Fuel System (W/O Dpf) On-Vehicle Inspection

Read Data List.

1. Warm up the engine.
   

2. Turn the ignition switch off.
   

3. Connect the intelligent tester to the DLC3.
   

4. Turn the ignition switch to ON.
   

5. Start the engine.
   

6. Turn the intelligent tester ON.
   

7. Enter the following menus: Powertrain / Engine and ECT / Data List.
   

8. Read the Data List.
   
   

   Tester Display	Measurement Item/Range (Display)	Normal Condition
   Fuel Press	Fuel pressure / Min.: 0 kPa, Max.: 250000 kPa	27000 to 37000 kPa: Idling
   Target Common Rail Pressure	Target common rail pressure / Min.: 0 kPa, Max.: 250000 kPa	25000 to 180000 kPa

Perform Active Test.

1. Connect the intelligent tester to the DLC3.
   

2. Turn the ignition switch to ON.
   

3. Start the engine.
   

4. Turn the intelligent tester ON.
   

5. Enter the following menus: Powertrain / Engine and ECT / Active Test.
   

6. Perform the Active Test.
   
   

   Tester Display	Test Detail	Control Range	Diagnostic Note
   Test the Fuel Leak	Pressurizes fuel inside common rail and checks for fuel leaks	Stop/Start	The fuel inside the common rail is pressurized to the specified value and the engine speed increases to 2000 rpm when Start is selected. The above conditions are preserved while Start is selected.

Using the hand pump mounted on the fuel filter cap, bleed air from the fuel system. Continue pumping until the pump resistance increases.

NOTICE:

1. The maximum hand pump pumping speed is 2 strokes per second.
   
2. The hand pump must be pushed with a full stroke during pumping.
   
3. When the fuel pressure at the supply pump inlet port reaches a saturated pressure, the hand pump resistance increases.
   
4. If pumping is interrupted during the air bleeding process, fuel in the fuel line may return to the fuel tank. Continue pumping until the hand pump resistance increases.
   
5. If the hand pump resistance does not increase despite consecutively pumping 200 times or more, there may be a fuel leak between the fuel tank and fuel filter, the hand pump may be malfunctioning, or the vehicle may have run out of fuel.
   
6. If air bleeding using the hand pump is incomplete, the common rail pressure does not rise to the pressure range necessary for normal use and the engine cannot be started.
   

Check if the engine starts.

NOTICE:

1. Even if air bleeding using the hand pump has been completed, the starter may need to be cranked for 10 seconds or more to start the engine.
   
2. Do not crank the engine continuously for more than 20 seconds. The battery may be discharged.
   
3. Use a fully-charged battery.
   

1. When the engine can be started, proceed to the next step.
   

2. If the engine cannot be started, bleed air again using the hand pump until the hand pump resistance increases (refer to the procedures above). Then start the engine.
   

Turn the engine switch off.

Connect the intelligent tester to the DLC3.

Turn the ignition switch ON (IG) and turn the intelligent tester on.

Clear the DTCs (Click here).

Start the engine.*1

Enter the following menus: Powertrain / Engine and ECT / Active Test / Test the Fuel Leak.*2

Perform the following test 5 times with on/off intervals of 10 seconds: Active Test / Test the Fuel Leak.*3

Allow the engine to idle for 3 minutes or more after performing the Active Test for the 5th time.

HINT:

When the Active Test "Test the Fuel Leak" is used to change the pump control mode, the actual fuel pressure inside the common rail drops below the target fuel pressure when the Active Test is off, but this is normal and does not indicate a pump malfunction.

Enter the following menus: Powertrain / Engine and ECT / DTC.

Read Current DTCs.

Clear the DTCs (Click here).

HINT:

It is necessary to clear the DTCs as DTC P1604 or P1605 may be stored when air is bled from the fuel system after replacing or repairing fuel system parts.

Repeat steps *1 to *3.

Enter the following menus: Powertrain / Engine and ECT / DTC.

Read Current DTCs.

OK:

No DTCs are output.

w/o Multi-information Display:

1. Check if the fuel filter warning light is illuminated.
   

   NOTICE:

   When the fuel filter warning light illuminates, the fuel filter is clogged. Replace the filter (Click here).





2. Check if the fuel filter warning light is blinking.
   

   NOTICE:

   When the fuel filter warning light is blinking and the buzzer sounds, immediately drain the water in the fuel filter.

w/ Multi-information Display:
Check the multi-information display.

NOTICE:

When the fuel system warning is displayed on the multi-information display and the buzzer sounds, replace the fuel filter (Click here) or drain the water in the fuel filter.

Drain water.

1. Detach the fuel hose clamp.
   
   

   
   
   
   

2. Disconnect the clogging switch connector and level warning switch connector.
   





3. Remove the 2 nuts and lift up the fuel filter assembly.
   

4. Connect a hose to the drain cock. Place the other end of the hose into a container under the drain cock.
   

5. Loosen the drain cock to drain water.
   

6. Tighten the drain cock by hand.
   

   NOTICE:

   Do not use any tools in this procedure.





7. Install the fuel filter assembly with the 2 nuts.
   

   Torque:

   20 N*m{199 kgf*cm, 14 ft.*lbf}

   
   
   
   
   
   

8. Connect the clogging switch connector and level warning switch connector.
   

9. Attach the fuel hose clamp.