Fuel Tank: Testing and Inspection

IMPORTANT: Before attempting the Fuel Tank Leak Check place a dry chemical (Class B) fire extinguisher near the work area.
1. Install the J 41415-40 Fill Tank Cap Adaptor.
2. Connect the J 41413 [1][2]EVAP Pressure/Purge Diagnostic Station to the fill tank cap adaptor.
3. With a scan tool, seal the EVAP system.
4. Raise the vehicle on a hoist. Refer to Vehicle Lifting Caution in Service Precautions.
5. With the Evaporative Emission System ([1][2]EVAP) diagnostic station, maintain 15 in. H2O (3.75 kPa) within the fuel tank.

IMPORTANT: It may be necessary to partially lower the fuel tank to inspect the top of the fuel tank and fuel sender assembly O-ring. Refer to Fuel Tank Replacement.

6. With the J 41416 ultrasonic leak detector, test for leaks in the fuel tank and [1][2]EVAP pipes.
7. Visually inspect for fuel leaking from the fuel tank.
8. If a leak is detected refer to the following component replacements:
^ Fuel tank leak, refer to Fuel Tank Replacement.
^ Fuel sender O-ring or fuel sender leak, refer to Fuel Sender Assembly Replacement.
^ Fuel or [1][2]EVAP pipe leak, refer to Fuel Hose/Pipes Replacement (Filter to Tank) in Fuel Supply Line or Fuel Return Line.