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In-Tank Fuel Lift Pump Flow/Diagnostic Test Procedure






*IN-TANK FUEL LIFT PUMP FLOW/DIAGNOSTIC TEST PROCEDURE


1. Using the Scan tool, check for DTCs. Troubleshoot any active DTCs before performing this test.

2. Disconnect the wiring harness from the lift pump at the fuel tank module connector and inspect the pins for damage. Fix or replace any damaged component.

3. Connect a voltmeter between the fuel lift pump supply and return pins at the fuel tank module connector.

4. Turn the ignition to the on position. Use the Scan tool to actuate the fuel lift pump, record the voltage on the voltmeter.

5. If the voltage is greater than 11.5 volts, go to step 14. If the voltage is less than 11.5 volts, go to step 6

6. Using a voltmeter, measure the battery voltage to determine that the voltage is greater than 11.5 volts. If the voltage is greater than 11.5 volts, go to step 7. If the voltage is not greater than 11.5 volts, troubleshoot for low battery voltage.

7. Remove the fuel lift pump relay from the PDC. Use a voltmeter to measure the voltage at the fuel lift pump relay voltage supply pin in the PDC. If the voltage is greater than 11.5 volts, go to step 8. If the voltage is not greater than 11.5 volts, fix or replace the harness.

8. Remove the fuel lift pump relay from the PDC. Install a spare relay in place of the fuel lift pump relay. Using the Scan tool, actuate the fuel lift pump. Use a voltmeter to measure the voltage between the fuel lift pump supply and return pins at the fuel tank module connector while the fuel lift pump is actuated. If the voltage is greater than 11.5 volts, replace the fuel lift pump relay. If the voltage is not greater than 11.5 volts, go to step 9.

9. Disconnect the wiring harness from the fuel tank module. Remove the lift pump relay from the PDC. Using an Ohmmeter, measure the resistance of the fuel lift pump power supply wire between the PDC relay output pin and the fuel tank module connector. If the resistance is less than 10 ohms, go to step 10. If it is greater than 10 ohms, fix or replace the harness.

10. Disconnect the wiring harness from the fuel tank module. Remove the fuel lift pump relay from the PDC. Using a voltmeter, measure the voltage between battery negative and the fuel lift pump power supply wire at the fuel module connector. If the voltage is less than 1 volt, go to step 11. If the voltage is greater than 1 volt, fix or replace the harness.

11. Disconnect the wiring harness from the fuel tank module. Remove the fuel lift pump relay from the PDC. Using an ohmmeter, measure the resistance between battery negative and the fuel lift pump power supply wire at the fuel module connector. If the resistance is less than 10 ohms, fix or replace the harness. If the resistance is greater than 10 ohms, go to step 12.

12. Disconnect the wiring harness from the fuel tank module. Using an Ohmmeter, measure the resistance of the fuel lift pump ground wire between the fuel tank module connector and battery negative. If the resistance is less than 10 ohms, go to step 13. If the resistance is greater than 10 ohms, fix or replace the harness.

13. Disconnect the wiring harness from the fuel tank module. Using a voltmeter, measure the voltage between the fuel lift pump ground wire and battery negative. If the voltage is less than 1 volt, go to step 14. If the voltage is greater than 1 volt, fix or replace the harness.

14. Reconnect the lift pump connector.

FLOW TEST.

1. Remove the fuel pump supply banjo fitting from the fuel injection pump.

2. Install fuel system test fitting 9014 into the fuel injection pump.

3. Connect one end of a section of fuel hose to the test fitting.

4. Put the other end of the fuel hose into an empty fuel container.

5. Use the scan tool to actuate the fuel lift pump.

6. While the lift pump is running, move the fuel hose from the fuel canister into a 1000ml graduated cylinder for 10 seconds.

7. Read and record the amount of fuel in the graduated cylinder after 10 seconds.

8. If you have more than 590ml in the graduated cylinder after 10 seconds, the test has successfully passed.

9. If you have less than 590ml of fuel in the graduated cylinder, inspect the fuel supply line from the fuel tank to the fuel filter housing and the fuel supply line between the fuel filter housing and the high pressure fuel pump for signs of damage, replace as necessary. If no damage is found, replace the fuel filter and retest.

10.Verify the Screened Banjo Bolt at the outlet of the fuel filter is free of debris. If debris is found, rinse screen with water, blow dry and reinstall. Retest vehicle. If flow meets specification then trace back the source of debris, if flow is still below spec repair damaged component.

11. If reading is still less than 590ml in 10 seconds, remove the fuel tank and fuel tank module. Inspect for damage and/or debris in and around the fuel tank module. If module is damaged, replace and retest.

12. If the module is not damaged, replace the fuel lift pump and retest to confirm fix.

Test complete

Repair

- Test complete.
- Perform POWERTRAIN VERIFICATION TEST. Powertrain Verification Test
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