Jeep XJ. Manual — part 871
Symptom:
*START AND STALL CONDITION
POSSIBLE CAUSES
CHECKING DTCS
CHECKING SKIM DTCS
FUEL PRESSURE OUT OF SPECS
FUEL PUMP CAPACITY (VOLUME) OUT OF SPECS
THROTTLE POSITION SENSOR SWEEP
TP SENSOR VOLTAGE GREATER THAN 0.92 VOLTS WITH THROTTLE CLOSED
ENGINE COOLANT TEMPERATURE SENSOR OPERATION
OTHER POSSIBLE CAUSES FOR START & STALL
RESTRICTED FUEL SUPPLY LINE
FUEL PUMP INLET STRAINER PLUGGED
FUEL PUMP MODULE
TEST
ACTION
APPLICABILITY
1
Turn the ignition on.
With the DRBIII
t, read DTC’s.
Are any DTCs present?
All
Yes
→
Refer to the Driveability Category and perform the appropriate
symptom.
Perform POWERTRAIN VERIFICATION TEST VER - 1.
No
→
2
Turn the ignition on.
NOTE: If you are unable to communicate with the SKIM, refer to the
Communication Category and perform the appropriate symptom.
With the DRBIII
t, read the SKIM codes.
Are there any SKIM DTCs?
All
Yes
→
Refer to the Vehicle Theft category and perform the appropriate
symptom.
Perform POWERTRAIN VERIFICATION TEST VER - 1.
No
→
245
STARTING
TEST
ACTION
APPLICABILITY
3
Turn the ignition off.
WARNING: The fuel system is under a constant pressure even with the
engine off. Before testing or servicing any fuel system hose, fitting or line,
the fuel system pressure must be released.
Install a fuel pressure gauge to the fuel rail test port.
Turn the ignition on.
With the DRBIII
t, actuate the ASD Fuel System test and observe the fuel pressure
gauge.
NOTE: Fuel pressure specification is 339.2 KPa +/- 34 KPa (49.2 psi +/- 5 psi).
Choose a conclusion that best matches your fuel pressure reading.
All
Below Specification
Within Specification
Above Specification
Replace the fuel filter/fuel pressure regulator.
Perform POWERTRAIN VERIFICATION TEST VER - 1.
Caution: Stop All Actuations.
4
Turn the ignition off.
WARNING: The fuel system is under a constant pressure even with the
engine off. Before testing or servicing any fuel system hose, fitting or line,
the fuel system pressure must be released.
Raise vehicle on hoist, and disconnect the fuel pressure line at the fuel pump module.
Install special 5/16
9 fuel line adapter tool #6539 between disconnected fuel line and
the fuel pump module.
Attach a fuel pressure test gauge to the
9T9 fitting on tool #6539.
Turn the ignition on.
With the DRBIII
t, actuate the ASD Fuel System test and observe the fuel pressure
gauge.
NOTE: Fuel pressure specification is 339.2 KPa +/- 34 KPa (49.2 psi +/- 5 psi).
Is the fuel pressure within specification now?
All
Yes
→
Repair/replace fuel supply line as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 1.
No
→
Caution: Stop All Actuations.
5
Turn the ignition off.
WARNING: The fuel system is under a constant pressure even with the
engine off. Before testing or servicing any fuel system hose,fitting or line,
the fuel system pressure must be released.
Remove the Fuel Pump Module and inspect the Fuel Inlet Strainer.
Is the Fuel Inlet Strainer plugged?
All
Yes
→
Replace the Fuel Pump Inlet Strainer.
Perform POWERTRAIN VERIFICATION TEST VER - 1.
No
→
Test Complete.
246
STARTING
*START AND STALL CONDITION —
Continued
TEST
ACTION
APPLICABILITY
6
Note: The fuel pressure must be within specification before continuing.
Turn the ignition off.
WARNING: The fuel system is under a constant pressure even with the
engine off. Before testing or servicing any fuel system hose, fitting or line,
the fuel system pressure must be released.
Disconnect the fuel supply line at the fuel rail.
Connect fuel line adapter #6539(5/16
9) or #6631(3/89) to the disconnected fuel supply
line. Insert the other end of the adapter into a graduated container.
Caution: Do not operate the fuel pump for more than 7 seconds in the next
step. Fuel pump module reservoir may run empty and damage to the fuel
pump will result.
Note: Specification: A good fuel pump will deliver at least 1/4 liter (1/2 pint)
of fuel in 7 seconds.
Turn the ignition on.
With the DRBIII
t, actuate the ASD Fuel System test for 7 seconds.
Is the fuel pump capacity within specification?
All
Yes
→
No
→
Check for a kinked/damaged fuel supply line between the fuel
tank and fuel rail. If OK, replace the fuel pump module.
Perform POWERTRAIN VERIFICATION TEST VER - 1.
Caution: Stop All Actuations.
7
Turn the ignition on.
With the DRBIII
t, read TPS VOLTS.
While monitoring the DRBIII
t, slowly open and close the Throttle.
Is the voltage change smooth?
All
Yes
→
No
→
Replace the Throttle Position Sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 1.
8
Turn the ignition on.
With the DRBIII
t, read Throttle Position voltage. Throttle must be against stop.
Is the voltage 0.92 or less with the Throttle closed?
All
Yes
→
No
→
Check for a binding throttle condition. If OK, replace the Throttle
Position Sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 1.
247
STARTING
*START AND STALL CONDITION —
Continued
TEST
ACTION
APPLICABILITY
9
Note: For this test to be valid, the thermostat must be operating correctly.
Note: This test works best if performed on a cold engine (cold soaked).
NOTE: If the vehicle was allow to sit over night with no engine start, coolant
temperature should be near ambient temperatures.
Turn the ignition on.
With the DRBIII
t, read the Engine Coolant Temperature value.
Note: If engine coolant temperature is above 82° C (180° F), allow the engine
to cool until 65° C (150° F) is reached.
Start the engine.
During engine warm-up, monitor the Engine Coolant Temperature value. The
temperature value change should be a smooth transition from start up to normal
operating temp 82° C (180° F). The value should reach at least 82° C (180° F).
Did the Engine Temperature value increase smoothly and did it reach at least 82° C
(180° F)?
All
Yes
→
No
→
Replace the Engine Coolant Temperature Sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 1.
10
The following additional items should be checked as a possible cause for a start and
stall condition.
Refer to any Technical Service Bulletins (TSB’s) that may apply to the symptom.
Fuel must be free of contamination.
The exhaust system must be free of any restrictions.
The engine compression must be within specifications.
The engine valve timing must be within specifications.
The engine must be free from vacuum leaks.
The throttle body must be free of carbon buildup and dirt.
Do any of the above conditions exist?
All
Yes
→
Repair as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 1.
No
→
Test Complete.
248
STARTING
*START AND STALL CONDITION —
Continued
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