Servico de Combustible

1/4/2021 Service Information
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Document ID# 883829 Print
1998 Saturn SL2/SC2/SW2
Fuel System Diagnosis

Energizing the Fuel Pump
All of the fuel system tests will require operation of the fuel pump to measure pressure, evaluate pressure decay,
or perform the pressure at calibrated flow tests.
Although the fuel pump can be controlled with the ignition, this is fairly awkward for the following reasons:
The pump is only energized for 2-3 seconds at Key ON. Then a wait of 10 seconds is required after Key
OFF before the pump can be powered again.
Some of the tests are run with the vehicle on the hoist with control of the pump under the car required.
The pressure at flow tests require the pump to run for 10-20 seconds.
Important
Once the fuel pump is commanded ON with the scan tool, it will be energized for 1 minute before it times out
and returns to the OFF status. Do not leave the vehicle unattended while running any of the system tests with the
pump ON.
The scan tool provides control of the fuel pump at the technician's finger-tips. The tool will run the pump for
1 minute after the ON command. This timer will then shut the pump OFF.
Fuel System Testing
The fuel system tests outlined in the fuel system diagnostic flow chart and detailed procedures, Tests 1-9,
provide a systematic approach to determining whether the fuel system, from fuel pump to the fuel injectors, is
functioning as intended.
For the engine to operate as designed, the fuel supply system must do the following:
Deliver fuel at the proper pressure

Deliver fuel with adequate volume
Maintain pressure after the engine, and fuel pump, are turned OFF
In addition, the fuel injectors must deliver the precise quantity of fuel at exactly the correct intervals with no
leakage of fuel when the injector is turned OFF.
The battery of tests outlined in the Fuel Supply Diagnosis flow chart are designed to evaluate all the
performance characteristics. Symptoms or complaints related to the fuel system include:
Hard starting
No start (Hot and/or cold)
Extended cranking
No/low power
Start/stall
Rough idle
Poor acceleration, stalling, stumbling
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Misfire/backfire
Rough/erratic idle
Surges/hesitates
Diagnostic trouble codes associated with fuel supply problems include DTC P0171 and P0172.
Important
The performance of the fuel pump (pressure and flow) is very dependent on supply voltage. The voltage must be
above 12 volts when running any of the diagnostic tests. Published test specifications cover the range of system
operation from 12-14 volts, but are biased towards the lower voltages (12-12.7 volts) since all tests are run with
the engine OFF. All accessory loads should be off when running any tests (DRLs, interior lights, radio, etc.) to
provide maximum available voltage for the tests. If voltage is below 12 volts, the battery must be charged before
running tests.
Test 1
Fuel Pump Operational Test -- Test to establish whether fuel pump is operating and providing fuel to the
injectors.
Test 2
Fuel System Pressure Test, at idle or engine OFF -- Tests the basic integrity of the fuel system to
determine whether regulated operating pressure is achieved under low load conditions.
Test 3 and 4
Fuel Pump Flow/Pressure Tests -- Tests to determine if the fuel pressure is within operating limits while
simulating the flow demand of the engine running at wide open throttle. These tests are run with the
engine OFF and provide a means, based on testing at 2 points in the system, of determining if the fuel
filter/pressure regulator and fuel pump are operating to design specifications.
The testing is performed using the SA9127E-7 Fuel Flow/Pressure Adapter which incorporates a precision
orifice to meter 50 liters/hr (13 gallons/hr) at a delivery pressure of 330 kPa (48 psi).

The flow/pressure adapter consists of the following:
Female, quick connect inlet fitting (1)

Male, quick connect fitting (2)
Precision orificed fitting (3)
ON/OFF flow control valve (4)
Female, quick connect outlet fitting (5)
Adapter fittings - male 3/8 inch and 5/16 inch quick-connects for fuel lines to 1/4" quick-connects on test
adapter (6)
It is connected with the inlet side (1) to the fuel feed, either at the fuel rail or at the filter/pressure regulator inlet,
the outlet (5) to fuel return (or drain), and the gage port (2) to the pressure gage. The ON/OFF control valve (4)
provides a means to control fuel flow for pressure and leakdown testing.
The test criteria is the fuel pressure read while the fuel pump is energized with the engine OFF. Refer to
Energizing the Fuel Pump. If the pressure measured is within specification, then the fuel supply is capable of
meeting all volume requirements of the engine.
Tests 5, 6, and 7
Fuel System Pressure Leakdown, Decay - These tests determine if the fuel system will maintain pressure
after the engine, and fuel pump, are shut OFF. Fuel pressure must be maintained after shut OFF to ensure
quick restarts and prevent fuel vapor from forming at the fuel rail, causing hard or extended cranks. The
tests are arranged to allow isolation of the problem components or area by evaluating components in
sequence.
Test 8
Fuel Injectors Tip Leakage Test - This test determines if the fuel injectors are leaking fuel into the intake
system. Leaking fuel injectors can cause problems with extended cranks, hard starting, and rich running
conditions, DTC P0172.
Test 9
Fuel Injector Balance Test - This test determines if the fuel injectors are metering an equal quantity of fuel
when they are commanded open. By measuring the fuel pressure drop during a timed cycle of opening
each injector, a relative evaluation of each injector's flow rate is made. This test is designed to identify
injectors with significant differences in flow rate but will not identify problems with an injector flow
pattern, i.e., improperly sized spray cone, non-uniform spray cone pattern, mis-directed spray cone, etc.
1 - Fuel Pump Operational Test

If the vehicle is not operating or will not start or run, then a determination must be made if the fuel pump is
working and fuel under pressure is being delivered to the fuel rail.
Caution
Do not allow smoking or the use of open flames in the area where work on the fuel or EVAP system
is taking place. Anytime work is being done on the fuel system, disconnect the negative battery
cable, except for those tests where battery voltage is required.
Caution
Whenever fuel line fittings are loosened or removed, wrap a shop cloth around the fitting and have
an approved container available to collect any fuel.
1. Remove the cap on the fuel pressure test port at the fuel rail and slightly depress the tip of the schrader
valve. Note whether fuel is present.
2. If fuel, under pressure, is present proceed to test 2 - FUEL SYSTEM PRESSURE TEST.
3. If no fuel is present, assure that there is fuel in the tank. Check fuel gage.
4. Evaluate the fuel pump electrical circuit. Refer to Engine Cranks but Does Not Run .
2 - Fuel System Pressure Test
This test will determine whether there is adequate fuel pressure delivered to the fuel injectors to start and run the
engine under low load conditions.
Caution
1. Remove the air induction tube.
2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure .
3. Connect the SA9127E Gage Bar Set and pressure gage to fuel pressure test port.
Important
Battery must be at a minimum of 12 volts when performing any fuel system test. Charge battery before
proceeding if below 12 volts.
4. Energize the fuel pump for a minimum of 10 seconds. Refer to Energizing the Fuel Pump.
A. Close the valve on the fuel gage pressure adapter.
B. Energize the fuel pump.
C. Record the fuel pressure, while the fuel pump is energized.
D. Relieve the fuel pressure.
E. Repeat this procedure a minimum of 2 times.
Fuel System Pressure, Battery Voltage - Minimum 12 Volts
Minimum - 40 psi (276 kPa)
Maximum - 55 psi (379 kPa)
5. Compare the pressure recorded to the published specification.
6. Return to Fuel System Diagnosis - Fuel Supply Chart and use the test result to make the appropriate
decision.
Fuel Pump Flow/Pressure Tests
These tests will determine whether the fuel system can supply adequate volume of fuel at the desired pressure to
operate the engine under full load conditions. The test is done at 2 points in the system, fuel rail and fuel pump,
to isolate and identify the problem component: fuel pump, filter pressure regulator, or fuel supply line.
3 - Fuel Pump Regulated Flow/Pressure Test
Caution
Important
Battery must be at a minimum of 12 volts when performing any fuel system test. Charge the battery before
proceeding if below 12 volts.

2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure in this manual.
3. Remove the fuel feed line retainer clip attachment screw , 10 mm hex.
Caution
4. Disconnect the fuel feed line at the fuel rail.
Notice

To properly utilize the fuel flow/pressure test adapter, it must always be connected with the fuel feed line
on the INLET. The inlet side is the side of the adapter and the fuel return or drain line connected to the
side with the flow control (ON/OFF) valve. If not connected properly, a zero pressure reading will always
be read. Use the appropriately sized connector fittings to hook up the adapter to the feed and return lines.
5. Connect the INLET side of the SA9127E-7 Fuel Flow/Pressure Test Adapter into fuel feed line 90 degree
quick connect and make sure the fitting is firmly latched.
6. Connect the fuel pressure gage to the test adapter.
7. Connect a fuel return hose to the quick connect on the test adapter and place the other end of the line into
an approved container or run a return hose back to the fuel filler pipe.
8. Turn the ON/OFF valve on the test adapter to ON.
The Regulated Fuel Pressure Under Flow at Fuel Rail is a Minimum 276 kPa (40 psi).
Important
The battery must be at a minimum of 12 volts when performing any fuel system test.
9. Energize the fuel pump for a minimum of 10 seconds. Refer to Energizing the Fuel Pump.
A. Record the fuel pressure, while the fuel pump is energized.
B. Repeat this procedure a minimum of 2 times.
10. Compare the pressure recorded to the published specification.
11. Refer to Fuel System Diagnosis - Fuel Supply Chart and use the test result to make the appropriate
decision.
4 - Fuel Pump Flow/Pressure Test
For this test, the vehicle will be raised on the hoist and a means of controlling the fuel pump from under the
vehicle is required. The scan tool readily provides this function. Refer to Energizing the Fuel Pump.
Caution

Important
The battery must be at a minimum of 12 volts when performing any fuel system test. Charge battery
before proceeding if below 12 volts.
1. Connect the scan tool to the vehicle and turn the ignition to ON.
3. Raise the vehicle to a comfortable working position.
Caution
4. Disconnect the fuel feed (5/16 in) and the fuel return (3/8 in) lines at the fuel filter/pressure regulator.
Notice
5. Connect the SA9127E-7 Fuel Flow/Pressure Test Adapter to the (1) feed and (2) return lines and make
sure the connections are firmly latched.
7. Turn the ON/OFF valve on the test adapter to ON.
Fuel Pressure Under Flow at Fuel Rail
12-12.4 volts Minimum 276 kPa (40 psi)
12.4-12.8 volts Minimum 276 kPa (44 psi)

8. Energize the fuel pump for a minimum of 10 seconds.
A. Record the fuel pressure while the pump is energized
9. Using the scan tool, determine the battery voltage, with the pump OFF, and record.
10. Compare the pressure and voltage recorded to the published specification.
11. Refer to Fuel System Diagnosis . Use the test result to make the appropriate decision.
5 - Fuel System Leakdown Test
The fuel system leakdown test will determine if the fuel system is able to hold fuel pressure when the fuel pump
is not operating. The system must hold pressure to assure that the fuel supply circuit, fuel lines, filter/regulator,
and fuel rail, is full of fuel. When the fuel supply is completely charged, fuel will be available at the injectors as
soon as the ignition is turned ON.
Caution
Caution
3. Connect the SA9127E Gage Bar Set to the fuel pressure port.
Important
4. Energize fuel pump for a minimum of 10 seconds. Refer to Energizing the Fuel Pump in this manual.
A. Record the fuel pressure.
5. Shut the fuel pump OFF and wait 5 minutes.
Fuel System Leakdown Test: The Maximum Pressure Decay after 5 minutes - 55 kPa (8 psi).
6. Record the fuel pressure and subtract from the pressure recorded in Step 4.1.
7. Compare the pressure loss, decay, to the published specification.
8. Refer to Fuel System Diagnosis . Use the test result to make the appropriate decision.
6 - Fuel Supply Leakdown Test
This test will determine if the fuel supply system, up to the fuel rail and injectors, will maintain pressure after
the fuel pump is turned off.
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Caution
Important
This test can be performed using the J 37287-100 Fuel Line Shut Off Quick Connect Adapter.
Important

Caution
3. Remove the fuel feed line retainer clip attachment screw, 10 mm hex.
4. Disconnect the fuel feed line at the fuel rail.
A. Connect the fuel feed line directly to the pressure gage using the J 37287-100 (3/8 in x 1/4 in).
Notice
To properly utilize the fuel flow/pressure test adapter, it must always be connected with the fuel feed
line on the INLET. The inlet side is the side of the adapter and the fuel return or drain line
connected to the side with the flow control (ON/OFF) valve. If not connected properly, a zero
pressure reading will always be read. Use the appropriately sized connector fittings to hook up the
adapter to the feed and return lines.
B. If using the fuel flow/pressure test adapter, connect the INLET to the fuel feed line and assure that
the flow valve is OFF.
5. Connect the pressure gage to the test adapter.
Fuel System Leakdown Test: Maximum Pressure Decay after 5 minutes - 55 kPa (8 psi).
6. Energize the fuel pump for a minimum of 10 seconds. Refer to Energizing the Fuel Pump in this manual.
A. Record the fuel pressure.
8. Record the fuel pressure and subtract from the pressure recorded in step 6.
10. Refer to Fuel System Diagnosis and use the test result to make the appropriate decision.
7 - Fuel Pump Leakdown Test

This test will determine if the fuel pump will maintain pressure after the pump is turned OFF.
For this test, the vehicle will be raised on the hoist and a means of controlling the fuel pump from under the
vehicle is required. The scan tool readily provides this function. Refer to Energizing the Fuel Pump.
Caution
Important
1. Connect the scan tool to the vehicle and turn the ignition to ON.
Caution
Fuel supply lines will remain pressurized for long periods of time after the engine is shutdown. This
pressure must be relieved before servicing the fuel system.
3. Raise the vehicle to a comfortable working position.
Caution
4. Disconnect the fuel feed (5/16 in) and fuel return (3/8 in) lines at the fuel filter/pressure regulator.

Notice
5. Connect the SA9127E-7 Fuel Flow/Pressure Test Adapter to the (1) feed and (2) return lines and make
sure the connections are firmly latched.
7. Turn the ON/OFF flow valve on the test adapter to ON.
8. Energize the fuel pump.
A. Cycle the ON/OFF flow valve at least 2 times over a 10 second interval.
B. Turn the ON/OFF flow valve to OFF.
C. Record the fuel pressure.
10. Record the fuel pressure and subtract from the pressure recorded in Step 8.3.
Fuel System Leakdown Test: Maximum Pressure Decay after 5 Minutes - 55 kPa (8 psi).
12. Return to Fuel System Diagnosis and use the test result to make the appropriate decision.
8 - Fuel Injector Tip Leakage Test

Caution
1. Remove the air induction tube and resonator.

2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure in this section.
Caution
3. Remove the throttle cable from the throttle cable support bracket.
4. Remove the upper power steering support brace.
5. Connect the SA9127E Gage Bar Set to the fuel pressure port.
Caution
Lay shop towels on the intake manifold and cam cover to collect any fuel.
Caution
Make sure the injectors are positioned to prevent fuel from being sprayed onto the engine. Make
sure that the injector retaining clips are properly installed.
6. Remove the fuel feed line clip attachment nut, 10 mm hex.

7. Remove the fuel rail assembly attachment bolts and pull the fuel rail back far enough so that the nozzles of
the fuel injectors are visible but still in the ports. Attach the fuel rail to the intake manifold with the safety
wire.
8. Connect the fuel pressure gage bar to the pressure adapter.
9. Wipe the tips of the fuel injectors free of any fuel or debris and place a clean white towel directly under
the fuel injectors. The clean white towel must lightly contact each fuel injector tip. This will serve as an
indicator of leaky fuel injectors by showing spots where fuel has leaked as well as block the injector ports
from any debris that might enter.
10. Connect the scan tool and turn the ignition ON. Refer to Energizing Fuel Pump.
Important
11. Energize the fuel pump using the scan tool and observe the fuel injector tips for leakage of fuel. If one or
more of the white towels becomes wet with fuel after five minutes, replace the faulty fuel injector. It is
very difficult to measure drops of fuel from a injector. Refer to Fuel Injector Replacement procedure.

Important
The pressure gage reading should be approximately 276-379 kPa (40-55 psi).
12. Test the assembly a minimum of 2 times.

13. Install the bleed hose from the J 39893 Pressure Test Adapter into an approved container and open the
valve to bleed system pressure. Once the pressure is bled, remove the fuel gage adapter from the fuel
pressure test port and recap it.
14. Lubricate the injector O-rings with clean engine oil and install the fuel rail assembly. Refer to Fuel Rail
Assembly Replacement .
15. Start the engine and check for leaks.
9 - Fuel Injector Balance Test
Caution
Important
If the engine is at operating temperature, allow a 10-minute cool down period.
1. On the SOHC (L24), remove the air intake tube. Refer to Intake Manifold Replacement .
2. Before the Fuel Injector Balance Test is started, the electrical connector should be tested using a J 34730
Noid Lite.
A. Disconnect the electrical connectors at the fuel injectors.
B. Connect a Noid Lite to the female connector.
C. Crank the engine.
D. If the Noid Lite does not blink, the electrical problem must be corrected before continuing.

Caution
3. Connect the SA9127E Gage Bar Set to the fuel test port.
4. Connect the SA9182E Electronic Fuel Injection Tester.
A. Connect the plug to a fuel injector.
B. Connect the red clip to the positive battery post.
C. Connect the black clip to a clean ground.
D. Check the power light. If it is not ON, check the battery connection again.
5. Set the switch on the fuel injector tester to the 50 Pulse - 10 MS setting.
Important
It may be necessary to cycle the key ON/OFF a minimum of 3 times to bleed all air from the system and
achieve maximum system pressure. The key must be OFF 30 seconds.
6. Cycle the ignition key ON/OFF several times, do not start the engine, and bleed off all the air in the
system using the pressure gage shut-off valve.
7. Turn the ignition to the OFF position for 10 seconds. After 10 seconds, turn the ignition key to the ON
position, do not start engine, and record the gage pressure, 1st reading.
8. Using the injector tester, pulse the #1 injector.
9. Record the pressure at the instant the gage needle stops moving, 2nd reading.
10. Repeat steps 6-9 for the remaining 3 injectors.
Notice
The engine must be started after four cylinders have been tested to prevent flooding or internal damage.
11. Add all the 2nd Readings together and divide by 4. This is the 2nd reading Average.
12. Subtract the Average of 2nd Readings from each 2nd Reading to obtain the Difference .
13. An injector is faulty if the Difference is greater than +/- 10 kPa (1.5 psi).
14. Check that all fuel injector connectors are connected. Pull back to ensure a positive engagement.
15. Remove the fuel gage bar adapter from the fuel pressure test port and recap it.
16. Install the air intake tube.
17. Start the engine and check for leaks.
EXAMPLE
Cylinder 1 2 3 4
1st Reading (psi) 45 45 45 45
2nd Reading (psi) 40 42 44 42
Average of
42 42 42 42
2nd readings (psi)
Difference
(2nd Reading - Avg -2 0 2 0
of 2nd Readings)
Allowable Difference -- +/- 1.5 psi (10 kPa)
Cylinder #1 is faulty (rich) or too much drop.
Cylinder #3 is faulty (lean) or not enough drop.
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Document ID# 883829 Print
1998 Saturn SL2/SC2/SW2

Servico de Combustible

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1/4/2021 Service Information

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Fuel System Diagnosis

Fuel System Testing

Deliver fuel at the proper pressure

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The flow/pressure adapter consists of the following:

Female, quick connect inlet fitting (1)

1 - Fuel Pump Operational Test

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2 - Fuel System Pressure Test

1. Remove the air induction tube.

Fuel Pump Flow/Pressure Tests

3 - Fuel Pump Regulated Flow/Pressure Test

1. Remove the air induction tube.

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4. Disconnect the fuel feed line at the fuel rail.

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4 - Fuel Pump Flow/Pressure Test

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12.4-12.8 volts Minimum 276 kPa (44 psi)

5 - Fuel System Leakdown Test

1. Remove the air induction tube.

6 - Fuel Supply Leakdown Test

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1. Remove the air induction tube.

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7 - Fuel Pump Leakdown Test

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8 - Fuel Injector Tip Leakage Test

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1. Remove the air induction tube and resonator.

6. Remove the fuel feed line clip attachment nut, 10 mm hex.

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12. Test the assembly a minimum of 2 times.

9 - Fuel Injector Balance Test

If the engine is at operating temperature, allow a 10-minute cool down period.

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(2nd Reading - Avg -2 0 2 0

Cylinder #3 is faulty (lean) or not enough drop.

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