LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Saturn >> 2003 >> Ion 1 Automatic >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls - System & Component Testing >> Emission Systems & Sub-Systems >> Fuel Tank Leak Test >> Diagnostic Procedure
April 5, 2026: LEMON Manuals is launched! Read the announcement.

Diagnostic Procedure

WARNING: 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. Did you perform the Diagnostic System Check - Engine Controls? If yes, go to next step. If no, go to DIAGNOSTIC SYSTEM CHECK - ENGINE CONTROLS under SELF-DIAGNOSTIC SYSTEM in SELF-DIAGNOSTICS - 2.2L ION article.
  2. Raise and support the vehicle. Inspect the fuel tank and the fuel pipes for damage or external leaks. Did you find fuel leaking from the fuel tank? If yes, go to step  6 . If no, go to next step.
  3. Turn ignition switch to RUN position, engine OFF. Command the fuel pump relay ON using a scan tool. Inspect for fuel leaking from the fuel pipes. Did you find fuel leaking from the fuel pipes? If yes, go to step  7 . If no, go to next step.
  4. Turn ignition switch to OFF position. Install Fuel Tank Cap Adapter (J 41415-40), or equivalent. Connect Evaporative Emissions System Tester (EEST) (J 41413-200, J 41413-100) to the Fuel Tank Cap Adapter. Turn ignition switch to RUN position, engine OFF. Seal the EVAP system using a scan tool. DO NOT exceed 15 in. H2O. Pressurize the fuel tank with the EEST. Did fuel leak from the fuel tank? If yes, go to step  6 . If no, go to next step.
  5. Maintain pressure in the fuel tank with the EEST. The fuel tank may need to be partially lowered. Using Ultrasonic Leak Detector (J 41416), check 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.
    • The fuel sender housing and fuel sender seal.
    • The FTP sensor seal.
    • The EVAP vapor pipes.
    • The fuel fill pipe, the fuel fill hose, and the fuel fill cap.

    Did you find and correct the condition? If yes, go to step  8 . If no, go to DIAGNOSTIC AIDS  .

  6. Replace the fuel tank. See FUEL TANK under FUEL SYSTEMS in REMOVAL & INSTALLATION - ION article. After repair, go to step  8 .
  7. Replace the leaking fuel pipe. After repair, go to next step.
  8. Operate the system to verify the repair. Did you correct the condition? If yes, system is okay at this time. If no, go to step  2 .
scientia non olet · About LEMON Manuals