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.

NOTICE: Do not start the engine.

(c) Select the active test mode on the TOYOTA hand-held tester.
(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.





(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
- H-fuse
- Fuses
- EFI main relay
- Circuit opening relay
- Fuel pump
- ECM
- Wiring connections

(g) Turn the ignition switch OFF.
(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 0926-5012 (09268-41190, 90405-06167)

Torque: 29 N.m (300 kgf.cm, 22 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.
(See step 1 in check fuel pump operation (a) to (f))
(h) Turn the ignition switch ON.
(i) Measure the fuel pressure.

Fuel pressure: 265-304 kPa (2.7-3.1 kgf/sq. cm, 38-44 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

(j) Disconnect the TOYOTA hand-held tester from the DLC3.
(k) Reinstall the fuse cover on the instrument panel.
(l) Start the engine.
(m) Measure the fuel pressure at idle.

Fuel pressure: 226-265 kPa (2.3-2.7 kgf/sq.cm, 33-38 psi)

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

Fuel pressure: 147 kPa (1.5 kgf/sq.cm, 21 psi) or more

If pressure is not as specified, check the fuel pump, pressure regulator and/or injectors.
(p) After checking fuel pressure, disconnect the negative (-) terminal cable from the battery and carefully remove the SST to prevent gasoline from splashing. SST 09263-45012
(q) Reconnect the fuel inlet hose with 2 new gaskets and the union bolt.

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

(r) Reconnect the negative (-) terminal cable to the battery.
(s) Check for fuel leakage.
3. REMOVE REAR SEAT CUSHION
4. REMOVE SERVICE HOLE COVER
5. DISCONNECT FUEL PUMP AND SENDER GAUGE CONNECTOR





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, lead wire or fuel pump bracket.





7. INSPECT FUEL PUMP OPERATION
Connect a tester lead from terminal 4 of the connector to the positive (+) terminal of the battery; connect another tester lead from terminal 5 of the connector to the negative (-) terminal of the battery.

NOTICE:
- These tests must be done quickly (within 10 seconds) to prevent the coil from burning out.
- Keep the fuel pump as far away from the battery as possible.
- Always connect or disconnect at the battery. If operation is not as specified, replace the fuel pump, lead wire or fuel pump bracket.

8. RECONNECT FUEL PUMP AND SENDER GAUGE CONNECTOR
9. REINSTALL SERVICE HOLE COVER
10. REINSTALL REAR SEAT CUSHION