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.
Important: This check requires a fuel sender assembly, a fuel sender gasket, a fuel filler pipe and hose assembly, and a fuel filler cap to be installed in the fuel tank.
- Disconnect the negative battery cable.
- Relieve the fuel system pressure. Refer to the Fuel Pressure Relief .
- Drain the fuel tank. Refer to Fuel Tank Draining .
- Remove the fuel tank. Refer to the appropriate procedure:
- Fuel Tank Replacement
- Remove the fuel feed, fuel return, and EVAP pipes from the fuel sender and the fuel tank (except cutaway van side tank).
- Reinstall the fuel tank filler pipe and hose.
- Install the fuel filler cap.
- Cap the fuel feed pipe and the fuel return pipe on the fuel sender assembly.
- Connect a piece of hose to the EVAP pipe on the fuel sender assembly.
- Apply a soap solution to the outside of the fuel tank.
- Apply 7-10 kPa (1-1.5 psi) air pressure to the piece of hose on the fuel tank vent pipe. Air bubbles appearing from the fuel tank indicate a leak.
- Replace the fuel tank if the tank is leaking. Refer to the appropriate procedure:
- Fuel Tank Replacement
Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.
