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Fuel Delivery Diagnosis

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  1. Install fuel pressure gauge. See BASIC FUEL SYSTEM CHECKS . Turn ignition on. If pressure is 50-60 psi (3.5-4.2 kg/cm2 ), fuel quality or a flooded engine may be cause of problem. If fuel pressure is not as specified, go to next step.
  2. If pressure is present but not as specified, diagnose fuel system. See FUEL SYSTEMS in appropriate SYSTEM & COMPONENT TESTING article. If pressure is not present, go to next step.
  3. Using scan tool, command fuel pump on and off and listen for clicking at fuel pump relay. Relay is located in underhood fuse block. If relay clicks, go to next step. If relay does not click, go to step  8.
  4. Remove fuel pump relay from fuse block. Using a test light connected to ground, probe fuel pump relay control circuit (terminal No. 1140) at relay cavities. See Fig 1. If test light illuminates, go to next step. If test light does not illuminate, check 15-amp fuel pump fuse, located in underhood fuse block. Replace fuse as necessary and retest. If fuse blows again, check for short to ground in fuel pump relay circuits No. 120 (Gray wire) and No. 1140 (Dark Green/White wire) or for shorted fuel pump motor. If circuits and fuel pump motor are okay, check for open in fuel pump relay control circuit No. 1140 (Dark Green/White wire). See WIRING DIAGRAMS article.
  5. Reinstall fuel pump relay. Raise and support vehicle. Disconnect fuel tank 10-pin in-line harness connector. Connect a Noid Light (J34730-405) between harness connector terminals No. 120 (Gray wire) and No. 650 (Black wire). See WIRING DIAGRAMS article. Using scan tool, command fuel pump relay on. If Noid light illuminates, go to next step. If Noid light does not illuminate, go to step  7.
  6. Check circuits for open between fuel tank in-line harness connector and fuel tank unit. Check for terminal tightness at harness connector. Repair as necessary. If circuits or terminals are okay, replace fuel pump motor.
  7. Connect a test light between ground and fuel tank in-line harness connector circuit No. 120 (Gray wire). Using scan tool, command fuel pump on. If test light illuminates, repair open in circuit No. 650 (Black wire). If test light does not illuminate, repair open in circuit No. 120 (Gray wire) to fuel pump relay.
  8. Substitute fuel pump relay with front wiper relay or with known-good relay. Using scan tool, command fuel pump on and off. If relay does not click, go to next step. If relay clicks, check for terminal tightness at fuse block. Repair as necessary. If terminals are okay, replace fuel pump relay.
  9. Connect a test light between ground and fuel pump relay terminal No. 465 (Gray wire) in relay cavities. If test light illuminates, repair open in fuel pump relay terminal No. 150 (Gray wire). See Fig 1. If test light does not illuminate, go to next step.
  10. Turn ignition off. Disconnect PCM harness connector J1. Check continuity between fuel pump relay terminal No. 465 (Gray wire) in relay cavities. If continuity exists, repair for short to ground in circuit. If continuity does not exist, go to next step.
  11. Check fuel pump relay terminal No. 465 (Gray wire) for open or terminal tightness. Repair as necessary. If circuit or terminal is okay, replace PCM.
Fig 1: Identifying Fuel Pump Relay Cavities (2.2L - Saturn)
G00132344Courtesy of GENERAL MOTORS CORP.
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