Component Tests and General Diagnostics

Fuel System Diagnosis (China)

Diagnostic Instructions

* Perform the Diagnostic System Check - Vehicle Diagnostic System Check - Vehicle prior to using this diagnostic procedure.
* Review Strategy Based Diagnosis Strategy Based Diagnosis for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions Diagnostic Procedure Instructions provides an overview of each diagnostic category.

Circuit/System Description

The engine control module (ECM) supplies voltage to the fuel pump control module when the ECM detects that the ignition is ON. The voltage from the ECM to the fuel pump control module remains active for two seconds, unless the engine is in Crank or Run. While this voltage is being received, the fuel pump control module closes the ground switch of the fuel pump and also supplies a varying voltage to the fuel tank module in order to maintain the desired fuel rail pressure.

The fuel system is an electronic returnless on-demand design. A returnless fuel system reduces the internal temperature of the fuel tank by not returning hot fuel from the engine to the fuel tank. Reducing the internal temperature of the fuel tank results in lower evaporative emissions.

An electric turbine style fuel pump attaches to the primary fuel pump module inside the fuel tank. The fuel pump supplies fuel through the fuel filter and the fuel feed pipe to the high pressure fuel pump. The high pressure fuel pump supplies fuel to a variable-pressure fuel rail. Fuel enters the combustion chamber through precision multi-hole fuel injectors. The high pressure fuel pump, fuel rail pressure, fuel injection timing, and injection duration are controlled by the engine control module (ECM).

The primary fuel tank module also contains a primary jet pump and a secondary jet pump. Fuel pump flow loss, caused by vapor expulsion in the pump inlet chamber, is diverted to the primary jet pump and the secondary jet pump through a restrictive orifice located on the pump cover. The primary jet pump fills the reservoir of the primary fuel tank module. The secondary jet pump creates a venturi action which causes the fuel to be drawn from the secondary side of the fuel tank, through the fuel transfer pipe, to the primary side of the fuel tank.

Diagnostic Aids

The fuel injectors are calibrated to begin operating at 2 Mpa (290 psi) at 20-32°C (68-90°F). This specification will vary when the temperature is outside of this range.

Reference Information
Description and Operation

Fuel System Description Fuel System Description
Electrical Information Reference

* Circuit Testing Circuit Testing
* Connector Repairs Connector Repairs
* Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections
* Wiring Repairs Wiring Repairs

Scan Tool Reference

Control Module References Control Module References for scan tool information
Special Tools

* CH 48027 - Digital Pressure Gauge
* J 37287 - Fuel Line Shut-off Adapter
* For equivalent regional tools, refer to Special Tools (Diagnostic Tools) Special Tools (Diagnostic Tools).

Circuit/System Verification

Note:
* Repair all fuel system related DTCs before performing this diagnostic.
* Inspect the fuel system for damage or external leaks before proceeding.
* Verify that adequate fuel is in the fuel tank before proceeding.
* The Fuel Pump Enable may need to be commanded ON a few times in order to obtain the highest possible fuel pressure.
* Before proceeding with this test review the User Manual CH 48027-5 for Safety Information and Instructions.

1. Ignition OFF, all accessories OFF, install a CH 48027 - Gauge. Refer to Fuel Pressure Gauge Installation and Removal Testing and Inspection.

Note: DO NOT perform the Fuel System Diagnosis if the engine coolant temperature is above 60°C (150°F). High fuel pressure readings may result due to hot soak fuel boiling. With the engine OFF, the fuel pressure may increase beyond the pressure relief regulator valve's setting point of 690 kPa (100 psi) ± 5 percent.

2. Ignition ON, engine OFF, command the fuel pump ON with a scan tool. Verify the fuel pressure is between 345-690 kPa (50-100 psi) with the fuel pump running.
3. Engine idling at normal operating temperature, the Fuel Pump Flow Control Module Fuel Pressure Sensor parameter should read between 300-400 kPa (43-58 psi).

Circuit/System Testing

Note:
* The Fuel Pump Enable may need to be commanded ON a few times in order to obtain the highest possible fuel pressure.
* DO NOT start the engine.

1. Ignition ON, engine OFF, command the Fuel Pump Enable ON with a scan tool and observe the fuel pressure gauge while the fuel pump is operating. Verify the fuel pressure is between 345-690 kPa (50-100 psi).

• If the fuel pressure is greater than the specified range test for a restriction in the return side of the fuel filter. If the fuel filter tests normal, replace the primary fuel tank module.
• If the fuel pressure is less than the specified range, test, inspect, and repair the items listed below. If all items test normal, replace the primary fuel tank module.

* Restricted fuel feed pipe
* Restricted or plugged fuel filter
* Inspect the harness connectors and the ground circuits of the fuel pump for poor connections.

2. Verify that the fuel pressure, after the fuel pump is turned off, decreases to 500-599 kPa (72-87 psi), and does not decrease more than 34 kPa (5 psi) in 1 minute from that point.

• If the fuel pressure stays above 600 kPa (87 psi), replace the primary fuel tank module.
• If the fuel pressure decreases more than the specified value, perform the following procedure:

1. Ignition OFF, relieve the fuel pressure. Refer to Fuel Pressure Relief Service and Repair.
2. Install the J 37287 - Adapter between the chassis fuel feed hose and the engine compartment fuel feed pipe.
3. Open the valve on the J 37287 - Adapter.
4. Ignition ON, command the Fuel Pump Enable ON with a scan tool and bleed the air from the CH 48027 - Gauge.
5. Command the Fuel Pump Enable ON and then OFF with a scan tool.
6. Close the valve on the J 37287 - Adapter.
7. Monitor the fuel pressure for 1 min.

• If the fuel pressure does not decrease more than 34 kPa (5 psi) within the specified time, replace the primary fuel tank module.

3. Relieve the fuel pressure to 69 kPa (10 psi). Verify that the fuel pressure does not decrease more than 14 kPa (2 psi) in 5 min.

• If the fuel pressure decreases more than the specified value, replace the primary fuel tank module.

4. Operate the vehicle within the conditions of the customer's concern while monitoring the fuel pressure with the CH 48027 - Gauge. The fuel pressure should not drop off during acceleration, cruise or hard cornering.

• If the fuel pressure drops off, test, inspect, and repair the items listed below. If all items test normal, replace the primary fuel tank module.

* Restricted fuel feed pipe
* Restricted or plugged fuel filter
* Inspect the harness connectors and the ground circuits of the fuel pump for poor connections

5. If the fuel system tests normal, refer to Symptoms - Engine Controls Symptoms - Engine Controls , Fuel Injector Solenoid Coil Test Fuel Injector Solenoid Coil Test , and Fuel Injector Balance Test Fuel Injector Balance Test.

Repair Instructions

Perform the Diagnostic Repair Verification Verification Tests after completing the diagnostic procedure.

* Fuel Feed Pipe Replacement (Engine) Fuel Feed Pipe Replacement (Engine)
* Fuel Filter Replacement (China) Fuel Filter Replacement (China)
* Fuel Injector Replacement Service and Repair
* Fuel Line Replacement - Chassis Fuel Line Replacement - Chassis
* Primary Fuel Tank Module Replacement (China) Primary Fuel Tank Module Replacement (China)