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On-Vehicle Inspection

  1. CHECK FUEL PUMP OPERATION AND FOR FUEL LEAKS 
    1. Connect the intelligent tester to the DLC3.
      1. Turn the power switch ON (IG).
        NOTE: Do not start the engine.
      2. Push the intelligent tester main switch ON.
      3. Select the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / FUEL PUMP / SPD.
    2. Check the fuel pump operation.
      1. Check for pressure in the fuel inlet tube from the fuel line. Check that sound of fuel flowing in the fuel tank can be heard.

        If no sound can be heard, check the integration relay, fuel pump, ECM and wiring connector.

        Fig 1: Connecting Intelligent Tester To DLC3
        G05303079Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Check for fuel leaks.
      1. Check that there are no fuel leaks anywhere on the system after performing maintenance. If there is a fuel leak, repair or replace parts as necessary.
  2. CHECK FUEL PRESSURE 
    1. Check that the battery positive voltage is above 12 V.
    2. Discharge the fuel system pressure (see PRECAUTION  ).
    3. Disconnect the cable from the negative (-) battery terminal.
    4. When checking fuel pressure of direct injection side: Disconnect the fuel pump main tube.
      1. Remove the fuel pipe clamp.
        Fig 2: Identifying Fuel Tube Connector
        G04947837Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Pinch the connector and pull the fuel tube (see PRECAUTION  ).
        CAUTION:
        • Always read the precautions (see PRECAUTION  ) before disconnecting the fuel tube connector (quick type A).
        • The fuel tube may spray fuel as a result of pressure that remains in the tube. Do not allow fuel to be sprayed in the engine compartment.
          Fig 3: Pinching Connector And Pull Fuel Tube
          G04947862Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. When checking fuel pressure of port injection side: Disconnect the fuel pump main tube.
      1. Remove the fuel pipe clamp.
        Fig 4: Locating Fuel Pipe Clamp
        G04947863Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Pinch the connector and pull the fuel tube.
        CAUTION:
        • Always read the precautions (see PRECAUTION  ) before disconnecting the fuel tube connector (quick type A).
        • The fuel tube may spray fuel as a result of pressure that remains in the tube. Do not allow fuel to be sprayed in the engine compartment.
    6. Install SST (pressure gauge) as shown in the illustration.
      Fig 5: Pinching Connector And Pull Fuel Tube
      G04947864Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 6: Installing SST (Pressure Gauge)
      G04947865Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09268-31010 (90467-13001, 95336-08070, 09268-41500), 09268-45014 (09268-41200, 09268-41220, 09268-41250) 

    7. Wipe off any gasoline.
    8. Reconnect the cable to the negative (-) battery terminal.
    9. Operate the fuel pump.
      1. Connect the intelligent tester to the DLC3.
      2. Turn the power switch ON (IG).
        NOTE: Do not start the engine.
      3. Push the intelligent tester main switch ON.
      4. Select the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / FUEL PUMP/SPD.
    10. Measure the fuel pressure.

      Standard fuel pressure: 196 to 588 kPa (2 to 6 kgf/cm 2  , 28 to 85 psi) 

      HINT:

      • If the fuel pressure is higher than the specification, replace the fuel pump (built into fuel tank).
      • If the pressure is lower than the specification, check the fuel hoses, connections and fuel pump (built into fuel tank).
    11. Connect the intelligent tester to the DLC3.
    12. Set the vehicle to the "INSPECTION MODE" (see INSPECTION MODE PROCEDURE ).
    13. Start the engine.
    14. Measure the fuel pressure at idle.

      Standard fuel pressure: 196 to 588 kPa (2 to 6 kgf/cm 2  , 28 to 85 psi) 

      If the pressure is not as specified, check the fuel pump and injectors.

    15. Stop the engine.
    16. Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped.

      Standard fuel pressure: 147 kPa (1.5 kgf/cm 2  , 21 psi) or more 

      If the pressure is not as specified, check the fuel pump or injectors.

      Fig 7: Connecting Intelligent Tester To DLC3
      G05303079Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    17. After checking the fuel pressure, disconnect the cable from the negative (-) battery terminal and carefully remove SST and the fuel tube connector to prevent fuel from spilling.
    18. Reconnect the fuel pump main tube (see PRECAUTION  ).
    19. Check for fuel leaks.
  3. CHECK FUEL PRESSURE (for High Pressure) 
    1. Connect the intelligent tester to the DLC3.
      1. Turn the power switch ON (IG).
      2. Set the vehicle to the "INSPECTION MODE" (see INSPECTION MODE PROCEDURE ).
      3. Push the intelligent tester main switch ON.
    2. Start and warm up the engine.
    3. Run the engine at idle.
    4. Select the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / FUEL PRESS.
    5. Check the high pressure side fuel pressure.

      Standard fuel pressure: 3.5 to 4.5 MPa (35.7 to 45.9 kgf/cm 2  , 508 to 653 psi) 

      If the pressure is not as specified, check the fuel pump, high pressure side fuel pump, fuel pressure sensor and wirings.

    6. Stop the engine.
      Fig 8: Connecting Intelligent Tester To DLC3
      G05285048Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. PERFORM INITIALIZATION 
    1. Perform initialization (see INITIALIZATION (2006/02-2006/07) ).
      NOTE: Certain systems need to be initialized after reconnecting the cable to the negative (-) battery terminal.
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