Fuel Delivery System Test
Fuel Delivery System Test
For a complete wiring diagram, refer to.
Test Step 1 - Check Fuel Pump Operation
• Turn the ignition on.
• Diagnose and repair any fuel pump control circuit or relay DTCs before continuing with this test.
• With a scan tool, actuate the fuel pump control to ON (100%).
• It may be necessary to use a mechanics stethoscope in the next step.
• Listen for fuel pump operation at the fuel tank. The fuel pump should operate smoothly, without excessive noise. If necessary, compare to a known good vehicle of similar year, make, and model.
• If the pump has excessive noise or grinding, the pump should be replaced.
Stop all actuation tests before continuing.
Does the fuel pump operate when actuated?
Yes
• Go to Test Step 2
No
• Go to Test Step 7
Test Step 2 - Check Fuel Pressure
• Turn the ignition off.
The fuel system is under a constant pressure even with the engine off. Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury.
• Install a fuel pressure gauge on the fuel rail.
• Turn the ignition on.
• With the scan tool, actuate the fuel pump relay control. Observe the fuel pressure gauge.
• The fuel pressure specification is 407 KPa +/- 34 KPa (59 psi +/- 5 psi).
Stop all actuation tests before continuing.
Select the conclusion that best matches the result of the test:
Fuel pressure is within the stated specification
• Test complete.
Fuel pressure is less than the stated specification
• Go to Test Step 3
Fuel pressure is more than the stated specification
• Replace the fuel filter/pressure regulator.
• Perform the PCM Verification Test. Refer to => [ PCM Verification Test ] PCM Verification Test.
Test Step 3 - Restricted Fuel Supply Line
• Turn the ignition off.
The fuel system is under a constant pressure, even with the engine off. Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury.
• Raise vehicle on hoist, and disconnect the fuel pressure line at the fuel pump module.
• Install special 5/16 fuel line adapter tool #6539 between disconnected fuel line and the fuel pump module.
• Attach a fuel pressure test gauge to the T fitting on tool #6539.
• Turn the ignition on.
• With the scan tool, actuate the fuel pump relay control. Observe the fuel pressure gauge.
• Fuel pressure specification is 407 KPa +/- 34 KPa (59 psi +/- 5 psi).
Stop all actuation tests before proceeding.
Is the fuel pressure within specification?
Yes
• Repair or replace fuel supply line as necessary.
• Perform the PCM Verification Test. Refer to => [ PCM Verification Test ] PCM Verification Test.
No
• Go to Test Step 4
Test Step 4 - Saddle Fuel Tank
Is the vehicle equipped with a saddle type fuel tank?
Yes
• Go to Test Step 5
No
• Go to Test Step 6
Test Step 5 - Fuel Tank Siphon Hose or Fuel Line Restricted or Damaged
• Turn the ignition off.
The fuel system is under a constant pressure, even with the engine off. Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury.
• Gain access to the fuel pump module and the fuel tank module.
• Inspect the fuel line and siphon hose between the fuel pump module and the fuel tank module. Look for disconnected or damaged lines and hoses.
• Inspect the fuel pressure regulator for damage or a condition that might cause a fuel flow problem. Make sure that it is seated in the module properly.
Were any problems found?
Yes
• Repair as necessary.
• Perform the PCM Verification Test. Refer to => [ PCM Verification Test ] PCM Verification Test.
No
• Go to Test Step 6
Test Step 6 - Fuel Pump Inlet Strainer
• Turn the ignition off.
The fuel system is under a constant pressure even with the engine off. Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury.
• Remove the fuel pump module and inspect the fuel inlet strainer for damage or a condition that might cause a fuel flow problem.
Were any problems found?
Yes
• Replace the fuel pump inlet strainer.
• Perform the PCM Verification Test. Refer to => [ PCM Verification Test ] PCM Verification Test.
No
• Replace the fuel pump module.
• Perform the PCM Verification Test. Refer to => [ PCM Verification Test ] PCM Verification Test.
Test Step 7 - Fuel Pump Ground Circuit Open or High Resistance
• Turn the ignition off.
• Disconnect the fuel pump module harness connector.
• Using a test lamp connected to 12 volts, check the fuel pump motor ground circuit at the fuel pump module harness connector.
• The test lamp should be illuminated and bright. Compare the brightness to that of a direct connection to the battery.
Is the test lamp brightly illuminated?
Yes
• Replace the fuel pump module.
• Perform the PCM Verification Test. Refer to => [ PCM Verification Test ] PCM Verification Test.
No
• Repair the fuel pump ground circuit for an open circuit or high resistance.
• Perform the PCM Verification Test. Refer to => [ PCM Verification Test ] PCM Verification Test.