Fuel Pump: Testing and Inspection

Fuel Tank Assembly:

Fuel Pump:

FUEL PUMP ELECTRICAL CHECK

1. Turn ignition "ON" and listen for fuel pump.

^ Fuel pump should run for approx. 5 seconds when ignition is turned "ON" (should be audible but you may need a second person listening at the fuel filler with the filler cap removed, to tell if it's operating).

If OK, go to FUEL PUMP PRESSURE AND CHECK VALVE TEST (below).

If not OK, check fuel pump relay and fuse #13.

Fuel Pump Relay Socket Terminal ID:

2. Remove fuel pump relay and connect jumper wire between receptacle terminals #48 and #52.

^ Fuel pump should run (should be audible, but you may need a second person listening at the fuel filler with the filler cap removed, to tell if it's operating).

Fuel Tank Electrical Harness Connector:

If not, disconnect electrical connector at the tank and repeat step 3 while monitoring voltage between terminals #1 and #4 of the harness connector at the tank.

^ Should have battery voltage while jumper wire is connected. If voltage is OK and pump does not run, replace pump. If no voltage is present, check for open or short to ground in wiring between fuel pump relay terminal #52 and fuse #13, or between fuse #13 and fuel pump.

FUEL PUMP PRESSURE AND CHECK VALVE TEST

Connecting Fuel Pressure Gauge:

1. Disconnect fuel supply line from fuel rail and connect to fuel pressure gauge as shown in illustration (shut-off valve in the closed position).
2. Operate fuel pump until gauge pressure is approx. 73 psi (5 bar), then turn pump "OFF". (Operate pump by bridging terminals of fuel pump relay socket as in step 2 of electrical test above.)

NOTE: If pressure excedes the specified value, bleed off excess pressure by carefully opening shut-off valve on gauge. Cover with clean rag to avoid spraying fuel.

If after 10 seconds of pump operation the specified pressure is not reached, check for plugged fuel filter or kinked/pinched fuel supply line. If filter and line are OK, replace fuel pump.

3. Wait 10 minutes then observe residual pressure on gauge.

^ Should be 49 psi (3.4 bar) minimum.

If less than specified and there are no leaks, replace fuel pump check valve.

FUEL PUMP VOLUME TEST

1. Reconnect fuel supply line to fuel rail (line must be connected because this test checks for adequate volume under normal pressure).

Checking Fuel Pump Volume:

2. Disconnect fuel return line at connector next to fuel distributor (see illustration), and direct outlet from fuel distributor into suitable measuring container. You may need to add an extra piece of hose to do this safely.
3. Remove fuel filler cap.
4. Connect voltmeter between electrical terminals of fuel pump, with pump connected.
5. Energize fuel pump for 15 seconds (see step 2 of electrical test above) and note operating voltage at the pump.

Fuel Pump Volume Vs. Supply Voltage:

6. Check volume of fuel in container after 15 seconds of operation and compare with chart.

^ If volume is less than that specified for the noted operating voltage, check for restricted or plugged fuel filter and/or supply line. If filter and line are OK, replace fuel pump.