Toyota Yaris: Sfi System / Fuel Pump Control Circuit

Toyota Yaris XP210 (2020-2022) Reapir and Service Manual / Engine & Hybrid System / G16e-gts (engine Control) / Sfi System / Fuel Pump Control Circuit

DESCRIPTION

The fuel pump circuit consists of the ECM, fuel pump and fuel pump control ECU (which operates the fuel pump). Based on the engine output, the ECM determines the fuel pump speed. The speed is then converted to a duty signal and sent to the fuel pump control ECU. Based on the signal sent from the ECM, the fuel pump control ECU adjusts the fuel pump operation speed.

WIRING DIAGRAM

Refer to DTC P062712.

Click here

CAUTION / NOTICE / HINT

NOTICE:

Inspect the fuses for circuits related to this system before performing the following procedure.

PROCEDURE

1.

CHECK FUEL LEAK

(a) Check around and beneath the vehicle for fuel leaks, fumes, etc.

OK:

No fuel leaks present.

NG

REPAIR OR REPLACE FUEL LEAK POINT

OK

2.

PERFORM ACTIVE TEST USING GTS (ACTIVATE THE CIRCUIT RELAY (BRUSHLESS))

(a) Check whether the fuel pump operating sound occurs when performing the Active Test on the GTS.

Powertrain > Engine > Active Test

Tester Display

Activate the Circuit Relay (Brushless)

Standard:

GTS Operation

Standard

ON

Operating sounds can be heard from fuel pump (for low pressure side)

NG

GO TO STEP 7

OK

3.

PERFORM ACTIVE TEST USING GTS (CONTROL THE FUEL PUMP DUTY RATIO (BRUSHLESS))

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

Click here

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

Powertrain > Engine > Active Test

Active Test Display

Control the Fuel Pump Duty Ratio (Brushless)

Data List Display

Target Fuel Pressure (Low) / Target Fuel Pressure 2

Fuel Pump Control Duty Ratio

Standard:

GTS Operation

Standard

Low

Data List value and fuel pressure gauge are within +/-50 kPa of each other

High

NG

REPLACE FUEL PRESSURE SENSOR (FOR LOW PRESSURE SIDE)

OK

4.

READ VALUE USING GTS (FUEL PRESSURE)

(a) Read the values displayed on the GTS while the engine is cranking.

Powertrain > Engine > Data List

Tester Display

Target Fuel Pressure (Low) / Target Fuel Pressure 2

Fuel Pressure (Low) / Fuel Pressure 2

Low Fuel Pressure Sensor

Result

Proceed to

Low Fuel Pressure Sensor value is within +/- 65 kPa of the Target Fuel Pressure (Low) / Target Fuel Pressure 2

A

Low Fuel Pressure Sensor value is higher than 65 kPa higher than the target fuel pressure (low)

B

Low Fuel Pressure Sensor value is higher than 65 kPa lower than the target fuel pressure (low)

C

B

REPLACE FUEL PUMP (FOR LOW PRESSURE SIDE)

C

GO TO STEP 6

A

5.

CHECK FUEL PRESSURE

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

Click here

(b) Start the engine.

(c) Measure the fuel pressure at idle.

Standard Fuel Pressure:

196 to 833 kPa (2.0 to 8.5 kgf/cm2, 28 to 121 psi)

HINT:

Refer to Standard Idle Speed.

Click here

(d) Stop the engine.

(e) Check that the fuel pressure remains as specified for 5 minutes.

Standard Fuel Pressure:

98 kPa (1.0 kgf/cm2, 14.2 psi) or higher

OK

PROCEED TO NEXT SUSPECTED AREA SHOWN IN PROBLEM SYMPTOMS TABLE

NG

REPLACE FUEL PUMP (FOR LOW PRESSURE SIDE)

6.

CHECK SHORTAGE OF FUEL

(a) 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.
NEXT

REPLACE FUEL PUMP (FOR LOW PRESSURE SIDE)

7.

PERFORM ACTIVE TEST USING GTS (FUEL PUMP SINGLE PHASE ENERGIZATION)

(a) Disconnect the fuel pump (for low pressure side) connector.

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

Powertrain > Engine > Active Test

Tester Display

Fuel Pump Single Phase Energization

Standard Voltage:

Tester Connection

GTS Operation

Specified Condition

O21-3 (BLPU) - Body ground

U Phase

4.4 to 8.4 V*

O21-4 (BLPV) - Body ground

V Phase

4.4 to 8.4 V*

O21-2 (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).

*a

Front view of wire harness connector

(to Fuel Pump (for low pressure side))

OK

REPLACE FUEL PUMP (FOR LOW PRESSURE SIDE)

NG

8.

CHECK HARNESS AND CONNECTOR (FUEL PUMP (FOR LOW PRESSURE SIDE) - FUEL PUMP CONTROL ECU)

(a) Disconnect the fuel pump (for low pressure side) connector.

(b) Disconnect the fuel pump control ECU connector.

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

Standard Resistance:

Tester Connection

Condition

Specified Condition

O21-3 (BLPU) - O1-2 (FPU)

Always

Below 1 Ω

O21-4 (BLPV) - O1-3 (FPV)

Always

Below 1 Ω

O21-2 (BLPW) - O1-4 (FPW)

Always

Below 1 Ω

O21-3 (BLPU) or O1-2 (FPU) - Body ground and other terminals

Always

10 kΩ or higher

O21-4 (BLPV) or O1-3 (FPV) - Body ground and other terminals

Always

10 kΩ or higher

O21-2 (BLPW) or O1-4 (FPW) - Body ground and other terminals

Always

10 kΩ or higher

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

9.

CHECK HARNESS AND CONNECTOR (POWER SOURCE OF FUEL PUMP CONTROL ECU)

(a) Disconnect the fuel pump control ECU connector.

(b) Turn the ignition switch to ON.

(c) Measure the voltage according to the value(s) in the table below.

Standard Voltage:

Tester Connection

Switch Condition

Specified Condition

O2-1 (+B) - O2-3 (GND)

Ignition switch ON

11 to 14 V

*a

Front view of wire harness connector

(to Fuel Pump Control ECU)

NG

GO TO STEP 12

OK

10.

INSPECT ECM (FPC TERMINAL)

(a) Disconnect the fuel pump control ECU connector.

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

Powertrain > Engine > Active Test

Tester Display

Fuel Pump Single Phase Energization

Standard Resistance:

Tester Connection

GTS Operation

Specified Condition

O2-2 (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.

OK

REPLACE FUEL PUMP CONTROL ECU

NG

11.

CHECK HARNESS AND CONNECTOR (FUEL PUMP CONTROL ECU - ECM)

(a) Disconnect the fuel pump control ECU connector.

(b) Disconnect the ECM connector.

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

Standard Resistance:

Tester Connection

Condition

Specified Condition

O2-2 (FPC) - A106-6 (FPC)

Always

Below 1 Ω

O2-2 (FPC) or A106-6 (FPC) - Body ground and other terminals

Always

10 kΩ or higher

OK

REPLACE ECM

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

12.

CHECK HARNESS AND CONNECTOR (FUEL PUMP CONTROL ECU - BODY GROUND)

(a) Disconnect the fuel pump control ECU connector.

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

Standard Resistance:

Tester Connection

Condition

Specified Condition

O2-3 (GND) - Body ground

Always

Below 1 Ω

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

13.

CHECK HARNESS AND CONNECTOR (POWER SOURCE VOLTAGE OF EFI-MAIN NO. 2 RELAY)

(a) Remove the EFI-MAIN NO. 2 relay from the No. 5 luggage room relay block assembly.

(b) 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 holder) - Body ground

Always

11 to 14 V

*1

No. 5 Luggage Room Relay Block Assembly

*2

EFI-MAIN NO. 2 Relay

NG

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

OK

14.

INSPECT EFI-MAIN NO. 2 RELAY

Click here

NG

REPLACE EFI-MAIN NO. 2 RELAY

OK

15.

CHECK HARNESS AND CONNECTOR (EFI-MAIN NO. 1 RELAY - EFI-MAIN NO. 2 RELAY)

(a) Remove the EFI-MAIN NO. 2 relay from the No. 5 luggage room relay block assembly.

(b) Remove the EFI-MAIN NO. 1 relay, EFI-MAIN NO. 3 relay and EDU relay from the No. 1 engine room relay block assembly.

HINT:

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

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

Standard Resistance:

Tester Connection

Condition

Specified Condition

5 (EFI-MAIN NO. 1 relay holder) - 2 (EFI-MAIN NO. 2 relay holder)

Always

Below 1 Ω

5 (EFI-MAIN NO. 1 relay holder) or 2 (EFI-MAIN NO. 2 relay holder) - Body ground and other terminals

Always

10 kΩ or higher

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

16.

CHECK HARNESS AND CONNECTOR (EFI-MAIN NO. 2 RELAY - BODY GROUND)

(a) Remove the EFI-MAIN NO. 2 relay from the No. 5 luggage room relay block assembly.

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

Standard Resistance:

Tester Connection

Condition

Specified Condition

1 (EFI-MAIN NO. 2 relay holder) - Body ground

Always

Below 1 Ω

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

17.

CHECK HARNESS AND CONNECTOR (EFI-MAIN NO. 2 RELAY - FUEL PUMP CONTROL ECU)

(a) Remove the EFI-MAIN NO. 2 relay from the No. 5 luggage room relay block assembly.

(b) Disconnect the fuel pump control ECU connector.

(c) 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 holder) - O2-1 (+B)

Always

Below 1 Ω

5 (EFI-MAIN NO. 2 relay holder) or O2-1 (+B) - Body ground and other terminals

Always

10 kΩ or higher

OK

GO TO ECM POWER SOURCE CIRCUIT

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

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