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Fuel System Electrical Test

WARNING: Relieve fuel pressure before connecting fuel pressure gauge. See FUEL SYSTEM PRESSURE RELEASE  under FUEL SYSTEM.
  1. Perform On-Board Diagnostic II (OBD-II) System Check. See ON-BOARD DIAGNOSTIC II (OBD-II) SYSTEM CHECK in appropriate SELF-DIAGNOSTICS article. After performing OBD-II system check, go to next step.
  2. Install fuel pressure tester to fuel inlet line test fitting. Using scan tool, command fuel pump on. Fuel pressure should build up immediately. If fuel pressure builds up immediately, go to next step. If fuel pressure does not build up, go to step  4 .
  3. Verify fuel pump is not running by removing gas cap and listening for fuel pump motor. Using scan tool, command fuel pump on. If fuel pump runs for 2 seconds and turns off, fuel electrical system is operating properly. Test is complete. If fuel pump does not run or runs continuously, go to step  12 .
  4. Turn ignition off. Remove fuel pump relay from fuse/relay box located in engine compartment. Using a test light connected to ground, probe battery feed circuit at fuel pump relay plug-in. See FUEL PUMP RELAY BATTERY FEED WIRE IDENTIFICATION  table. If test light illuminates, go to step  6 . If test light does not illuminate, go to next step.
    FUEL PUMP RELAY BATTERY FEED WIRE IDENTIFICATION

    Application Wire Color
    Rodeo & Rodeo Sport White/Black
    Trooper & VehiCROSS White
  5. Repair open or short in battery feed wire between fuel pump relay and fuse/relay box in engine compartment. See FUEL PUMP RELAY BATTERY FEED WIRE IDENTIFICATION  table.
  6. Connect a test light between fuel pump relay plug-in terminals for relay pull-in coil. See FUEL PUMP RELAY PULL-IN COIL WIRE IDENTIFICATION  table. Turn ignition on. If test light illuminates for 2 seconds then turns off, go to step  12 . If test light does not illuminate, go to next step.
    FUEL PUMP RELAY PULL-IN COIL WIRE IDENTIFICATION

    Application Wire From PCM Ground Wire
    Rodeo & Rodeo Sport 2.2L Pink/White Black/Blue
    Rodeo & Rodeo Sport 3.2L Pink/White Black
    Trooper & VehiCROSS Red/White Black
  7. Using test light connected to negative battery terminal, probe fuel pump relay plug-in terminal coming from PCM. See FUEL PUMP RELAY PULL-IN COIL WIRE IDENTIFICATION  table. Turn ignition on. If test light illuminates for 2 seconds and then turns off, go to next step. If test light does not illuminate, go to step  9 .
  8. Repair open in ground circuit between fuel pump relay and ground. See FUEL PUMP RELAY PULL-IN COIL WIRE IDENTIFICATION  table.
  9. Check for open or short in wire between fuel pump relay and White PCM 32-pin harness connector terminal E13 (Passport 2.2L, Rodeo 2.2L & Rodeo Sport), Blue PCM 32-pin harness connector terminal E13 (VehiCROSS) or Blue PCM 80-pin harness connector terminal F42 (Rodeo 3.2L and Trooper). Repair as necessary. If no problem was found, go to next step.
  10. Check for poor connections at fuel pump relay and White PCM 32-pin harness connector terminal E13 (Passport 2.2L, Rodeo 2.2L & Rodeo Sport), Blue PCM 32-pin harness connector terminal E13 (VehiCROSS) or Blue PCM 80-pin harness connector terminal F42 (Passport 3.2L, Rodeo 3.2L and Trooper). Repair as necessary. If no problem was found, go to next step.
  11. Replace and reprogram PCM. See PCM PROGRAMMING PROCEDURE under SELF-DIAGNOSTIC SYSTEM in appropriate SELF-DIAGNOSTICS article. Verify system is operating properly.
  12. If removed, reinstall fuel pump relay. Disconnect fuel pump electrical connector at fuel tank. Using a test light connected to ground, probe fuel pump harness connector feed wire. See FUEL PUMP POWER FEED WIRE IDENTIFICATION  table. Using scan tool, command fuel pump on. If test light illuminates for 2 seconds, go to step  15 . If test light does not illuminate for 2 seconds, go to next step.
    FUEL PUMP POWER FEED WIRE IDENTIFICATION

    Application Wire Color
    Rodeo & Rodeo Sport 2.2L Black/Red
    Rodeo 3.2L, Rodeo Sport 3.2L & Trooper Black/Orange
    VehiCROSS Blue/Red
  13. Operate horn to verify horn relay is functional. Substitute horn relay for fuel pump relay. Repeat test procedure from step  12 . If test light does not illuminate for 2 seconds, go to next step. If test light does illuminate for 2 seconds, go to step  17 .
  14. Check for open or short circuit in feed wire between fuel pump relay and fuel pump connector at fuel tank. See FUEL PUMP POWER FEED WIRE IDENTIFICATION  table. Check for blown FUEL PUMP fuse (20-amp Passport, Rodeo and Rodeo Sport, 15-amp on VehiCROSS and Trooper) located in fuse/relay box in engine compartment. Repair or replace as necessary. Reinstall horn relay.
  15. Connect a test light between fuel pump harness connector ground wire (Black wire) and power feed wire. See FUEL PUMP POWER FEED WIRE IDENTIFICATION  table. Using scan tool, command fuel pump on. If test light illuminates for 2 seconds, go to step  18 . If test light does not illuminate for 2 seconds, go to next step.
  16. Repair open circuit in Black wire between fuel pump and ground. Test drive vehicle to confirm repairs.
  17. Replace fuel pump relay. Reinstall horn relay. Test drive vehicle to confirm repairs.
  18. Replace fuel pump. Test drive vehicle to confirm repairs.
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