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FUEL SYSTEM (w/ DPF) ON-VEHICLE INSPECTION

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  1. Click here

    CHECK FUEL PRESSURE


    1. Read the Data List

      Note:

      In the table below, the values listed under "Normal Condition" are reference values. Do not depend solely on these reference values when deciding whether a part is faulty or not.

      Tip:

      Using the intelligent tester to read the Data List allows the values or states of switches, sensors, actuators and other items to be read without removing any parts. This non-intrusive inspection can be very useful because intermittent conditions or signals may be discovered before parts or wiring is disturbed. Reading the Data List information early in troubleshooting is one way to save diagnostic time.


      1. Warm up the engine.

      2. Turn the engine switch off.

      3. Connect the intelligent tester to the DLC3.

      4. Turn the engine switch on (IG).

      5. Turn the intelligent tester on.

      6. Enter the following menus: Powertrain / Engine / Data List.

      7. According to the display on the tester, read the Data List.

        Tester Display Measurement Item/Range Normal Condition
        Fuel Press

        Fuel pressure/

        Min.: 0 kPa, Max.: 250000 kPa

        		 30000 to 80000 kPa when idling.
        Target Common Rail Pressure

        Target common rail pressure/

        Min.: 0 kPa, Max.: 250000 kPa

        		 25000 to 200000 kPa when the engine is running.
  2. Click here

    INSPECT FOR FUEL LEAK


    1. Perform the Active Test.


      1. Connect the intelligent tester to the DLC3.

      2. Turn the engine switch on (IG).

      3. Turn the intelligent tester on.

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

      5. Perform the Active Test.

        Intelligent Tester Display Test Part Control Range Diagnostic Note
        Test the Fuel Leak Pressurize common rail interior and check for fuel leaks Stop/Start

        • The fuel pressure inside the common rail increases to the specified value and the engine speed increases to 2000 rpm when the Active Test is performed.

        • The above conditions are maintained while the Active Test is being performed.
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    CHECK PRESSURE DISCHARGE VALVE

    Tip:

    • This is the procedure for troubleshooting fuel pressure control malfunctions and combustion problems.

    • Malfunctions can be determined by checking the fuel pressure when performing fuel cut and operating the pressure discharge valve with the intelligent tester.

    • During "Pressure Discharge Valve Check", the intelligent tester measures the fuel pressure while the engine is running, after the engine is stopped, and after the pressure discharge valve operates.


    1. Connect the intelligent tester to the DLC3.

    2. Turn the engine switch on (IG).

    3. A01DMAF

      Turn the intelligent tester on.

      Note:

      The following conditions must be met:


      • The engine is idling.

      • The vehicle is stopped.

      • The fuel pressure is not extremely high (e.g. below 100 MPa).

      • The fuel pressure sensor is normal.

      • The battery voltage is higher than 8 V.

    4. Enter the following menus: Powertrain / Engine / Utility / Pressure Discharge Valve Check.

    5. A01DPPZ

      Press "Next".

    6. A01DR4A

      Press "Next" again to proceed.

    7. A01DO3U

      Select "Close to Open Check".

    8. Press "Next".

    9. A01DRIB

      Read the value of "Open and Engine OFF".

      OK
      0.5 MPa or less
      Tip:

      • When the system is normal, the value of "Open and Engine OFF" should be at or close to 0 MPa.

      • When the fuel pressure value of "Open and Engine OFF" does not become equal to or less than 0.5 MPa, the pressure discharge valve may be stuck closed.

      • When the fuel pressure values of "Close and Engine OFF" and "Open and Engine OFF" are both 0 MPa, the pressure discharge valve may be stuck open or there may be a fuel leak.

      • A01DTH7E09

        Perform "Always Closed Check" if the value is not 0 MPa when the pressure discharge valve is open during "Close to Open Check". If the results are the same as during "Close to Open Check", there is a pressure discharge valve operation malfunction.

      Table 1. Text in Illustration
      *1 Fuel Press (Always Closed Check) *2 Fuel Press (Close to Open Check)
      *3 Engine Speed *4 Fuel Cut Operation Signal
      *5 Pressure Discharge Valve Operation Prohibition *6 Pressure Discharge Valve Operation (Always Closed Check)
      *7 Pressure Discharge Valve Operation (Close to Open Check) - -
      *a Fuel Press Recorded Point *b Closed (on)
      *c Open (on) - -
      A01DQPB Pressure Discharge Valve Operation Start - -
  4. Click here

    BLEED AIR FROM FUEL SYSTEM


    1. A01DS6C

      Using the hand pump mounted on the fuel filter cap, bleed air from the fuel system. Continue pumping until the pump resistance increases.

      Note:

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

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

      • 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.

    2. 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.

      2. 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.

    3. Turn the engine switch off.

    4. Connect the intelligent tester to the DLC3.

    5. Turn the engine switch on (IG) and turn the intelligent tester on.

    6. Clear the DTCs (Click here).

    7. Start the engine.*1

    8. A01DLTIE05

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

      Table 2. Text in Illustration
      *a

      Reference

      (Active Test Operation)

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

    10. A01DUBQE04

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

      Tip:

      When the Active Test "Test the Fuel Leak" is used to change the pump control mode, the actual fuel pressure inside the common rail drops below the target fuel pressure when the Active Test is off, but this is normal and does not indicate a pump malfunction.

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

    12. Read Current DTCs.

    13. Clear the DTCs (Click here).

      Tip:

      It is necessary to clear the DTCs as DTC P1604 or P1605 may be stored when air is bled from the fuel system after replacing or repairing fuel system parts.

    14. Repeat steps *1 to *3.

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

    16. Read Current DTCs.

      OK
      No DTCs are output.
  5. Click here

    CHECK FUEL FILTER WARNING LIGHT AND DRAIN WATER


    1. Check the fuel filter multi-information display.

      Note:

      When the fuel system warning is displayed on the multi-information display, replace the fuel filter (Click here) or drain the water in the fuel filter.

    2. A01DMBVE01

      Drain water.

      Table 3. Text in Illustration
      *A w/ Fuel Heater
      *B w/ Clogging Switch

      1. w/ Fuel Heater:

        Disconnect the level warning switch connector and fuel heater connector.

      2. w/ Clogging Switch:

        Disconnect the level warning switch connector and clogging switch connector.

      3. Remove the 2 nuts and lift up the fuel filter assembly.

      4. A01DRGBE01

        Connect a hose to the fuel filter drain plug. Place the other end of the hose into a container under the fuel filter drain plug.

        Table 4. Text in Illustration
        *1 Fuel Filter Drain Plug
        *2 Container

      5. Loosen the fuel filter drain plug to drain water.

      6. Tighten the fuel filter drain plug by hand.

        Note:

        Do not use any tools in this procedure.

      7. Install the fuel filter assembly with the 2 nuts.

        18 N*m 184 kgf*cm 13 ft.*lbf

      8. w/ Fuel Heater:

        Connect the level warning switch connector and fuel heater connector.

      9. w/ Clogging Switch:

        Connect the level warning switch connector and clogging switch connector.