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Test NS-4: Start & Stall Condition

NOTE: For circuit identification, see WIRING DIAGRAMS article. After each repair procedure has been completed, reconnect all components. Perform TEST VER-1  to ensure system is functioning properly.
WARNING: Fuel system is under high pressure and fuel pressure must be released before opening fuel system. See FUEL SYSTEM PRESSURE RELEASE .
  1. Turn ignition off. Release fuel pressure. On 2.7L engine, use Adapter (6539) between fuel rail and fuel supply line, then connect Fuel Pressure Gauge (C-4799-B) to adapter. On 3.2L and 3.5L, connect Fuel Pressure Gauge (C-4799-B) to fuel rail. On all vehicles, turn ignition on. Using scan tool, actuate ASD fuel system test. Observe and record fuel pressure. Fuel pressure should be 54-64 (3.8-4.5 kg/cm2 ). Stop fuel system activation. If fuel pressure is less than specified, go to next step. If fuel pressure is as specified, go to step  12. If fuel pressure is more than specified, replace fuel filter/pressure regulator.
  2. Turn ignition on. Using scan tool, read TP sensor voltage while slowly opening and closing throttle. If voltage change is smooth, go to next step. If voltage change is not smooth, replace TP sensor.
  3. Turn ignition on. Using scan tool, read TP sensor voltage. Ensure throttle is closed against throttle stop. If voltage is .92 volt or less, no problem is indicated at this time. Test is complete. If voltage is more than .92 volt, check for binding throttle. Repair throttle linkage as necessary. If throttle is not binding, replace TP sensor.
  4. Using scan tool, select INPUTS/OUTPUTS and read VEH THEFT SECURITY status. If scan tool indicates FUEL ON, go to next step. If scan tool indicates FUEL OFF, use scan tool and toggle FUEL ON. Recheck system operation.
  5. Turn ignition off. Remove rear seat to access fuel pump module 10-pin C308 in-line connector. Disconnect fuel pump module 10-pin C308 connector. Visually inspect connector for corroded, damaged, pushed-out or miswired terminals. Repair connector as necessary. If connector is okay, turn ignition on. Using scan tool, actuate ASD fuel system test. Using a test light connected to ground, probe Dark Green/White wire at C308 harness connector. If test light illuminates brightly, stop fuel system activation and go to next step. If test light is not illuminated or is not bright, repair high resistance or open in Dark Green/White wire between C308 connector and terminal "D" at fuel pump relay socket in PDC. See Figure.
    NOTE: To diagnose the following step, thermostat is assumed to be functioning properly. Manufacturer also recommends allowing vehicle to sit overnight in order to have a totally cold engine.
  6. Turn ignition on. Using scan tool, read ENG COOLANT TPM DEG value. If engine was allowed to sit overnight, scan tool temperature value should be near ambient air temperature. If engine coolant temperature is more than 180°F (82.2°C), allow engine coolant temperature to cool down to 150°F (65.5.°C) before proceeding. If engine coolant temperature is 150°F (65.5°C) or less, start engine. Using scan tool, monitor ENG COOLANT TPM DEG until engine coolant temperature reaches 180°F (82.2°C). Temperature value should increase smoothly from start-up to normal operating temperature and temperature should reach at least 180°F (82.2°C). If temperature value increased smoothly and temperature reached at least 180°F (82.2°C), go to next step. If temperature value did not increase smoothly and/or temperature did not reach at least 180°F (82.2°C), replace ECT sensor.
  7. Turn ignition off. With a test light connected to positive battery terminal, probe Black wire at C308 harness connector. If test light illuminates brightly, reconnect C308 connector and go to next step. If test light is not illuminated or is not bright, repair high resistance or open in Black wire between C308 connector and ground. Ground is located under passenger's seat.
  8. Inspect fuel supply line between fuel tank and fuel rail for signs of damage or restrictions. If no signs of damage or restrictions exist in fuel supply line, go to next step. If signs of damage or restrictions exist in fuel supply line, repair or replace fuel supply line as necessary.
  9. Check the following additional items as a possible cause for a start and stall condition:
    • Ensure engine valve timing is within specification.
    • Ensure engine compression is within specification.
    • Ensure engine exhaust system is free of restrictions.
    • Ensure fuel is not contaminated.
    • Check for any technical service bulletins that may apply.

    Repair any mechanical problems as necessary. If no mechanical problems exist, go to next step.

  10. Remove fuel pump module from fuel tank. See FUEL PUMP MODULE under FUEL SYSTEMS in appropriate REMOVAL, OVERHAUL & INSTALLATION article. Inspect fuel pump inlet strainer on bottom of fuel pump module for restrictions. If fuel pump inlet strainer is not restricted, replace fuel pump module. If fuel pump inlet strainer is restricted, replace fuel pump inlet strainer.
  11. At this time, fuel pump module is assumed to be defective. Replace fuel pump module.
  12. Turn ignition on. Using scan tool, read TP sensor voltage while slowly opening and closing throttle. If voltage change is smooth, go to next step. If voltage change is not smooth, replace TP sensor.
  13. Turn ignition on. Using scan tool, read TP sensor voltage. Ensure throttle is closed against throttle stop. If voltage is .92 volt or less, no problem is indicated at this time. Test is complete. If voltage is more than .92 volt, check for binding throttle. Repair throttle linkage as necessary. If throttle is not binding, replace TP sensor.
  14. Using scan tool, select INPUTS/OUTPUTS and read VEH THEFT SECURITY status. If scan tool indicates FUEL ON, go to next step. If scan tool indicates FUEL OFF, use scan tool and toggle FUEL ON. Recheck system operation.
    NOTE: To diagnose the following step, thermostat is assumed to be functioning properly. Manufacturer also recommends allowing vehicle to sit overnight in order to have a totally cold engine.
  15. Turn ignition on. Using scan tool, read ENG COOLANT TPM DEG value. If engine was allowed to sit overnight, scan tool temperature value should be near ambient air temperature. If engine coolant temperature is more than 180°F (82.2°C), allow engine coolant temperature to cool down to 150°F (65.5.°C) before proceeding. If engine coolant temperature is 150°F (65.5°C) or less, start engine. Using scan tool, monitor ENG COOLANT TPM DEG until engine coolant temperature reaches 180°F (82.2°C). Temperature value should increase smoothly from start-up to normal operating temperature and temperature should reach at least 180°F (82.2°C). If temperature value increased smoothly and temperature reached at least 180°F (82.2°C), go to next step. If temperature value did not increase smoothly and/or temperature did not reach at least 180°F (82.2°C), replace ECT sensor.
  16. Turn ignition off. Release fuel pressure. Disconnect fuel supply from fuel rail. Connect Fuel Line Adapter (6539 for 5/16" fuel line or 6631 for 3/8" fuel line) to disconnected fuel supply line. Place other end of fuel line adapter in graduated cylinder. Turn ignition on. Using scan tool, actuate ASD fuel system test to operate fuel pump for no more than 7 seconds and note fuel pump volume. DO NOT operate fuel pump for more than 7 seconds or fuel pump may be damaged. Stop ASD fuel system test and go to next step.
  17. Fuel pump volume should be at least .52 pint (.25 liter) in 7 seconds. If fuel pump volume is as specified, remove fuel line adapter, reconnect fuel supply line and go to next step. If fuel pump volume is not as specified, remove fuel line adapter and reconnect fuel supply line. Check for restricted fuel supply line between fuel rail and fuel pump module on top of fuel tank. If no kinks or restrictions exist in fuel supply line, improper fuel pump volume may be caused by restricted fuel pump inlet strainer on bottom of fuel pump module or defective fuel pump module. Replace components as necessary.
  18. Check the following additional items as a possible cause for a start and stall condition:
    • Ensure engine valve timing is within specification.
    • Ensure engine compression is within specification.
    • Ensure engine exhaust system is free of restrictions.
    • Ensure fuel is not contaminated.
    • Check for any technical service bulletins that may apply.

    Repair any mechanical problems as necessary. If no mechanical problems exist, go to next step.

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