Toyota Yaris: Fuel System / On-vehicle Inspection

Toyota Yaris XP210 (2020-2022) Reapir and Service Manual / Engine & Hybrid System / G16e-gts (fuel) / Fuel System / On-vehicle Inspection

ON-VEHICLE INSPECTION

PROCEDURE

1. CHECK FUEL PUMP OPERATION AND INSPECT FOR FUEL LEAK

(a) Check fuel pump operation.

(1) Connect the GTS to the DLC3.

(2) Turn the ignition switch to ON.

NOTICE:

Do not start the engine.

(3) Turn the GTS on.

(4) Enter the following menus: Powertrain / Engine / Active Test / Activate the Circuit Relay.

Powertrain > Engine > Active Test

Tester Display

Activate the Circuit Relay

(5) Check for pressure in the fuel tube sub-assembly from the fuel line. Check that sounds of fuel flowing from the fuel tank assembly can be heard. If no sounds can be heard, check the relay, fuel pump, ECM and wiring connectors.

(b) Inspect for fuel leaks.

(1) Check that there are no fuel leaks from the fuel system after doing any maintenance or repairs. If there is a fuel leak, repair or replace parts as necessary.

(c) Turn the ignition switch off.

(d) Disconnect the GTS from the DLC3.

2. CHECK FUEL PRESSURE

(a) Discharge fuel system pressure.

Click here

(b) Measure the auxiliary battery voltage.

Standard Voltage:

11 to 14 V

(c) Disconnect the cable from the negative (-) auxiliary battery terminal.

Click here

(d) Open the cover of the EFI fuel pipe clamp and remove the EFI fuel pipe clamp from the fuel tube connector.

Open

Pull

(e) Disconnect the fuel tube sub-assembly from the fuel pipe.

Click here

(f) Install SST (EFI fuel pressure gauge) as shown in the illustration.

SST: 09268-45101

09268-41250

09268-41260

09268-41280

09268-41500

09268-41700

95336-08070

*1

Fuel Tube Sub-assembly (Vehicle Side)

*a

SST (Hose Band)

*b

SST (T-joint)

*c

SST (Gauge)

*d

SST (Hose Joint)

*e

SST (Hose)

*f

SST (Fuel Tube Connector)

*g

Fuel Pipe (Vehicle Side)

(g) Wipe up any spilled fuel.

(h) Connect the cable to the negative (-) auxiliary battery terminal.

(i) Connect the GTS to the DLC3.

(j) Turn the ignition switch to ON.

NOTICE:

Do not start the engine.

(k) Turn the GTS on.

(l) Enter the following menus: Powertrain / Engine / Active Test / Activate the Circuit Relay.

Powertrain > Engine > Active Test

Tester Display

Activate the Circuit Relay

(m) Measure the fuel pressure.

Standard Fuel Pressure:

280 to 664 kPa (2.9 to 6.8 kgf/cm2, 41 to 96 psi)

  • If the fuel pressure is less than the standard, check the fuel hoses and their connections, fuel pump, fuel filter and fuel main valve assembly.
  • If the result is not as specified, replace the fuel main valve assembly.

(n) Disconnect the GTS from the DLC3.

(o) Start the engine.

(p) Measure the fuel pressure at idle.

Standard Fuel Pressure:

280 to 664 kPa (2.9 to 6.8 kgf/cm2, 41 to 96 psi)

HINT:

Refer to Standard Idle Speed.

Click here

(q) Stop the engine.

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

Standard Fuel Pressure:

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

If the result is not as specified, check the fuel pump, fuel main valve assembly and/or port fuel injector assemblies.

(s) After checking the fuel pressure, disconnect the cable from the negative (-) auxiliary battery terminal and carefully remove SST to prevent fuel from spraying.

(t) Connect the fuel tube sub-assembly to the fuel pipe.

Click here

(u) Install the EFI fuel pipe clamp to the fuel tube connector and close the cover of the EFI fuel pipe clamp.

(v) Inspect for fuel leaks.

Click here

3. CHECK FUEL PRESSURE (for High Pressure)

(a) Connect the GTS to the DLC3.

(b) Turn the ignition switch to ON.

(c) Turn the GTS on.

(d) Enter the following menus: Powertrain / Engine / Data List / Engine Speed, Coolant Temperature, Fuel Pressure (High) and Injection Mode.

Powertrain > Engine > Data List

Tester Display

Engine Speed

Coolant Temperature

Fuel Pressure (High)

(e) Start the engine and warm it up until the engine coolant temperature is 75°C (167°F) or higher with all the accessories switched off.

(f) According to the display on the GTS, read the Data List.

Standard:

GTS Display

Condition

Specified Condition

Fuel Pressure (High)

  • Shift position: P or neutral
  • A/C: Off
  • Engine warmed up
  • Engine Speed: 3000 rpm

4000 to 20000 kPag

If the result is not as specified, check the fuel pump, fuel pump assembly, fuel pressure sensor and wire harnesses.

(g) Stop the engine.

    System Diagram

    S..

    Fuel Tank

    ..

    Other information:

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