GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2006 🢒 ION 🢒 Engine 🢒 Engine Controls - 2.4L 🢒 Fuel System Diagnosis

Diagnostic Fault Information

Always perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure.

Circuit/System Description

The control module enables the fuel pump relay when the ignition switch is turned ON. The control module will disable the fuel pump relay within 2 seconds unless the control module detects ignition reference pulses. The control module continues to enable the fuel pump relay as long as ignition reference pulses are detected. The control module disables the fuel pump relay within 2 seconds if ignition reference pulses cease to be detected and the ignition remains ON.

The fuel tank stores the fuel supply. An electric turbine style fuel pump attaches to the fuel pump module inside the fuel tank. The fuel pump supplies high pressure fuel through the fuel filter and the fuel feed pipe to the fuel injection system. The fuel pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pump also supplies fuel to a venturi pump located on the bottom of the fuel pump module. The function of the venturi pump is to fill the fuel pump module reservoir. The fuel pressure regulator, a part of the fuel pump module, maintains the correct fuel pressure to the fuel injection system. The fuel pump module contains a reverse flow check valve. The check valve and the fuel pressure regulator maintain fuel pressure in the fuel feed pipe and the fuel rail in order to prevent long cranking times.

Reference Information

Electrical Information Reference

    •  Circuit Testing
    •  Connector Repairs
    •  Testing for Intermittent Conditions and Poor Connections
    •  Wiring Repairs

Scan Tool Reference

    •  Scan Tool Data List
    •  Scan Tool Data Definitions
    •  Scan Tool Output Controls

Special Tools Required

    • SA9127E-7 Fuel Pressure/Flow Adapter
    • SA9127E Gage Bar Set

Circuit/System Verification

Important: 

   • Inspect the fuel system for damage or external leaks before proceeding.
   • Verify that adequate fuel is in the fuel tank before proceeding.

  1. Turn ON the ignition, with the engine OFF.
  2. Command the fuel pump relay ON with a scan tool.
    3. ⇒If the fuel pump does not operate, refer to Fuel Pump Electrical Circuit Diagnosis .
  3. Turn OFF the ignition.
  4. Turn OFF all accessories.
  5. Install a SA9127E . Refer to Fuel Pressure Gage Installation and Removal .
  6. Turn ON the ignition, with the engine OFF.

    7. Important: 

       • The fuel pump relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure.
       • DO NOT start the engine.

  7. Command the fuel pump relay ON with a scan tool.
  8. Observe the SA9127E with the fuel pump commanded ON. The fuel pressure should be 345-414 kPa (50-60 psi).
    9. ⇒If the fuel pressure is less than 345 kPa (50 psi), inspect for a restricted fuel filter, a restricted fuel feed pipe, poor connections at the harness connectors and ground circuits of the fuel pump, or a faulty fuel pump module.
    ⇒If the fuel pressure is more than 414 kPa (60 psi), inspect for a restriction in the return side of the fuel filter or a faulty fuel pump module.

    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.

  9. Monitor the SA9127E for 5 minutes. The fuel pressure should not decrease more than 55 kPa (8 psi).
    10. ⇒If the fuel pressure decreases more than 55 kPa (8 psi), refer to Circuit/System Testing.
  10. Relieve the fuel pressure to 69 kPa (10 psi).
  11. Monitor the SA9127E for 5 minutes. The fuel pressure should not decrease more than 14 kPa (2 psi).
    12. ⇒If the fuel pressure decreases more than 14 kPa (2 psi), replace the fuel pump module.
  12. Remove the SA9127E . Refer to Fuel Pressure Gage Installation and Removal .
  13. Operate the vehicle within the conditions to reproduce the original symptoms.
  14. Monitor the O2 and the Fuel Trim parameters with a scan tool.
    15. ⇒If the scan tool parameters indicate a lean condition, inspect for a restricted fuel filter, a restricted fuel feed pipe, poor connections at the harness connectors and ground circuits of the fuel pump, or a faulty fuel pump module.
    ⇒If the scan tool parameters do not indicate a lean condition, go to Symptoms - Engine Controls .

Circuit/System Testing
  1. Turn OFF the ignition.
  2. Relieve the fuel pressure. Refer to Fuel Pressure Relief .
  3. Remove the SA9127E from the fuel pressure test connection.
  4. Raise the vehicle. Refer to Lifting and Jacking the Vehicle .
  5. Disconnect the fuel feed pipe and the fuel return pipe from the fuel filter. Refer to Plastic Collar Quick Connect Fitting Service .
  6. Connect the fuel feed pipe to the inlet side of SA9127E-7 .
  7. Connect the fuel return pipe to the ON/OFF valve side of the SA9127E-7 .
  8. Connect the fuel pressure gage to the SA9127E-7 .
  9. Open the valve on the SA9127E-7 .
  10. Turn ON the ignition, with the engine OFF.
  11. Command the fuel pump relay ON for a minimum of 10 seconds with a scan tool.
  12. Close the valve on the SA9127E-7 .
  13. Monitor the fuel pressure gage for 5 minutes.
    14. ⇒If the fuel pressure decreases more than 55 kPa (8 psi), replace the fuel pump module.
    ⇒If the fuel pressure does not decrease more than 55 kPa (8 psi), locate and replace the leaking fuel injectors.

Repair Instructions

Important: Always perform the Diagnostic Repair Verification after completing the diagnostic procedure.

    •  Fuel Filter Replacement
    •  Fuel Hose/Pipes Replacement - Chassis
    •  Fuel Injector Replacement
    •  Fuel Pump Module Replacement