Fuel Pump: Testing and Inspection

WARNING: Do not smoke during the test. Keep open flame away from your work area.


1. Remove the fuel filler cap and listen closely at fuel filler port, you should be able to hear the pump run for approx. 2 seconds after the ignition is first turned on. If the pump makes noise, turn off the ignition and proceed to step 2. If the pump does not make noise, turn off the ignition and proceed to step 3.

Fuel Pump Jumper Wire:

2. Connect the BLK/YEL wire and the YEL/BLK wire with a jumper wire.
a. Relieve fuel pressure.

^ Disconnect the negative battery cable.

Fig. 53 Bleeding Off Fuel Pressure:

^ Use a box end wrench on the 6mm service bolt at the top of the fuel filter, while holding the special banjo bolt with another wrench.
^ Place a rag or shop towel over the 6mm service bolt.
^ SLOWLY loosen the 6mm service bolt one complete turn.
b. After relieving fuel system pressure, tighten service bolt.
c. Disconnect the fuel return hose from the regulator.
d. Turn the ignition switch ON for 10 seconds and measure the amount of fuel flow.

Fuel Pressure Regulator Return Hose:

AMOUNT SHOULD BE: 7.8 oz. (230 cc) minimum in 10 seconds at 12 volts.
e. If fuel flow is less than 7.8 oz. (230 cc), check the following:
^. Clogged fuel filter
^. Clogged or collapsed fuel line
^. If there is no fuel flow, proceed to step 2

2. Remove the rear seat.
3. Disconnect the 4P connector.
CAUTION: Be sure to turn the ignition switch OFF before disconnecting the 4P connector.

Fuel Pump Jumper Wire:

4. Remove main relay connector and connect the BLK/YEL (5) wire and the YEL/BLK (7) wire with a jumper wire.

Fuel Pump Connector:

6. Check that battery voltage is available at the fuel pump connector when the ignition switch is turned ON (positive probe to the YEL/BLK wire, negative probe to the BLK wire).
a. If battery voltage is available, replace the fuel pump and retest.
b. If there is no voltage, see "DIAGNOSIS AND TESTING" under "Computers and Control Systems".