Technical Training Series

Fuel
Pumps
Technical
Training Series
Fuel System Diagnostics
for Successful
Fuel Pump Installation

Sponsored By:

Why Fuel Pumps Fail

We all know that just replacing an electric fuel pump wont solve a no-fuel
complaint because the pump itself is only part of the fuel delivery system.
A good technician must diagnose the no-fuel problem in order to properly
service the vehicle. Here are a few of the most common reasons an electric
fuel pump fails.

Loss of current or low voltage. The pump cant run without

electricity, so anything that prevents current or voltage from
reaching the pump will make it stop. This includes
corroded, loose or broken wiring.

Dirt. Sediment or other debris in the tank can clog the pickup strainer, accelerate pump wear, damage the pump and/or
cause the pumps check valve to stick open (which can
cause a hard-starting condition due to loss of pressure
when the engine is shut off). When dirt has caused
a pump failure or if there appears to be a lot of
dirt or sediment in the tank, the tank should be
thoroughly cleaned to prevent a repeat failure.

Rust. Corrosion inside the tank produces rust,

which can flake off and plug up the pickup strainer
and have the same damaging effects on the pump as dirt. Rust
is caused by condensation, which occurs during cool, humid
weather when the fuel tank is low. Keeping the tank full will
minimize the formation of condensation. If the tank is badly
rusted or leaking, it should also be replaced.

Normal wear. Most pumps are designed for long-term durability and performance,
but their lifespan depends on lubrication and cooling provided by the fuel itself.
Frequent driving with a low fuel level may occasionally starve the pump for
lubrication and cooling, which can lead to accelerated wear or even pump damage.

Failure Signs
Noise may sometimes be an indication of excessive pump wear. Some
pumps are inherently noisier than others, often because of the way in
which theyre mounted inside the tank. Noise also can be caused by a
loose or missing rubber noise insulator around the pump, or physical
contact with the bottom of the tank or tank baffles.

Fuel System Foul Ups

Are fuel pump returns from your shop increasing? Understanding the
root cause of technician diagnostic errors is the first step to successfully
managing fuel system parts purchases and returns.

ver the years, vehicle fuel

systems have become more
complex as OEMs look to
improve fuel burning and engine
efficiency. And during that time,
industry parts suppliers have
noted that too many technicians
are returning brand-new fuel
pumps as defective, only to later
discover that the root cause of the
problem was a bad crankshaft
sensor or fuel pump relay. As a
technician, its important that you
keep up with modern fuel system
technology. So in order to avoid
some of the most common technician mistakes in fuel system diagnosis, lets look at how some of
todays most common fuel systems
operate, and what some of the common
failures and silver bullet fixes may be.

Inaccurate Level Readings

A vehicles fuel level must be accurately measured by the PCM in order to detect evaporative
leaks. Consequently, newer fuel gauge configurations often incorporate a small module that
may require as much as 20 minutes to compute
the actual fuel level in the fuel tank. Without
this particular bit of knowledge, many amateur
technicians may assume that a tank is half-full
of fuel when, in fact, it is not.
In addition, a fuel pump inlet strainer may be
installed which may interfere with the travel on
the fuel level sensors float arm and causes an
optimistic fuel level reading. Dented fuel tanks
may also cause a false reading by pushing the
fuel level sensor and fuel pump inlet filter
above the remaining fuel level in the tank.

Whatever the case, the engine may

be running out of gas simply
because the instrument panel fuel gauge is
providing a false reading.

Silently Working
Under normal circumstances, most fuel
pumps produce an audible noise for several seconds after the ignition switch is
turned on. The relatively silent two-speed

The leading cause of fuel pump failure

is fuel tank contamination.

fuel pumps used in many import and domestic

vehicles may, however, lead a technician to
believe that the fuel pump is defective. Since
the fuel pump speed in these applications is
dependent upon engine speed and load, a fuel
pressure gauge should be used to determine if
the pump is operating and if its delivering the
correct fuel pump pressure.
Of course, if the gauge doesnt show fuel
pressure, we must remember how most fuel

Running the Relays

A fuel pump relay is a high-current electrical
switch operated by a low-current circuit in the
PCM. As with all electrical switches, the contact points on the fuel pump relay eventually
wear out, which reduces electric current flow
to the fuel pump. Since this reduced current
flow also reduces fuel pump speed, the
engine may experience difficulty starting in
cold weather, when battery voltage may be
lower than normal.

Clogged fuel filters also cause rapid fuel pump wear,

which is why the fuel filter should be changed at 30,000mile intervals and after installing a new fuel pump.
pumps are activated. When the ignition switch
is turned on, the PCM activates the fuel pump
for a few seconds to purge air from the fuel
injectors and ensure proper fuel pressure for
the engines cranking cycle. Once the engine is
cranked, the PCM looks for the presence of
cranking speed and ignition triggering.
Depending upon design, the PCM turns off the
fuel pump if one or both of these inputs are
missing. This specific sequence of events is
necessary to prevent fuel from flooding an
engine with an inoperative ignition system or
the fuel pump from emptying the fuel tank
during a serious accident.

No-Go Airflow
A dirty or defective airflow sensor often causes
stalling and surging complaints normally associated with a worn fuel pump. In the case of
many imports, a signal from a vane-type airflow sensor activates the fuel pump relay. If an
air leak is present in the duct between the airflow sensor and the throttle plate, the sensor
wont activate the fuel pump during cranking,
and the engine will fail to start. A simple test is
to remove the air filter and manually open the
airflow sensor vane a slight amount during
cranking. If the fuel pump activates, the problem exists with the air duct, not the fuel pump.

Finding Faulty Fuel Pumps

Where do you begin your diagnosis if you have an engine
that cranks, but wont start?
If ignition and compression are both OK, that leaves fuel as the obvious culprit. Now the
question is, whats wrong with the fuel delivery system? Well, the most likely causes are:
1.
2.
3.
4.

A dead fuel pump (could be the pump, pump relay or wiring circuit);
A plugged fuel filter;
Low fuel pressure (weak pump or restricted line); or
No pulse signal to injectors (bad injector relay or PCM driver circuit).

On most vehicles, the pump is energized by the PCM via a relay. The pump circuit also
may be wired though an oil pressure switch and/or an inertia safety switch that kills the
pump in case of an accident. Refer to a wiring diagram to find out whats involved before
jumping to any conclusions.
Other electrical problems that can affect the pump include low voltage in the pumps power
supply circuit or high resistance in the pumps ground circuit. Either may prevent the pump
from running or spinning fast enough to generate normal fuel pressure.

Tests For Diagnosing A Faulty Fuel Pump

Dead Head Pressure: This checks the maximum output
pressure of the fuel pump. With the return line blocked, the
pump should produce pressure thats significantly higher than
its normal operating pressure at idle. If the pressure rating
does not go up with the return line blocked, the pump may not
be able to deliver enough fuel at higher engine speeds.
Possible causes include a worn pump, low voltage at the
pump, a plugged fuel filter or inlet sock in the tank, an
obstructed fuel line or almost empty fuel tank.
Fuel Volume Test: A fuel pump that delivers normal pressure
may still cause driveability problems if it cant deliver enough
fuel volume to meet the engines needs. A fuel volume test may
therefore be the best way to evaluate the pumps condition.
A fuel volume test measures the volume of fuel delivered
over a specified interval. This test can be done by connecting a
fuel flow gauge into the fuel supply line, or by disconnecting
the fuel return line from the fuel pressure regulator and connecting a hose from the regulator to a large container.
Caution: Make sure there are no open sparks or flames
nearby while doing this test!
With the engine off, energize the pump and measure the
volume of fuel delivered during the specified interval of time.
As a rule, a good pump should deliver about one quart of fuel
in 30 seconds.

Misdiagnosis is the leading cause of fuel pump

returns. If the engine runs
but displays driveability
symptoms that you
suspect are fuel-related,
attempt to eliminate
other possible causes by:
1. Checking the vehicles
OBD system;
2. Checking the ignition
system;
3. Checking for vacuum
leaks;
4. Checking the EGR &
PCV systems; and
5. Running a power
balance test.

Fuel System Delivery Overview

Guide To Successful Fuel System Repairs

Fuel Filler Cap

To ensure proper fuel delivery pressure and
evaporative emission control system operation, and to avoid fuel contamination, make
sure that the fuel filter cap seals properly
and replace it if necessary.
Fuel Tank
The leading cause of fuel pump failure is
fuel tank contamination. Thorough in-tank
cleaning is required with every fuel pump
replacement.
Supply and Return Lines
Clogged or restricted lines force the fuel
pump to work harder to deliver fuel, contributing to potential system problems.

Pressure Regulator
4 Fuel
A faulty regulator can contribute to pump
failure or be easily misdiagnosed as a fuel
pump problem. Check or replace it as a
part of fuel pump service.

Fuel System Wiring

Inspect the harness carefully for damaged
wires, a melted/bubbled or worn/loose

plastic connector or burn/score marks on

wire terminals. Faulty wiring is easily misdiagnosed as a fuel pump problem and can
create potentially dangerous conditions.

Fuel Pump Strainer

The first line of defense against premature
pump failure. A new strainer is required
with every fuel pump replacement.

Fuel Pump
AIRTEX fuel pumps are precision built to
exacting standards that meet or exceed OE
specifications. Check and diagnose the entire
fuel system before replacing the pump.

Filter
8 Fuel
A restricted in-line fuel filter creates significant backpressure, contributing to premature pump failure. Protect your investment
by replacing the in-line fuel filter as a part
of fuel pump service.
Injectors
9 Fuel
Faulty fuel injectors can create driveability
issues that are often misdiagnosed as a fuel
pump problem.