1Gd-Ftv Fuel. Fuel System On-Vehicle Inspection

INSPECT FOR FUEL LEAK
CHECK PRESSURE DISCHARGE VALVE
BLEED AIR FROM FUEL SYSTEM
CHECK FUEL FILTER WARNING LIGHT AND DRAIN WATER

Fuel System -- On-Vehicle Inspection

1. INSPECT FOR FUEL LEAK

NOTICE:

During Active Test mode, the engine speed becomes high and the combustion noise becomes loud, so pay attention.
During Active Test mode, the fuel pressure becomes high. Be extremely careful not to expose your eyes, hands, or body to escaping fuel.

HINT:

Using the GTS to perform Active Tests allow relays, VSVs, actuators and other items to be operated without removing any parts. This non-intrusive functional inspection can be very useful because intermittent operation may be discovered before parts or wiring is disturbed. Performing Active Tests early in troubleshooting is one way to save diagnostic time. Data List information can be displayed while performing Active Tests.

Check that there are no leaks from any part of the fuel system when the engine is stopped. If there is fuel leakage, repair or replace parts as necessary.

Start the engine and check that there are no leaks from any part of the fuel system. If there is fuel leakage, repair or replace parts as necessary.

Disconnect the return hose from the common rail assembly.

Start the engine and check for fuel leaks from the return pipe. If there is fuel leakage, replace the common rail assembly.

Perform the Active Test.
1. Connect the GTS to the DLC3.
2. Turn the engine switch on (IG).
3. Turn the GTS on.
4. Enter the following menus: Powertrain / Engine / Active Test / Test the Fuel Leak.
5. If the GTS is not available, fully depress the accelerator pedal quickly. Increase the engine speed to the maximum and maintain that speed for 2 seconds. Repeat this operation several times.
6. Check that there are no leaks from any part of the fuel system.
  HINT:
  A return pipe leakage of less than 10 cc (0.6 cu in.) per minute is acceptable.
  If there is fuel leakage, repair or replace parts as necessary

Reconnect the return hose to the common rail assembly.

2. CHECK PRESSURE DISCHARGE VALVE

HINT:

This is the procedure for troubleshooting fuel pressure control malfunctions and combustion problems.
Malfunctions can be determined by checking the fuel pressure when performing fuel cut and operating the pressure discharge valve with the GTS.
During "Pressure Discharge Valve Check", the GTS measures the fuel pressure while the engine is running, after the engine is stopped, and after the pressure discharge valve operates.

Connect the GTS to the DLC3.

Turn the engine switch on (IG).

Turn the GTS on.
NOTICE:
The following conditions must be met:
1. The engine is idling.
2. The vehicle is stopped.
3. Fuel pressure is not extremely high (below 100000 kPa).
4. Fuel pressure is not extremely low (higher than 26000 kPa).
5. The fuel pressure sensor is normal.
6. The battery voltage is higher than 8 V.

Enter the following menus: Powertrain / Engine / Utility / Pressure Discharge Valve Check.

Press "Next".

Press "Next" again to proceed.

Select the check type "Close to Open Check" or "Always Closed Check".
HINT:
1. "Close to Open Check" opens the pressure discharge valve after the engine stops.
2. "Always Closed Check" holds the pressure discharge valve closed during the check.

Press "Next".

Perform troubleshooting based on the measurement results.

OK:: 0.5 MPa or less

HINT:

During "Close to Open Check", if there is no large change in fuel pressure when the pressure discharge valve is closed while the engine is running and after the engine is stopped, and if the value is 0 MPa when the pressure discharge valve is open, the system is normal.
Perform "Always Closed Check" if the value is not 0 MPa when the pressure discharge valve is open during "Close to Open Check". If the results are the same as during "Close to Open Check", there is a pressure discharge valve operation malfunction.

If a large amount of fuel is leaking, the fuel pressure decreases when the engine is stopped. However, the condition of the pressure discharge valve can still be determined by comparing the measurement results of "Close to Open Check" and "Always Closed Check".

Text in Illustration
*1	Fuel Press (Always Closed Check)	*2	Fuel Press (Close to Open Check)
*3	Engine Speed	*4	Fuel Cut Operation Signal
*5	Pressure Discharge Valve Operation Prohibition	*6	Pressure Discharge Valve Operation (Always Closed Check)
*7	Pressure Discharge Valve Operation (Close to Open Check)	-	-
*a	Fuel Press Recorded Point	*b	Closed (on)
*c	Open (on)	-	-
	Pressure Discharge Valve Operation Start	-	-

3. BLEED AIR FROM FUEL SYSTEM

Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155

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 GTS to the DLC3.

Turn the engine switch on (IG) and turn the GTS on.

Clear the DTCs.
1. w/ Urea SCR System: (LandCruiser RM000000PDK1E5X.html)
2. w/o Urea SCR System: (LandCruiser RM000000PDK1ENX.html)

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 /Trouble Codes.

Read Current DTCs.

Clear the DTCs.
1. w/ Urea SCR System: (LandCruiser RM000000PDK1E5X.html)
  w/o Urea SCR System: (LandCruiser RM000000PDK1ENX.html)
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 / Trouble Codes.

Read Current DTCs.
OK:
No DTCs are output.

4. CHECK FUEL FILTER WARNING LIGHT AND DRAIN WATER

Check the fuel filter multi-information display.
NOTICE:
When the fuel system warning is displayed on the multi-information display, replace the fuel filter (LandCruiser RM0000045HW008X.html) or drain the water in the fuel filter.

Drain water.
1. Disconnect the 2 connectors.
2. Remove the 2 nuts and lift up the fuel filter assembly.
3. Connect a hose to the fuel filter drain plug. Place the other end of the hose into a container under the fuel filter drain plug.
  Text in Illustration
  *1
  Fuel Filter Drain Plug
  *2
  Container
4. Loosen the fuel filter drain plug to drain water.
5. Tighten the fuel filter drain plug by hand.
  NOTICE:
  Do not use any tools in this procedure.
6. Install the fuel filter assembly with the 2 nuts.
  Torque:
  18 N*m{184 kgf*cm, 13 ft.*lbf}
7. Connect the 2 connectors.

Text in Illustration
*1	Fuel Filter Drain Plug
*2	Container