Inspection Procedure 21: Fuel pump system












OPERATION



FUNCTION



PROBABLE CAUSES



DIAGNOSIS PROCEDURE
note
    *1: Vehicles for General Export
    *2: Vehicles for GCC

STEP 1. Connector check: D-417 fuel pump relay (1) connector and D-413 fuel pump relay (2) connector

Q. Is the check result normal?
Go to Step 2 .
Repair or replace the connector.

STEP 2. Check fuel pump relay.

  • Fuel pump relay, continuity check (Refer to ).

Q. Is the check result normal?
Go to Step 3 .
Replace the fuel pump relay.

STEP 3. Perform resistance measurement at D-417 fuel pump relay (1) connector.

  • Remove relay, and measure at junction block side.
  • Resistance between terminal No. 2 and earth.
OK: Continuity (2 Ω or less)

Q. Is the check result normal?

Go to Step 5 .
Go to Step 4 .

STEP 4. Perform voltage measurement at D-417 fuel pump relay (1) connector.

  • Remove relay, and measure at junction block side.
  • Ignition switch: ON
  • Voltage between terminal No. 3 and earth.
OK: System voltage

Q. Is the check result normal?

Go to Step 6 .
Go to Step 5 .

STEP 5. Connector check: D-309 ignition switch connector

Q. Is the check result normal?


    Check intermediate connector D-403, and repair if necessary. If intermediate connector is normal, check and repair harness between D-417 (terminal No. 3) fuel pump relay (1) connector and D-309 (terminal No. 2) ignition switch connector.

    • Check power supply line for open circuit and damage.
Repair or replace the connector.

STEP 6. Perform voltage measurement at D-417 fuel pump relay (1) connector.

  • Remove relay, and measure at junction block side.
  • Voltage between terminal No. 4 and earth.
OK: System voltage

Q. Is the check result normal?
Go to Step 7 .

    Check intermediate connectors D-241 and D-401, and repair if necessary. If intermediate connectors are normal, check and repair harness between D-417 (terminal No. 4) fuel pump relay (1) connector and battery.

    • Check power supply line for open/short circuit.

STEP 7. Perform voltage measurement at D-413 fuel pump relay (2) connector.

  • Remove relay, and measure at junction block side.
  • Ignition switch: ON
  • Voltage between terminal No. 3 and earth.
OK: System voltage

Q. Is the check result normal?

Go to Step 9 .
Go to Step 8 .

STEP 8. Connector check: D-309 ignition switch connector

Q. Is the check result normal?

    Check intermediate connector D-403, and repair if necessary. If intermediate connector is normal, check and repair harness between D-309 (terminal No. 2) ignition switch connector and D-413 (terminal No. 3) fuel pump relay (2) connector.

    • Check power supply line for open circuit.
Repair or replace the connector.

STEP 9. Connector check: D-243 engine-ECU <M/T> connector or D-212 engine-A/T-ECU <A/T> connector

Q. Is the check result normal?
Go to Step 10 .
Repair or replace the connector.

STEP 10. Perform voltage measurement at D-243 engine-ECU <M/T> connector or D-212 engine-A/T-ECU <A/T> connector.

  • Disconnect connector, and measure at harness side.
  • Ignition switch: ON
  • Voltage between terminal No. 8 (*1) or 16 (*2) and earth.
OK: System voltage

Q. Is the check result normal?
Go to Step 11 .

    Check intermediate connectors D-231 and D-405, and repair if necessary. If intermediate connectors are normal, check and repair harness between D-413 (terminal No. 2) fuel pump relay (2) connector and D-243 (terminal No. 8 (*1) or 16 (*2)) engine-ECU <M/T> connector or D-212 (terminal No. 8 (*1) or 16 (*2)) engine-A/T-ECU <A/T> connector.

    • Check earthing line for open/short circuit.

STEP 11. Connector check: E-10 fuel pump connector

Q. Is the check result normal?
Go to Step 12 .
Repair or replace the connector.

STEP 12. Perform voltage measurement at E-10 fuel pump connector.

  • Disconnect connector, and measure at harness side.
  • Ignition switch: ON
  • Using a jumper wire, connect D-243 (terminal No. 8 (*1) or 16 (*2)) engine-ECU <M/T> connector or D-212 (terminal No. 8 (*1) or 16 (*2)) engine-A/T-ECU <A/T> connector and earth.
  • Voltage between terminal No. 5 and earth.
OK: System voltage

Q. Is the check result normal?
Go to Step 15 .
Go to Step 13 .

STEP 13. Check harness between D-417 (terminal No. 1) fuel pump relay (1) connector and D-413 (terminal No. 1) fuel pump relay (2) connector.

  • Check power supply line for open/short circuit.

Q. Is the check result normal?
Go to Step 14 .
Repair the damaged harness wire.

STEP 14. Check harness between D-413 (terminal No. 4) fuel pump relay (2) connector and E-10 (terminal No. 5) fuel pump connector.
note Before checking harness, check intermediate connectors D-409 <L. H. drive vehicles> or D-422 <R. H. drive vehicles>, D-220 <L. H. drive vehicles> and E-09, and repair if necessary.

  • Check output line for open/short circuit and damage.

Q. Is the check result normal?
Replace the engine-ECU <M/T> or engine-A/T-ECU <A/T>.
Repair the damaged harness wire.

STEP 15. Perform resistance measurement at E-10 fuel pump connector.

  • Disconnect connector, and measure at harness side.
  • Resistance between terminal No. 4 and earth.
OK: Continuity (2 Ω or less)

Q. Is the check result normal?
Go to Step 16 .

    Check intermediate connector E-09, and repair if necessary. If intermediate connector is normal, check and repair harness between E-10 (terminal No. 4) fuel pump connector and body earth.

    • Check earthing line for open circuit and damage.

STEP 16. Connector check: D-309 ignition switch connector

Q. Is the check result normal?
Go to Step 17 .
Repair or replace the connector.

STEP 17. Check harness between D-309 (terminal No. 2) ignition switch connector and D-417 (terminal No. 3) fuel pump relay (1) connector.
note Before checking harness, check intermediate connector D-403, and repair if necessary.

  • Check power supply line for damage.

Q. Is the check result normal?
Go to Step 18 .
Repair the damaged harness wire.

STEP 18. Check harness between battery and D-417 (terminal No. 4) fuel pump relay (1) connector.
note Before checking harness, check intermediate connectors D-241 and D-401, and repair if necessary.

  • Check power supply line for damage.

Q. Is the check result normal?
Go to Step 19 .
Repair the damaged harness wire.

STEP 19. Check harness between D-417 (terminal No. 1) fuel pump relay (1) connector and D-413 (terminal No. 1) fuel pump relay (2) connector.

  • Check power supply line for damage.

Q. Is the check result normal?
Go to Step 20 .
Repair the damaged harness wire.

STEP 20. Check harness between D-309 (terminal No. 2) ignition switch connector and D-413 (terminal No. 3) fuel pump relay (2) connector.
note Before checking harness, check intermediate connector D-403, and repair if necessary.

  • Check power supply line for damage.

Q. Is the check result normal?
Go to Step 21 .
Repair the damaged harness wire.

STEP 21. Check harness between D-413 (terminal No. 4) fuel pump relay (2) connector and E-10 (terminal No. 5) fuel pump connector.
note Before checking harness, check intermediate connectors D-409 <L. H. drive vehicles> or D-422 <R. H. drive vehicles>, D-220 <L. H. drive vehicles> and E-09, and repair if necessary.

  • Check power supply line for damage.

Q. Is the check result normal?
Go to Step 22 .
Repair the damaged harness wire.

STEP 22. Check harness between D-413 (terminal No. 2) fuel pump relay (2) connector and D-243 (terminal No. 8 (*1) or 16 (*2)) engine-ECU <M/T> connector or D-212 (terminal No. 8 (*1) or 16 (*2)) engine-A/T-ECU <A/T> connector.
note Before checking harness, check intermediate connectors D-231 and D-405, and repair if necessary.

  • Check earthing line for damage.

Q. Is the check result normal?
Replace the fuel pump.
Repair the damaged harness wire.