GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2003 🢒 SSR 🢒 Engine 🢒 Engine Controls - 4.8L, 5.3L, and 6.0L 🢒 Fuel System Diagnosis

Fuel System Diagnosis Without Returnless Fuel System

System Description

The control module enables the fuel pump relay when the ignition switch is turned ON. The control module will disable the fuel pump relay within two seconds unless the control module detects ignition reference pulses. The control module continues to enable the fuel pump relay as long as ignition reference pulses are detected. The control module disables the fuel pump relay within two seconds if ignition reference pulses cease to be detected and the ignition remains ON.

The fuel tank stores the fuel supply. The electric fuel pump supplies fuel through an in-line fuel filter to the fuel injection system. The pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pressure regulator maintains the correct fuel pressure to the fuel injection system. A separate pipe returns unused fuel to the fuel tank.

Test Description

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

  1. This step tests for an internal fuel leak.

    2.

  2. This step tests the fuel pump check valve for a leak down condition.

    3.

  3. This step tests the fuel pressure regulator.

    4.

  4. This step tests for a loss of fuel pressure between the fuel feed pipe shut-off adapter and the fuel pump.

    5.

  5. This step tests for a leaking fuel injector or for a leaking fuel pressure regulator.

    6.

  6. This step tests for a restricted fuel return pipe.

    7.

  7. This step determines if the fuel pressure regulator or the fuel pump is the cause of the low fuel pressure.

    8.

  8. This step verifies that a circuit condition is not the cause of a fuel pressure concern.

Fuel System Diagnosis

Step

Action

Values

Yes

No

Schematic Reference: Fuel Hose/Pipes Routing Diagram

1

Did you perform the Diagnostic System Check-Engine Controls?

--

Go to Step 2

Go to Diagnostic System Check - Engine Controls

2

Important: Before you proceed with this diagnostic, inspect the fuel system for damage and for external leaks.

  1. Turn ON the ignition, with the engine OFF.
  2. Command the fuel pump relay ON with a scan tool.

Does the fuel pump turn ON when commanded with a scan tool?

 

Go to Step 3

Go to Intermittent Conditions

3

Important: Before you proceed with this diagnostic, inspect the fuel system for damage and for external leaks.

  1. Turn OFF the ignition.
  2. Turn OFF all accessories.

    3. Caution: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete.

  3. Install the J 34730-1A Fuel Pressure Gage. Refer to Fuel Pressure Gage Installation and Removal .
  4. Turn ON the ignition, with the engine OFF.

    5. Important: 

       • You may need to command the fuel pump ON several 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 with the fuel pump commanded ON.

Is the fuel pressure within the specified value?

380-427 kPa (55-62 psi)

Go to Step 4

Go to Step 12

4

Important: The fuel pressure may vary slightly when the fuel pump stops operating. After the fuel pump stops operating, the fuel pressure should stabilize, then remain constant.

Observe the fuel pressure gage for 1 minute.

Does the fuel pressure drop more than the specified value?

34 kPa

(5 psi)

Go to Step 9

Go to Step 5

5

  1. Relieve the fuel pressure to the first specified value.
  2. Observe the fuel pressure gage for 1 minute.

Does the fuel pressure drop more than the second specified value?

69 kPa

(10 psi)

14 kPa

(2 psi)

Go to Step 24

Go to Step 6

6

  1. Turn OFF the ignition for 15 seconds.
  2. Turn ON the ignition, with the engine OFF.
  3. Monitor the fuel pressure gage.
  4. Start the engine.

Does the fuel pressure drop the specified value when the engine is started?

21-69 kPa

(3-10 psi)

Go to Step 7

Go to Step 8

7
  1. Operate the vehicle within the conditions of the customer's concerns.
  2. Monitor the fuel-related parameters with a scan tool.

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

--

Go to Step 17

Go to Symptoms - Engine Controls

8
  1. Disconnect the vacuum hose from the fuel pressure regulator.
  2. Monitor the fuel pressure gage.
  3. Idle the engine.
  4. Apply 12-14 inches of vacuum to the fuel pressure regulator with a hand-held vacuum pump.

Does the fuel pressure drop the specified value when the vacuum is applied?

21-69 kPa (3-10 psi)

Go to Step 21

Go to Step 23

9

  1. Turn OFF the ignition.
  2. Disconnect the vacuum hose from the fuel pressure regulator.
  3. Turn ON the ignition, with the engine OFF.
  4. Command the fuel pump ON with a scan tool.
  5. Inspect for a fuel leak from the vacuum port of the fuel pressure regulator .

Is the fuel pressure regulator leaking fuel?

--

Go to Step 23

Go to Step 10

10

  1. Turn OFF the ignition.
  2. Relieve the fuel pressure. Refer to Fuel Pressure Relief .
  3. Disconnect the fuel feed hose and the fuel return hose from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .
  4. Install the J 37287 Fuel Line Shut-Off Adapters between the fuel hoses and the fuel rail pipes.
  5. Open the valves on the fuel pipe shut-off adapters.
  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 pressure gage.
  9. Command the fuel pump ON and OFF with a scan tool.
  10. Close the fuel feed pipe shut-off valve.
  11. Monitor the fuel pressure gage for 1 minute.

Does the fuel pressure remain constant?

--

Go to Step 19

Go to Step 11

11

  1. Turn OFF the ignition.
  2. Open the shut-off valve for the fuel feed pipe.
  3. Turn ON the ignition, with the engine OFF.
  4. Command the fuel pump ON and OFF with a scan tool.
  5. Close the shut-off valve for the fuel return pipe.
  6. Monitor the fuel pressure gage for 1 minute.

Does the fuel pressure remain constant?

--

Go to Step 23

Go to Step 20

12

Is the fuel pressure more than the specified value?

427 kPa (62 psi)

Go to Step 14

Go to Step 13

13

Is the fuel pressure more than the specified value?

0 kPa (0 psi)

Go to Step 16

Go to Step 17

14

  1. Turn OFF the ignition.
  2. Relieve the fuel pressure. Refer to Fuel Pressure Relief .
  3. Disconnect the fuel return hose from the fuel rail return pipe. Refer to Metal Collar Quick Connect Fitting Service .
  4. Attach a length of flexible fuel hose to the fuel rail outlet passage.
  5. Place the open end of the flexible fuel hose into an approved gasoline container.
  6. Turn ON the ignition, with the engine OFF.
  7. Monitor the fuel pressure gage with the fuel pump operating.

Is the fuel pressure within the specified value?

380-427 kPa (55-62 psi)

Go to Step 22

Go to Step 15

15

Inspect the fuel rail outlet passage for a restriction.

Did you find and correct the condition?

--

Go to Step 25

Go to Step 23

16

  1. Turn OFF the ignition.
  2. Relieve the fuel pressure. Refer to Fuel Pressure Relief .
  3. Disconnect the fuel return hose from the fuel rail return pipe. Refer to Metal Collar Quick Connect Fitting Service .
  4. Install the J 37287 between the fuel return pipe and the fuel rail.
  5. Open the valve on 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. Notice: DO NOT allow the fuel pressure to exceed 517 kPa (75 psi). Excessive pressure may damage the fuel system.

  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 rise above the specified value?

427 kPa (62 psi)

Go to Step 23

Go to Step 17

17

Inspect the following components for restrictions:

    • The fuel filter
    • The fuel feed pipe

Did you find and correct the condition?

--

Go to Step 25

Go to Step 18

18

Test for an intermittent and for a poor connection at the harness connectors and the ground circuits of the fuel pump. Refer to Testing for Intermittent Conditions and Poor Connections , and to Connector Repairs in Wiring Systems.

Did you find and correct the condition?

--

Go to Step 25

Go to Step 19

19
  1. Remove the fuel sender assembly. Refer to Fuel Sender Assembly Replacement .
  2. Inspect the following components:
    3. • The fuel pump flex hose for damage
    • The in-tank fuel pump harness connectors for bad connections
    • The fuel strainer for restrictions
    • The fuel tank for contaminants

Did you find and correct the condition?

--

Go to Step 25

Go to Step 24

20
  1. Turn OFF the ignition.
  2. Raise the fuel rail, with the fuel lines connected. Refer to Fuel Injection Fuel Rail Assembly Replacement .
  3. Turn ON the ignition, with the engine OFF.
  4. Command the fuel pump relay ON with a scan tool.
  5. Locate and replace the leaking fuel injector. Refer to Fuel Injector Replacement .

Did you complete the replacement?

--

Go to Step 25

--

21

Repair the vacuum source to the fuel pressure regulator.

Did you complete the repair?

--

Go to Step 25

--

22

Locate and repair the restricted fuel return line.

Did you complete the repair?

--

Go to Step 25

--

23

Important: Before your replace the fuel pressure regulator, inspect for a missing or damaged fuel pressure regulator O-ring seal.

Replace the fuel pressure regulator. Refer to Fuel Pressure Regulator Replacement .

Did you complete the replacement?

--

Go to Step 25

--

24

Replace the fuel pump. Refer to Fuel Sender Assembly Replacement .

Did you complete the replacement?

--

Go to Step 25

--

25

Operate the system in order to verify the repair.

Did you correct the condition?

--

System OK

Go to Step 3