FUEL SYSTEM ON-VEHICLE INSPECTION
PROCEDURE
CHECK FUEL PRESSURE
Read 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 GTS 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.
Warm up the engine.
Turn the ignition switch off.
Connect the GTS to the DLC3.
Turn the ignition switch to ON.
Turn the GTS on.
Enter the following menus: Powertrain / Engine and ECT / Data List / Target Common Rail Pressure and Fuel Press.
Powertrain > Engine > Data List
Tester Display
Target Common Rail Pressure
Fuel Press
Read the Data List.
Tester Display
Measurement Item/Range
Normal Condition
Fuel Press
Fuel pressure/
Min.: 0 kPa, Max.: 250000 kPa
Idling: 27000 to 45000 kPa
Target Common Rail Pressure
Target common rail pressure/
Min.: 0 kPa, Max.: 250000 kPa
32000 to 200000 kPa when engine running
INSPECT FOR FUEL LEAK
Tip:Using the GTS to perform Active Tests allow relays, VSVs, actuators and other items to be operated without removing any parts. This non-intrusive functional inspection can be very useful because intermittent operation may be discovered before parts or wiring is disturbed. Performing Active Tests early in troubleshooting is one way to save diagnostic time. Data List information can be displayed while performing Active Tests.
Perform the Active Test.
Connect the GTS to the DLC3.
Turn the ignition switch to ON.
Start the engine.
Turn the GTS tester on.
Enter the following menus: Powertrain / Engine and ECT / Active Test / Test the Fuel Leak.
Powertrain > Engine > Active Test
Tester Display
Test the Fuel Leak
Perform the Active Test.
Tester Display
Test Part
Control Range
Diagnostic Notes
Test the Fuel Leak
Pressurizes common rail internal fuel pressure, and checks for fuel leaks
Stop/Start
Fuel pressure inside common rail pressurized to specified value and engine speed increased to 2000 rpm when ON is selected
Above conditions preserved while test is ON
Tip:If this Active Test is performed when the engine is cold, combustion may become unstable. However, this is not a malfunction. It is only necessary to confirm that the pressure rises to the target pressure and that there are no fuel leaks.
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 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.
Connect the GTS to the DLC3.
Turn the ignition switch to ON.
-
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. less than 100 MPa).
The fuel pressure sensor is normal.
The battery voltage is higher than 8 V.
Tip:When the fuel pressure is unstable, the fuel pressure may decrease to a level where the test cannot be performed. In this situation, wait until the fuel pressure meets the test condition, and then perform the test.
Enter the following menus: Powertrain / Engine and ECT / Utility / Pressure Discharge Valve Check.
Powertrain > Engine > Utility
Tester Display
Pressure Discharge Valve Check
-
Press "Next".
-
Press "Next" again to proceed.
Select the check type for "Valve Check for Graph".
-
Press "Next" again to proceed.
Press "Start" again to proceed.
*a
Engine Speed
*b
Fuel Pressure
*c
Pressure Discharge Valve
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-
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Select the check type for "Close to Open Check" or "Always Closed Check".
Tip:"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.
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Press "Next".
Perform troubleshooting based on the measurement results.
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.
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.
*a
Fuel Press
(Always Closed Check)
*b
Fuel Press
(Close to Open Check)
*c
Engine Speed
*d
Fuel Cut Operation Signal
*e
Pressure Discharge Valve Operation Prohibition
*f
Pressure Discharge Valve Operation
(Always Closed Check)
*g
Pressure Discharge Valve Operation
(Close to Open Check)
*h
0 kPa
*i
0 rpm
*j
On
*k
Off
*l
Closed (on)
*m
Open (on)
*n
Fuel Press Recorded
*o
Pressure Discharge Valve Operation Start
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BLEED AIR FROM FUEL SYSTEM
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Using the hand pump mounted on the fuel filter cap, bleed the 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 fuel 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 assembly. 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 assembly and fuel filter assembly, 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.
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.
When the engine can be started, proceed to the next step.
If the engine cannot be started, bleed the air again using the hand pump until the hand pump resistance increases (refer to the procedures above). Then start the engine.
Turn the ignition switch off.
Connect the GTS to the DLC3.
Turn the ignition switch to ON and turn the GTS on.
Clear the DTCs.
Powertrain > Engine > Clear DTCs
Start the engine.*1
Enter the following menus: Powertrain / Engine and ECT / Active Test / Test the Fuel Leak.*2
Powertrain > Engine > Active Test
Tester Display
Test the Fuel Leak
Perform the following test 5 times with on/off intervals of 10 seconds: Active Test / Test the Fuel Leak.*3
Allow the engine to idle for 3 minutes or more after performing the Active Test for the 5th time.
*a
Active Test Operation
*b
ON
*c
OFF
*d
1st time
*e
2nd time
*f
5th time
*g
10 seconds
*h
3 minutes
*i
Time
-
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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.
Enter the following menus: Powertrain / Engine and ECT / Trouble Codes.
Powertrain > Engine > Trouble Codes
Read Current DTCs.
Clear the DTCs.
Powertrain > Engine > Clear DTCs
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.
Repeat steps *1 to *3.
Enter the following menus: Powertrain / Engine and ECT / Trouble Codes.
Powertrain > Engine > Trouble Codes
Read Current DTCs.
OK
No DTCs are output.
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CHECK FUEL FILTER WARNING LIGHT AND DRAIN WATER
Check the fuel filter on 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 or drain the water in the fuel filter.
Drain water.
Remove the air cleaner cap sub-assembly.
Remove the air cleaner element sub-assembly.
Remove the air cleaner case sub-assembly.
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*1
Drain Cock
*2
Container
Connect a hose to the drain cock. Place the other end of the hose into a container under the drain cock.
Loosen the drain cock to drain water.
Tighten the drain cock by hand.
Note:Do not use any tools in this procedure.
Install the air cleaner case sub-assembly.
Install the air cleaner element sub-assembly.
Install the air cleaner cap sub-assembly.