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Fuel System Pressure Test

SPECIAL TOOLS

G06064437
 Adapter, Fuel Pressure Test
310-180
G06064438
 Fuel Pressure Test Kit
310-D009 (D95L-7211A) or equivalent
WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.
WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.
WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury.
WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.
WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury.

All vehicles 

  1. Release the fuel system pressure. For additional information, refer to FUEL SYSTEM PRESSURE RELEASE  .
  2. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  3. Disconnect the fuel tube-to-fuel jumper tube quick connect coupling. For additional information, refer to QUICK CONNECT COUPLING  .

    All vehicles except Gasoline Turbocharged Direct Injection (GTDI) 

  4. Install the Fuel Pressure Test Adapter and the Fuel Pressure Test Kit between the fuel tube and the fuel jumper tube.
    Fig 1: Installing Fuel Pressure Test Adapter And Fuel Pressure Test Kit Between Fuel Tube And Fuel Jumper Tube
    G06064439Courtesy of FORD MOTOR CO.

    3.5L GTDI vehicles 

  5. Install the Fuel Pressure Test Adapter and the Fuel Pressure Test Kit between the fuel tube and the fuel jumper tube.
    Fig 2: Installing Fuel Pressure Test Adapter And Fuel Pressure Test Kit Between Fuel Tube And Fuel Jumper Tube
    G06261678Courtesy of FORD MOTOR CO.

    All vehicles 

    6. NOTE: The Fuel Pump (FP) control module electrical connector was previously disconnected to release the fuel system pressure and must be reconnected to test the fuel system pressure.
  6. Connect the FP control module electrical connector.
  7. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
    8. NOTE: Carry out an ignition ON engine OFF visual inspection for fuel leaks prior to completing the fuel system pressure test.
    NOTE: After completing the fuel system pressure test, open the drain valve on the Fuel Pressure Test Kit and release any residual fuel into a suitable container prior to removing the tool.
  8. Test the fuel system pressure to make sure it is within the specified range. For additional information, refer to SPECIFICATIONS  .
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