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Test NS-5: Checking Fuel System (3.0L)

NOTE: For connector terminal ID, see CONNECTOR IDENTIFICATION  . For wiring diagram, see WIRING DIAGRAMS article.
  1. Ensure throttle cables at throttle body are not holding the throttle open. If throttle cables are not holding throttle open, go to next step. If throttle cables are holding throttle open, repair components as necessary. Perform TEST VER-1A  .
  2. Turn ignition on with engine off. Using scan tool, actuate ASD fuel system test. Check for fuel pump operating sound at fuel pump. Fuel pump is located in the fuel tank. If fuel pump operates, go to next step. If fuel pump does not operate, go to step  15 .
  3. Ensure ignition is off. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE  . Connect Fuel Pressure Adapter (6433) and fuel pressure gauge at fuel supply line, located at front of fuel rail, near air intake plenum.
  4. Ensure fuel tank is at least 1/4 full. Turn ignition on with engine off. Using scan tool, actuate ASD fuel system test and note fuel pressure. Fuel pressure should be 43-53 psi (3.0-3.7 kg/cm2 ). If fuel pressure exceeds specification, go to next step. If fuel pressure does not exceed specification, go to step  8 .
  5. Using scan tool, stop actuation of ASD fuel system test. Turn ignition off. Release fuel pressure. Remove fuel pressure gauge. Reinstall fuel supply line.
  6. Inspect fuel filter for restrictions. Fuel filter is located on top of fuel tank, near fuel pump module on top of fuel tank. See Figure . Fuel lines are permanently attached to fuel filter. If necessary to remove fuel filter, disconnect fuel lines at fuel pump module and fuel supply line. If fuel filter is not restricted, go to next step. If fuel filter is restricted, replace fuel filter. Perform TEST VER-1A  .
  7. Inspect fuel return line between fuel pump module and fuel filter for restrictions. If fuel return line is not restricted, replace fuel pressure regulator. Fuel pressure regulator is mounted on bottom of fuel pump module located on top of fuel tank. Perform TEST VER-1A  . If fuel return line is restricted, replace fuel return line. Perform TEST VER-1A  .
  8. Recheck fuel pressure. Record fuel pressure. Fuel pressure should be 43-53 psi (3.0-3.7 kg/cm2 ). If fuel pressure is less than specified, go to next step. If fuel pressure is within specification, test is complete.
  9. Using scan tool, stop actuation of ASD fuel system test. Turn ignition off. Release fuel pressure. Remove fuel pressure gauge. Reinstall fuel supply line. Install Fuel Pressure Adapter (6631) and fuel pressure gauge on fuel supply line between fuel pump outlet on fuel pump module and fuel filter. See Figure .
  10. Turn ignition on with engine off. Using scan tool, actuate ASD fuel system test and note fuel pressure. If fuel pressure is not at least 2 psi (.14 kg/cm2 ) more than fuel pressure recorded in step  8 , go to next step. If fuel pressure is at least 2 psi (.14 kg/cm2 ) more than fuel pressure recorded in step  8 , replace fuel filter. Perform TEST VER-1A  .
  11. Using scan tool, stop actuation of ASD fuel system test. Turn ignition off. Release fuel pressure. Remove fuel pressure gauge and fuel pressure adapter. Reinstall fuel supply line. Remove fuel pump module with fuel pump from fuel tank.
  12. Inspect fuel pump inlet strainer on bottom of fuel pump for restrictions. If fuel pump inlet strainer is not restricted, reinstall fuel pump module. Go to next step. If fuel pump inlet strainer is restricted, replace fuel pump inlet strainer. Perform TEST VER-1A  .
  13. Ensure ignition is off. Release fuel pressure if not previously done. Install fuel pressure adapter and fuel pressure gauge between fuel filter outlet and chassis fuel supply line to the fuel rail. Fuel filter is located on top of fuel tank, near fuel pump module on top of fuel tank. See Figure .
  14. Ensure fuel tank is at least 1/4 full. Turn ignition on with engine off. Using scan tool, actuate ASD fuel system test and note fuel pressure. Record fuel pressure. If fuel pressure is not at least 2 psi (.14 kg/cm2 ) more than fuel pressure recorded in step  8 , replace fuel pump module. Perform TEST VER-1A  . If fuel pressure is at least 2 psi (.14 kg/cm2 ) more than fuel pressure recorded in step  8 , repair restriction in chassis fuel supply line between fuel filter and fuel rail. Perform TEST VER-1A  .
  15. Ensure ignition is off. Disconnect fuel pump module connector. Fuel pump module is located on top of fuel tank. See Figure . This is the connector for fuel pump and fuel level sending unit.
  16. Ensure fuel pump module connector terminals are clean and have a tight fit on fuel pump module. Using ohmmeter, check resistance between ground and terminal No. 1 (Black wire) on fuel pump module connector. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open ground circuit on Black wire between fuel pump module and ground connection. Ground connection is located on ground junction block located behind driver's side rear quarter trim panel, just behind rear wheel. Perform TEST VER-1A  .
  17. Turn ignition off. Remove fuel pump relay. Fuel pump relay is located in power distribution center at driver's side front corner of engine compartment, near battery. See Figure .
  18. Turn ignition on with engine off. Note cavities in power distribution center for fuel pump relay. See Figure .
  19. Using voltmeter, check voltage at cavity No. 30 in power distribution center for fuel pump relay. See Figure . This is the fused B+ circuit from fuse No. 5 (20-amp) to fuel pump relay. If voltage is more than 10 volts, go to next step. If voltage is 10 volts or less, check for defective fuse No. 5 or repair open from battery to fuse No. 5 and to fuel pump relay. Fuse No. 5 is located in power distribution center at driver's side front corner of engine compartment, near battery and receives constant battery voltage. Perform TEST VER-1A  .
  20. Turn ignition off. Reinstall fuel pump relay. Ensure fuel pump module connector is disconnected. Turn ignition on with engine off. Using scan tool, actuate ASD fuel system test. Using voltmeter, check voltage at terminal No. 4 (Dark Green/White wire) on fuel pump module connector. If voltage is more than 10 volts, go to next step. If voltage is 10 volts or less, repair open on Dark Green/White wire between cavity No. 87 in power distribution center for fuel pump relay and fuel pump module connector. Perform TEST VER-1A  .
  21. Turn ignition off. Remove fuel pump relay. Install substitute fuel pump relay with same part number. Attempt to start engine. If engine does not start, fuel pump is assumed to be defective. Replace fuel pump along with fuel pump module. Perform TEST VER-1A  . If engine starts, replace original fuel pump relay. Perform TEST VER-1A  .
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