Test Sequence

-- Connect the Vehicle Diagnostic Tester -1- as follows:

Fig 1: Connecting Evaporative Emissions Tester To Vehicle

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-- Connect the diagnostic cable connector -2- to the Data Link Connector (DLC) inside the driver footwell.

-- Switch the ignition on.

-- Select Output Diagnostic Test Mode  for the fuel pump in the Vehicle Diagnostic Tester.

Fuel pump must now accelerate slowly up to maximum RPM.

-- Turn off the ignition.

If Fuel Pump Does Not Start

-- Remove the bench seat. .

-- Make sure the connector on the Fuel Pump Control Module -J538- secure. Pull on it. Repeat the fuel pump functionality test if the connector was not connected correctly. Refer to FUEL PUMPS, CHECKING FUNCTION AND POWER SUPPLY .

Fuel Pump Runs without Function

Fig 2: Identifying Fuel Pump (FP) Control Module J538 Connector

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-- Release and remove the connector from the Fuel Pump Control Module -J538- -arrow-.

-- Check the contacts on the connector and on the Fuel Pump Control Module -J538- for damage.

-- Check the voltage supply between contacts -1 and 6- using Multimeter.

Fig 3: Checking Fuel Pump (FP) Control Module J538 Electrical Harness Connector Terminals 1 To 6 For Voltage

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• Specified value: approximately battery voltage

Voltage Supply Not OK

-- Locate and repair open circuit in wiring according to the wiring diagram. Refer to appropriate Wiring Diagram.

Voltage Supply OK

Fig 4: Identifying Cover With Fuel Pump Control Module J538

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-- Remove cover -1- with Fuel Pump Control Module -J538- -2- from fuel delivery unit.

-- Unclip the cover -1- at the tabs -arrows- using the Trim Removal Wedge 3409.

Fig 5: Identifying Right Cover

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-- Pull on the connector -arrow- without pressing the release to make sure the connection is secure.

Fig 6: Fuel Pump Control Module Connector

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-- Repeat the fuel pump functionality test if the connector was not connected correctly. Refer to FUEL PUMPS, CHECKING FUNCTION AND POWER SUPPLY .

Fuel Pump Runs without Function

-- Disconnect the connector -arrow-.

-- Check the contacts on the connector and on the fuel delivery unit for damage.

-- Check the wiring harness between the Fuel Pump Control Module -J538- and the fuel delivery unit. Refer to appropriate Wiring Diagram.

-- Remove the fuel lines -1 and 2- from the flange. Disconnect the connector couplings. Refer to CONNECTOR COUPLINGS, SEPARATING .

Fig 7: Fuel Lines At Flange

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Vehicles with Parking Heater

-- If the vehicle has an auxiliary heater, then disconnect the connector and the fuel line from the Metering Pump -V54-.

Continuation for All Vehicles 

Fig 8: Identifying Locking Ring And Wrench T10202

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-- Fuel Tank, Draining. Refer to FUEL TANK, DRAINING .

-- Remove the locking ring using the Wrench - Fuel Sending Unit T10202.

-- Lift the fuel delivery unit flange.

-- Lift up the cover -3- for the fuel delivery unit.

Fig 9: Identifying Fuel Delivery Unit Flange

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-- Check if the electrical wiring between the flange and fuel pump is connected.

-- Inspect the terminal for damages

If an Open Circuit Is Not Detected

-- If the fuel pump is faulty, replace the fuel delivery unit. Refer to FUEL DELIVERY UNIT .

Tightening Specification 

• Refer to OVERVIEW - FUEL DELIVERY UNIT/FUEL LEVEL SENSOR