Fuel Pump: Testing and Inspection

Fuel System Pressure Test





WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury.

WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury.

All vehicles

1. Release the fuel system pressure. For additional information, refer to Fuel System Pressure Release Service and Repair.

2. Disconnect the battery ground cable. For additional information, refer to Battery.

Vehicles with 2.5L engine

3. Disconnect the fuel jumper tube-to-fuel rail quick connect coupling. For additional information, refer to Quick Connect Coupling Quick Connect Coupling.

4. Install the Fuel Pressure Test Kit between the fuel jumper tube and the fuel rail.





Vehicles with 3.0L engine

5. Disconnect the fuel jumper tube-to-fuel tube quick connect coupling. For additional information, refer to Quick Connect Coupling Quick Connect Coupling.

6. Install the Fuel Pressure Test Kit between the fuel jumper tube and the fuel tube.





All vehicles

7. NOTE: The Fuel Pump (FP) module fuse was removed previously to release the fuel system pressure and must be installed to test the fuel system pressure.

Install the FP module fuse.

8. Connect the battery ground cable. For additional information, refer to Battery.

9. NOTE: It may take more than one key cycle to pressurize the fuel system.

Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine.

10. NOTE: When the fuel system pressure test is completed, open the drain valve on the Fuel Pressure Test Kit and release fuel system pressure and drain any residual fuel into a suitable container prior to removing the tool.

Test the fuel system pressure to make sure it is within the specified range. For additional information, refer to Specifications.