Fuel Tank Leak Check

CAUTION: Place a dry chemical (Class B) tire 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.

CAUTION: Refer to the Battery Disconnect Caution in Service Precautions.

1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief Procedure. Fuel Pressure Release
3. Drain the fuel tank. Refer to Fuel Tank Draining Procedure. Fuel Tank
4. Remove the fuel tank. Refer to the appropriate procedure:
5. Fuel Tank Replacement (Passenger/cargo Van) or Fuel Tank Replacement (Cutaway Van Rear Tank) or Fuel Tank Replacement (Cutaway Van Side Tank)
6. Remove the fuel feed, fuel return, and [1][2]EVAP pipes from the fuel sender and the fuel tank (except cutaway van side tank).
7. Reinstall the fuel tank filler pipe and hose.
8. Install the fuel filler cap.
9. Cap the fuel feed pipe and the fuel return pipe on the fuel sender assembly.
10. Connect a piece of hose to the [1][2]EVAP pipe on the fuel sender assembly.
11. Apply a soap solution to the outside of the fuel tank.
12. 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.
13. Replace the fuel tank if the tank is leaking. Refer to the appropriate procedure:
14. Fuel Tank Replacement (Passenger/Cargo Van) or Fuel Tank Replacement (Cutaway Van Rear Tank) or Fuel Tank Replacement (Cutaway Van Side Tank)