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.
Tech Tips
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.
Warm up the engine.
Turn the ignition switch off.
Connect the intelligent tester to the DLC3.
Turn the ignition switch to ON.
Turn the intelligent tester on.
Enter the following menus: Powertrain / Engine / Data List.
Read the Data List.
Tester Display | Measurement Item/Range | Normal Condition |
---|---|---|
for DPF: Common Rail Pressure for CCo: 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
Tech Tips
Using the intelligent tester 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 Active Test.
Connect the intelligent tester to the DLC3.
Turn the ignition switch to ON.
Start the engine.
Turn the intelligent tester on.
Enter the following menus: Powertrain / Engine / Active Test.
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 | Performs inspection of the high pressure fuel system.
|
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 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.
Connect the intelligent tester to the DLC3.
Turn the ignition switch to ON.
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. less than 100 MPa).
The fuel pressure sensor is normal.
The battery voltage is higher than 8 V.
Enter the following menus: Powertrain /Engine / Utility / Pressure Discharge Valve Check.
Press "Next".
Press "Next" again to proceed.
Select the "Close to Open Check".
Press "Next".
Read the value of "Open and Engine OFF".
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 close.
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.
BLEED AIR FROM FUEL SYSTEM
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
Hand pump pumping speed: Max. 2 strokes/ sec.
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.
Start the engine.
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 intelligent tester to the DLC3.
Turn the ignition switch to ON and turn the intelligent tester on.
Clear the DTCs.
for DPF: Click here
for CCo: Click here
Start the engine.*1
Enter the following menus: Powertrain / Engine and ECT / Active Test / Test the Fuel Leak.*2
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 fifth time.
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.
Enter the following menus: Powertrain / Engine and ECT / DTC.
Read Current DTCs.
When no DTCs are output, the air bleeding is completed.
If any DTCs are output, proceed to the next step.
Clear the DTCs.
for DPF: Click here
for CCo: Click here
Repeat steps *1 to *3.
Enter the following menus: Powertrain / Engine and ECT / DTC.
Read Current DTCs.
OK |
---|
No DTCs are output. |
CHECK FUEL FILTER WARNING LIGHT AND DRAIN WATER
Check the fuel filter 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.
Drain water.
Remove the air cleaner cap.
Remove the air cleaner element.
Remove the air cleaner case.
*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.
Install the air cleaner element.
Install the air cleaner cap.