For 1990-2009 cars

### System Description

When you turn the ignition switch to the ON position, the control module enables the fuel pump relay, which in turn powers the fuel pump. The fuel pump remains ON as long as the engine is cranking or running and the control module receives ignition reference pulses. If there are no ignition reference pulses, the control module shuts the fuel pump OFF within 2 seconds after the ignition was switched to the ON position, or if the engine stops.

The fuel tank stores the fuel supply. The fuel pump is an electric pump that is attached to the primary fuel tank module assembly. The fuel pump also supplies fuel to the siphon jet pump, also attached to the primary fuel tank module. The siphon jet pump draws fuel from the secondary side of the fuel tank to the primary side of the fuel tank. The fuel pump is designed to provide fuel at a pressure above the pressure that is needed by the fuel injectors. A fuel pressure regulator, which is also located in the fuel tank, is attached to the primary fuel tank module. The fuel pressure regulator keeps the fuel available to the fuel injectors at a regulated pressure. The fuel pressure regulator does not compensate for changes in intake manifold vacuum. Unused fuel is returned from the fuel filter to the fuel tank by a separate fuel return pipe.

### Test Description

The numbers below refer to the step numbers on the diagnostic table.

1. This step verifies that the fuel pump is operating.

2. This step verifies that the vehicle is not out of fuel. If the right fuel sender is below 0.8 volt, and the left fuel sender is above 0.8 volt, a fuel transfer condition exists.

3. This step tests for an internal fuel leak. If the fuel pressure drops during this test, then an internal loss of pressure is indicated.

4. This step isolates the condition. Replace the primary fuel tank module assembly, if the fuel pressure remains constant, after closing the valve on the fuel pipe shut-off adapter. Locate and replace the leaking fuel injector if the pressure continues to decrease after closing the valve on the adapter.

5. This step isolates the condition. Replace the primary fuel tank module assembly for a stuck open or leaking fuel pressure regulator, if the fuel pressure increases above the specified value.

6. This step verifies that a circuit condition is not the cause of a fuel pressure concern. Inspect all fuel pump electrical circuits thoroughly.

Step | Action | Values | Yes | No
--- | --- | --- | --- | ---
Schematic Reference: Fuel Hose/Pipes Routing Diagram
1 | Did you perform the Diagnostic System Check - Vehicle? | -- | Go to Step 2 | Go to Diagnostic System Check - Vehicle
2 |

1. Turn ON the ignition, with the engine OFF.
2. Observe the DTC information with a scan tool.

Did DTC P0461, P0462, P0463, P2066, P2067, P2068, or P2636 fail the last test?

--

Go to Diagnostic Trouble Code (DTC) List - Vehicle

Go to Step 3

3 |

• | Additional DTCs may set when using the Fuel Pump output control.

• | Inspect the fuel system for the following conditions before proceeding with this diagnostic procedure:

- | Damage to the fuel system

- | External fuel leaks

Command the fuel pump ON with a scan tool.

Does the fuel pump operate?

--

Go to Step 4

Go to Fuel Pump Electrical Circuit Diagnosis

4 | Observe the Fuel Level Sensor Right voltage parameter with a scan tool. Is the voltage less than the specified value? | 0.8 V | Go to Step 5 | Go to Step 7
5 | Observe the Fuel Level Sensor Left voltage parameter with a scan tool. Is the voltage less than the specified value? | 0.8 V | Go to Step 6 | Go to Step 15
6 |

1. Add the specified amount of fuel.
2. Operate the vehicle within the conditions of the customer concern.
3. Monitor the fuel trim related parameters with a scan tool. Refer to Scan Tool Data List .

Do any of the scan tool parameters indicate a lean condition?

19 L (5 gal)

Go to Step 16

Go to Symptoms - Engine Controls

7 |

1. Turn OFF the ignition.
2. Install a fuel pressure gage. Refer to Fuel Pressure Gage Installation and Removal .
3. Turn ON the ignition, with the engine OFF.
4. External fuel leaks

Command the fuel pump ON with a scan tool.

• | The fuel pump may need to be commanded ON a few times in order to obtain the highest possible fuel pressure.

• | DO NOT start the engine.

5. Command the Fuel pump ON with a scan tool.
6. Observe the fuel pressure gage, while the fuel pump is operating.

Is the fuel pressure within the specified range?

380-410 kPa (55-60 psi)

Go to Step 8

Go to Step 12

8 | Important: The fuel pressure will drop when the fuel pump stops operating. After the fuel pump stops operating, the fuel pressure should stabilize and remain constant.

1. Allow the fuel pressure to stabilize.
2. Monitor the fuel pressure gage for 1 minute.

Does the fuel pressure decrease by more than the specified value?

34 kPa (5 psi)

Go to Step 11

Go to Step 9

9 |

1. Relieve the fuel pressure to the first specified value.
2. Monitor the fuel pressure gage for 5 minutes.

Does the fuel pressure decrease by more than the second specified value?

69 kPa (10 psi)

14 kPa (2 psi)

Go to Step 20

Go to Step 10

10 |

1. Operate the vehicle within the conditions of the customer concern.
2. Monitor the fuel related parameters with a scan tool.

Do any of the scan tool parameters indicate a lean condition?

--

Go to Step 16

Go to Symptoms - Engine Controls

11 |

1. Turn OFF the ignition.
2. Relieve the fuel pressure. Refer to Fuel Pressure Relief .
3. Disconnect the fuel feed pipe from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .
4. Install the appropriate J 37287 Fuel Pipe Shut-Off Adapter between the fuel feed pipe and the fuel rail inlet.
5. Open the valve on the fuel feed pipe shut-off adapter.
6. Command the fuel pump ON with a scan tool.
7. Bleed the air from the fuel system.
8. Command the fuel pump ON with a scan tool.
9. Close the fuel pipe shut-off valve.
10. Monitor the fuel pressure gage for 1 minute.

Does the fuel pressure remain constant?

--

Go to Step 20

Go to Step 19

12 | Is the fuel pressure more than the specified value? | 410 kPa (60 psi) | Go to Step 13 | Go to Step 14
13 | Inspect the fuel return hose/pipe for a restriction. Did you find and correct the condition? | -- | Go to Step 21 | Go to Step 20
14 |

1. Turn OFF the ignition.
2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
3. Disconnect the fuel return hose from the fuel return outlet of the fuel filter. Refer to Plastic Collar Quick Connect Fitting Service .
4. Install the appropriate J 37287 between the return outlet of the fuel filter and the fuel return hose.
5. Open the valve in the fuel pipe shut-off adapter.
6. Turn ON the ignition, with the engine OFF.
7. Command the fuel pump ON with a scan tool.
8. Bleed the air from the fuel system.
9. Monitor the fuel pressure gage.
10. Slowly close the valve in the fuel pipe shut-off adapter.
11. Command the fuel pump ON with a scan tool.

Does the fuel pressure increase to more than the specified value?

380-410 kPa (55-60 psi)

Go to Step 20

Go to Step 16

15 |

1. Remove both fuel tank modules. Refer to Primary Fuel Tank Module Replacement and Secondary Fuel Tank Module Replacement .
2. Inspect the fuel feed pipe of the siphon jet pump for a restriction.
3. Inspect the fuel strainer for contaminants. Refer to Alcohol/Contaminants-in-Fuel Diagnosis .

Did you find and correct the condition?

--

Go to Step 21

Go to Step 20

16 | Inspect the following components for a restriction:

• | The fuel filter

• | The fuel feed pipe

Did you find and correct the condition?

--

Go to Step 21

Go to Step 17

17 | Inspect the harness connectors and ground circuits of the fuel pump for poor connections. Refer to Testing for Intermittent Conditions and Poor Connections and Connector Repairs . Did you find and correct the condition? | -- | Go to Step 21 | Go to Step 18
18 |

1. Remove the primary fuel tank module. Refer to Primary Fuel Tank Module Replacement .
2. Inspect the following items:

• | The fuel pump flex hose for damage

• | The in-tank fuel pump harness connectors for poor connections

• | The fuel strainer for a restriction

• | For contaminates in the fuel tank--Refer to Alcohol/Contaminants-in-Fuel Diagnosis .

Did you find and correct the condition?

--

Go to Step 21

Go to Step 20

19 |

1. Turn OFF the ignition.
2. Raise the fuel rail, with the fuel lines connected. Refer to Fuel Injector and Fuel Rail Replacement .
3. Turn ON the ignition, with the engine OFF.
4. Command the fuel pump ON with a scan tool.
5. Locate and replace the leaking fuel injector. Refer to Fuel Injector and Fuel Rail Replacement .

Did you complete the replacement?

--

Go to Step 21

--

20 | Replace the primary fuel tank module. Refer to Primary Fuel Tank Module Replacement . Did you complete the replacement? | -- | Go to Step 21 | --
21 | Operate the system in order to verify the repair. Did you correct the condition? | -- | System OK | Go to Step 3