FUEL SYSTEM ON-VEHICLE INSPECTION


  1. TILT UP CAB

    CAUTION:


    • Make sure that the vehicle is on a level surface before tilting the cab up.

    • Make sure that all the doors are closed before tilting the cab up.

    • Make sure that nobody is inside or near the cab when tilting it up.

    • Be sure to have 2 people tilt the cab up when a heavy object such as a roof rack or cargo carrier is installed to the cab.

    • Be sure to remove anything set on top of the cab before tilting it up.

    • Make sure that the cab is securely locked in place after it is tilted up.

    • Make sure that there are no tools, cloths, etc. left in the engine room before tilting the cab back down.

    • Make sure that the cab is securely locked in place after tilting it back down.

  2. INSPECT FUEL PRESSURE


    1. Read the Data List.


      1. Warm up the engine.

      2. Turn the ignition switch off.

      3. Replace the normal DLC3 cable (12 V specification) for the intelligent tester with the 24 V DLC3 cable.

        Note

        Be sure to use the 24 V DLC3 cable when connecting the intelligent tester to the DLC3. Using the normal DLC3 cable (12 V specification) will cause damage to the tester.

      4. Connect the intelligent tester to the DLC3.

      5. Start the engine.

      6. Turn the intelligent tester on.

      7. Enter the following menus: Powertrain / Engine and ECT / Data List / Fuel Press.

      8. Read the value.

        Note


        • The Data List values vary largely depending on minor differences in measurement conditions, the measurement environment and the age of the vehicle, and it is difficult to show accurate standard values. Therefore, a malfunction may occur even if the values are within the standard range.

        • For subtle symptoms such as hesitation and rough idle, it is necessary to collect data from the same vehicle model under the same conditions and make a comparison of all items in the Data List to make an accurate decision.

        Tester Display Measurement Item/Range Inspection Condition Reference Value Trouble Area
        Fuel Press

        Fuel pressure:

        Min.: 0 kPa, Max.: 655350 kPa

        		 While idling (engine fully warmed up, A/C off, and shift lever in neutral) Approximately 20000 to 30000 kPa

        • PCR1 voltage (fuel pressure sensor)


        • PCV+ and PCV- voltage (suction control valve)

        • Clogging before the fuel pump or in the sedimenter
        At 2000 rpm (A/C off and shift lever in neutral) Approximately 90000 to 100000 kPa

        • PCR1 voltage (fuel pressure sensor)


        • PCV+ and PCV- voltage (suction control valve)

        • Clogging before the fuel pump or in the sedimenter
        At 3000 rpm (A/C off and shift lever in neutral) Approximately 120000 to 135000 kPa

        • PCR1 voltage (fuel pressure sensor)


        • PCV+ and PCV- voltage (suction control valve)

        • Clogging before the fuel pump or in the sedimenter
        During engine stall (A/C off and shift lever in D) 170000 kPa or higher

        • PCR1 voltage (fuel pressure sensor)


        • PCV+ and PCV- voltage (suction control valve)

        • Clogging before the fuel pump or in the sedimenter

  3. INSPECT FOR FUEL LEAK


    1. Perform the Active Test.


      1. Replace the normal DLC3 cable (12 V specification) for the intelligent tester with the 24 V DLC3 cable.

        Note

        Be sure to use the 24 V DLC3 cable when connecting the intelligent tester to the DLC3. Using the normal DLC3 cable (12 V specification) will cause damage to the tester.

      2. Connect the intelligent tester to the DLC3.

      3. Start the engine.

      4. Turn the intelligent tester on.

      5. Enter the following menus: Powertrain / Engine and ECT / Active Test.

      6. Perform the Active Test.

        Tester Display Test Part Control Range Diagnostic Note
        Test the Fuel Leak Pressurizes common rail interior and checks for fuel leaks Stop or Start

        • The fuel pressure inside the common rail is increased to a specified value and the engine speed is increased to 2000 rpm when Start is selected

        • The above conditions are preserved while the control parameter of the test is Start

    2. Check for leaks from the fuel system while performing the Active Test (with a fuel pressure applied).

  4. BLEED AIR FROM FUEL SYSTEM


    1. A01CHFE

      Loosen the bleeder plug.

      Text in Illustration
      A01CHW8 Bleeder Plug

      Note

      Make sure that the drain plug and bleeder plug of the filter on the fuel tank side are closed.

    2. A01CHX4

      Bleed air using the priming pump on the fuel tank side.

      Note


      • Place a container, etc. underneath the fuel filter to prevent fuel from spraying.

      • The hand pump must be pushed with a full stroke during pumping.

      • The maximum hand pump pumping speed is 2 strokes per second.

      • When the fuel pressure at the supply pump inlet port reaches a saturated pressure, the hand pump resistance increases.

      • If pumping is interrupted during the air bleeding process, fuel in the fuel line may return to the fuel tank. Continue pumping until the hand pump resistance increases.

      • If the hand pump resistance does not increase despite consecutively pumping 200 times or more, there may be a fuel leak between the fuel tank and fuel filter, the hand pump may be malfunctioning, or the vehicle may have run out of fuel.

      • If air bleeding using the hand pump is incomplete, the common rail pressure does not rise to the pressure range necessary for normal use and the engine cannot be started.

    3. Tighten the bleeder plug.

      Torque:
      6.9 N*m  { 70 kgf*cm, 61 in.*lbf }

    4. Check if the engine starts.

      Note


      • Even if air bleeding using the hand pump has been completed, the starter may need to be cranked for 10 seconds or more to start the engine.

      • Do not crank the engine continuously for more than 20 seconds. The battery may be discharged.

      • Use a fully-charged battery.


      1. When the engine can be started, proceed to the next step.

        Tech Tips

        If the engine cannot be started, bleed air again using the hand pump until the hand pump resistance increases (refer to the procedures above). Then start the engine.

    5. Turn the ignition switch off.

    6. Connect the intelligent tester to the DLC3.

    7. Turn the ignition switch to ON and turn the intelligent tester on.

    8. Clear the DTCs Click here.

    9. Start the engine.*1

    10. A01CJCTE05
      Text in Illustration
      *a

      Reference

      (Active Test operation)

      Enter the following menus: Powertrain / Engine and ECT / Active Test / Test the Fuel Leak.*2

    11. Perform the following test 5 times with on/off intervals of 10 seconds: Active Test / Test the Fuel Leak.*3

      A01CHBIE15
      Text in Illustration
      *a Active Test operation *b Time
      *c ON *d OFF
      *e 1st time *f 2nd time
      *g 5th time *h 10 seconds
      *i 3 minutes or more - -

    12. Allow the engine to idle for 3 minutes or more after performing the Active Test for the 5th time.

    13. Enter the following menus: Powertrain / Engine and ECT / DTC.

    14. Read Current DTCs.


      1. If no DTCs are output, air bleeding is completed.

      2. If DTCs are output, perform the following procedure.

    15. Clear the DTCs Click here.

    16. Repeat steps *1 to *3.

    17. Enter the following menus: Powertrain / Engine and ECT / DTC.

    18. Read Current DTCs.

      OK
      No DTCs are output