For 1990-2009 cars

### Description

The fuel tank leak test is used to locate any fuel or fuel vapor escaping the fuel tank area. Fuel vapors escaping above the fuel level will be detected when the evaporative emission (EVAP) diagnostics complete one test cycle. The malfunction indicator lamp (MIL) will illuminate after the EVAP diagnostics complete two test cycles.

### Diagnostic Aids

• | Operate the vehicle under the condition of the customer's concern. Under high temperature conditions the fuel vapors may increase to the point of EVAP canister vapor saturation. Fuel vapors would then be released into the atmosphere. Once the engine is running and the EVAP purge is enabled, all fuel vapor release would be eliminated.

• | Movement of the EVAP pipes or the fuel pipes may help find an intermittent condition.

### Test Description

The numbers below refer to the step numbers on the diagnostic table.

1. Perform this procedure in order to determine that no EVAP diagnostic trouble code (DTC) is present.

2. This test locates fuel leakage in the fuel pipes.

3. This tests for fuel leaks below the fuel tank fuel level.

4. This test locates fuel vapors escaping above the fuel level in the fuel tank .

Step | Action | Yes | No
--- | --- | --- | ---
1 | Did you perform the Diagnostic System Check-Engine Controls? | Go to Step 2 | Go to Diagnostic System Check - Engine Controls
2 |

Caution: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.

1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Inspect the fuel tank and the fuel pipes for damage or external leaks.

Did you find fuel leaking from the fuel tank?

Go to Step 6

Go to Step 3

3 |

1. Turn ON the ignition, with the engine OFF.
2. Command the fuel pump relay ON with a scan tool.
3. Inspect for fuel leaking from the fuel pipes.

Did you find fuel leaking from the fuel pipes?

Go to Step 7

Go to Step 4

4 |

1. Turn OFF the ignition.
2. Install the J 41415-40 Fuel Tank Cap Adapter.
3. Connect the J 41413-200 Evaporative Emissions System Tester (EEST) to the Fuel Tank Cap Adapter.
4. Turn ON the ignition, with the engine OFF.
5. Seal the EVAP system with a scan tool.

Important : DO NOT exceed 15 inches H2O.

6. Pressurize the fuel tank with the J 41413-200 .

Did fuel leak from the fuel tank?

Go to Step 6

Go to Step 5

5 |

1. Maintain pressure in the fuel tank with the J 41413-200 .

Important: The fuel tank may need to be partially lowered. Refer to Fuel Tank Replacement .

2. With the J 41416 Ultrasonic Leak Detector, test for leaks above the fuel level in the following locations:

• | The fuel tank, the fill limiter vent valve, the pressure relief valve and the rollover valves--Refer to Fuel Tank Replacement .

• | The fuel sender housing and fuel sender seal--Refer to Fuel Sender Assembly Replacement .

• | The fuel tank pressure (FTP) sensor seal--Refer to Fuel Tank Pressure Sensor Replacement .

• | The EVAP vapor pipes.

• | The fuel fill pipe, the fuel fill hose, and the fuel fill cap--Refer to Filler Tube Replacement .

Did you find and correct the condition?

Go to Step 8

Go to Diagnostic Aids

6 | Replace the fuel tank. Refer to Fuel Tank Replacement . Did you complete the replacement? | Go to Step 8 | --
7 | Replace the leaking fuel pipe. Refer to Fuel Hose/Pipes Replacement - Rear . Did you complete the replacement? | Go to Step 8 | --
8 | Operate the system in order to verify the repair. Did you correct the condition? | System OK | Go to Step 2