Toyota Corolla Cross: 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 (IG).

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 (Brushless)

(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 sound can be heard, check the 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 off.

(d) Disconnect the GTS from the DLC3.

2. CHECK FUEL PRESSURE

(a) Discharge the 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 fuel pipe clamp and remove the 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: 09268-00010 09268-00020 09268-00030 SST: 09268-45101 09268-41260 09268-41280 09268-41700 95336-08070

*a SST (Pressure Gauge) *b SST (Hose Joint) *c SST (Hose) *d SST (T-joint) *e SST (Fuel Tube Connector) *f SST (Hose Band) *g Fuel Pipe (Vehicle Side)

(g) Wipe up any spilled fuel.

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

Click here

(i) Connect the GTS to the DLC3.

(j) Turn the ignition switch to ON (IG).

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 (Brushless)

(m) Measure the fuel pressure.

Standard Fuel Pressure:

300 to 640 kPa (3.1 to 6.5 kgf/cm2, 44 to 93 psi)

• If the fuel pressure is more than the standard, replace the fuel pressure regulator assembly.
• If the fuel pressure is less than the standard, check the fuel hoses and their connections, fuel pump and fuel pressure regulator assembly.

(n) Put the engine in Inspection Mode (Maintenance Mode).

Powertrain > Hybrid Control > Utility

Tester Display
Inspection Mode

(o) Start the engine.

(p) Measure the fuel pressure at idle.

Standard Fuel Pressure:

300 to 640 kPa (3.1 to 6.5 kgf/cm2, 44 to 93 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 pressure regulator assembly and/or 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 fuel pipe clamp to the fuel tube connector and close the cover of the 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 power switch on (IG).

(c) Turn the GTS on.

(d) Put the engine in Inspection Mode (Maintenance Mode).

Powertrain > Hybrid Control > Utility

Tester Display
Inspection Mode

(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) 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)
Injection Mode

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

HINT:

During charge control, the engine speed is set at idle. Therefore, the engine speed will not increase when the accelerator pedal is depressed. In this case, read the Data List after charge control has completed.

Standard:

GTS Display	Condition	Specified Condition
Fuel Pressure (High)	Shift position: P A/C: Off Engine warmed up Engine Speed: 2500 rpm Injection Mode: Direct	3000 to 25000 kPag

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

(h) Stop the engine.

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