Katerina Swanson
Testing a boat fuel tank pickup can be a tricky process. Before you begin, it's important to check for any fuel smells or leaks, as this could indicate a problem with the tank. If you suspect an issue, it may be necessary to remove the tank for a closer inspection. Once you have accessed the tank, you can begin testing the fuel sender, which will involve cleaning the terminals and checking for correct resistance readings. If the sender is functioning correctly, you can move on to testing the fuel tank itself. To do this, you will need to gather the necessary tools, such as hose pinch pliers, an inflatable pipe plug, and a low-pressure air pressure gauge. By following the correct procedure, which includes closing off all potential air escape routes and pumping air into the tank, you can effectively pressure test your boat's fuel tank and identify any leaks.
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What You'll Learn
Locate the fuel fill hose and the vent hose access ports
To locate the fuel fill hose and the vent hose access ports, you must first identify the two main portions of the fuel tank. The first portion is the fill and vent part, which is typically located towards the front of the tank. The fill hose and vent hose are usually found next to each other. The fill hose allows fuel to be added to the tank, while the vent hose releases air pressure from the tank when fuel expands due to heat.
The second portion is the pick-up tubes and sender section, which is located at the back or aft of the tank. This section may be more challenging to access, especially in older boats manufactured before the mid-2000s. In some cases, you may need to remove certain structures, such as a leaning post with a livewell, to access the access port for this section.
Once you have identified the two main portions, you can locate the specific access ports for the fuel fill hose and the vent hose. These access ports are usually found on either the starboard or port side of the gunwale, near the fill port.
In some boats, the fuel fill and vent hoses may be routed differently. For example, they could be routed to the back of the boat, with the fuel cap and vent at the rear. Alternatively, the hoses could be routed through the flotation foam under the floor or through a plastic dryer tube on the starboard side.
By understanding the typical locations and variations in fuel tank designs, you can effectively locate the fuel fill hose and vent hose access ports on your boat.
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Prepare the inflatable pipe plug and pressure gauge
To prepare the inflatable pipe plug and pressure gauge, you will need a few tools. These include a pair of hose pinch pliers, an inflatable pipe plug, and a low-pressure air pressure gauge that can be connected to a 3/8" fuel hose with a Schrader valve. The Schrader valve is important as it allows you to put air into the tank.
Once you have gathered these tools, locate the fuel fill hose and the vent hose access ports, as well as the fuel pickup access. The fuel fill hose and vent hose access ports are usually located towards the front of the tank, while the fuel pickup access is at the back or aft of the tank. Some older boats may not have access ports for the fuel pickup tubes and sender section, so you may need to remove certain parts of the boat to reach the access port.
After locating the access ports, install the inflatable pipe plug into the fuel fill port and pump it up to shut off the fuel fill hose. This will allow you to close off all locations where air could escape. Next, you will need to pinch off the fuel tank vent hose. Be careful when handling the hose as older hoses may be prone to damage and splitting.
Now, you are ready to remove the fuel hose from the pickup tube fitting. This step may require a utility knife to slice a section of the fuel hose connected to the tube, especially if the hose has shrunk and stuck onto the hose barb over time. After removing the fuel hose, install the low-pressure air pressure gauge and hose. Ensure that your pressure testing tool is leak-free around the tee-fitting, the gauge, and the Schrader valve.
With the inflatable pipe plug and pressure gauge installed, you can move on to the next steps of testing your boat's fuel tank pickup.
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Pump air into the tank
To test a boat fuel tank pickup by pumping air into the tank, you will need a few tools. These include a pair of hose pinch pliers, an inflatable pipe plug, and a low-pressure air pressure gauge that can be tee-ed into a 3/8" fuel hose with a Schrader valve. You will also need an air pump or a tank of compressed air.
First, locate the fuel fill hose, the vent hose access ports, and the fuel pickup access. The fill and vent parts are usually located towards the front of the tank, while the pickup tubes and sender section are at the back. There should be access ports on either the starboard or port side of the gunwale where the fill port is located.
Once you have located the access ports, install the inflatable pipe plug into the fuel fill port and pump it up to shut off the fuel fill hose. Make sure that the plug is seated nicely in the hose and that there are no spots where air can leak out. Then, pinch off the fuel tank vent hose.
Now, remove the fuel hose from the pickup tube fitting and install the low-pressure air pressure gauge and hose. It is important not to exceed 3 lbs of pressure when pumping air into the tank.
After pumping air into the tank, spray the sender and all fittings and ports on the tank with soapy water and look for air bubbles. If there are no air bubbles, ensure that the vent and the fill hose are plugged off properly and that there are no leaks around the tee-fitting, the gauge, or the Schrader valve.
Keep in mind that, contrary to what some people may believe, air pressure testing of fuel tanks is not standard industry practice. In fact, the ASME safety standard for pressure vessels specifically forbids pressure testing with compressed gas. Instead, a hydrostatic test is typically performed, where the tank is filled with water and then pressurised hydraulically.
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Spray the tank with soapy water and look for air bubbles
To test a boat fuel tank pickup, one of the methods is to spray the tank with soapy water and look for air bubbles. This is a simple and easy way to pressure test a boat fuel tank at home without the need for expensive tools.
Firstly, locate the fuel fill hose and the vent hose access ports, as well as the fuel pickup access. Install an inflatable pipe plug into the fuel fill port and pump it up to shut off the fuel fill hose. Next, pinch off the fuel tank vent hose. After that, remove the fuel hose from the pickup tube fitting and install a low-pressure air pressure gauge and hose. Now, pump up the tank with air but do not exceed 3 lbs of pressure.
Once the tank is pumped up, spray the sender and all the fittings and ports on the tank with soapy water. Keep an eye out for any air bubbles forming. If there are no air bubbles, check the tools to ensure that the vent and the fill hose are plugged off properly. Also, make sure that the pressure testing tool doesn't have any leaks around the tee-fitting, the gauge, or the Schrader valve.
This process of spraying with soapy water and checking for air bubbles helps to identify leaks in the tank, particularly in the fittings and sender, which are common sources of leaks. It is also a method used to identify air leaks in the fuel system.
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Check the bilge for signs of fuel
Checking the bilge for signs of fuel is a crucial step in identifying fuel leaks in boats. The bilge, being the lowest point in a boat, is where leaked fuel will accumulate. Thus, it is essential to regularly inspect this area for any signs of fuel accumulation.
To check the bilge for fuel, you'll need to open up the bilge compartment and look for any fuel floating on the water or collected in the bilge. If you notice fuel in the bilge, it indicates a problem, such as a leaking fuel tank or faulty fuel lines. It is important to address this issue promptly to prevent further complications and potential safety hazards.
In some cases, you may not always see visible fuel in the bilge. However, the presence of fuel stains, wet spots, or drips on the bilge floor or walls can also indicate a leak. Therefore, it is important to carefully inspect all areas of the bilge for any signs of fuel accumulation or related damage.
Additionally, the sense of smell can be a valuable tool in detecting fuel leaks. Fuel has a distinct odour, and you may notice a faint or strong smell of gasoline or diesel in the bilge area. If you detect this odour, it could signify a fuel leak, even if you don't see any visible signs of fuel.
It is important to note that fuel leaks can pose a severe risk and require prompt attention. If you suspect a fuel leak, it is advisable to consult a marine professional or seek guidance from boating forums and communities to address the issue effectively and ensure the safety of your vessel.
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Frequently asked questions
If you are experiencing fuel problems with your boat, such as a strong fuel smell or fuel in the bilge, you should consider testing your fuel tank.
You will need a pair of Hose Pinch Pliers, an Inflatable Pipe Plug, and a low-pressure air pressure gauge that can be tee-ed into a 3/8″ fuel hose with a Schrader valve. You will also need an air pump or a tank of compressed air.
First, locate the fuel fill hose and the vent hose access ports, as well as the fuel pick-up access. Install the inflatable pipe plug into the fuel fill port and pump it up to shut off the fuel fill hose. Pinch off the fuel tank vent hose and remove the fuel hose from the pickup tube fitting. Install the low-pressure air pressure gauge and hose and pump air into the tank, ensuring you do not exceed 3 lbs of pressure. Spray soapy water on the sender, fittings, and ports on the tank and look for air bubbles.
