Fuel Tank: Testing and Inspection

WARNING: Before attempting the Fuel Tank Leak Check, place a dry chemical (Class B) fire extinguisher near work area.

Before removing the fuel tank for a suspected leak, make sure the fuel pipes are not leaking onto the fuel tank. Once the fuel tank is removed, make sure fuel is not leaking around the fuel sender assembly O-ring.

This check requires a fuel sender assembly and an O-ring to be installed in the fuel tank.

1. Relieve the fuel system pressure. Refer to Fuel Pressure Release Procedure.
2. Drain the fuel tank. Refer to Draining Fuel Tank.
3. Remove the fuel tank. Refer to Fuel Tank.
4. Cap the fuel feed pipe, the fuel return pipe, and the EVAP pipe on the fuel sender assembly.
5. Plug the fuel tank filler pipe opening.
6. Connect a piece of hose to the fuel tank EVAP pipe.
7. Submerge the fuel tank in water or apply a soap solution to the outside of the fuel tank.
8. Apply 7 to 10 kPa (1 to 1.5 psi) air pressure to the piece of hose on the fuel tank EVAP pipe.

Air bubbles appearing from the fuel tank indicate a leak. Replace the fuel tank if it is leaking. Refer to Fuel Tank.