Driveability - Gas - Non-Dtc Based Diagnostics: Diagnosis Dodge Durango III

DIAGNOSTIC TEST

1. CHECKING THE EXHAUST SYSTEM FOR LEAKS Turn the ignition off. Raise the vehicle in accordance with the Service Information. WARNING: The normal operating temperature of the exhaust system is very high. Never work around or attempt to service any part of the exhaust system until it has cooled. Special care should be taken when working near the catalytic converter. The temperature of the converter rises to a high level after a short period of engine operating time. Connect Exhaust Cone (special tool #8404-EC, Exhaust Cone) or (special tool #8404-ECT, Exhaust Cone, Truck) to Air Pressure Regulator (with hose) W-18-MIL-1146AS. CAUTION: The air pressure must not exceed 27.6 kPa (4 psi), otherwise engine damage can occur. Attach shop air to the air pressure regulator. Adjust the Air Pressure Regulator to 27.6 kPa (4 psi) Insert the exhaust cone into the vehicle tail pipe. If the vehicle is equipped with dual exhaust. Use the (special tool #8404-ECT, Exhaust Cone, Truck) with equipped attached plug, plug one side of the dual exhaust pipe. Pressurize the other as described above. Apply Mopar® Air Leak Detector PN 05191804AA (or an equivalent leak finder liquid) to the following areas: All welded joints from the exhaust manifold to 45.72 cm (18 inches) behind the downstream O2 sensor O2 sensor seal points O2 sensor boss welds Flange/joint connection(s) Exhaust manifold to cylinder head connection(s) EGR solenoid gasket base and tube seal points (if equipped) Watch for the Mopar® Air Leak Detector PN 05191804AA (or the equivalent leak finder liquid) to bubble. Use the following definitions to help determine if system or component repair/replacement is necessary: Type 1 Leak is defined as a leak where very small foam like bubbles 1 mm (0.04 of an inch) or less appear. Any Type 1 or greater leaks found in welded joints, O2 sensor seal points or O2 sensor boss welds must be repaired or the component must be replaced. Type 2 Leak is defined as a leak where larger bubbles pea size, 8 mm (0.3 of an inch) or greater appear. Any Type 2 or greater leaks found in flange or joint connections, exhaust manifold to cylinder head connections, or EGR gasket and tube seal points must be repaired or the components must be replaced. Leak Location Repair required if results at 27.6 kPa (4 psi) reveal bubble size: Welded joints Type 1, 1 mm (0.04 of an inch) or greater O2 Sensor seal points Type 1, 1 mm (0.04 of an inch) or greater O2 Sensor boss welds Type 1, 1 mm (0.04 of an inch) or greater Flange / joint connections Type 2, 8 mm (0.3 of an inch) or greater Exhaust Manifold to cylinder head connections Type 2, 8 mm (0.3 of an inch) or greater EGR gasket and tube seal points Type 2, 8 mm (0.3 of an inch) or greater If a leak is found that matches the above definition, repair or replace the component as necessary. Once the repair is complete, repeat the procedure to verify that all leaks have been repaired. Were any exhaust leaks found? Yes Repair or replace the leaking exhaust parts as necessary. Perform the POWERTRAIN VERIFICATION TEST. Refer to «POWERTRAIN VERIFICATION TEST»(ref-466029-S26275093572012042300000) . No Test complete.

Scheme 490

For a complete wiring diagram, refer to appropriate SYSTEM WIRING DIAGRAMS article .

1. FUEL PUMP OPERATION Ignition on, engine not running. With a scan tool, actuate the Fuel System test. NOTE: It may be necessary to use a mechanics stethoscope in the next step. Listen for fuel pump operation at the fuel tank. Does the Fuel Pump operate? Yes Go To 2 . No Go To 5 . CAUTION: Stop All Actuations.
2. FUEL PRESSURE WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. Turn the ignition off. Install Fuel Pressure Decay Tester (special tool #8978A, Decay Tool, Fuel) at the engine. Ignition on, engine not running. Using the scan tool, actuate the ASD Fuel System test and observe the fuel pressure gauge. NOTE: Fuel pressure specification is 407 KPa +/- 34 KPa (59 psi +/- 5 psi). CAUTION: Stop All Actuations. Choose a conclusion that best matches your fuel pressure reading. Below Specification Go To 3 . Within Specification Test Complete. Above Specification Replace the fuel filter/fuel pressure regulator. Perform the POWERTRAIN VERIFICATION TEST. Refer to «POWERTRAIN VERIFICATION TEST»(ref-466029-S26275093572012042300000) .
3. RESTRICTED FUEL SUPPLY LINE WARNING: The fuel system is under a constant pressure even with the engine off. Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Turn the ignition off. Disconnect the Fuel Pressure Decay Tester (special tool #8978A, Decay Tool, Fuel). Raise the vehicle on a hoist, and disconnect the fuel pressure line at the fuel pump module. Install the Fuel Pressure Decay Tester (special tool #8978A, Decay Tool, Fuel) between the fuel supply line and the fuel pump module. Ignition on, engine not running. Using the scan tool, actuate the ASD Fuel System test and observe the fuel pressure gauge. NOTE: Fuel pressure specification is 407 KPa +/- 34 KPa (59 psi +/- 5 psi). CAUTION: Stop All Actuations. Is the fuel pressure within specification now? Yes Repair/replace fuel supply line as necessary. Perform the POWERTRAIN VERIFICATION TEST. Refer to «POWERTRAIN VERIFICATION TEST»(ref-466029-S26275093572012042300000) . No Go To 4 .
4. CHECKING FUEL INLET STRAINER WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. Turn the ignition off. Remove the Fuel Pump Module and inspect the Fuel Inlet Strainer. Is the Fuel Inlet Strainer plugged? Yes Replace the Fuel Pump Inlet Strainer. Perform the POWERTRAIN VERIFICATION TEST. Refer to «POWERTRAIN VERIFICATION TEST»(ref-466029-S26275093572012042300000) . No Replace the Fuel Pump Module. Perform the POWERTRAIN VERIFICATION TEST. Refer to «POWERTRAIN VERIFICATION TEST»(ref-466029-S26275093572012042300000) .
5. (A109) FUEL PUMP RELAY OUTPUT CIRCUIT OPEN Turn the ignition off. Remove the Fuel Pump Relay from the IPM. Disconnect the Fuel Pump Module harness connector. Measure the resistance of the (A109) Fuel Pump Relay Output circuit from the relay connector to the fuel pump module connector. Is the resistance below 5.0 Ohms? Yes Replace the Fuel Pump Relay. Perform the POWERTRAIN VERIFICATION TEST. Refer to «POWERTRAIN VERIFICATION TEST»(ref-466029-S26275093572012042300000) . No Repair the open in the (A109) Fuel Pump Relay Output circuit. Perform the POWERTRAIN VERIFICATION TEST. Refer to «POWERTRAIN VERIFICATION TEST»(ref-466029-S26275093572012042300000) .

1. OXYGEN SENSOR, WIRING, OR CONNECTORS NOTE: Diagnose and repair any O2 sensor or rationality DTCs before proceeding with this test. NOTE: When performing this procedure as part of another diagnostic process, it may be necessary to repeat this test for all of the oxygen sensors on the vehicle. Turn the ignition off. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Oxygen sensor and the PCM. Look for any chafed, pierced, pinched, or partially broken wires. Look for broken, bent, pushed out or corroded terminals. Turn the ignition on. Monitor the scan tool data relative to the sensor and wiggle test the wiring and connectors. Look for the data to change or for a DTC to set during the wiggle test. If necessary, check each sensor circuit for high resistance or a shorted condition. Were any problems found? Yes Repair as necessary. Perform the POWERTRAIN VERIFICATION TEST. Refer to «POWERTRAIN VERIFICATION TEST»(ref-466029-S26275093572012042300000) . No Go to 2 .
2. OXYGEN SENSOR VOLTAGE Start the engine and allow it to reach normal operating temperature. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. With a scan tool, monitor all O2 Sensor voltage readings. Is the voltage switching between 2.5 and 3.4 volts for all O2 sensors? Yes Go to 3 . Perform the POWERTRAIN VERIFICATION TEST. Refer to «POWERTRAIN VERIFICATION TEST»(ref-466029-S26275093572012042300000) . No Go to 4 .
3. O2 SENSOR HEATER OPERATION Turn the ignition off. NOTE: Wait a minimum of 10 minutes to allow the O2 Sensor to cool down before continuing the test. Allow the O2 Sensor voltage to stabilize at 5.0 volts. Turn the ignition on. With a scan tool, actuate the O2 Sensor heater. With the scan tool, monitor O2 Sensor voltage for at least 2 minutes. Does the voltage stay above 4.5 volts? Yes Go to 4 . Perform the POWERTRAIN VERIFICATION TEST. Refer to «POWERTRAIN VERIFICATION TEST»(ref-466029-S26275093572012042300000) . No Test complete.
4. O2 SENSOR Turn the ignition off. NOTE: Check for contaminants that may cause improper O2 Sensor operation, such as contaminated fuel, unapproved silicone, or evidence of oil or coolant. Disconnect the O2 Sensor harness connector. Turn the ignition on. With a scan tool, monitor the O2 Sensor voltage. NOTE: The voltage should be approximately 5.0 volts with the connector disconnected. Connect a jumper wire between the signal circuit and the return circuit in the O2 Sensor harness connector. NOTE: The voltage should drop from 5.0 volts to 2.5 volts with the jumper wire in place. Is the O2 Sensor voltage displayed on the scan tool as described? Yes Replace the O2 Sensor. Perform the POWERTRAIN VERIFICATION TEST. Refer to «POWERTRAIN VERIFICATION TEST»(ref-466029-S26275093572012042300000) . No Go to 5 .
5. O2 SENSOR SIGNAL CIRCUIT Using the wiring diagram/schematic as a guide, inspect the O2 Sensor Signal circuit and connectors between the O2 sensor and the PCM. Check the O2 Sensor signal circuit for a short to ground, open circuit, short to voltage, or high resistance. Were any problems found? Yes Repair as necessary. Perform the POWERTRAIN VERIFICATION TEST. Refer to «POWERTRAIN VERIFICATION TEST»(ref-466029-S26275093572012042300000) . No Go to 6 .
6. O2 SENSOR RETURN CIRCUIT Using the wiring diagram/schematic as a guide, inspect the O2 Sensor Return circuit and connectors between the O2 sensor and the PCM. Check the O2 Sensor return circuit for a short to ground, open circuit, short to voltage or high resistance. Were any problems found? Yes Repair as necessary. Perform the POWERTRAIN VERIFICATION TEST. Refer to «POWERTRAIN VERIFICATION TEST»(ref-466029-S26275093572012042300000) . No Go to 7 .
7. POWERTRAIN CONTROL MODULE (PCM) Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the O2 sensor and the PCM. Look for any chafed, pierced, pinched, or partially broken wires. Look for broken, bent, pushed out or corroded terminals. Monitor the scan tool data relative to the components tested in this procedure and wiggle test the wiring and connectors. Look for the data to change or for a DTC to set during the wiggle test. Refer to any Technical Service Bulletins that may apply. Were any problems found? Yes Repair as necessary. Perform the POWERTRAIN VERIFICATION TEST. Refer to «POWERTRAIN VERIFICATION TEST»(ref-466029-S26275093572012042300000) . No Replace and program the Powertrain Control Module (PCM) in accordance with the Service Information. Perform the POWERTRAIN VERIFICATION TEST. Refer to «POWERTRAIN VERIFICATION TEST»(ref-466029-S26275093572012042300000) .

1. NO START PRE-TEST NOTE: Verify no DTCs are set in the Occupant Restraint Controller. If DTCs are present, they may be the cause of a No Start condition. NOTE: The following list of items must be checked before continuing with any No Start diagnostic tests. The battery must be fully charged and in good condition. A low charged battery may produce invalid test results. If the battery is low, charge the battery and then attempt to start the vehicle by cranking the engine for 15 seconds, three consecutive times. This will allow any DTCs to set that may have been erased due to a dead battery. Try to communicate with PCM using a scan tool. If communication between the scan tool and PCM is not allowed, inspect fuses. If the PCM reports a No Response condition, and perform the No Response from PCM diagnostic procedure. Refer to «NO RESPONSE FROM PCM (POWERTRAIN CONTROL MODULE) (NGC)»(ref-465945-S33904623932012042300000) . Make sure the PCM Power and Ground circuits are OK. Using the scan tool, read PCM DTCs. If any DTCs are present, they must be repaired before continuing with any other No Start diagnostic tests. for the related P-code that is reported by the PCM. Refer to «DIAGNOSTIC CODE INDEX»(ref-466007-S05328738022012042300000) . Make sure that the Bus is functional. Attempt to communicate with the Instrument Cluster and VTSS, If you are unable to establish communications, for the proper Diagnostic procedures. Refer to «DIAGNOSIS AND TESTING»(ref-465945-S21111524872012042300000) . The Sentry Key Immobilizer System (Wireless Ignition Node) must be operating properly. Check for proper communication with the scan tool and check for DTCs that may be stored in the WIN. Repair the DTCs before continuing. If no DTCs are found, using the scan tool, select Clear PCM (BATT Disconnect). Crank the engine several times. Using the scan tool, read DTCs. If a DTC is present, perform the DTC diagnostics before continuing. Were any problems found? Yes Repair as necessary. Perform the POWERTRAIN VERIFICATION TEST. Refer to «POWERTRAIN VERIFICATION TEST»(ref-466029-S26275093572012042300000) . No Go To 2 .
2. OPEN FUSE Check for any open fuses in the IPM or Junction Block that may be related to the No Start condition. Are any of the fuses open? Yes Replace the open fuse and check the related circuit(s) for a short to ground. Perform the POWERTRAIN VERIFICATION TEST. Refer to «POWERTRAIN VERIFICATION TEST»(ref-466029-S26275093572012042300000) . No Go To 3 .
3. CRANKSHAFT POSITION SENSOR Turn the ignition off. Disconnect the CKP Sensor. Attempt to start the engine. Does the engine start? Yes Replace the Crankshaft Position Sensor in accordance with the Service Information. Perform the POWERTRAIN VERIFICATION TEST. Refer to «POWERTRAIN VERIFICATION TEST»(ref-466029-S26275093572012042300000) . No Go To 4 .
4. CAMSHAFT POSITION SENSOR Turn the ignition off. Connect the CKP Sensor. Disconnect the CMP Sensor. Attempt to start the engine. Does the engine start? Yes Replace the Camshaft Position Sensor in accordance with the Service Information. Perform the POWERTRAIN VERIFICATION TEST. Refer to «POWERTRAIN VERIFICATION TEST»(ref-466029-S26275093572012042300000) . No Go To 5 .
5. FUSED B+ CIRCUIT CHECK Turn the ignition off. Disconnect the C1 PCM harness connector. CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install the PCM Pinout Box (special tool #8815A, Kit, NGC, 38 Position) to perform diagnosis. Using a 12-volt test light connected to ground, probe the Fused B+ circuits. Does the test light illuminate brightly? Yes Go To 6 . No Repair the open or short to ground in the Fused B+ circuit. Perform the POWERTRAIN VERIFICATION TEST. Refer to «POWERTRAIN VERIFICATION TEST»(ref-466029-S26275093572012042300000) .
6. (A142) ASD RELAY OUTPUT CIRCUIT OPEN Turn the ignition off. Remove the ASD relay from the IPM. Disconnect the C3 PCM harness connector. Verify the ASD Relay is getting voltage on the Fused B+ circuits before continuing. CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install the PCM Pinout Box (special tool #8815A, Kit, NGC, 38 Position) to perform diagnosis. Measure the resistance of the (A142) ASD Relay Output circuit from the ASD Relay connector to the appropriate terminals of PCM Pinout Box (special tool #8815A, Kit, NGC, 38 Position), Ignition coil, and the fuel injectors. Is the resistance below 5.0 Ohms? Yes Go To 7 . No Repair the open in the (A142) ASD Relay Output circuit. Perform the POWERTRAIN VERIFICATION TEST. Refer to «POWERTRAIN VERIFICATION TEST»(ref-466029-S26275093572012042300000) .
7. FUEL PUMP DELIVERY Verify that the Fuel tank is not empty before continuing. Follow the diagnostics for Checking the Fuel Delivery System . Refer to the «CHECKING THE FUEL DELIVERY SYSTEM»(ref-466014-S25626257022012042300000) diagnostic procedure. Was the No Start condition solved after following the Checking the Fuel Delivery System diagnostic procedure? Yes Test Complete. No Go To 8 .
8. ENGINE MECHANICAL Check for any of the following conditions/mechanical problems. ENGINE COMPRESSION - must be within specifications ENGINE EXHAUST SYSTEM - must be free of any restrictions or leaks. ENGINE VALVE TIMING - must be within specifications, check for broken timing components Are there any engine mechanical problems? Yes Repair as necessary. Perform the POWERTRAIN VERIFICATION TEST. Refer to «POWERTRAIN VERIFICATION TEST»(ref-466029-S26275093572012042300000) . No Go To 9 .
9. POWERTRAIN CONTROL MODULE (PCM) NOTE: Before continuing, check the PCM harness connector terminals for corrosion, damage, or terminal push out. Repair as necessary. Using the schematics as a guide, inspect the wire harness and connectors. Pay particular attention to all Power and Ground circuits. Were there any problems found? Yes Repair as necessary. Perform the POWERTRAIN VERIFICATION TEST. Refer to «POWERTRAIN VERIFICATION TEST»(ref-466029-S26275093572012042300000) . No Replace and program the Powertrain Control Module in accordance with the Service Information. Perform the POWERTRAIN VERIFICATION TEST. Refer to «POWERTRAIN VERIFICATION TEST»(ref-466029-S26275093572012042300000) .

1. ETC STARTER INHIBIT NOTE: This ETC equipped engine will try to relearn ETC position when the key is left in the on position for an extended period of time and will not allow the starter to crank during this procedure. This procedure can take up to 2.5 seconds. To verify the cause of the no crank condition or delayed crank use the scan tool, and read the ETC Starter Inhibit mileage. The controller will store the mileage at which the no start condition occurred because of the ETC testing procedure. This is considered normal operation for a vehicle equipped with an Electronic Throttle Control System and no repairs are necessary. Is a mileage stored under the ETC Starter Inhibit? Yes Test Complete. No Refer to the appropriate diagnostic procedure for further assistance if any other DTC's are set. Perform the POWERTRAIN VERIFICATION TEST. Refer to «POWERTRAIN VERIFICATION TEST»(ref-466029-S26275093572012042300000) .

FUEL DELIVERY SYSTEM OUTPUT - FLOW TEST

For a complete wiring diagram, refer to appropriate SYSTEM WIRING DIAGRAMS article .

Scheme 491

Scheme 492

Scheme 493

Scheme 494

1. CHECK FUEL DELIVERY SYSTEM FOR LEAKS AND DAMAGE WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. Visually and physically inspect the fuel delivery system for external leaks and damage. Is the system leaking or damaged? Yes Repair or replace as necessary. Perform the POWERTRAIN VERIFICATION TEST. Refer to «POWERTRAIN VERIFICATION TEST»(ref-466029-S26275093572012042300000) . No Go To 2 .
2. INSTALL APPROPRIATE FUEL LINE ADAPTERS / FITTING FROM THE GAS AND DIESEL FUEL PRESSURE/DECAY TESTER 8978A Turn the ignition off. WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. Disconnect the frame rail fuel supply line connector between the fuel supply line and the fuel rail. Install the appropriate Fuel Line Adapters / Fitting from the Gas and Diesel Fuel Pressure/Decay Tester (special tool #8978A, Decay Tool, Fuel). Proceed Go To 3 .
3. INSTALL FUEL PRESSURE GAUGE ASSEMBLY WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. Connect the Gas and Diesel Fuel Pressure/Decay Tester (special tool #8978A, Decay Tool, Fuel), Fuel Inlet Hose (1) and Fuel Outlet Hose (2) to the Fuel Line Adapters / Fitting. Connect special tool Drain Extension Hose 535680 (3) to the Fuel Pressure Gauge Assembly Drain Hose (5). Connect Reservoir Assembly 534960 (4) to Drain Extension Hose 535680 (3). WARNING: To reduce the risk of fire and possible serious or fatal injury, place Reservoir Assembly 534960 (4) on the floor and out of the way so that it is not a trip hazard. Proceed Go To 4 .
4. CHECK FUEL PRESSURE WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. Perform the following procedure to purge air from the system: Open the Fuel System Isolation Valve (1). Close the Flow Test Valve (2). Ignition on, engine not running. With the scan tool, actuate the fuel pump. Open the Flow Test Valve (1) for 10 seconds, then close the Valve. CAUTION: Stop All Actuations. Turn the ignition off. Disconnect, empty and then reconnect the Reservoir Assembly. Turn the ignition on, wait five seconds, turn the ignition off and then wait one minute before proceeding. Read the Fuel Pressure Gauge (3) and record the reading. Non SRT-4 fuel pressure specification is 407 kPa +/- 34 kPa (59 psi +/- 5 psi). SRT-4 fuel pressure specification is 552 kPa +/- 34 kPa (80 psi +/- 5 psi). Is the fuel pressure within specifications? Yes Go To 5 . No Perform the «CHECKING THE FUEL DELIVERY SYSTEM»(ref-466014-S25626257022012042300000) diagnostic procedure.
5. CHECK FUEL DELIVERY SYSTEM OUTPUT WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. Ignition on, engine not running. With the scan tool, actuate the fuel pump. Open the Flow Test Valve (1) for 20 seconds, then close the Valve. CAUTION: Stop All Actuations. Turn the ignition off. Measure the amount of fuel in the Reservoir Assembly (2). The fuel output specification is ml/s X 20 seconds = fuel flow in ml. FUEL FLOW ENGINE ml/s ml per 20 Seconds 4 Cylinder and 6 Cylinder 20.8333A 417 8 Cylinder 38.88889 778 SRT-4 50 1000 Does the amount of fuel in the reservoir meet or exceed the specification? Yes Test complete. No Perform the «CHECKING THE FUEL DELIVERY SYSTEM»(ref-466014-S25626257022012042300000) diagnostic procedure.

1. CHECKING FUEL PRESSURE WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. Turn the ignition off. Install the Fuel Pressure Decay Tester (special tool #8978A, Decay Tool, Fuel) at the engine. Ignition on, engine not running. With a scan tool, actuate the ASD Fuel System test and observe the fuel pressure gauge. NOTE: Fuel pressure specification is 407 kPa +/- 34 kPa (59 psi +/- 5 psi). Choose a conclusion that best matches your fuel pressure reading. Below Specification Go To 2 . Within Specification Go To 4 .
2. RESTRICTED FUEL SUPPLY LINE WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. Turn the ignition off. Remove the Fuel Pressure Decay Tester (special tool #8978A, Decay Tool, Fuel). Raise the vehicle on a hoist, and disconnect the fuel pressure line at the fuel pump module. Install the Fuel Pressure Decay Tester (special tool #8978A, Decay Tool, Fuel) between the fuel supply line and the fuel pump module. Ignition on, engine not running. With the scan tool, actuate the ASD Fuel System test and observe the fuel pressure gauge. NOTE: Fuel pressure specification is 407 kPa +/- 34 kPa (59 psi +/- 5 psi). Is the fuel pressure within specification? Yes Visually and physically inspect the fuel supply lines between the fuel tank and the fuel rail. Repair/replace as necessary. Perform the POWERTRAIN VERIFICATION TEST. Refer to «POWERTRAIN VERIFICATION TEST»(ref-466029-S26275093572012042300000) . No Go To 3 .
3. CHECKING THE FUEL INLET STRAINER WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. Turn the ignition off. Remove the Fuel Pump Module and inspect the Fuel Inlet Strainer. Is the Fuel Inlet Strainer plugged? Yes Replace the Fuel Pump Inlet Strainer. Perform the POWERTRAIN VERIFICATION TEST. Refer to «POWERTRAIN VERIFICATION TEST»(ref-466029-S26275093572012042300000) . No Replace the Fuel Pump Module. Perform the POWERTRAIN VERIFICATION TEST. Refer to «POWERTRAIN VERIFICATION TEST»(ref-466029-S26275093572012042300000) .
4. FUEL PUMP MODULE NOTE: Before continuing visually and physically inspect the fuel delivery system for external leaks or damage. Repair/replace as necessary. WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. Turn the ignition off. Install the Fuel Pressure Decay Tester (special tool #8978A, Decay Tool, Fuel) at the intake manifold. Start the engine and allow the fuel system to reach maximum pressure. Turn the ignition off. Close the Fuel System Isolation Valve and then wait 5 minutes before proceeding. NOTE: Fuel specification is 407 KPa +/- 34 KPa (59 psi +/- 5 psi). Read the Fuel Inlet and Fuel Outlet Pressure Gauges. The pressure should not drop more than 10 psi on either gauge. Monitor the fuel pressure gauge for a minimum of 5 minutes. Does the fuel pressure drop more than 10 psi? Yes - On Fuel Inlet Gauge Replace Fuel Pump Module. Perform the POWERTRAIN VERIFICATION TEST. Refer to «POWERTRAIN VERIFICATION TEST»(ref-466029-S26275093572012042300000) . Yes - On Fuel Outlet Gauge Replace the leaking fuel injector(s). Perform the POWERTRAIN VERIFICATION TEST. Refer to «POWERTRAIN VERIFICATION TEST»(ref-466029-S26275093572012042300000) . No If directed here by another test, return to that test. Otherwise, test complete.