FUEL SYSTEM(w/ DPF) ON-VEHICLE INSPECTION

PROCEDURE


  1. CHECK FUEL PRESSURE


    1. Read the Data List.


      1. Warm up the engine.

      2. Turn the engine switch off.

      3. Connect the GTS to the DLC3.

      4. Turn the engine switch to ON (IG).

      5. Start the engine.

      6. Turn the GTS on.

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

      8. Read the Data List.

        Tester Display Measurement Item/Range (Display) Normal Condition
        Common Rail Pressure Fuel pressure / Min.: 0 kPa, Max.: 250000 kPa 27000 to 49000 kPa: Idling
        Target Common Rail Pressure Target common rail pressure / Min.: 0 kPa, Max.: 250000 kPa 25000 to 200000 kPa

        Note

        The shift lever should be in neutral and the A/C switch and all accessory switches should be off.

  2. INSPECT FOR FUEL LEAK


    1. Perform the Active Test.


      1. Connect the GTS to the DLC3.

      2. Turn the engine switch to ON (IG).

      3. Start the engine.

      4. Turn the GTS on.

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

      6. Perform the Active Test.

        Tester Display Test Detail Control Range Diagnostic Note
        Test the Fuel Leak Pressurizes fuel inside common rail and checks for fuel leaks Stop/Start

        • The fuel inside the common rail is pressurized to the specified value and the engine speed increases to 2000 rpm when Start is selected.

        • The above conditions are preserved while Start is selected.

  3. CHECK PRESSURE DISCHARGE VALVE

    Tech Tips


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

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

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


    1. Connect the GTS to the DLC3.

    2. Turn the engine switch ON (IG).

    3. A01XAP5

      Turn the GTS 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.

      Tech Tips

      When the common rail pressure is unstable, the fuel pressure may decrease to a level where the test cannot be performed. In this situation, wait until the common rail pressure meets the test condition, and then perform the test.

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

    5. A01X23Z

      Press "Next".

    6. A01WZGQ

      Press "Next" again to proceed.

    7. Select the check type for "Valve Check for Graph".


      1. A01XANB

        Press "Next" again to proceed.

      2. Press "Start" again to proceed.

        A01X3EGE05

    8. Select the check type for "Close to Open Check" or "Always Closed Check".

      Tech Tips


      • "Close to Open Check" opens the pressure discharge valve after the engine stops.

      • "Always Closed Check" holds the pressure discharge valve closed during the check.


      1. A01XANB

        Press "Next".

      2. Perform troubleshooting based on the measurement results.

        A01X652
        OK
        0.5 MPa or less

        Tech Tips


        • 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.

        • 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.

          A01X75PE01

  4. BLEED AIR FROM FUEL SYSTEM


    1. A01X33D

      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 GTS to the DLC3.

    5. Turn the engine switch ON (IG) and turn the GTS on.

    6. Clear the DTCs Click here.

    7. Start the engine.*1

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

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

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

      A01X07LE04

      Tech Tips

      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 / Trouble Codes.

    12. Read Current DTCs.

    13. Clear the DTCs Click here.

      Tech Tips

      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 / Trouble Codes.

    16. Read Current DTCs.

      OK
      No DTCs are output.

  5. CHECK FUEL FILTER WARNING LIGHT AND DRAIN WATER


    1. w/o Multi-information Display:


      1. A01X074E02
        *1 On
        *2 Off
        *3 Illuminated

        Check if the fuel filter warning light is illuminated.

        Note

        When the fuel filter warning light illuminates, the fuel filter is clogged. Replace the filter Click here.

      2. A01X6HRE01
        *1 On
        *2 Off
        *3 Blinking

        Check if the fuel filter warning light is blinking.

        Note

        When the fuel filter warning light is blinking and the buzzer sounds, immediately drain the water in the fuel filter.

    2. w/ Multi-information Display:

      Check the multi-information display.

      Note

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

    3. Drain water.


      1. Detach the fuel hose clamp.

        A01X7U8E03
        Text in Illustration
        *A w/ Fuel Heater *B w/o Fuel Heater
        *1 Clogging Switch Connector *2 Level Warning Switch Connector

      2. Disconnect the clogging switch connector and level warning switch connector.

      3. A01X6V2E03
        Text in Illustration
        *1 Drain Cock
        *2 Container

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

      4. Connect a hose to the drain cock. Place the other end of the hose into a container under the drain cock.

      5. Loosen the drain cock to drain water.

      6. Tighten the drain cock by hand.

        Note

        Do not use any tools in this step.

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

        Torque:
        20 N*m  { 199 kgf*cm, 14 ft.*lbf }

      8. Connect the clogging switch connector and level warning switch connector.

      9. Attach the fuel hose clamp.