GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2004 🢒 VUE - AWD 🢒 Engine 🢒 Engine Controls - 3.5L (L66) 🢒 Fuel Tank Leak Test

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.

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

    4.

  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

Important: Ensure that the vehicle underbody temperature is similar to the ambient temperature and allow the surrounding air to stabilize before starting the diagnostic procedure. System flow will be less with higher temperatures.

  1. Turn OFF the ignition.
  2. Connect the J 41413-200 Evaporative Emissions System Tester (EEST) power supply clips to a known good 12-volt source.

    3. Important: The GE-41415-50 fuel cap adapter, may not be available for the start of production. Once the J41415-50 is available, start the diagnosis at the fuel fill cap.

  3. Install the nitrogen/smoke supply hose onto one of the following sources:
    4. • Connect the GE-41415-50 to the fuel fill pipe, and the J 41413-200 nitrogen/smoke supply hose to the fuel cap adapter.
    • Connect the J 41413-200 nitrogen/smoke supply hose to the EVAP service port.
    • Turn the nitrogen/smoke valve on the J 41413-200 control panel to NITROGEN.
  4. Turn ON the ignition with the engine OFF.
  5. Command the EVAP vent valve closed with a scan tool.

    6. Important : DO NOT exceed 15 inches H2O.

  6. Use the remote switch to introduce nitrogen into the fuel tank.

Did fuel leak from the fuel tank?

Go to Step 6

Go to Step 5

5

Important: Ensure that the vehicle underbody temperature is similar to the ambient temperature and allow the surrounding air to stabilize before starting the diagnostic procedure. System flow will be less with higher temperatures.

  1. Turn OFF the ignition.
  2. Connect the J 41413-200 Evaporative Emissions System Tester (EEST) power supply clips to a known good 12-volt source.

    3. Important: The GE-41415-50 fuel cap adapter, may not be available for the start of production. Once the J41415-50 is available, start the diagnosis at the fuel fill cap.

  3. Install the nitrogen/smoke supply hose onto one of the following sources:
    4. • Connect the GE-41415-50 to the fuel fill pipe, and the J 41413-200 nitrogen/smoke supply hose to the fuel cap adapter.
    • Connect the J 41413-200 nitrogen/smoke supply hose to the EVAP service port.
  4. Turn ON the ignition with the engine OFF.
  5. Command the EVAP vent valve closed with a scan tool.
  6. Turn the nitrogen/smoke valve on the J 41413-200 control panel to SMOKE.
  7. Use the remote switch to introduce smoke into the fuel system for 60 seconds.
  8. Inspect the entire EVAP/fuel system for exiting smoke with the J 41413-SPT High Intensity White Light.
  9. Continue to introduce smoke at 15 second intervals until the leak source has been located.

Did you locate and repair a leak source?

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 - Chassis .

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