Fuel Tank: Testing and Inspection

NOTE: Perform the FUEL TANK LEAK TEST only after the fuel tank has been removed and cleaned. Refer to COMPONENT REPAIR AND REPLACEMENT PROCEDURES/FUEL TANK ASSEMBLY and MAINTENANCE PROCEDURES/FUEL SYSTEM CLEANING.

1. Plug all outlets as follows:
a. Install the filler neck and hoses, upper neck assembly and filler cap.
b. Install the fuel pump and fuel gauge sending unit with the seals and plug the fuel lines.
c. Install a short piece of fuel line on the fuel level sending unit vent tube.

CAUTION: More than 1 1/2 lbs. of pressure will permanently damage the tank.

2. Apply air pressure to the tank through the vent tube. When air can be heard escaping from the filler neck cap, approximately 7.0 to 10.0 kPa (1.0 to 1.5 psi) pinch the fuel line hose to retain pressure.
3. Test suspect area for leaks with a soap solution or by submersion. If a leak is detected, repair or replace the tank or leaking component.