Leak Test

Diagnostic Instructions

- Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure.
- Review Strategy Based Diagnosis for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions provides an overview of each diagnostic category.

System Testing

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. Check that fuel does not leak from the fuel gauge O-ring when you have removed the fuel tank. If these safety instructions are not observed this can result in personal injury.

1. Remove the fuel tank.
2. Remove the evaporative emission (EVAP) canister.
3. Plug the fuel feed pipe and the EVAP pipes on the fuel tank.
4. Plug the fuel filler neck opening.
5. Submerge the fuel tank in water or apply a soapy solution to the outside of the tank.
6. Apply 7-15 kPa (1-2 psi) air pressure to the fuel tank vent pipe.
7. Air bubbles appearing from the fuel tank indicate a leak.
8. Replace the fuel tank if the tank is leaking.

Repair Instructions

Perform the Diagnostic Repair Verification after completing the diagnostic procedure.
- Fuel Tank Replacement (AWD) Fuel Tank Replacement (FWD)
- Fuel Tank Filler Pipe Replacement (AWD) Fuel Tank Filler Pipe Replacement (FWD)
- Fuel Tank Fuel Pump Module Replacement (AWD)