On-Vehicle Inspection

ON-VEHICLE INSPECTION

1. Check fuel pump operation.





(a) Connect the TOYOTA hand-held tester to the DLC3.
(b) Turn the ignition switch ON and TOYOTA hand-held tester main switch ON.
(c) Select the active test mode on the TOYOTA hand-held tester.

NOTICE: Do not start the engine.

(d) Please refer to the TOYOTA hand-held tester operator's manual for further details.
(e) If you have no TOYOTA hand-held tester, connect the positive (+) and negative (-) leads from the battery to the fuel pump connector. (See step 7)





(f) Check that there is pressure in the fuel inlet hose from the fuel filter.

HINT: If there is fuel pressure, you will hear the sound of fuel flowing.

If there is no pressure, check these parts:
- Fusible link
- Fuses (AM2 30A, IGN 5A)
- EFI main relay
- Fuel pump
- ECM
- Wiring connections
(g) Turn the ignition switch to LOCK.
(h) Disconnect the TOYOTA hand-held tester from the DLC3.
2. Check fuel pressure.
(a) Check the battery positive voltage is above 12 V.
(b) Disconnect the negative (-) terminal cable from the battery.





(c) Remove the union bolt and 2 gaskets, and disconnect the fuel inlet hose from the fuel filter outlet.

CAUTION:
- Put a shop towel under the fuel filter.
- Slowly loosen the union bolt.





(d) Install the fuel inlet hose and SST (pressure gauge) to the fuel filter outlet with the 3 gaskets and SST (union bolt). SST O9268-5O12

Torque: 29 N.m (300 kgf.cm, 21 ft.lbf)

(e) Wipe off any splattered gasoline.
(f) Reconnect the negative (-) terminal cable to the battery.
(g) Connect the TOYOTA hand-held tester to the DLC3.
(h) Measure the fuel pressure.

Fuel Pressure:
301 - 347 kPa (3.1 - 3.5 kgf/cm2, 44 - 50 psi)

If pressure is high, replace the fuel pressure regulator.
If pressure is low, check these parts:
- Fuel hoses and connections.
- Fuel pump.
- Fuel filter.
- Fuel pressure regulator.
(i) Disconnect the TOYOTA hand-held tester from the DLC3.
(j) Start the engine.
(k) Measure the fuel pressure at idle.

Fuel pressure:
301 - 347 kPa (3.1 - 3.5 kgf/cm2, 44 - 50 psi)

(l) Stop the engine.
(m) Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped.

Fuel pressure:
147 kPa (1.5 kgf/cm2, 21 psi) or more

If pressure is not as specified, check the fuel pump, pressure regulator and/or injectors.
(n) After checking fuel pressure, disconnect the negative (-) terminal cable from the battery and carefully remove the SST to prevent gasoline from splashing.
SST 09268-45012
(o) Reconnect the fuel inlet hose with 2 new gaskets and the union bolt.

Torque: 29 Nm (300 kgf-cf, 21 ft lbf)

(p) Reconnect the negative (-) terminal cable to the battery.
(q) Check for fuel leakage.
6. Inspect fuel pump resistance.





Using an ohmmeter, measure the resistance between terminals 4 and 5.

Resistance: 0.2 - 3.0 ohm at 20°C (68°F)

If the resistance is not as specified, replace the fuel pump.
7. Inspect fuel pump operation.





Connect the positive (+) lead from the battery to terminal 4 of the connector, and the negative (-) lead to terminal 5. Check that the fuel pump operates.

NOTICE:
- These tests must be done quickly (within 10 seconds) to prevent the coil burning out.
- Keep the fuel pump as far away from the battery as possible.
- Always do the switching at the battery side.
If operation is not as specified, replace the fuel pump or lead wire.
8. Reconnect fuel pump & sender gauge connector.
9. Reinstall floor service hole cover.
10. Reinstall rear seat cushion.