Fuel System Inspection Checklist

This fuel system inspection checklist provides systematic evaluation of all fuel delivery and evaporative emission components to identify fire hazards, fuel leaks, and emissions failures. Aligned with NFPA 30A (Motor Fuel Dispensing), EPA EVAP system requirements under the Clean Air Act, and OSHA 29 CFR 1910.106 (flammable liquid safety). Perform this inspection whenever fuel odor, driveability concerns, or fuel system warning lights are reported.

Industry: Automotive Service
Frequency: Per Customer Complaint / Annual
Estimated Time: 30-45 minutes
Role: Master Technician / Fuel System Diagnostic Technician
Total Items: 30
Compliance: NFPA 30A (Motor Fuel Dispensing Facilities), EPA Clean Air Act - EVAP System Standards, OSHA 29 CFR 1910.106 (Flammable Liquids), SAE J1297 Alternative Fuel Standards, EPA OBD-II EVAP Monitor Requirements

Fuel Tank & Fuel Line Integrity

Inspect fuel tank and all fuel lines for leaks, corrosion, and physical damage. Fuel leaks are a fire and safety hazard requiring immediate repair.

Fuel tank free of corrosion holes, physical damage, and fuel odor?
All steel and rubber fuel lines free of cracks, corrosion, and chafing damage?
Fuel lines properly secured and routed away from heat sources and sharp edges?
Fuel filler neck and cap gasket intact - no fuel odor or visible cracks?
Fuel cap seals correctly and passes pressure retention (no EVAP P0455)?
No active fuel leaks found anywhere in fuel system?

Fuel Pump & Delivery System

Verify fuel pump pressure and volume delivery meets engine fuel system specifications for reliable starting and performance.

Fuel pressure at specification for fuel system type (typically 45-65 PSI for port injection)?
Fuel pressure holds after engine shutdown (no rapid drop indicating check valve or injector leak)?
Fuel pump volume output adequate (should deliver minimum 1 pint / 16 oz per minute)?
Fuel pump operates quietly - no whine, groan, or laboring sound?
Fuel filter within service interval or replaced if restricted (where serviceable)?

Fuel Injector Condition & Performance

Assess fuel injector operation and spray pattern for efficient combustion and emissions compliance.

Fuel injector balance test shows no more than 3-5% variation between cylinders?
No injector circuit codes (P0200-P0261 series) present in ECM?
Engine idle quality smooth - no misfires, roughness, or rich/lean cylinder?
Injector O-rings and seals leak-free (no fuel odor or wet spots at injectors)?

EVAP System Inspection

Inspect evaporative emission control system components. EVAP leaks cause hydrocarbon emissions and OBD-II monitor failures.

No EVAP system fault codes (P0440-P0458 series) in ECM memory?
EVAP charcoal canister free of fuel saturation (no raw fuel smell from canister)?
EVAP purge valve activates on command - no stuck open or closed condition?
EVAP vent valve operates correctly and EVAP system holds vacuum?
Smoke test performed (if EVAP code present) - all leaks located and documented?

Fuel System Safety & Fire Hazard Assessment

Final safety assessment ensuring no fuel-related fire hazards exist before returning vehicle to customer.

No fuel odor detected inside vehicle cabin or trunk?
Fire extinguisher accessible in work area during fuel system work?
Engine bay free of accumulated fuel residue or wet spots after service?
Road test completed with no driveability concerns or fuel system warning lights?
Customer advised of all fuel system findings - safety items clearly communicated?
Fuel system repair urgency rated (OK / Monitor / Immediate Safety Repair)?
Written repair estimate provided for identified fuel system issues?

Fuel Economy & Efficiency Assessment

Identify fuel system issues affecting fuel economy.

Short-term and long-term fuel trims within +/- 5% (indicates no major mixture issue)?
MAF sensor output within specification at idle and WOT?
Throttle body clean - no heavy carbon buildup on blade or bore?

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Why Use This Fuel System Inspection Checklist?

This fuel system inspection checklist helps automotive service teams maintain compliance and operational excellence. Designed for master technician / fuel system diagnostic technician professionals, this checklist covers 30 critical inspection points across 6 sections. Recommended frequency: per customer complaint / annual.

Ensures compliance with NFPA 30A (Motor Fuel Dispensing Facilities), EPA Clean Air Act - EVAP System Standards, OSHA 29 CFR 1910.106 (Flammable Liquids), SAE J1297 Alternative Fuel Standards, EPA OBD-II EVAP Monitor Requirements, UK Petroleum Consolidation Act, India Motor Vehicles Act - Fuel System Requirements. Regulatory-aligned for audit readiness and inspection documentation.

Frequently Asked Questions

What does the Fuel System Inspection Checklist cover?

This checklist covers 30 inspection items across 6 sections: Fuel Tank & Fuel Line Integrity, Fuel Pump & Delivery System, Fuel Injector Condition & Performance, EVAP System Inspection, Fuel System Safety & Fire Hazard Assessment, Fuel Economy & Efficiency Assessment. It is designed for automotive service operations and compliance.

How often should this checklist be completed?

This checklist should be completed per customer complaint / annual. Each completion takes approximately 30-45 minutes.

Who should use this Fuel System Inspection Checklist?

This checklist is designed for Master Technician / Fuel System Diagnostic Technician professionals in the automotive service industry. It can be used for self-assessments, team audits, and regulatory compliance documentation.

Can I download this checklist as a PDF?

Yes, this checklist is available as a free PDF download. You can also use it digitally in the POPProbe mobile app for real-time data capture, photo documentation, and automatic reporting.