FUEL SYSTEM ON-VEHICLE INSPECTION

PROCEDURE


  1. INSTALL FUEL PUMP OPERATION AND INSPECT FOR FUEL LEAK


    1. Check the fuel pump operation.


      1. Connect the GTS to the DLC3.

      2. Turn the power switch on (IG).

        Note

        Do not start the engine.

      3. Turn the GTS on.

      4. Enter the following menus: Powertrain / Engine / Active Test / Activate the Circuit Relay.


        Powertrain > Engine > Active Test
        Tester Display
        Activate the Circuit Relay

      5. Check for pressure in the fuel tube sub-assembly from the fuel line. Check that sounds of fuel flowing from the fuel tank assembly can be heard. If no sounds can be heard, check the relay, fuel pump, ECM and wiring connectors.

    2. Inspect for fuel leaks.


      1. Check that there are no fuel leaks anywhere in the system after performing maintenance.

        If there is a fuel leak, repair or replace parts as necessary.

    3. Turn the power switch off.

    4. Disconnect the GTS from the DLC3.

  2. CHECK FUEL PRESSURE


    1. Check the battery voltage.

    2. Discharge the fuel system pressure.

    3. Disconnect the cable from the negative (-) auxiliary auxiliary battery terminal.

      Note


      • After turning the power switch off, waiting time may be required before disconnecting the cable from the auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the auxiliary battery terminal notice before proceeding with work.

        Click here

      • When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

        Click here

    4. for Port Injection Side:


      1. B004R3Q

        Disconnect the fuel tube sub-assembly.

        Click here

    5. for Direct Injection Side:


      1. B004VV5

        Disconnect the No. 2 fuel tube sub-assembly.

        Click here

    6. B004VFPC01
      *1 Fuel Tube Sub-assembly (Vehicle Side)
      *a SST (Hose Band)
      *b SST (T-joint)
      *c SST (Gauge)
      *d SST (Hose Joint)
      *e SST (Hose)
      *f SST (Fuel Tube Connector)
      *g Fuel Pipe (Vehicle Side)

      Install SST (pressure gauge) as shown in the illustration.

      SST
      09268-45101   ( 09268-41250, 09268-41260, 09268-41280, 09268-41500, 09268-41700, 95336-08070 )

    7. Wipe up any spilled fuel.

    8. Connect the cable to the negative (-) auxiliary battery terminal.

    9. Connect the GTS to the DLC3.

    10. Turn the power switch on (IG).

      Note

      Do not start the engine.

    11. Turn the GTS on.

    12. Enter the following menus: Powertrain / Engine / Active Test / Activate the Circuit Relay.


      Powertrain > Engine > Active Test
      Tester Display
      Activate the Circuit Relay

    13. Measure the fuel pressure.

      Standard Fuel Pressure
      196 to 833 kPa (2.0 to 8.5 kgf/cm2, 28 to 121 psi)

      • If the fuel pressure is less than the standard, check the fuel hoses and their connections, fuel pump, fuel filter assembly and fuel main valve assembly.

      • If the result is not as specified, replace the fuel main valve assembly.

    14. Disconnect the GTS from the DLC3.

    15. Put the engine in inspection mode (2WD for measuring exhaust gas).

      Click here

    16. Start the engine.

    17. Measure the fuel pressure at idle.

      Standard Fuel Pressure
      196 to 833 kPa (2.0 to 8.5 kgf/cm2, 28 to 121 psi)

      Tech Tips

      Refer to Standard Idle Speed.

    18. Stop the engine.

    19. Check that the fuel pressure remains as specified for 5 minutes.

      Standard Fuel Pressure
      98 kPa (1.0 kgf/cm2, 14 psi) or more

      If the result is not as specified, check the fuel pump, fuel main valve assembly and/or fuel injector assemblies.

    20. After checking the fuel pressure, disconnect the cable from the negative (-) auxiliary battery terminal and carefully remove SST to prevent fuel from spraying.

      Note

      When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

      Click here

    21. for Direct Injection Side:


      1. Connect the No. 2 fuel tube sub-assembly.

        Click here

    22. for Port Injection Side:


      1. Connect the fuel tube sub-assembly.

        Click here

    23. Install new No. 2 fuel pipe clamp to the fuel tube connector.

    24. Inspect for fuel leaks.

  3. CHECK FUEL PRESSURE (for High Pressure)


    1. Connect the GTS to the DLC3.

    2. Turn the power switch on (IG).

    3. Turn the GTS on.

    4. Put the engine in inspection mode (2WD for measuring exhaust gas).

      Click here

    5. Start and warm up the engine.

    6. Enter the following menus: Powertrain / Engine / Active Test / Control the Injection Mode / Direct / Data List / Fuel Pressure (High).


      Powertrain > Engine > Active Test
      Active Test Display
      Control the Injection Mode
      Data List Display
      Fuel Pressure (High)

    7. Check the high pressure side fuel pressure at idle (shift lever in N, engine warmed up and A/C off).

      Standard Fuel Pressure
      1800 to 2800 kPa (18.4 to 28.6 kgf/cm2, 261 to 406 psi)

      If the result is not as specified, check the fuel pump, fuel pump assembly, fuel pressure sensor and wire harnesses.

    8. Stop the engine.