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On-Vehicle Inspection [10/2022 - ]: Procedure

  1. CHECK FUEL PUMP OPERATION AND INSPECT FOR FUEL LEAK 
    1. Check fuel pump operation.
      NOTE:

      Do not start the engine.

      Powertrain > Engine > Active Test 

      Tester Display
      Activate the Circuit Relay (Brushless)
      1. Check for pressure in the fuel tube sub-assembly from the fuel line. Check that sounds of fuel flowing from the fuel tank assembly can be heard. If no sounds can be heard, check the relay, fuel pump, ECM and wiring connectors.
    2. Inspect for fuel leaks.
      1. Check that there are no fuel leaks from the fuel system after doing any maintenance or repairs. If there is a fuel leak, repair or replace parts as necessary.
  2. CHECK FUEL PRESSURE (for 1Motor-HEV Model) 

    Pre-procedure1

    • Discharge fuel system pressure.

      HINT: 

      Refer to PRECAUTION [10/2022 - ] 

    • Measure the auxiliary battery voltage.

      Standard Voltage

      Tester Connection Condition Specified Condition Result
      Positive (+) auxiliary battery terminal - Negative (-) auxiliary battery terminal 20°C (68°F) 11 to 14 V V
    • GTY1073440Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Open
      Pull

      Open the cover of the fuel pipe clamp and remove the fuel pipe clamp from the fuel tube connector.

    • Disconnect the fuel tube sub-assembly from the fuel pipe.
      GTY1129861Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Refer to PRECAUTION [10/2022 - ] 

    • Install SST (EFI fuel pressure gauge) as shown in the illustration.
      GTY1077222Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Fuel Tube Sub-assembly (Vehicle Side)
      *a SST (Hose Band)
      *b SST (T Joint)
      *c SST (Gauge)
      *d SST (Hose Joint)
      *e SST (Hose)
      *f SST (Fuel Tube Connector)
      *g Fuel Pipe (Vehicle Side)
      • SST: 09268-45101 
        1. 09268-41250
        2. 09268-41260
        3. 09268-41280
        4. 09268-41500
        5. 09268-41700
        6. 95336-08070
    • Wipe up any spilled fuel.
    • Connect the cable to the negative (-) auxiliary battery terminal.

      HINT: 

      Refer to INSTALLATION [10/2022 - ]

    • Measure the fuel pressure.
      NOTE:

      Do not start the engine.

      Powertrain > Engine > Active Test 

      Tester Display
      Activate the Circuit Relay (Brushless)

      Standard Fuel Pressure

      Specified Condition Result
      270 to 570 kPa
      2.8 to 5.8 kgf/cm2
      39 to 83 psi      		 kPa
      kgf/cm2
      psi
      • If the fuel pressure is more than the standard, replace the fuel main valve assembly.
      • If the fuel pressure is less than the standard, check the fuel hoses and their connections, fuel pump, fuel filter (fuel suction plate sub-assembly) and fuel main valve assembly.

    Pre-procedure2

    • Put the engine in Inspection Mode (Maintenance Mode).

      Powertrain > Hybrid Control > Utility 

      Tester Display
      Inspection Mode
    • Start the engine.
    • Measure the fuel pressure at idle.

      Standard Fuel Pressure

      Specified Condition Result
      270 to 570 kPa
      2.8 to 5.8 kgf/cm2
      39 to 83 psi      		 kPa
      kgf/cm2
      psi

      HINT: 

      Refer to Standard Idle Speed.

      Refer to PROCEDURE - Step 10

    Pre-procedure3

    • Disconnect the GTS from the DLC3.
    • Stop the engine.
    • Check that the fuel pressure remains as specified for 5 minutes.

      Standard Fuel Pressure

      Specified Condition Result
      270 kPa or higher
      2.8 kgf/cm2 or higher
      39 psi or higher      		 kPa
      kgf/cm2
      psi

      If the result is not as specified, check the fuel pump, fuel main valve assembly and/or port fuel injector assemblies.

    Post-procedure1

    • After checking the fuel pressure, disconnect the cable from the negative (-) auxiliary battery terminal and carefully remove SST to prevent fuel from spraying.

      HINT: 

      Refer to REMOVAL [10/2022 - ]

    • Connect the fuel tube sub-assembly to the fuel pipe.

      HINT: 

      Refer to PRECAUTION [10/2022 - ] 

    • Install the fuel pipe clamp to the fuel tube connector and close the cover of the fuel pipe clamp.
    • Connect the cable to the negative (-) auxiliary battery terminal.

      HINT: 

      Refer to INSTALLATION [10/2022 - ]

    • Inspect for fuel leaks.

      HINT: 

      See step  1

  3. CHECK FUEL PRESSURE (for Gasoline Model) 

    Pre-procedure1

    • Discharge fuel system pressure.

      HINT: 

      Refer to PRECAUTION [10/2022 - ] 

    • Measure the battery voltage.

      Standard Voltage

      Tester Connection Condition Specified Condition Result
      Positive (+) auxiliary battery terminal - Negative (-) auxiliary battery terminal 20°C (68°F) 11 to 14 V V
    • Open the cover of the fuel pipe clamp and remove the fuel pipe clamp from the fuel tube connector.
      GTY1073440Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Open
      Pull
    • Disconnect the fuel tube sub-assembly from the fuel pipe.
      GTY1132793Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Refer to PRECAUTION [10/2022 - ] 

    • Install SST (EFI fuel pressure gauge) as shown in the illustration.
      GTY1077222Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Fuel Tube Sub-assembly (Vehicle Side)
      *a SST (Hose Band)
      *b SST (T Joint)
      *c SST (Gauge)
      *d SST (Hose Joint)
      *e SST (Hose)
      *f SST (Fuel Tube Connector)
      *g Fuel Pipe (Vehicle Side)
      • SST: 09268-45101 
        1. 09268-41250
        2. 09268-41260
        3. 09268-41280
        4. 09268-41500
        5. 09268-41700
        6. 95336-08070
    • Wipe up any spilled fuel.
    • Connect the cable to the negative (-) auxiliary battery terminal.

      HINT: 

      Refer to INSTALLATION [10/2022 - ]

    • Measure the fuel pressure.
      NOTE:

      Do not start the engine.

      Powertrain > Engine > Active Test 

      Tester Display
      Activate the Circuit Relay (Brushless)

      Standard Fuel Pressure

      Specified Condition Result
      270 to 570 kPa
      2.8 to 5.8 kgf/cm2
      39 to 83 psi      		 kPa
      kgf/cm2
      psi
      • If the fuel pressure is more than the standard, replace the fuel main valve assembly.
      • If the fuel pressure is less than the standard, check the fuel hoses and their connections, fuel pump, fuel filter (fuel suction plate sub-assembly) and fuel main valve assembly.

    Pre-procedure2

    • Disconnect the GTS from the DLC3.
    • Start the engine.
    • Measure the fuel pressure at idle.

      Standard Fuel Pressure

      Specified Condition Result
      270 to 570 kPa
      2.8 to 5.8 kgf/cm2
      39 to 83 psi      		 kPa
      kgf/cm2
      psi

      HINT: 

      Refer to Standard Idle Speed.

      Refer to PROCEDURE - Step 10

    Pre-procedure3

    • Stop the engine.
    • Check that the fuel pressure remains as specified for 5 minutes.

      Standard Fuel Pressure

      Specified Condition Result
      270 kPa or higher
      2.8 kgf/cm2 or higher
      39 psi or higher      		 kPa
      kgf/cm2
      psi

      If the result is not as specified, check the fuel pump, fuel main valve assembly and/or port fuel injector assemblies.

    Post-procedure1

    • After checking the fuel pressure, disconnect the cable from the negative (-) auxiliary battery terminal and carefully remove SST to prevent fuel from spraying.

      HINT: 

      Refer to REMOVAL [10/2022 - ]

    • Connect the fuel tube sub-assembly to the fuel pipe.

      HINT: 

      Refer to PRECAUTION [10/2022 - ] 

    • Install the fuel pipe clamp to the fuel tube connector and close the cover of the fuel pipe clamp.
    • Connect the cable to the negative (-) auxiliary battery terminal.

      HINT: 

      Refer to INSTALLATION [10/2022 - ]

    • Inspect for fuel leaks.

      HINT: 

      See step  1

  4. CHECK FUEL PRESSURE (for High Pressure) (for 1Motor-HEV Model) 

    Pre-procedure1

    • Put the engine in Inspection Mode (Maintenance Mode).

      Powertrain > Hybrid Control > Utility 

      Tester Display
      Inspection Mode
    • Start the engine and warm it up until the engine coolant temperature is 75°C (167°F) or higher with all the accessories switched off.

      Powertrain > Engine > Data List 

      Tester Display
      Coolant Temperature
    • According to the display on the GTS, read the Data List.

      Powertrain > Engine > Data List 

      Tester Display
      Engine Speed
      Fuel Pressure (High)
      Injection Mode

      HINT: 

      During charge control, the engine speed is set at idle. Therefore, the engine speed will not increase when the accelerator pedal is depressed. In this case, read the Data List after charge control has completed.

      Standard

      GTS Display Condition Specified Condition Result
      Fuel Pressure (High)
      • Shift position: P
      • A/C: Off
      • Engine warmed up
      • Engine Speed: 2500 rpm
      • Injection Mode: Direct
      		 2000 to 32000 kPa kPa

      If the result is not as specified, check the fuel pump, fuel (engine room side) pump assembly, fuel pressure sensor and wire harnesses.

    Post-procedure1

    • None
  5. CHECK FUEL PRESSURE (for High Pressure) (for Gasoline Model) 

    Pre-procedure1

    • Start the engine and warm it up until the engine coolant temperature is 75°C (167°F) or higher with all the accessories switched off.

      Powertrain > Engine > Data List 

      Tester Display
      Coolant Temperature
    • According to the display on the GTS, read the Data List.

      Powertrain > Engine > Data List 

      Tester Display
      Engine Speed
      Fuel Pressure (High)
      Injection Mode

      HINT: 

      During charge control, the engine speed is set at idle. Therefore, the engine speed will not increase when the accelerator pedal is depressed. In this case, read the Data List after charge control has completed.

      Standard

      GTS Display Condition Specified Condition Result
      Fuel Pressure (High)
      • Shift position: P
      • A/C: Off
      • Engine warmed up
      • Engine Speed: 3000 rpm
      • Injection Mode: Direct
      		 2000 to 32000 kPa kPa

      If the result is not as specified, check the fuel pump, fuel (engine room side) pump assembly, fuel pressure sensor and wire harnesses.

    Post-procedure1

    • None
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