Fuel Pump: Testing and Inspection

FUEL PUMP

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.

NOTE: 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:
- H-fuse (80A)
- Fuses (AM2 20A, EFI 15A, IGN 7.5A)
- EFI main relay
- Circuit opening 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 air cleaner assembly.
d. Remove the 2 bolts, and disconnect the engine compartment R/B No.2 from the bracket on the body.




e. 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.

f. Install the fuel inlet hose and SST (pressure gauge) to the fuel filter outlet with the 3 gaskets and SST (union bolt).
SST 09268-45014

Torque: 29 Nm (300 kg.cm, 22 ft.lb)

g. Wipe off any splattered gasoline.
h. Connect the TOYOTA hand-held tester to the DLC3.
i. Reconnect the negative (-) terminal cable to the battery.
j. Turn the ignition switch ON.




k. Measure the fuel pressure.

Fuel pressure:
301 - 347 kPa (3.1 - 3.5 kg/Sq.cm, 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

l. Remove the TOYOTA hand-held tester from the DLC3.
m. Start the engine.
n. Measure the fuel pressure at idle.

Fuel pressure: 301 - 347 kPa (3.1 - 3.5 kg/Sq.cm, 44 - 50 psi)

o. Stop the engine.




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

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

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

q. After checking fuel pressure, disconnect the negative (-) terminal cable from the battery and carefully remove the SST to prevent gasoline from splashing.
SST O9268-45014

r. Reconnect the fuel inlet hose with 2 new gaskets and the union bolt.

Torque: 29 Nm (300 kg.cm, 21 ft.lb)

s. Reconnect the negative (-) terminal cable to the battery.
t. Check for fuel leakage.
u. Reinstall the engine comportment R/B No.2 and air cleaner assembly.

3. CHECK FUEL PUMP
a. Remove the LH rear seat assembly.
b. Remove the floor service hole cover.
c. Disconnect the fuel pump and sender gauge connector.

d. Inspect the fuel pump resistance.




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

Resistance: At 20 °C (68 °F): 0.2 - 3.0 Ohms

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

e. Inspect the 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.

NOTE: 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.

f. Reconnect the fuel pump and sender gauge connector.
g. Reinstall the floor service hole cover.
h. Reinstall the LH rear seat assembly.