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Use this test in conjunction with the Fuel Pump Pressure Test and Fuel Pump Capacity Test. Check Valve Operation: The electric fuel pump outlet contains a one-way check valve to prevent fuel flow back into the tank and to maintain fuel supply line pressure (engine warm) when pump is not operational. It is also used to keep the fuel supply line full of gasoline when pump is not operational. After the vehicle has cooled down, fuel pressure may drop to 0 psi (cold fluid contracts), but liquid gasoline will remain in fuel supply line between the check valve and fuel injectors. Fuel pressure that has dropped to 0 psi on a cooled down vehicle (engine OFF) is a normal condition. When the electric fuel pump is activated, fuel pressure should immediately (1 – 2 seconds) rise to specification. Abnormally long periods of cranking to restart a hot engine that has been shut down for a short period of time may be caused by: Fuel pressure bleeding past a fuel injector(s). Fuel pressure bleeding past the check valve in the fuel pump module. 1. Disconnect the fuel inlet line at fuel rail. Refer to Fuel Tubes/Lines/Hoses and Clamps for procedures. On some engines, air cleaner housing removal may be necessary before fuel line disconnection. 2. Obtain correct Fuel Line Pressure Test Adapter Tool Hose. Tool number 6539 is used for 5/16″ fuel lines and tool number 6631 is used for 3/8″ fuel lines. Fig.7 Connecting Adapter Tool (Typical) 3. Connect correct Fuel Line Pressure Test Adapter Tool Hose between disconnected fuel line and fuel rail (Fig. 7). 4. Connect the 0 – 414 kPa (0 – 60 psi) fuel pressure test gauge (from Gauge Set 5069) to the test port on the appropriate Adaptor Tool. The DRB III Scan Tool along with the PEP module, the 500 psi pressure transducer, and the transducer-to-test port adapter may also be used in place of the fuel pressure gauge. The fittings on both tools must be in good condition and free from any small leaks before performing the proceeding test. 5. Start engine and bring to normal operating temperature. 6. Observe test gauge. Normal operating pressure should be 339 kpa ±34 kPa (49.2 psi ±5 psi) . 7. Shut engine OFF. 8. Pressure should not fall below 30 psi for five minutes . 9. If pressure falls below 30 psi , it must be determined if a fuel injector, the check valve within the fuel pump module, or a fuel tube/line is leaking. 10. Again, start engine and bring to normal operating temperature. 11. Shut engine OFF. 12. Testing for fuel injector or fuel rail leakage: Clamp OFF the rubber hose portion of Adaptor Tool between the fuel rail and the test port “T” on Adapter Tool. If pressure now holds at or above 30 psi , a fuel injector or the fuel rail is leaking.

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WARNING: Begin fuel system trouble shooting and diagnosis with fuel system pressure test. Relieve fuel system pressure before disconnecting any components or installing fuel pressure gauge. TBI 1. Turn ignition off for 10 seconds. Turn ignition on, and listen at fuel tank for fuel pump operation. Pump should run 2 seconds (20 seconds on models with fuel module). If fuel pump runs, go to next step. If fuel pump does not run, go to step 7). 2. If fuel pump runs, turn ignition off. Verify fuel tank has fuel. Relieve fuel pressure. See FUEL SYSTEM PRESSURE RELIEF . Remove air cleaner, and plug air cleaner vacuum ports (if equipped). Disconnect fuel line between throttle body and fuel filter. Install Fuel Pressure Gauge (J-29658A) and Adapter (J- 2968A-85) between steel fuel line and flexible hose, ahead of in-line fuel filter. 3. Turn ignition on, and note reading on pressure gauge. If fuel pressure is 9-13 psi (.63-.91 kg/cm2 ), no problems exist. If pressure is less than 9 psi (.63 kg/cm2 ), go to step 5). If pressure is greater than 13 psi (.91 kg/cm2 ), turn ignition off, and bleed fuel pressure. Disconnect fuel return line downstream of pressure gauge. Insert return line into a gasoline container. 4. Turn ignition on. If pressure is now 9-13 psi (.63-.91 kg/cm2 ), correct restriction in fuel return line between disconnected point and fuel tank. If fuel pressure is greater than 13 psi (.91 kg/cm2 ), check for restricted return line (including fuel filter) downstream of pressure gauge. If no restrictions are present, replace fuel pressure regulator (TBI 700) or fuel meter cover/pressure regulator (TBI 220). 5. Check for restricted line between in-tank fuel pump and pressure regulator. If fuel line is okay, disconnect injector connector. Turn ignition on. Gradually pinch fuel pressure gauge outlet hose. Note pressure. CAUTION: DO NOT pinch off fuel return line completely. DO NOT allow fuel pressure build-up to exceed specification, as damage to fuel pressure regulator may occur. 6. If pressure is greater than 13 psi (.91 kg/cm2 ), replace fuel pressure regulator (TBI 700) or fuel meter cover/pressure regulator (TBI 220). If pressure is less than 9 psi (.63 kg/cm2 ), check for faulty fuel pump or incorrect part. Check fuel pump coupling hose and pump inlet filter in fuel tank. On models with dual fuel tanks, check for faulty fuel tank selector valve and meter switch.

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1. NOTE: When the battery has been disconnected or reconnected, volatile memory information will be lost. The affected systems will have to be programmed by the technician or customer. These systems include: radio station presets, clock settings, seat memory, mirror memory, window memory and customer input keyless, window memory and customer input keyless entry codes. Disconnect the battery ground cable. For additional information, refer to Section 14-01. 2. Drain the cooling system. For additional information, refer to section 03-03. 3. Remove the engine cover (covering the throttle body). 4. Disconnect the crankcase ventilation tube and the idle air control valve inlet tube from the air cleaner outlet tube. Remove the air cleaner outlet tube. 5. WARNING: THE FUEL SUPPLY LINES ON VEHICLES EQUIPPED WITH FUEL INJECTED ENGINES REMAIN PRESSURIZED FOR LONG PERIODS AFTER ENGINE SHUT DOWN. THE FUEL SYSTEM PRESSURE MUST BE RELIEVED PRIOR TO FUEL SYSTEM SERVICE, TO PREVENT POSSIBLE INJURY. Connect the Multiport Fuel Injection (MFI) Fuel Pressure Gauge (T80L-9974-B) to the fuel pressure relief valve on the fuel supply manifold. Open the manual valve on the gauge to relieve the fuel system pressure. Once the pressure is relieved, close the valve and remove the gauge. 6. Remove the locking clip from the pressure and return fuel line spring lock couplings. Using the spring lock coupling disconnect tools (D87L-9280-A for 3/8-inch line, D87L-9280-B for 1/2-inch line) on the couplings. Push the tool into the cage opening to release the female fitting from the garter spring. Remove the tool and pull the male coupling and fitting apart. Install protective caps over the lines and the fuel rail. 7. Disconnect the upper radiator hose from the water outlet connection and position it out of the way. 8. Disconnect the accelerator cable and the speed control actuator cable from the throttle body and the locator. Remove the screws retaining the cables to the accelerator cable bracket and position the cables out of the way. 9. Disconnect the wiring connectors from the throttle position sensor (TP), idle air control valve (IAC) and the engine coolant temperature sensor (ECT). Disconnect the wiring connectors from the LH fuel injectors and the two wiring locators from the fuel rail. Position the harness out of the way. 10. CAUTION: Do not pull directly on the ignition wires, the wires could separate from the connectors inside the boots. Disconnect the ignition wires from the LH spark plugs and position them out of the way. Refer to Section 03-07. 11. Remove the bolts retaining the spark plug wiring harness bracket to the intake manifold and the generator. Disconnect the ignition wires from the locators and remove the bracket. 12. Remove the serpentine drive belt from the generator pulley. Refer to Section 03-05. 13. Remove the generator retaining bolts and position it out of the way. 14. Remove the PCV valve and tube. 15. Disconnect the wiring connectors from the water temperature indicator sender unit and the EGR vacuum regulator solenoid. Disconnect the RH fuel injector connectors and harness locators from the fuel rail. Position the harness out of the way. 16. CAUTION: Do not pull directly on the ignition wires, the wires could separate from the connectors inside the boots. Disconnect the ignition wires from the RH spark plugs and position them out of the way. For additional information, refer to Section 03-07. 17. Disconnect the vacuum line from the fuel vapor storage canister purge valve. Disconnect the heater hose from the rear of the intake manifold. 18. Disconnect the main vacuum hose from the rear of the intake manifold. Disconnect the hose from the fuel vapor storage canister purge valve. 19. Disconnect the EGR tube nut from the EGR valve. 20. Disconnect the vacuum hose from the EGR valve. Remove the EGR valve and gasket. 21. Remvoe the water outlet connection housing. 22. Remove the intake manifold. Remove and discard the intake manifold gaskets.

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Circuit Description When you turn ON the ignition switch, the Vehicle Control Module (VCM) turns ON the in-tank fuel pump. The pump remains ON as long as the engine is cranking or running and the VCM is receiving reference pulses. If there are no reference pulses, the VCM shuts the fuel pump OFF within 2 seconds after the ignition was switched to the ON position or if the engine stops. The VCM will also turn ON the fuel pump for 2 seconds when the ignition is turned to the OFF position. An electric fuel pump pumps the fuel through an in-line filter to the Central SFI unit. The pump is attached to the fuel level meter assembly inside of the fuel tank. The pump is designed to provide fuel pressure above what is needed by the fuel injectors. The pressure regulator keeps the fuel available to the injectors at a regulated pressure. Unused fuel is returned to the fuel tank by the fuel return pipe. Diagnostic Aids Tools Required • J 34730-1A Fuel Pressure Gage in J 34730-E or • J 34730-1A Fuel Pressure Gage with J 34730-250 Fuel Pressure Adapter Kit. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. Wrap a shop towel around the fuel pressure connection to absorb any small amount of fuel leakage that may occur when installing the fuel pressure gauge. Turn ON the ignition, the fuel pressure should be 415-455 kPa (60-66 psi) for the Central SFI and 385-430 kPa (56-62 psi) for

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FUEL PRESSURE RELEASE Fuel Rail With Fuel Pressure Test Port 1. Disconnect negative battery cable. Remove fuel tank cap to release fuel tank pressure. 2. Remove protective cap from fuel pressure test port on fuel rail. Place one end of Fuel Pressure Gauge (5069) hose into approved gasoline container. Screw remaining end of fuel pressure gauge hose onto fuel pressure test port. Fuel pressure will be released into gasoline container. 3. After fuel pressure is released, remove fuel pressure gauge hose from fuel pressure test port. Reinstall protective cap on fuel pressure test port and fuel tank cap. Reinstall negative battery cable. Fuel Rail Without Fuel Pressure Test Port 1. Remove fuel pump relay from Power Distribution Center (PDC), located near windshield washer reservoir. Refer to label on PDC cover for relay location. 2. Start engine and allow to idle until engine stalls. Attempt to start engine several times. Once engine will not restart, turn ignition off. 3. Disconnect electrical connector from any fuel injector. Connect a jumper wire between one fuel injector terminal and positive battery terminal. Connect another jumper wire to remaining fuel injector terminal. CAUTION: DO NOT apply battery voltage to fuel injector for more than 4 seconds, or fuel injector may be damaged. 4. Momentarily touch remaining end of jumper wire to negative battery terminal for no more than 4 seconds. Cover fuel line at fuel rail with shop towel before disconnecting. Disconnect fuel line. 5. Disconnect jumper wires. Reinstall electrical connector on fuel injector. Reinstall fuel pump relay. Diagnostic Trouble Codes (DTCs) may be stored in Powertrain Control Module (PCM) when ASD relay is removed. To clear DTCs from PCM, see TESTS W/CODES – 2.5L article. FUEL PRESSURE TEST