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Home >> Saturn >> 2003 >> L200 Automatic >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls - System & Component Testing >> Fuel Systems >> Fuel Tank Leak Test >> Diagnostic Procedures
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Diagnostic Procedures

  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 SATURN "L" SERIES article.
    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.
  2. Raise vehicle. Inspect fuel tank and 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 on, with engine off. Command the fuel pump relay ON with 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 OFF the ignition. Install Fuel Tank Cap Adapter (J 41415-40). Connect the Evaporative Emissions System Tester (J 41413-200) to the Fuel Tank Cap Adapter. Turn ignition on, with engine off. Seal the EVAP system with a scan tool. DO NOT exceed 15 in. H2O. Pressurize the fuel tank with the Evaporative Emissions System Tester. 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 Evaporative Emissions System Tester. The fuel tank may need to be partially lowered. With the Ultrasonic Leak Detector (J 41416), test for leaks on top of the fuel level in the following locations: The fuel tank, fill limiter vent valve, pressure relief valve and rollover valves, fuel sender housing and fuel sender seal, EVAP vapor pipes, fuel fill pipe, fuel fill hose, and fuel fill cap. Did you find and correct the condition? If yes, go to step  8 . If no, problem is intermittent.
  6. Replace fuel tank. After replacement, go to step  8 .
  7. Replace leaking fuel pipe. After repairs, go to next step.
  8. Operate the system in order to verify the repair. Did you correct the condition? If yes, system is okay. If no, go to step  2 .
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