Fuel Pressure: Testing and Inspection

FUEL LINE PRESSURE INSPECTION [MZR 2.0, MZR 2.5]

WARNING:
- Fuel line spills and leakage from the pressurized fuel system are dangerous. Fuel can ignite and cause serious injury or death and damage. To prevent this, complete the following inspection with the engine stopped.
- Fuel is very flammable liquid. If fuel spills or leaks from the pressurized fuel system, it will cause serious injury or death and facility breakage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure", while referring to the "BEFORE SERVICE PRECAUTION".
- A person charged with static electricity could cause a fire or explosion, resulting in death or serious injury. Before performing work on the fuel system, discharge static electricity by touching the vehicle body.

CAUTION:
- Disconnecting/connecting the quick release connector without cleaning it may possibly cause damage to the fuel pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting using cloth or soft brush, and make sure that it is free of foreign material.

1. Complete the "BEFORE SERVICE PRECAUTION". Before Service Precaution

2. Remove the battery cover. Removal and Replacement

3. Disconnect the negative battery cable. Removal and Replacement

4. Disconnect the quick release connector. Quick Release Connector Removal/Installation






5. Turn the lever of the SST parallel to the hose as shown in the figure.






6. Insert the SST quick release connector into the fuel pipe until a click is heard.

7. Verify that the quick release connector is firmly connected by pulling it by hand.

8. Start the fuel pump using the following procedure.

Using M-MDS
- Connect the negative battery cable. Removal and Replacement
- Connect the M-MDS to the DLC-2.





- Using the simulation function "FP", start the fuel pump. On-Board Diagnostic Test

Without using M-MDS
- Remove the fuel pump relay.






CAUTION:
- Short the specified terminals because shorting the wrong terminal of the relay and fuse block may cause malfunctions.

- Using a jumper wire, short fuel pump relay terminals C and D in the relay and fuse block.





- Connect the negative battery cable and operate the fuel pump. Removal and Replacement

9. Operate the fuel pump for 10 s.

10. Measure the fuel line pressure.

- If not within the specification, inspect the following:

If it less than the specification:
- Fuel pump unit
- Fuel line for clogging or leakage

If it exceeds the specification:
- Fuel line clogging

Fuel pressure
- 350-430 kPa {3.57-4.38 kgf/cm2, 50.8-62.3 psi}

11. Stop the fuel pump using the following procedure.

Using M-MDS
- Using the simulation function "FP", stop the fuel pump. On-Board Diagnostic Test

Without using M-MDS
- Disconnect the negative battery cable to stop the fuel pump. Removal and Replacement

12. Measure the fuel hold pressure after 5 min.

- If not within the specification, inspect the following:

- Fuel line leakage

Fuel hold pressure
- 210 kPa {2.14 kgf/cm2, 30.5 psi} or more

13. Complete the "BEFORE SERVICE PRECAUTION". Before Service Precaution

14. Disconnect the SST.

15. Connect the quick release connector. Quick Release Connector Removal/Installation

16. Complete the "AFTER SERVICE PRECAUTION". After Service Precaution