Fuel Pump: Testing and 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. (See step 5)




f. Check that there is pressure in the fuel inlet pipe 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
- 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 09268-45012
Torque: 29 Nm (300 kg.cm, 21 ft.lb)
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.)
h. 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
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 kg/sq.cm, 44-50 psi)

i. 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 kg/Sq.cm, 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 kg.cm, 21 ft.lb)
p. Reconnect the negative (-) terminal cable to the battery.
q. Check for fuel leakage.

3. REMOVE FUEL TANK

4. 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.




5. 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.

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.

6. REINSTALL FUEL TANK