On-Vehicle Procedure

Fuel Tank Components:

Fuel Tank Leak Check

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

- Before removing the fuel tank for a suspected leak, make sure the fuel hoses are not leaking onto the fuel tank. Also, make sure fuel is not leaking around the fuel sender gasket.

Diagnostic Note
The only checks possible on vehicle are a visual inspection of the tank, and a leak check of the fuel tank bladder. If fuel is leaking from the tank, replace the tank and check for leaks.

On-Vehicle Procedure

NOTE: Numbers appearing after components in the following procedure are referenced in the image.

1. Disconnect the negative battery cable.

2. Relieve the fuel system pressure. Refer to the Fuel Pressure Release.

3. Drain the fuel tank. Refer to Draining Fuel Tank.

4. Remove the filler door bezel attaching screws and the bezel.

5. Lift the fuel tank filler pipe housing (1) and disconnect the drain hose (4) from the nipple (3).

6. Remove the fuel tank filler pipe housing (1).

7. Disconnect the fuel feed hose (10) and cap the pipe on the fuel sender assembly.

8. Disconnect the EVAP hose (6) between the fuel sender assembly and the fuel tank TEE fitting at the TEE.

9. Plug the EVAP hose (6) and cap the open end of the TEE fitting (9).

10. Disconnect the EVAP hose to the canister from the other side of the TEE fitting (8).

11. Connect a piece of hose to the open end of the TEE fitting (8) and place the other end into a container of water.

12. Install the fuel filler cap (2).

13. Disconnect the fuel return hose (5) from the fuel sender assembly.

14. Apply 7-10 kPa (1-1.5 psi) air pressure to the fuel return pipe on the fuel sender assembly. Continuous air bubbles appearing in the container indicate a leak in the bladder. A short burst of air bubbles is common at the start.

15. Replace the fuel tank if the bladder is leaking. Refer to Fuel Tank Replacement.