Diagnostic Test

CHECK THE FUEL DELIVERY SYSTEM FOR LEAKS AND DAMAGE
1. Visually inspect the fuel delivery system lines and connections 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 .
  No
  - Go To 2
CHECK FUEL PUMP OPERATION
NOTE:
Diagnose any Fuel Pump Relay or Fuel Pump Control Module DTCs before continuing with this procedure.
1. Turn the ignition on, engine not running.
2. Start the engine or crank the engine to allow the Fuel Pump to be commanded on.
  NOTE:
  It may be necessary to use a mechanics stethoscope in the next step.
3. Listen for fuel pump operation at the Fuel Tank.
  Does the Fuel Pump operate?
  
  Yes
  - Go To 3
  No
  - Check the power and ground circuits to the Fuel Pump Assembly. If the circuits test good, replace the Fuel Pump Assembly in accordance with the Service Information.
  - Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .
INSTALL APPROPRIATE FUEL LINE ADAPTERS/FITTING FROM THE GAS AND DIESEL FUEL PRESSURE/DECAY TESTER 8978A

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1. 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.
2. Release the fuel system pressure. Refer to the appropriate service information .
3. Disconnect the fuel rail supply line connector between the fuel supply line and the fuel rail.
4. 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 4
INSTALL THE FUEL PRESSURE GAUGE ASSEMBLY

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1. Connect the (special tool #8978A, Decay Tool, Fuel), with the Fuel Inlet Hose (1) toward the Fuel tank side and the Fuel Outlet Hose (2) toward the fuel rail side of the system using the Fuel Line Adapters/Fitting as needed.
2. Connect special tool Drain Extension Hose 535680 (3) to the Fuel Pressure Gauge Assembly Drain Hose (5).
3. 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 5
CHECK THE FUEL PRESSURE

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1. 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 (2) for 10 seconds, then close the Valve.
  - CAUTION: Stop All Actuations.
  - Turn the ignition off.
  - Disconnect, empty and then reconnect the Reservoir Assembly.
2. Turn the ignition on.
3. With the scan tool, actuate the Fuel Pump.
  NOTE:
  On vehicles equipped with a Fuel Pump Control Module and PWM Fuel Pump, actuate the Fuel Pump at 80%.
4. Read the Fuel Pressure Gauge (3) and record the reading.
  NOTE:
  The fuel pressure specification for all engines, not including an SRT-4, is 407 kPa +/- 34 kPa (58.0 psi +/- 3.0 psi). An SRT-4 engine fuel pressure specification is 552 kPa +/- 34 kPa (80.0 psi +/- 3.0 psi).
  
  Choose a conclusion that best matches your fuel pressure reading.
  
  Below Specification
  - Go To 10
  Within Specification
  - Go To 6
  Above Specification
  - Replace the fuel filter/fuel pressure regulator.
  - Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .
    CAUTION:
    Stop all actuation tests before proceeding.

CHECK THE FUEL DELIVERY SYSTEM OUTPUT

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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.

With the scan tool, continue to actuate the fuel pump.
Open the Flow Test Valve (1) for 20 seconds, then close the Valve.
CAUTION:
Stop all actuation tests before proceeding.
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	20.8333	417
8 Cylinder	38.88889	778
SRT-4	50	1000
10 cylinder	55.5	1110

Does the amount of fuel in the reservoir meet or exceed the specification?

Yes

Go To 7

Go To 8

CHECK THE FUEL DELIVERY SYSTEM FOR LEAK DOWN

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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.

NOTE:
If the engine is hot and heat soaking, the fuel pressure in the system could actually increase when the engine is off. This could lead to incorrect results and hide an issue. Using a fan to cool the fuel rail can help keep the pressure stabilized and make the testing more accurate.
1. Ignition on, engine not running.
2. With the scan tool, actuate the fuel pump.
3. Close the Fuel System Isolation Valve (1).
  CAUTION:
  Stop all actuation tests before proceeding.
4. Turn the ignition off and then wait five minutes before proceeding.
5. Read the Fuel Inlet (2) and Fuel Outlet (3) Pressure Gauges. The pressure should not drop more than 10 psi on either gauge.
  Does the fuel pressure drop more than 10 psi?
  
  Yes - On Fuel Inlet Gauge (2)
  
  NOTE:
  If equipped with Saddle tank, refer to Service information for verification of fuel pressure regulator location.
  - Replace the Fuel Pump Assembly.
  - Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .
  Yes - On Fuel Outlet Gauge (3)
  - Replace the leaking Fuel Injector(s).
  - Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .
  No
  - If directed here by another test, return to that test. Otherwise, test complete.

CHECK FOR RESTRICTED FUEL SUPPLY LINE

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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.
Raise the vehicle on a hoist, and disconnect the fuel pressure line at the Fuel Pump Assembly.
Install the Fuel Pressure Decay Tester between the fuel supply line and the Fuel Pump Assembly.
Again, purge air from the system.
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 actuation tests before proceeding.
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	20.8333	417
8 Cylinder	38.88889	778
SRT-4	50	1000
10 cylinder	55.5	1110

Does the amount of fuel in the reservoir meet or exceed the specification?

Yes

Repair/replace fuel supply line as necessary.
Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .

Go To 9
CAUTION:
Stop all actuation tests before proceeding.

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.
1. Turn the ignition off.
2. Remove the Fuel Pump Assembly 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 .
  No
  - Replace the Fuel Pump Assembly.
  - Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .
CHECK FOR RESTRICTED FUEL SUPPLY LINE

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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.
1. Turn the ignition off.
2. Disconnect the Fuel Pressure Decay Tool.
3. Raise the vehicle on a hoist, and disconnect the fuel pressure line at the Fuel Pump Assembly.
4. Install the Fuel Pressure Decay Tool between the fuel supply line and the Fuel Pump Assembly.
5. Again, purge air from the system.
6. Turn the ignition on.
7. With the scan tool, actuate the Fuel Pump.
  NOTE:
  On vehicles equipped with a PWM Fuel Pump, actuate the Fuel Pump at or above 80%.
8. Read the Fuel Pressure Gauge (3) and record the reading.
  NOTE:
  The fuel pressure specification for all engines, including a Non SRT-4 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 now within specification?
  
  Yes
  - Repair/replace fuel supply line as necessary.
  - Perform the POWERTRAIN VERIFICATION TEST. Refer to the appropriate service information .
  No
  - Go To 11
    CAUTION:
    Stop all actuation tests before proceeding.
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.
1. Turn the ignition off.
2. Remove the Fuel Pump Assembly 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 the appropriate service information .
  No
  - Replace the Fuel Pump Assembly.
  - Perform the POWERTRAIN VERIFICATION TEST. Refer to the appropriate service information .