Fuel System Diagnosis
Fuel System Diagnosis |
Diagnostic Instructions |
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Perform the
Diagnostic System Check - Vehicle
prior to using this diagnostic procedure.
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Review
Strategy Based Diagnosis
for an overview of the diagnostic approach.
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Diagnostic Procedure Instructions
provides an overview of each diagnostic category.
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Circuit/System Description |
When the ignition is turned ON, the engine control module (ECM) supplies power to the in-tank fuel pump, by energizing the fuel pump relay. The in-tank fuel pump remains ON as long as the engine is cranking or running and the ECM receives crankshaft reference pulses. If there are no reference pulses, the ECM turns the in-tank fuel pump OFF, 2 s after the ignition switch is turned ON or 2 s after the engine stops running. The electric fuel pump is incorporated into the modular fuel pump and sender assembly and is located inside the fuel tank. The fuel pump supplies fuel through a fuel filter, also located in the modular fuel pump and sender assembly, through the fuel feed pipes, to the fuel rail assembly. The fuel pump provides fuel at a pressure above the pressure needed by the fuel injectors. The fuel pressure regulator, located in the modular fuel pump and sender assembly, keeps the fuel available to the fuel injectors at a regulated pressure. When the fuel pressure rises above the pressure regulator calibration, the pressure is relieved, with excess fuel exhausted into the modular fuel pump and sender assembly reservoir.
Reference Information |
Description and Operation
Fuel System Description
Electrical Information Reference
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Circuit Testing
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Connector Repairs
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Testing for Intermittent Conditions and Poor Connections
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Wiring Repairs
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Scan Tool Reference
Control Module References for scan tool information
Special Tools
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CH48027
Digital Pressure Gauge
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EN 37287
Fuel Line Shut-Off Adapters
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For equivalent regional tools, refer to Special Tools .
Circuit/System Verification |
Note | ||
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Inspect the fuel system for damage or external leaks before proceeding.
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Verify that an adequate amount of fuel is in the fuel tank before proceeding.
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The fuel pump relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure.
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1. |
Ignition ON, command the KR23A Fuel Pump Relay ON with a scan tool. You should hear the G12 Fuel Pump turn ON and OFF.
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2. |
If the G12 Fuel Pump does not turn ON, refer to
Fuel Pump Electrical Circuit Diagnosis
.
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3. |
Ignition OFF and all accessories off, install the
CH 48027
Digital Pressure Gauge.
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4. |
Ignition ON, command the KR23A Fuel Pump Relay ON with a scan tool. Verify the fuel pressure is between 365-414 kPa (53-60 PSI) and remains steady for 5 m.
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Circuit/System Testing |
1. |
Ignition ON, engine OFF, command the KR23A Fuel Pump Relay ON with a scan tool and observe the fuel pressure gauge while the G12 Fuel Pump is operating. Verify the fuel pressure is between 345-414 kPa (50-60 PSI). |
2. |
If the fuel pressure is greater than the specified range, replace the G12 Fuel Pump.
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3. |
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 G12 Fuel Pump.
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Restricted fuel feed pipe
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Restricted or clogged strainer
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Restricted or plugged fuel filter
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Inspect the G12 Fuel Pump harness connectors and the ground circuits of the fuel pump for poor connections.
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4. |
Verify the fuel pressure does not decrease greater than 34 kPa (5 PSI) in 1 min. |
5. |
If the fuel pressure decreases more than the specified value, perform the following procedure:
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5.1. |
Ignition OFF, relieve fuel pressure.
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5.2. |
Install the
EN 37287
Fuel Line Shut-Off Adapters between the fuel feed pipe and the fuel rail.
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5.3. |
Open the valve on the
EN 37287
Fuel Line Shut-Off Adapter.
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5.4. |
Ignition ON, command the fuel pump relay ON with a scan tool and bleed the air from the digital pressure gauge.
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5.5. |
Close the valve on the
EN 37287
Fuel Line Shut-Off Adapters.
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5.6. |
Verify the fuel pressure does not decrease greater than 34 kPa (5 PSI) in 1 minute.
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5.7. |
If the fuel pressure decreases more than 34 kPa (5 PSI) within the specified time, locate and replace the leaking fuel injector(s).
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5.8. |
If the fuel pressure does not decrease more than 34 kPa (5 PSI) within the specified time, replace the G12 Fuel Pump.
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6. |
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.
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7. |
If the fuel pressure decreases more than the specified value, replace the G12 Fuel Pump.
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8. |
Remove the
EN 37287
Fuel Line Shut-Off Adapters and
CH 48027
Digital Pressure Gauge.
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9. |
Operate the vehicle within the conditions of the customers concern while monitoring fuel related parameters with a scan tool. The scan tool parameters should not indicate a lean condition.
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10. |
If the scan tool parameters indicate a lean condition, test for a restricted fuel feed pipe, restricted fuel filter, or poor connections at the harness connectors and ground circuits of the fuel pump. If all test normal, replace the fuel pump.
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11. |
If the fuel system tests normal, refer to
Symptoms - Engine Controls
.
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Repair Instructions |
Perform the Diagnostic Repair Verification after completing the diagnostic procedure.
Fuel Tank Fuel Pump Module Replacement