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Fuel Pressure Test

NOTE: For additional information on fuel pressure and fuel pump testing procedures, see appropriate NO TROUBLE CODE (NTC) TEST and NO START (NS) TEST in TESTS W/CODES - NON-TURBO article.
CAUTION: When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in the GENERAL INFORMATION section before disconnecting battery.
  1. Disconnect negative battery cable. Release fuel pressure. See FUEL PRESSURE RELEASE under FUEL SYSTEM.
  2. Using fuel pressure gauge hose, connect Fuel Pressure Gauge (C-4799) to fuel pressure test port on fuel rail, located at center of fuel rail. Connect scan tool to Data Link Connector (DLC), located below the driver's side of instrument panel. See Fig 1 .
    Fig 1: Identifying Data Link Connector
    G95E32692Courtesy of CHRYSLER CORP.
  3. Turn ignition on. Using scan tool, actuate ASD fuel system test to activate fuel pump and pressurize fuel system. Note fuel pressure. Fuel pressure should be within specification. See FUEL PRESSURE SPECIFICATIONS  table. If no fuel pressure exists, fuel pump relay and control circuit may be defective. See FUEL PUMP RELAY  under FUEL SYSTEM. If fuel pressure is correct, go to step 8).
  4. If fuel pressure exceeds specification, go to step 7). If fuel pressure is less than specified, check for clogged fuel filter. Fuel filter is located on frame rail, near fuel tank. Replace fuel filter if clogged, and recheck fuel pressure. If fuel pressure is now okay, go to step 8). If fuel pressure is still not within specification, go to next step.
  5. Check for fuel pressure in fuel return hose at fuel pressure regulator. Fuel pressure regulator is installed at "T" fitting at end of fuel filter, located on frame rail, near fuel tank.
  6. If fuel pressure exists in fuel return hose, fuel pressure regulator is leaking. If no fuel pressure exists in fuel return hose, low fuel pressure is caused by defective fuel pump. Fuel pump is located in fuel tank. Replace components as necessary. See REMOVE/INSTALL/OVERHAUL - NON-TURBO article.
  7. If fuel pressure exceeds specification, check for restricted fuel return hose or pipe. If fuel return hose or pipe are not restricted, check for binding valve in fuel pressure regulator. Fuel pressure regulator is installed at "T" fitting at end of fuel filter, located on frame rail, near fuel tank. See Fig 2 .
    Fig 2: Identifying Data Link Connector
    G95E32692Courtesy of CHRYSLER CORP.
  8. Turn ignition on. Using scan tool, actuate ASD fuel system test to activate fuel pump and pressurize fuel system. Note fuel pressure. Fuel pressure should be within specification. See FUEL PRESSURE SPECIFICATIONS  table. If no fuel pressure exists, fuel pump relay and control circuit may be defective. See FUEL PUMP RELAY  under FUEL SYSTEM. If fuel pressure is correct, go to step 8).
  9. If fuel pressure exceeds specification, go to step 7). If fuel pressure is less than specified, check for clogged fuel filter. Fuel filter is located on frame rail, near fuel tank. Replace fuel filter if clogged, and recheck fuel pressure. If fuel pressure is now okay, go to step 8). If fuel pressure is still not within specification, go to next step.
  10. Check for fuel pressure in fuel return hose at fuel pressure regulator. Fuel pressure regulator is installed at "T" fitting at end of fuel filter, located on frame rail, near fuel tank.
  11. If fuel pressure exists in fuel return hose, fuel pressure regulator is leaking. If no fuel pressure exists in fuel return hose, low fuel pressure is caused by defective fuel pump. Fuel pump is located in fuel tank. Replace components as necessary. See REMOVE/INSTALL/OVERHAUL - NON-TURBO article. Once correct fuel pressure is obtained, go to next step.
  12. With scan tool actuated and fuel pressure obtained, turn ignition off and note fuel pressure. Fuel pressure should not decrease within 2 minutes.
  13. If fuel pressure decreases gradually after ignition is turned off, check for leaky fuel injector or leaky valve in fuel pressure regulator. Fuel pressure regulator installed at "T" fitting at end of fuel filter, located on frame rail, near fuel tank. Replace components as necessary. See the Fig 3 .
    Fig 3: Identifying Data Link Connector
    G95E32692Courtesy of CHRYSLER CORP.
  14. Turn ignition on. Using scan tool, actuate ASD fuel system test to activate fuel pump and pressurize fuel system. Note fuel pressure. Fuel pressure should be within specification. See FUEL PRESSURE SPECIFICATIONS  table. If no fuel pressure exists, fuel pump relay and control circuit may be defective. See FUEL PUMP RELAY  under FUEL SYSTEM. If fuel pressure is correct, go to step 8).
  15. If fuel pressure exceeds specification, go to step 7). If fuel pressure is less than specified, check for clogged fuel filter. Fuel filter is located on frame rail, near fuel tank. Replace fuel filter if clogged, and recheck fuel pressure. If fuel pressure is now okay, go to step 8). If fuel pressure is still not within specification, go to next step.
  16. Check for fuel pressure in fuel return hose at fuel pressure regulator. Fuel pressure regulator is installed at "T" fitting at end of fuel filter, located on frame rail, near fuel tank.
  17. If fuel pressure exists in fuel return hose, fuel pressure regulator is leaking. If no fuel pressure exists in fuel return hose, low fuel pressure is caused by defective fuel pump. Fuel pump is located in fuel tank. Replace components as necessary. See REMOVE/INSTALL/OVERHAUL - NON-TURBO article. Go to step 11).
  18. If fuel pressure decreases immediately after ignition is turned off, check valve in fuel pump is held open. Replace fuel pump, located in fuel tank. See the Fig 4 .
    Fig 4: Identifying Data Link Connector
    G95E32692Courtesy of CHRYSLER CORP.
  19. Turn ignition on. Using scan tool, actuate ASD fuel system test to activate fuel pump and pressurize fuel system. Note fuel pressure. Fuel pressure should be within specification. See FUEL PRESSURE SPECIFICATIONS  table. If no fuel pressure exists, fuel pump relay and control circuit may be defective. See FUEL PUMP RELAY  under FUEL SYSTEM. If fuel pressure is correct, go to step 8).
  20. If fuel pressure exceeds specification, go to step 7). If fuel pressure is less than specified, check for clogged fuel filter. Fuel filter is located on frame rail, near fuel tank. Replace fuel filter if clogged, and recheck fuel pressure. If fuel pressure is now okay, go to step 8). If fuel pressure is still not within specification, go to next step.
  21. Check for fuel pressure in fuel return hose at fuel pressure regulator. Fuel pressure regulator is installed at "T" fitting at end of fuel filter, located on frame rail, near fuel tank.
  22. If fuel pressure exists in fuel return hose, fuel pressure regulator is leaking. If no fuel pressure exists in fuel return hose, low fuel pressure is caused by defective fuel pump. Fuel pump is located in fuel tank. Replace components as necessary. See REMOVE/INSTALL/OVERHAUL - NON-TURBO article. Go to step 11).
  23. Ensure ignition is off. Remove scan tool. Release fuel pressure. Remove fuel pressure gauge.
FUEL PRESSURE SPECIFICATIONS

Application psi (kg/cm2 )
Talon Non-Turbo (1) 47-50 (3.3-3.5)
(1) Manufacturer lists fuel pressure with engine off, ignition on and using scan tool to activate fuel pump.
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