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HOMESERVICE MANUALSSATURN2009ASTRA XR, 4D HATCHBACK, AUTOMATICREPAIR AND DIAGNOSISENGINE PERFORMANCETESTING & DIAGNOSISENGINE CONTROLS AND FUEL - 1.6L (LDE OR LLU) AND 1.8L (2H0) - TROUBLESHOOTING & DIAGNOSISFUEL SYSTEM DIAGNOSISCIRCUIT/SYSTEM TESTING
2009 Saturn Astra XR, 4D Hatchback, Automatic

Circuit/System Testing

2009 Saturn Astra XR, 4D Hatchback, AutomaticSECTION Circuit/System Testing
    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.
  1. Ignition ON, engine OFF, command the fuel pump relay ON with a scan tool and observe the fuel pressure gage while the fuel pump is operating. Verify the fuel pressure is between 345-414 kPa (50-60 psi).
    • If the fuel pressure is greater than the specified range, replace the fuel pump module.
    • If the fuel pressure is less than the specified range, test, inspect, and repair the items listed below. If all items test normal, replace the fuel pump module.
      • Restricted fuel feed pipe
      • Inspect the harness connectors and the ground circuits of the fuel pump for poor connections.
  2. Verify that the fuel pressure does not decrease more than 34 kPa (5 psi) in 5 minutes.
    • If the fuel pressure decreases more than the specified value, perform the following procedure:
      1. Ignition OFF, relieve the fuel pressure.
      2. Disconnect the front fuel pump fuel feed hose from the fuel rail.
      3. Connect the front fuel pump fuel feed hose to the inlet side of SA9127E-7  using the J 43937  .
      4. Connect the fuel rail to the ON/OFF valve side of the SA9127E-7  using the J 43937  .
      5. Cap the pressure test port on the SA9127E-7  with the J 43936  .
      6. Open the valve on the SA9127E-7  .
      7. Ignition ON, command the fuel pump relay ON with a scan tool and bleed the air from the CH-48027-100  .
      8. Command the fuel pump relay ON for a minimum of 10 seconds with a scan tool.
      9. Close the valve on the SA9127E-7  .
      10. Monitor the fuel pressure for 1 minute.
        • If the fuel pressure decreases more than 34 kPa (5 psi) within the specified time, locate and replace the leaking fuel injector(s).
        • If the fuel pressure does not decrease more than 34 kPa (5 psi) within the specified time, replace the fuel pump module.
  3. Relieve the fuel pressure to 69 kPa (10 psi). Verify that the fuel pressure does not decrease more than 14 kPa (2 psi) in 5 minutes.
    • If the fuel pressure decreases more than the specified value, replace the fuel pump module.
  4. Operate the vehicle within the conditions of the customer's concern while monitoring the fuel pressure with the CH-48027-100  . The fuel pressure should not drop off during acceleration, cruise, or hard cornering.
    • If the fuel pressure drops off, test, inspect, and repair the items listed below. If all items test normal, replace the fuel pump module.
      • Restricted fuel feed pipe
      • Inspect the harness connectors and the ground circuits of the fuel pump for poor connections.
  5. If the fuel system tests normal, refer to Symptoms - Engine Controls .
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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.