L200 L4-2.2L VIN F (2002)
Fuel Pressure Release: Service and Repair
TOOLS REQUIRED
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SA9127E Gauge Bar Set
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.
Prior to servicing any fuel system components (fuel rail, injectors, filter, pressure regulator, fuel tank, fuel pump module, etc.) any pressure built up in
the system must be relieved. There are two preferred methods:
1. Start and run vehicle then disable fuel pump with Scan tool.
This method is the cleanest since no fuel, under pressure, will be present at any fitting or connection that needs to be serviced.
This method is preferred when removing any components of the fuel system that require disconnecting fuel lines. If performance tests are to be run
on the system underhood, procedure 2 will be preferable since the Gauge Bar Set SA9127E will also be required for the testing.
This method is also preferable to disconnecting the fuel pump relay since no DTC's will be set and there is no concern about voltage spikes to the
PCM if the relay should be re-installed with the key On.
1.1 Connect Scan tool and start vehicle.
1.2 Turn Scan tool On and locate SPECIAL FUNCTIONS.
1.3 Select POWERTRAIN, then select FUEL SYSTEM.
1.4 Select FUEL PUMP, then command fuel pump Off.
1.5 Engine will die in 3-5 seconds, turn key Off, and proceed with component removal/installation.
CAUTION: DO NOT ALLOW SMOKING OR THE USE OF OPEN FLAMES IN THE AREA WHERE WORK ON THE FUEL SYSTEM
IS TAKING PLACE. ANY TIME WORK IS BEING DONE ON THE FUEL SYSTEM, DISCONNECT THE NEGATIVE BATTERY
CABLE, EXCEPT FOR TESTS WHERE BATTERY VOLTAGE IS REQUIRED.
2. Bleed pressure at service test port.
This method will require collection of fuel as pressure is relieved. Use of a suitable container is required.
2.1 Locate service test port on fuel rail transfer line and remove protective cap.
2.2 Connect gauge bar (53476) to Fuel Gauge Pressure Adapter (309725) using a flexible hose from Gauge Bar Set SA9127E.
2.3 Make sure needle valve on pressure adapter is closed (Off).
NOTE: Do not use any tools to tighten the adapter to the fuel line pressure port. If the adapter Will not seal with finger tightening, then the seal is
defective or damaged and needs to be replaced. Excessive torque on the adapter will damage the fuel line test port.
2.4 Connect pressure adapter to fuel line test port.
2.5 Route drain hose from pressure adapter into a suitable container or route fuel hack to fuel tank.
2.6 Open valve on pressure adapter and bleed off pressure (and fuel).