Fuel Pump: Testing and Inspection

INSPECTION

Check Fuel Pump Operation
1. Turn the ignition switch ON. Do not start the engine.





2. Using SST, connect terminals FP and +B of the data link connector 1 (SST 09843-18020).

HINT: The data link connector 1 is located under the driver's seat.





3. Check that there is pressure in the fuel inlet hose. At this time, you will hear fuel return noise from the fuel return hose.
4. Remove the SST from the data link connector 1 (SST 09843-18020).
5. Turn the ignition switch OFF.
6. If there is no pressure, check the following parts:
- H-fuses (MAIN 50 A, AM2 20 A).
- Fuses (EFI 15 A, IGN 7.5 A).
- EFI main relay.
- Fuel pump.
- Wiring connections.

Check Fuel Pressure

1. Check that the battery voltage is above 11 volts.





2. Disconnect the negative (-) terminal of the battery.

CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the LOCK position and the negative (-) terminal cable is disconnected from the battery.

3. Remove the right hand engine service hole cover.





- Remove the 3 screws and scuff plate.
- Remove the bolt and disconnect the right hand seat belt from the front floor panel.
- Remove the 4 bolts and right hand front seat.





- Remove the 2 bolts and right hand front seat leg.





- Remove the 2 bolts and jack holder.
- Remove the 9 bolts and right hand engine service hole cover.





4. Place a suitable container or shop rag under the delivery pipe.
5. Slowly loosen the union bolt of the fuel pipe and disconnect the fuel pipe from the delivery pipe.
6. Drain the fuel from the delivery pipe.





7. Install SST (pressure gauge) to the delivery pipe with 3 new gaskets and SST (union bolt) as shown in the illustration (SST 09268-45012).

Torque: 30 Nm (22 ft lb)

8. Wipe off any splattered gasoline.
9. Reconnect the battery negative terminal.





10. Using SST, connect terminals FP and +B of the data link connector 1 (SST 09843-18020).
11. Turn the ignition switch ON.





12. Measure the fuel pressure.

Fuel pressure: 265 - 304 kPa (38 - 44 psi)

If pressure is high, replace the fuel pressure regulator. If pressure is low, check the following parts:
- Fuel hoses and connections.
- Fuel pump.
- Fuel filter.
- Fuel pressure regulator.
13. Remove the SST from the data link connector 1 (SST 09843-18020).
14. Start the engine and warm up the engine for at least 2 minutes.





15. Disconnect the vacuum hose from the fuel pressure regulator and plug the hose end.
16. Measure the fuel pressure at idle.

Fuel pressure: 265 - 304 kPa (38 - 44 psi)





17. Reconnect the vacuum hose to the fuel pressure regulator.
18. Measure the fuel pressure at idle.

Fuel pressure: 206 - 245 kPa (30 - 36 psi)

If not within the specified pressure, check the vacuum hose and fuel pressure regulator.





19. Inspect high-temperature line pressure.
- Start the engine. Warm up the engine until the engine coolant temperature is 80°C (176°F) or more, then stop the engine.
- Restart the engine.
- Measure the fuel pressure.

Fuel pressure: 265 - 304 kPa (38 - 44 psi)

If pressure is low, check the following parts:
- engine control module
- Fuel pressure control VSV
- Engine coolant temp. sensor
- Wiring
- Measure the fuel pressure at idle two minutes later.

Fuel pressure: 206 - 245 kPa (30 - 36 psi)

20. Stop the engine. Check that the fuel pressure remains above 147 kPa (21 psi) for 5 minutes after the engine is turned OFF.
If not within specification, check the fuel pump, fuel pressure regulator and/or injectors.
21. After checking fuel pressure, disconnect the battery negative (-) terminal and carefully remove the SST to prevent gasoline from splashing.





22. Connect the fuel pipe to the delivery pipe with 2 new gaskets and the union bolt.

Torque: 30 Nm (22 ft lb)

23. Connect the battery negative (-) terminal.
24. Start the engine and check for fuel leakage.





25. Install the right hand engine service hole cover.
- Install the right hand engine service hole cover with the 9 bolts.

Torque: 14 Nm (10 ft lb)

- Install the jack holder with the 2 bolts.

Torque: 14 Nm (10 ft lb)





- Install the right hand front seat leg with the 2 bolts.

Torque: 39 Nm (29 ft lb)





- Install the right hand front seat with the 4 bolts.

Torque: 39 Nm (29 ft lb)

- Connect the right hand seat belt to the front floor panel.

Torque: 42 Nm (31 ft lb)

- Install the scuff plate with the 3 screws.