FUEL SYSTEM ON-VEHICLE INSPECTION

PROCEDURE

  1. CHECK FUEL PUMP OPERATION AND INSPECT FOR FUEL LEAK

    1. Check fuel pump operation.

      1. Connect the GTS to the DLC3.

      2. Turn the ignition switch to ON and turn the GTS on.

        Note:

        Do not start the engine.

      3. Enter the following menus: Powertrain / Engine and ECT / Active Test / Actuator Test of FPC.

        Powertrain > Engine and ECT > Active Test

        Tester Display

        Actuator Test of FPC

      4. Check for pressure in the fuel inlet tube from the fuel line. Check that sounds of fuel flowing from the fuel tank assembly can be heard. If no sounds can be heard, check the No. 1 integration relay, fuel suction tube with pump and gauge assembly, ECM and wiring connectors.

    2. Inspect for fuel leaks.

      1. Check that there are no fuel leaks from the fuel system after doing any maintenance or repairs. If there is a fuel leak, repair or replace parts as necessary.

    3. Turn the ignition switch off.

    4. Disconnect the GTS from the DLC3.

  2. CHECK FUEL PRESSURE

    1. Measure the battery voltage.

      Standard Voltage

      11 to 14 V

    2. Disconnect the cable from the negative (-) battery terminal.

      Note:

      When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

      Click hereClick hereClick here

    3. Remove the No. 1 fuel filter protector.

    4. A355154

      w/o Fuel Heater Relay:

      1. Disconnect the No. 3 fuel hose from the fuel filter assembly.

        Click here

    5. A401847C01

      *A

      w/ Fuel Heater Relay

      *B

      w/o Fuel Heater Relay

      Disconnect the No. 3 fuel hose from the fuel filter assembly.

      Click here

    6. A354347C01

      *1

      Fuel Tube Sub-assembly (Vehicle Side)

      *a

      SST (Hose Band)

      *b

      SST (T-joint)

      *c

      SST (Gauge)

      *d

      SST (Hose Joint)

      *e

      SST (Hose)

      *f

      SST (Fuel Tube Connector)

      *g

      Fuel Pipe (Vehicle Side)

      Install SST (EFI fuel pressure gauge) as shown in the illustration.

      09268-45101

      09268-41250

      09268-41260

      09268-41280

      09268-41500

      09268-41700

      95336-08070

      Note:

      • Do not use SST that has been used on gasoline vehicles.

      • Always use different SST for gasoline and diesel vehicles.

    7. Wipe up any spilled fuel.

    8. Connect the cable to the negative (-) battery terminal.

      Note:

      When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

      Click hereClick hereClick here

    9. Connect the GTS to the DLC3.

    10. Turn the ignition switch to ON and turn the GTS on.

      Note:

      Do not start the engine.

    11. Enter the following menus: Powertrain / Engine and ECT / Active Test / Actuator Test of FPC.

      Powertrain > Engine and ECT > Active Test

      Tester Display

      Actuator Test of FPC

    12. Measure the fuel pressure.

      Standard Fuel Pressure

      450 to 700 kPa (4.6 to 7.1 kgf/cm2, 65 to 102 psi)

      • If the fuel pressure is more than the standard, check the fuel filter assembly.

      • If the fuel pressure is less than the standard, check the fuel hoses, their connections and fuel pump.

    13. Disconnect the GTS from the DLC3.

    14. Start the engine.

    15. Measure the fuel pressure at idle.

      Standard Fuel Pressure

      450 to 700 kPa (4.6 to 7.1 kgf/cm2, 65 to 102 psi)

      Tip:

      Refer to Standard Idle Speed.

      Click here

    16. Stop the engine.

    17. Connect the No. 3 fuel hose to the fuel filter assembly.

      Click here

    18. w/o Fuel Heater Relay:

      1. Install the No. 3 fuel pipe clamp to the fuel tube connector.

    19. Install the No. 1 fuel filter protector.

    20. Inspect for fuel leaks.

      Click here

  3. CHECK FUEL PRESSURE (for High 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 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.

    2. Warm up the engine.

    3. Turn the ignition switch off.

    4. Connect the GTS to the DLC3.

    5. Turn the ignition switch to ON.

    6. Turn the GTS on.

    7. Enter the following menus: Powertrain / Engine and ECT / Data List / Target Common Rail Pressure and Common Rail Pressure.

      Powertrain > Engine and ECT > Data List

      Tester Display

      Target Common Rail Pressure

      Common Rail Pressure

    8. Check that the internal fuel pressure of the common rail assembly is as specified.

      OK

      Common Rail Pressure is within +/-10000 kPa of Target Common Rail Pressure when the engine is idling and running at 3000 rpm without load.

  4. CHECK PRESSURE DISCHARGE VALVE ASSEMBLY

    1. Connect the GTS to the DLC3.

    2. Start the engine.

    3. Turn the GTS on.

    4. Enter the following menus: Powertrain / Engine and ECT / Active Test / Actuator Test of Pressure Control Valve.

      Powertrain > Engine and ECT > Active Test

      Tester Display

      Actuator Test of Pressure Control Valve

      OK

      Condition

      Specified Condition

      5% (Fuel Pressure Control valve OFF)

      Normal engine speed

      95% (Fuel Pressure Control valve ON)

      The engine stops