Aircraft Fuel System Repair. Troubleshooting the Fuel System. Location of Leaks and Defects. Close visual inspection is required whenever a leak or defect is suspected in a fuel system. Leaks can often be traced to the connection point of two fuel lines o

Aircraft Fuel System Repair

The integrity of an aircraft fuel system is critical and should not be compromised. Any evidence of malfunction or leak should be addressed before the aircraft is released for flight. The danger of fire, explosion, or fuel starvation in flight makes it imperative that fuel system irregularities be given top priority. Each manufacturer’s maintenance and operation instructions must be used to guide the technician in maintaining the fuel system in airworthy condition. Follow the manufacturer’s instructions at all times. Component manufacturers and STC holder instructions should be used when applicable. Some general instructions for fuel system maintenance and repair are given in the following sections.

Troubleshooting the Fuel System

Knowledge of the fuel system and how it operates is essential when troubleshooting. Manufacturers produce diagrams and descriptions in their maintenance manuals to aid the technician. Study these for insight. Many manuals have troubleshooting charts or flow diagrams that can be followed. As with all troubleshooting, a logical sequence of steps to narrow the problem to a specific component or location should be followed. Defects within the system can often be located by tracing the fuel flow from the tank through the system to the engine. Each component must be functioning as designed and the cause of the defect symptom must be ruled out sequentially.

Location of Leaks and Defects

Close visual inspection is required whenever a leak or defect is suspected in a fuel system. Leaks can often be traced to the connection point of two fuel lines or a fuel line and a component. Occasionally, the component itself may have an internal leak. Fuel leaks also occur in fuel tanks and are discussed below. Leaking fuel produces a mark where it travels. It can also cause a stronger than normal odor. Gasoline may collect enough of its dye for it to be visible or an area clean of dirt may form. Jet fuel is difficult to detect at first, but it has a slow evaporation rate. Dirt and dust eventually settle into it, which makes it more visible. When fuel leaks into an area where the vapors can collect, the leak must be repaired before flight due to the potential for fire or explosion. Repair could be deferred for external leaks that are not in danger of being ignited. However, the source of the leak should be determined and monitored to ensure it does not become worse. Follow the aircraft manufacturer’s instructions on the repair of fuel leaks and the requirements that need to be met for airworthiness. Detailed visual inspection can often reveal a defect.

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