Fuel Pump Control Circuit [11/2022 - ]: Procedure

1. Check around and beneath the vehicle for fuel leaks, fumes, etc.

   OK

   No fuel leaks present.

   Result

   Proceed to
   OK
   NG

Result: 

NG 

REPAIR OR REPLACE FUEL LEAK POINT 

Result: 

OK 

See step  2

1. Enter the following menus.

   Powertrain > Engine > Active Test 

   Tester Display
   Activate the Circuit Relay (Brushless)

2. Check whether the fuel pump operating sound occurs when performing the Active Test on the GTS.

   Standard

   GTS Operation	Standard
   ON	Operating sounds can be heard from fuel pump (for low pressure side)

   Result

   Proceed to
   OK
   NG

Result: 

NG 

See step  8

Result: 

OK 

See step  3

1. Install the fuel pressure gauge (for low pressure line of low pressure side).

   Refer to ON-VEHICLE INSPECTION [11/2022 - ]

2. Enter the following menus.

   Powertrain > Engine > Active Test 

   Active Test Display
   Control the Fuel Pump Duty Ratio (Brushless)

   Data List Display
   Fuel Pressure (Low) / Fuel Pressure 2

3. Compare the values in the Data List using the GTS and the fuel pressure gauge when the Active Test was performed.

   Standard

   GTS Operation	Standard
   Low	Data List value and fuel pressure gauge are within +/-50 kPag of each other
   High

   HINT: 

   Perform "Inspection After Repair" after replacing the No. 2 fuel pressure sensor (for low pressure side).

   Refer to INITIALIZATION [11/2022 - ]

   Result

   Proceed to
   OK
   NG

Result: 

NG 

REPLACE NO. 2 FUEL PRESSURE SENSOR (FOR LOW PRESSURE SIDE) 

Refer to REMOVAL [11/2022 - ]

Result: 

OK 

See step  4

1. Enter the following menus.

   Powertrain > Engine > Data List 

   Tester Display
   Target Fuel Pressure (Low) / Target Fuel Pressure 2
   Fuel Pressure (Low) / Fuel Pressure 2
   Low Fuel Pressure Sensor

2. Read the values displayed on the GTS while the engine is cranking.

   Result

   Result	Proceed to
   Low Fuel Pressure Sensor value is within +/- 65 kPag of the Target Fuel Pressure (Low) / Target Fuel Pressure 2	A
   Low Fuel Pressure Sensor value is more than 65 kPag higher than the target fuel pressure (low) / Target Fuel Pressure 2	B
   Low Fuel Pressure Sensor value is more than 65 kPag lower than the target fuel pressure (low) / Target Fuel Pressure 2	C

   HINT: 

   Perform "Inspection After Repair" after replacing the fuel pump (for low pressure side).

   Refer to INITIALIZATION [11/2022 - ]

Result: 

B 

REPLACE FUEL PUMP (FOR LOW PRESSURE SIDE) 

Refer to REMOVAL [11/2022 - ]

HINT: 

Relief blockage such as clogging of the jet pump is suspected.

Result: 

C 

See step  6

Result: 

A 

See step  5

1. Install the fuel pressure gauge (for low pressure line of low pressure side).

   Refer to ON-VEHICLE INSPECTION [11/2022 - ]

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

   Refer to INSPECTION MODE PROCEDURE [09/2021 - ]

3. Start the engine.
4. Measure the fuel pressure at idle.

   Standard Fuel Pressure

   196 to 833 kPa (2.0 to 8.5 kgf/cm ² , 28 to 121 psi)

   HINT: 

   Refer to Standard Idle Speed.

   Refer to DATA LIST / ACTIVE TEST [11/2022 - ]

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

   Standard Fuel Pressure

   98 kPa (1.0 kgf/cm ² , 14.2 psi) or more

   HINT: 

   Perform "Inspection After Repair" after replacing the fuel pump (for low pressure side).

   Refer to INITIALIZATION [11/2022 - ]

   Result

   Proceed to
   OK
   NG

Result: 

OK 

PROCEED TO NEXT SUSPECTED AREA SHOWN IN PROBLEM SYMPTOMS TABLE 

Refer to PROBLEM SYMPTOMS TABLE [11/2022 - ]

Result: 

NG 

REPLACE FUEL PUMP (FOR LOW PRESSURE SIDE) 

Refer to REMOVAL [11/2022 - ]

1. Check the amount of fuel remaining.

   HINT: 

   • No fuel remains in the fuel tank: Malfunction of the fuel sender gauge assembly is suspected.
   • Only the fuel pump side fuel chamber has no fuel remaining: Malfunction of the jet pump is suspected.
   • Fuel remains in the fuel tank: Malfunction of the fuel pump (for low pressure side) is suspected.
   • Perform "Inspection After Repair" after replacing the fuel pump (for low pressure side).

     Refer to INITIALIZATION [11/2022 - ]

   Result

   Proceed to
   NEXT

Result: 

NEXT 

See step  7

Refer to REMOVAL [11/2022 - ]

Result

Result: 

NEXT 

END 

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Disconnect the fuel pump (for low pressure side) connector.
2. Enter the following menus.

   Powertrain > Engine > Active Test 

   Tester Display
   Fuel Pump Single Phase Energization

3. Operate the fuel pump control ECU using the Active Test function and measure the voltage according to the value(s) in the table below.

   Standard Voltage

   Tester Connection	GTS Operation	Specified Condition
   O220-3 (BLPU) - Body ground	U Phase	4.4 to 8.4 V*
   O220-4 (BLPV) - Body ground	V Phase	4.4 to 8.4 V*
   O220-2 (BLPW) - Body ground	W Phase	4.4 to 8.4 V*

   HINT: 

   • *: This Active Test restricts the fuel pump control ECU output duty cycle to 50%. Therefore, the output voltage of the fuel pump control ECU will be approximately 50% of the power source voltage.
   • Before performing this inspection, check that the auxiliary battery voltage is between 11 and 14 V (not depleted).
   • Perform "Inspection After Repair" after replacing the fuel pump (for low pressure side).

     Refer to INITIALIZATION [11/2022 - ]

   Result

   Proceed to
   OK
   NG

Result: 

NG 

See step  10

Result: 

OK 

See step  9

Refer to REMOVAL [11/2022 - ]

Result

Result: 

NEXT 

END 

1. Disconnect the fuel pump control ECU connector.
2. Disconnect the fuel pump (for low pressure side) connector.
3. Measure the resistance according to the value(s) in the table below.

   Standard Resistance

   Tester Connection	Condition	Specified Condition
   O67-2 (FPU) - O220-3 (BLPU)	Always	Below 1 Ω
   O67-3 (FPV) - O220-4 (BLPV)	Always	Below 1 Ω
   O67-4 (FPW) - O220-2 (BLPW)	Always	Below 1 Ω
   O67-2 (FPU) or O220-3 (BLPU) - Body ground and other terminals	Always	10 kΩ or higher
   O67-3 (FPV) or O220-4 (BLPV) - Body ground and other terminals	Always	10 kΩ or higher
   O67-4 (FPW) or O220-2 (BLPW) - Body ground and other terminals	Always	10 kΩ or higher

   Result

   Proceed to
   OK
   NG

Result: 

NG 

REPAIR OR REPLACE HARNESS OR CONNECTOR 

Result: 

OK 

See step  11

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Disconnect the fuel pump control ECU connector.
2. Turn the ignition switch to ON.
3. Measure the voltage according to the value(s) in the table below.

   Standard Voltage

   Tester Connection	Switch Condition	Specified Condition
   O66-1 (+B) - O66-3 (GND)	Ignition switch ON	11 to 14 V

   Result

   Proceed to
   OK
   NG

Result: 

NG 

See step  14

Result: 

OK 

See step  12

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Disconnect the fuel pump control ECU connector.
2. Enter the following menus.

   Powertrain > Engine > Active Test 

   Tester Display
   Fuel Pump Single Phase Energization

3. Operate the fuel pump control ECU using the Active Test function and measure the resistance according to the value(s) in the table below.

   Standard Resistance

   Tester Connection	GTS Operation	Specified Condition
   O66-2 (FPC) - Body ground	Before Active Test → During Active Test	Before Active Test: Resistance is stable → During Active Test: Resistance fluctuates*

   HINT: 

   *: Using the Active Test, duty control of the transistors in the ECM will be performed. Due to the duty control, resistance of the FPC terminal will be unstable during the Active Test. If the resistance is stable before the Active Test and fluctuates while performing the Active Test, it can be determined that the transistor is operating. If the transistor does not operate during the Active Test, the ECM may be malfunctioning.

   Result

   Proceed to
   OK
   NG

Result: 

OK 

REPLACE FUEL PUMP CONTROL ECU 

Refer to REMOVAL [11/2022 - ]

Result: 

NG 

See step  13

1. Disconnect the fuel pump control ECU connector.
2. Disconnect the ECM connector.
3. Measure the resistance according to the value(s) in the table below.

   Standard Resistance

   Tester Connection	Condition	Specified Condition
   O66-2 (FPC) - A47-16 (FPC)	Always	Below 1 Ω
   O66-2 (FPC) or A47-16 (FPC) - Body ground and other terminals	Always	10 kΩ or higher

   Result

   Proceed to
   OK
   NG

Result: 

OK 

REPLACE ECM 

Refer to REMOVAL [11/2022 - ]

Result: 

NG 

REPAIR OR REPLACE HARNESS OR CONNECTOR 

1. Disconnect the fuel pump control ECU connector.
2. Measure the resistance according to the value(s) in the table below.

   Standard Resistance

   Tester Connection	Condition	Specified Condition
   O66-3 (GND) - Body ground	Always	Below 1 Ω

   Result

   Proceed to
   OK
   NG

Result: 

NG 

REPAIR OR REPLACE HARNESS OR CONNECTOR 

Result: 

OK 

See step  15

1. Remove the EFI-MAIN NO. 2 relay from the No. 1 engine room relay block.
2. Measure the voltage according to the value(s) in the table below.

   Standard Voltage

   Tester Connection	Condition	Specified Condition
   3 (EFI-MAIN NO. 2 relay) - Body ground	Always	11 to 14 V

   Result

   Proceed to
   OK
   NG

Result: 

NG 

REPAIR OR REPLACE HARNESS OR CONNECTOR (AUXILIARY BATTERY - EFI-MAIN NO. 2 RELAY) 

Result: 

OK 

See step  16

1. Remove the EFI-MAIN NO. 2 relay from the No. 1 engine room relay block.
2. Measure the resistance according to the value(s) in the table below.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1	EFI-MAIN NO. 2 Relay

   Standard Resistance

   Tester Connection	Condition	Specified Condition
   3 - 5	Auxiliary battery voltage not applied between terminals 1 and 2	10 kΩ or higher
   	Auxiliary battery voltage applied between terminals 1 and 2	Below 1 Ω

3. Install the EFI-MAIN NO. 2 relay.

   Result

   Proceed to
   OK
   NG

Result: 

NG 

REPLACE EFI-MAIN NO. 2 RELAY 

Result: 

OK 

See step  17

1. Remove the EFI-MAIN NO. 1 relay and EFI-MAIN NO. 2 relay from the No. 1 engine room relay block.
2. Remove the VVT relay and EFI-MAIN NO. 3 relay from the No. 1 engine room relay block.

   HINT: 

   Remove the VVT relay and EFI-MAIN NO. 3 relay connected between the checked terminals as the coil inside the relay influences the measurement value.

3. Measure the resistance according to the value(s) in the table below.

   Standard Resistance

   Tester Connection	Condition	Specified Condition
   3 (EFI-MAIN NO. 1 relay) - 1 (EFI-MAIN NO. 2 relay)	Always	Below 1 Ω
   3 (EFI-MAIN NO. 1 relay) or 1 (EFI-MAIN NO. 2 relay) - Body ground and other terminals	Always	10 kΩ or higher

   Result

   Proceed to
   OK
   NG

Result: 

NG 

REPAIR OR REPLACE HARNESS OR CONNECTOR 

Result: 

OK 

See step  18

1. Remove the EFI-MAIN NO. 2 relay from the No. 1 engine room relay block.
2. Measure the resistance according to the value(s) in the table below.

   Standard Resistance

   Tester Connection	Condition	Specified Condition
   2 (EFI-MAIN NO. 2 relay) - Body ground	Always	Below 1 Ω

   Result

   Proceed to
   OK
   NG

Result: 

NG 

REPAIR OR REPLACE HARNESS OR CONNECTOR 

Result: 

OK 

See step  19

1. Remove the EFI-MAIN NO. 2 relay from the No. 1 engine room relay block.
2. Disconnect the fuel pump control ECU connector.
3. Measure the resistance according to the value(s) in the table below.

   Standard Resistance

   Tester Connection	Condition	Specified Condition
   5 (EFI-MAIN NO. 2 relay) - O66-1 (+B)	Always	Below 1 Ω
   5 (EFI-MAIN NO. 2 relay) or O66-1 (+B) - Body ground and other terminals	Always	10 kΩ or higher

   Result

   Proceed to
   OK
   NG

Result: 

OK 

GO TO ECM POWER SOURCE CIRCUIT 

Refer to ECM Power Source Circuit [11/2022 - ] 

Result: 

NG 

REPAIR OR REPLACE HARNESS OR CONNECTOR