GM Service Manual Online
For 1990-2009 cars only

Caution: 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. Once removed, make sure that the fuel is not leaking around the fuel sender O-ring. Failure to follow these precautions may result in personal injury.

  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure .
  2. Remove the fuel tank. Refer to Fuel Tank Replacement .
  3. Plug all outlets as follows:
  4. • Plug the filler neck and vent hoses.
    • Install the fuel tank sender with the seal and plug the fuel lines.
    • Install a short piece of fuel line on the fuel tank vapor vent tube.
  5. Apply air pressure to the fuel tank through the vapor vent tube. Approximately 7 to 10 kPa (1 to 1.5 psi), then pinch the fuel line hose to retain pressure.
  6. Test suspect area for leaks with a soap solution or by submersion. If there is a leak is noted, replace the tank. Refer to Fuel Tank Replacement .