FUEL PUMP UNIT REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop]

• To ensure reliability of the i-stop system, replace the fuel pump unit with a new one if the number of times the fuel pump unit can operate has exceeded the upper limit.

• When replacing the fuel pump unit, perform the following procedure. When replacing the PCM simultaneously, perform the PCM configuration first. (See PCM REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].) (See PCM CONFIGURATION [MZR 2.0 DISI i-stop].)

STEP

ACTION

NOTE

1

Replace the fuel pump unit.

2

Reset the number of times the fuel pump unit can operate using the M-MDS.

(See OPERATION AMOUNT RESET PROCEDURE [MZR 2.0 DISI i-stop].)

Verify the i-stop warning light (amber).

•  If it flashes, go to the next step.

•  If it does not flash, go to Step 4.

3

Clear applicable DTCs using the M-MDS.

(See DTC TABLE [MZR 2.0 DISI i-stop].)

(See AFTER REPAIR PROCEDURE [MZR 2.0 DISI i-stop].)

4

Close the bonnet.

•  Because the sub battery recharge is not available while the bonnet is open, the procedure is not completed.

5

Warm up the engine. (no electrical load)

6

Switch the ignition off.

7

Long-press the i-stop OFF switch for 3 s within 5 s after switching the ignition ON.

8

Start the engine.

9

Press the i-stop OFF switch.

Verify that the i-stop indicator light (green) flashes.

•  If it does not flash, go back to Step 7.

10

Maintain the idle status (no electrical load) until the i-stop indicator light (green) turns off.

•  For operating i-stop, learning is required for the following two items:

Initial learning/recharging for battery charge condition

―  If the engine is left idling, the operation time differs depending on the battery charge condition, however, a maximum of approx. 60 min. is required to finish the operation.
(Battery charge condition can be verified using data logger function in M-MDS.)

ISC learning

―  ISC learning is performed by leaving the engine idling for approx. 10 min. when the vehicle is warmed up and there is no load on the engine.

•  If the above two operations are successfully completed, the i-stop indicator light (green) turns off.

11

Verify that the engine stops via the i-stop control and then restarts.

•  If it cannot be verified, inspect the i-stop system-related units for DTCs.

―  PCM (See DTC TABLE [MZR 2.0 DISI i-stop].)

―  ABS HU/CM (with ABS) (See ON-BOARD DIAGNOSIS [ABS])

―  TCM (ATX) (See ON-BOARD DIAGNOSTIC SYSTEM DTC TABLE [FS5A-EL])

―  DSC HU/CM (with DSC) (See ON-BOARD DIAGNOSIS [DYNAMIC STABILITY CONTROL (DSC)].)

―  EHPAS control module (See ELECTRO HYDRAULIC POWER ASSIST STEERING (EHPAS) ON-BOARD DIAGNOSIS.)

―  Water heater unit (with water heater system) (See DTC TABLE [WATER HEATER SYSTEM].)

―  Climate control unit (with full-auto air conditioner) (See DTC TABLE [FULL-AUTO AIR CONDITIONER].)

―  Keyless control module (with advanced keyless entry and push button start system) (See DTC TABLE [ADVANCED KEYLESS ENTRY AND PUSH BUTTON START SYSTEM].)

―  BCM (See DTC TABLE [BCM])

Note

•  When checking that the engine stops and restarts, verify vehicle conditions that meet the i-stop permit conditions.

12

Switch the ignition off, and start the engine.

•  The display function for the i-stop indicator light (green) is reset.

1	Quick release connector (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)
2	Set plate
3	Fuel pump unit
4	O-ring

STEP	ACTION	NOTE
1	Replace the fuel pump unit.
2	Reset the number of times the fuel pump unit can operate using the M-MDS. (See OPERATION AMOUNT RESET PROCEDURE [MZR 2.0 DISI i-stop].) Verify the i-stop warning light (amber). • If it flashes, go to the next step. • If it does not flash, go to Step 4.
3	Clear applicable DTCs using the M-MDS. (See DTC TABLE [MZR 2.0 DISI i-stop].) (See AFTER REPAIR PROCEDURE [MZR 2.0 DISI i-stop].)
4	Close the bonnet.	• Because the sub battery recharge is not available while the bonnet is open, the procedure is not completed.
5	Warm up the engine. (no electrical load)
6	Switch the ignition off.
7	Long-press the i-stop OFF switch for 3 s within 5 s after switching the ignition ON.
8	Start the engine.
9	Press the i-stop OFF switch. Verify that the i-stop indicator light (green) flashes. • If it does not flash, go back to Step 7.
10	Maintain the idle status (no electrical load) until the i-stop indicator light (green) turns off.	• For operating i-stop, learning is required for the following two items: Initial learning/recharging for battery charge condition ― If the engine is left idling, the operation time differs depending on the battery charge condition, however, a maximum of approx. 60 min. is required to finish the operation. (Battery charge condition can be verified using data logger function in M-MDS.) ISC learning ― ISC learning is performed by leaving the engine idling for approx. 10 min. when the vehicle is warmed up and there is no load on the engine. • If the above two operations are successfully completed, the i-stop indicator light (green) turns off.
11	Verify that the engine stops via the i-stop control and then restarts. • If it cannot be verified, inspect the i-stop system-related units for DTCs. ― PCM (See DTC TABLE [MZR 2.0 DISI i-stop].) ― ABS HU/CM (with ABS) (See ON-BOARD DIAGNOSIS [ABS]) ― TCM (ATX) (See ON-BOARD DIAGNOSTIC SYSTEM DTC TABLE [FS5A-EL]) ― DSC HU/CM (with DSC) (See ON-BOARD DIAGNOSIS [DYNAMIC STABILITY CONTROL (DSC)].) ― EHPAS control module (See ELECTRO HYDRAULIC POWER ASSIST STEERING (EHPAS) ON-BOARD DIAGNOSIS.) ― Water heater unit (with water heater system) (See DTC TABLE [WATER HEATER SYSTEM].) ― Climate control unit (with full-auto air conditioner) (See DTC TABLE [FULL-AUTO AIR CONDITIONER].) ― Keyless control module (with advanced keyless entry and push button start system) (See DTC TABLE [ADVANCED KEYLESS ENTRY AND PUSH BUTTON START SYSTEM].) ― BCM (See DTC TABLE [BCM])	Note • When checking that the engine stops and restarts, verify vehicle conditions that meet the i-stop permit conditions.
12	Switch the ignition off, and start the engine.	• The display function for the i-stop indicator light (green) is reset.