GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2002 🢒 Grand Prix 🢒 Engine 🢒 Engine Controls - 3.8L 🢒 Fuel System Diagnosis

System Description

When you turn ON the ignition switch, the control module enables the fuel pump relay which powers the fuel pump ON. The fuel pump remains ON as long as the engine is cranking or running and the control module receives ignition reference pulses. If there are no ignition reference pulses, the control module shuts the fuel pump OFF within 2 seconds after the ignition was switched to the ON position or if the engine stops.

The fuel tank stores the fuel supply. The electric fuel pump supplies fuel through an in-line fuel filter to the fuel injection system. The pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pressure regulator maintains the correct fuel pressure to the fuel injection system. A separate pipe returns unused fuel to the fuel tank.

Test Description

The numbers below refer to the step numbers on the diagnostic table.

  1. This step verifies that the fuel pump is operating.

    2.

  2. This step tests for an internal fuel leak. If the fuel pressure decreases during this test, an internal loss of pressure is indicated.

    3.

  3. This step tests the fuel pressure regulator. The fuel pressure regulator is controlled by engine vacuum. With engine vacuum applied, the pressure should decrease by the specified value.

    4.

  4. This step inspects the fuel pressure regulator for a fuel leak from the vacuum port. If fuel leaks from the fuel pressure regulator while the fuel pump is commanded ON, replace the fuel pressure regulator.

    5.

  5. This step tests for a loss of fuel pressure between the shut-off adapter on the fuel feed pipe and the fuel pump.

    6.

  6. This step tests for a leaking fuel injector, or fuel pressure regulator. If the fuel pressure remains constant during this test, the fuel injectors are not leaking fuel.

    7.

  7. This step tests for a restricted fuel return pipe. If the fuel pressure is within the specified values, a restriction in the fuel return pipe is indicated.

    8.

  8. This step determines if the fuel pressure regulator, or the fuel pump, is the cause of the low fuel pressure. If the pressure rises above the specified value, the fuel pump is OK.

    9.

  9. This step verifies that a circuit condition is not the cause of a fuel pressure concern. Inspect all fuel pump electrical circuits thoroughly.

Step

Action

Values

Yes

No

1

Did you perform the Diagnostic System Check-Engine Controls?

--

Go to Step 2

Go to Diagnostic System Check - Engine Controls

2

Important: Inspect the fuel system for damage, or external leaks, before proceeding with this diagnostic.

  1. Turn ON the ignition, with the engine OFF.
  2. Command the fuel pump ON with a scan tool.

Does the fuel pump operate?

--

Go to Step 3

Go to Fuel Pump Electrical Circuit Diagnosis

3

Important: Verify that adequate fuel is in the fuel tank before proceeding with this diagnostic.

  1. Turn OFF the ignition.
  2. Turn OFF all accessories.
  3. Install the fuel pressure gage. Refer to Fuel Pressure Gage Installation and Removal .
  4. Turn ON the ignition, with the engine OFF.

    5. Important: The fuel pump may need to be commanded ON a few times, in order to obtain the highest possible fuel pressure.

  5. Command the fuel pump ON with a scan tool.
  6. DO NOT start the engine.
  7. Observe the fuel pressure gage, with the fuel pump commanded ON.

Is the fuel pressure within the specified range?

364-405 kPa (53-59 psi) VIN K

334-375 kPa (48-54 psi) VIN 1

Go to Step 4

Go to Step 12

4

Important: The fuel pressure may vary slightly when the fuel pump stops operating. After the fuel pump stops operating, the fuel pressure should stabilize and remain constant.

Monitor the fuel pressure gage for 1 minute.

Does the fuel pressure decrease by more than the specified value?

34 kPa (5 psi)

Go to Step 9

Go to Step 5

5
  1. Relieve the fuel pressure to the first specified value.
  2. Monitor the fuel pressure gage for 5 minutes.

Does the fuel pressure decrease by more than the second specified value?

69 kPa (10 psi)

14 kPa (2 psi)

Go to Step 24

Go to Step 6

6

  1. Turn OFF the ignition for 15 seconds.
  2. Turn ON the ignition, with the engine OFF.
  3. Monitor the fuel pressure gage.
  4. Start the engine.

Does the fuel pressure decrease by the specified value when the engine is started?

21-69 kPa (3-10 psi)

Go to Step 7

Go to Step 8

7
  1. Operate the vehicle within the conditions of the customer's concern.
  2. Monitor the fuel related parameters with a scan tool.

Do any of the scan tool parameters indicate a lean condition?

--

Go to Step 17

Go to Symptoms - Engine Controls

8
  1. Disconnect the vacuum hose from the fuel pressure regulator.
  2. Monitor the fuel pressure gage.
  3. Idle the engine.
  4. Apply 34-47 kPa (12-14 in) of vacuum to the fuel pressure regulator with a hand held vacuum pump.

Does the fuel pressure decrease by the specified value when the vacuum is applied?

21-69 kPa (3-10 psi)

Go to Step 21

Go to Step 23

9

  1. Turn OFF the ignition.
  2. Remove the vacuum hose from the fuel pressure regulator.
  3. Turn ON the ignition, with the engine OFF.
  4. Command the fuel pump ON with a scan tool.
  5. Inspect for a fuel leak from the fuel pressure regulator vacuum port.

Is the fuel pressure regulator leaking fuel?

--

Go to Step 23

Go to Step 10

10

  1. Turn OFF the ignition.
  2. Relieve the fuel pressure. Refer to Fuel Pressure Relief .
  3. Disconnect the fuel feed hose and the fuel return hose from the fuel rail pipes. Refer to Metal Collar Quick Connect Fitting Service .
  4. Install the J 37287 Fuel Line Shut-Off Adapters between the fuel hoses and the fuel rail pipes.
  5. Open the valves on the fuel pipe shut-off adapters.
  6. Turn ON the ignition, with the engine OFF.
  7. Command the fuel pump ON with a scan tool.
  8. Bleed the air from the fuel pressure gage.
  9. Command the fuel pump ON and then OFF with a scan tool.
  10. Close the fuel feed pipe shut-off valve.
  11. Monitor the fuel pressure gage for 1 minute.

Does the fuel pressure remain constant?

--

Go to Step 19

Go to Step 11

11

  1. Turn OFF the ignition.
  2. Open the fuel feed pipe shut-off valve.
  3. Turn ON the ignition, with the engine OFF.
  4. Command the fuel pump ON and then OFF with a scan tool.
  5. Close the fuel return pipe shut-off valve.
  6. Monitor the fuel pressure gage for 1 minute.

Does the fuel pressure remain constant?

--

Go to Step 23

Go to Step 20

12

Is the fuel pressure more than the specified value?

405 kPa (59 psi) VIN K

375 kPa (54 psi) VIN 1

Go to Step 14

Go to Step 13

13

Is the fuel pressure more than the specified value?

0 kPa (0 psi)

Go to Step 16

Go to Step 17

14

  1. Turn OFF the ignition.
  2. Relieve the fuel pressure. Refer to Fuel Pressure Relief .
  3. Disconnect the fuel return hose from the fuel rail pipe. Refer to Metal Collar Quick Connect Fitting Service .
  4. Attach a length of flexible fuel hose to the fuel rail outlet passage.
  5. Place the open end of the flexible fuel hose into an approved gasoline container.
  6. Turn ON the ignition, with the engine OFF.
  7. Monitor the fuel pressure gage while the fuel pump is operating.

Is the fuel pressure within the specified range?

364-405 kPa (53-59 psi) VIN K

334-375 kPa (48-54 psi) VIN 1

Go to Step 22

Go to Step 15

15

Inspect the fuel rail return pipe and the fuel rail outlet passage for a restriction.

Did you find and correct the condition?

--

Go to Step 25

Go to Step 23

16

  1. Turn OFF the ignition.
  2. Relieve the fuel pressure. Refer to Fuel Pressure Relief .
  3. Disconnect the fuel return hose from the fuel rail pipe. Refer to Metal Collar Quick Connect Fitting Service .
  4. Install the J 37287 between the fuel return pipe and the fuel rail.
  5. Open the valve in the fuel pipe shut-off adapter.
  6. Turn ON the ignition, with the engine OFF.
  7. Bleed the air from the fuel system.
  8. Monitor the fuel pressure gage.

    9. Notice: DO NOT allow the fuel pressure to exceed 517 kPa (75 psi). Excessive pressure may damage the fuel system.

  9. Slowly close the valve in the fuel return pipe shut-off adapter.
  10. Command the fuel pump ON with a scan tool.

Does the fuel pressure increase to more than the specified value?

405 kPa (59 psi) VIN K

375 kPa (54 psi) VIN 1

Go to Step 23

Go to Step 17

17

Inspect the following components for a restriction:

    • The fuel filter
    • The fuel feed pipe

Did you find and correct the condition?

--

Go to Step 25

Go to Step 18

18

Inspect the harness connectors and the ground circuits of the fuel pump for poor connections. Refer to Testing for Intermittent Conditions and Poor Connections and Connector Repairs in Wiring Systems.

Did you find and correct the condition?

--

Go to Step 25

Go to Step 19

19
  1. Remove the fuel sender assembly. Refer to Fuel Sender Assembly Replacement .
  2. Inspect the following items:
    3. • The fuel pump flex hose for damage
    • The in tank fuel pump harness connectors for poor connections
    • The fuel strainer for a restriction
    • Contaminates in the fuel tank

Did you find and correct the condition?

--

Go to Step 25

Go to Step 24

20
  1. Turn OFF the ignition.
  2. Raise the fuel rail, with the fuel lines connected. Refer to Fuel Injection Fuel Rail Assembly Replacement .
  3. Turn ON the ignition, with the engine OFF.
  4. Command the fuel pump ON with a scan tool.
  5. Locate and replace the leaking fuel injector. Refer to Fuel Injector Replacement .

Did you complete the replacement?

--

Go to Step 25

--

21

Repair the vacuum source to the fuel pressure regulator.

Did you complete the repair?

--

Go to Step 25

--

22

Locate and repair the restricted fuel return pipe.

Did you complete the repair?

--

Go to Step 25

--

23

Important: Inspect for a missing or damaged O-ring seal before replacing the fuel pressure regulator.

Replace the fuel pressure regulator. Refer to Fuel Pressure Regulator Replacement .

Did you complete the replacement?

--

Go to Step 25

--

24

Replace the fuel pump. Refer to Fuel Sender Assembly Replacement .

Did you complete the replacement?

--

Go to Step 25

--

25

Operate the system in order to verify the repair.

Did you correct the condition?

--

System OK

Go to Step 3