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Checking Fuel Delivery: Testing

  1. Turn the ignition on. With the DRBIII® scan tool, actuate the ASD fuel system test. Listen for fuel pump operation at the fuel tank. It may be necessary to use a mechanics stethoscope. Does the fuel pump operate? If yes, go to next step. If no go, to step  5.
    CAUTION: Stop all actuations.
    2. WARNING: 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. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE under FUEL SYSTEMS in REMOVAL & INSTALLATION - NEON, SRT-4 & SX (CANADIAN) article.
    CAUTION: Stop all actuations.
  2. Turn the ignition off. Install a fuel gauge. Turn the ignition on. With the DRBIII® scan tool, actuate the ASD fuel system test and observe the fuel pressure gauge. Fuel pressure specification is 53-63 psi (366-434 kPa). Choose a conclusion that best matches your fuel pressure reading. If fuel pressure is less than specification, go to next step. If within specification, the fuel delivery system is operating normally. If above specification, replace the fuel filter/fuel pressure regulator.
    3. WARNING: 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. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE under FUEL SYSTEMS in REMOVAL & INSTALLATION - NEON, SRT-4 & SX (CANADIAN) article.
    CAUTION: Stop all actuations.
  3. Turn the ignition off. Raise vehicle on hoist, and disconnect the fuel pressure line at the fuel pump module. Install special 5/16" Fuel Line Adapter (6539) between the disconnected fuel line and the fuel pump module. Attach a fuel pressure test gauge to the T-fitting on the fuel line adapter. Turn the ignition on. With the DRBIII® scan tool, actuate the ASD fuel system test and observe the fuel pressure gauge. Fuel pressure specification is 53-63 psi (366-434 kPa). Is the fuel pressure within specification now? If yes, repair/replace fuel supply line as necessary. See FUEL PUMP MODULE under FUEL SYSTEMS in REMOVAL & INSTALLATION - NEON, SRT-4 & SX (CANADIAN) article. If no go to next step.
    4. WARNING: 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. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE under FUEL SYSTEMS in REMOVAL & INSTALLATION - NEON, SRT-4 & SX (CANADIAN) article.
  4. Turn the ignition off. Remove the fuel pump module and inspect the fuel inlet strainer. See FUEL PUMP MODULE under FUEL SYSTEMS in REMOVAL & INSTALLATION - NEON, SRT-4 & SX (CANADIAN) article. Is the fuel inlet strainer plugged? If yes, replace the fuel pump inlet strainer. If no, replace the fuel pump module.
  5. Turn the ignition off. Disconnect the fuel pump module harness connector. Turn the ignition on. With the DRBIII® scan tool, actuate the ASD fuel system test. Using a 12-volt test light connected to ground, probe the (A141) fuel pump relay output circuit at the fuel pump module harness connector. See Figure. Does the test light illuminate brightly? If yes, go to next step. If no, go to step  8.
    CAUTION: Stop all actuations.
  6. Turn the ignition off. Disconnect the fuel pump module harness connector. Check connectors, it is critical that the connector is free from any signs of corrosion or deformities. Clean/repair as necessary. Using a test light connected to battery voltage, probe the (Z1) fuel pump ground circuit at the fuel pump module harness connector. Does the test light illuminate brightly? If yes, go to next step. If no, repair the open/high resistance in the (Z1) fuel pump ground circuit.
  7. If there are no possible causes remaining, replace fuel pump module. See FUEL PUMP MODULE under FUEL SYSTEMS in REMOVAL & INSTALLATION - NEON, SRT-4 & SX (CANADIAN) article.
  8. Turn the ignition off. Remove the fuel pump relay from the PDC. See Figure or Figure . PDC is located in engine compartment. With a 12-volt test light connected to ground, probe the fuel pump relay fused B+ circuit at the PDC. See Figure or Figure . Does the test light illuminate? If yes, go to next step. If no, repair the fuel pump relay fused B+ circuit. Check for open fuse in the PDC.
  9. Turn the ignition off. Remove the fuel pump relay from the PDC. See Figure or Figure . PDC is located in engine compartment. Disconnect the fuel pump module harness connector. Check the connectors, it is critical that the connector is free from any signs of corrosion or deformities. Measure the resistance of the (A141) fuel pump relay output circuit from the relay connector to the fuel pump module connector. Is the resistance below 5.0 ohms? If yes, replace the fuel pump relay. If no, repair the (A141) fuel pump relay output circuit for an open.
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