RM35X0E _51 Engine / Hybrid System _078720 7GR-FKS ENGINE CONTROL _0381907 SFI SYSTEM J

7GR-FKS ENGINE CONTROL  SFI SYSTEM  Fuel Pump Control Circuit  


DESCRIPTION

The fuel pump (for low pressure side) circuit consists of the ECM, fuel pump (for low pressure side) and fuel pump control ECU (which operates the fuel pump (for low pressure side)). 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 (for low pressure side) operation speed.

WIRING DIAGRAM

A439420E03
0.385,6.281 2.073,6.479 1.688,0.198 10 false *: Shielded 0.583,5.281 2.271,5.479 1.688,0.198 10 false Battery 1.438,2.75 2.042,3.156 0.604,0.406 10 false EFI-MAIN NO. 2 2.167,1.583 3.115,1.844 0.948,0.26 10 false EFI MAIN 1.5,1.417 2.281,1.677 0.781,0.26 10 false EFI-MAIN 2.031,2.927 3.719,3.125 1.688,0.198 10 false EFI MAIN NO. 2 3.625,6.052 5.313,6.25 1.688,0.198 10 false Fuel Pump Control ECU 6.083,4.583 6.49,4.802 0.406,0.219 10 false FPC 6.313,6.052 6.719,6.271 0.406,0.219 10 false ECM 2.156,3.917 3.844,4.115 1.688,0.198 10 false BLPU 2.156,4.448 3.844,4.646 1.688,0.198 10 false BLPV 2.135,4.979 3.823,5.177 1.688,0.198 10 false BLPW 2.156,5.531 3.844,5.729 1.688,0.198 10 false BLPE 1.615,6.167 2.813,6.583 1.198,0.417 10 false Fuel Pump (for Low Pressure Side) 1.594,6.031 3.281,6.229 1.688,0.198 10 false X5 6.052,0.635 6.781,1.031 0.729,0.396 10 false MREL 5.729,0.458 6.063,0.781 0.333,0.323 10 false 25 5.781,4.5 6.01,4.719 0.229,0.219 10 false 9 2.625,3.792 3.031,4.01 0.406,0.219 10 false 3 2.625,4.854 3.031,5.073 0.406,0.219 10 false 2 2.625,4.323 3.031,4.542 0.406,0.219 10 false 4 2.625,5.385 3.031,5.604 0.406,0.219 10 false 1 3.646,3.906 4.052,4.125 0.406,0.219 10 false N47 3.729,4.26 4.135,4.479 0.406,0.219 10 false 3 3.719,4.781 4.125,5 0.406,0.219 10 false 4 3.719,5.323 4.125,5.542 0.406,0.219 10 false 1 4.896,3.938 5.302,4.156 0.406,0.219 10 false 1 4.896,4.49 5.302,4.708 0.406,0.219 10 false 2 4.896,5.063 5.302,5.281 0.406,0.219 10 false 3 3.74,3.698 4.146,3.917 0.406,0.219 10 false 2 3.646,4.448 4.052,4.667 0.406,0.219 10 false N47 3.656,4.979 4.063,5.198 0.406,0.219 10 false N47 3.656,5.521 4.063,5.74 0.406,0.219 10 false N47 3.99,3.917 5.677,4.115 1.688,0.198 10 false FPU 4.521,4.135 6.208,4.333 1.688,0.198 10 false +B 4,4.448 5.688,4.646 1.688,0.198 10 false FPV 4.01,4.979 5.698,5.177 1.688,0.198 10 false FPW 4,5.521 5.688,5.719 1.688,0.198 10 false FPG 4.427,4.688 4.833,4.906 0.406,0.219 10 false FPC 4.417,5.271 4.823,5.49 0.406,0.219 10 false GND 4.813,4.125 5.219,4.344 0.406,0.219 10 false N46 4.813,4.688 5.219,4.906 0.406,0.219 10 false N46 4.813,5.271 5.219,5.49 0.406,0.219 10 false N46 3.24,5.667 3.646,5.885 0.406,0.219 10 false * 1.156,0.458 1.313,0.656 0.156,0.198 10 false 4 1.146,1.083 1.302,1.281 0.156,0.198 10 false 1 3.156,0.448 3.313,0.646 0.156,0.198 10 false 8 0.469,4.479 1.417,4.74 0.948,0.26 10 false FL MAIN 5.729,4.688 6.135,4.906 0.406,0.219 10 false N1 5.708,0.646 6.115,0.865 0.406,0.219 10 false A1 3.104,0.646 3.51,0.865 0.406,0.219 10 false 1E 3.115,2.115 3.521,2.333 0.406,0.219 10 false 1D 3.156,1.917 3.313,2.115 0.156,0.198 10 false 7 3.115,2.615 3.521,2.833 0.406,0.219 10 false 1D 3.146,2.417 3.302,2.615 0.156,0.198 10 false 6 1.094,0.646 1.5,0.865 0.406,0.219 10 false 1E 1.125,1.271 1.531,1.49 0.406,0.219 10 false A 1.438,3.323 3.125,3.521 1.688,0.198 10 false No. 1 Integration Relay

CAUTION / NOTICE / HINT

NOTICE:

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


PROCEDURE

1.INSPECT FUEL PUMP CONTROL ECU
A337223C55
4.292,0.208 4.656,0.49 0.365,0.281 2.667,0.219 3.042,0.479 0.375,0.26 5,2.365 4.719,1.323 false 4.458,2.375 4.458,1.333 false 3.917,2.375 4.177,1.333 false 3.438,2.375 3.24,1.458 false 3.083,2.375 3.01,1.448 false 2.615,2.375 2.719,1.448 false 2.146,2.375 2.469,1.438 false 0.281,0.188 0.594,0.385 0.313,0.198 10 false *1 4.354,0.25 4.667,0.448 0.313,0.198 10 false N46 2.729,0.24 3.042,0.438 0.313,0.198 10 false N47 4.958,2.417 5.271,2.615 0.313,0.198 10 false +B 3.792,2.417 4.167,2.646 0.375,0.229 10 false GND 4.365,2.417 4.74,2.646 0.375,0.229 10 false FPC 3.354,2.417 3.729,2.646 0.375,0.229 10 false FPG 2.969,2.417 3.344,2.646 0.375,0.229 10 false FPU 2.5,2.417 2.875,2.646 0.375,0.229 10 false FPV 2.042,2.417 2.417,2.646 0.375,0.229 10 false FPW
*1 Fuel Pump Control ECU - -


a.

Remove the fuel pump control ECU.

Click hereEngine / Hybrid System>7GR-FKS (FUEL)>FUEL PUMP ECU>REMOVAL


b.

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

Standard Resistance:
Tester Connection Condition Specified Condition
N46-1 (+B) - N46-3 (GND) Always 200 Ω or higher
N46-1 (+B) - N46-2 (FPC) Always 2 kΩ or higher
N46-2 (FPC) - N46-3 (GND) Always 10 kΩ or higher
N47-1 (FPG) - N46-3 (GND) Always 1 kΩ or higher
N47-2 (FPU) - N46-3 (GND) Always 2 kΩ or higher
N47-3 (FPV) - N46-3 (GND) Always 2 kΩ or higher
N47-4 (FPW) - N46-3 (GND) Always 2 kΩ or higher


HINT:

This procedure checks for an internal short of the fuel pump control ECU when its transistor is stuck on.



Result:
Proceed to
OK
NG



OK

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

NG

REPLACE FUEL PUMP CONTROL ECU

Click hereEngine / Hybrid System>7GR-FKS (FUEL)>FUEL PUMP ECU>REMOVAL


2.CHECK HARNESS AND CONNECTOR (POWER SOURCE OF FUEL PUMP CONTROL ECU)
A430912C04
0.542,1.125 0.906,1.375 0.365,0.25 1.125,1.76 1.375,1.333 false 2.333,1.729 2.063,1.344 false 0.229,0.323 0.542,0.521 0.313,0.198 10 false *a 0.604,1.156 0.917,1.354 0.313,0.198 10 false N46 0.99,1.771 1.302,1.969 0.313,0.198 10 false +B 2.219,1.76 2.531,1.958 0.313,0.198 10 false GND
*a Front view of wire harness connector
(to 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 Condition Specified Condition
N46-1 (+B) - N46-3 (GND) Ignition switch ON 11 to 14 V


HINT:

Make a note of the measured voltage as it may be used in a following Active Test.



Result:
Proceed to
OK
NG



OK

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

NG

7.CHECK HARNESS AND CONNECTOR (FUEL PUMP CONTROL ECU - BODY GROUND)
3.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
N46-2 (FPC) - N1-9 (FPC) Always Below 1 Ω
N46-2 (FPC) or N1-9 (FPC) - Body ground and other terminals Always 10 kΩ or higher



Result:
Proceed to
OK
NG



OK

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

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

4.PERFORM ACTIVE TEST USING GTS (FUEL PUMP SINGLE PHASE ENERGIZATION)
A337225C53
2.677,0.229 3.052,0.51 0.375,0.281 3.25,2.292 3,1.458 false 2.208,2.281 2.458,1.458 false 2.729,2.271 2.729,1.49 false 0.208,0.156 0.521,0.354 0.313,0.198 10 false *1 2.74,0.271 3.052,0.469 0.313,0.198 10 false N47 3.167,2.302 3.5,2.51 0.333,0.208 10 false FPU 2.615,2.302 2.927,2.5 0.313,0.198 10 false FPV 2.031,2.302 2.417,2.51 0.385,0.208 10 false FPW
*1 Fuel Pump Control ECU - -


a.

Disconnect the N47 fuel pump control ECU connector.


b.

Connect the GTS to the DLC3.


c.

Turn the ignition switch to ON.


d.

Turn the GTS on.


e.

Enter the following menus: Powertrain / Engine / Active Test / Fuel Pump Single Phase Energization.

Powertrain > Engine > Active Test
Tester Display
Fuel Pump Single Phase Energization
50004 372 49

f.

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

Standard Voltage:
Tester Connection GTS Operation Specified Condition
N47-2 (FPU) - Body ground U Phase 4.4 to 8.4 V*
N47-3 (FPV) - Body ground V Phase 4.4 to 8.4 V*
N47-4 (FPW) - Body ground W Phase 4.4 to 8.4 V*


HINT:
·

*: This Active Test restricts the fuel pump control ECU assembly output duty cycle to 50%. Therefore, the output voltage of the fuel pump control ECU assembly will be approximately 50% of the power source voltage measured in a previous step.

·

Before performing this inspection, check that the battery voltage is between 11 and 14 V (not depleted).




Result:
Result Proceed to
The U phase, V phase and W phase are all normal A
The U phase, V phase or W phase is abnormal B
The U phase, V phase and W phase are all abnormal C



A

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

B

REPLACE FUEL PUMP CONTROL ECU

Click hereEngine / Hybrid System>7GR-FKS (FUEL)>FUEL PUMP ECU>REMOVAL


C

6.INSPECT ECM (FPC TERMINAL)
5.CHECK HARNESS AND CONNECTOR (FUEL PUMP CONTROL ECU - FUEL PUMP (FOR LOW PRESSURE SIDE))
a.

Disconnect the fuel pump control ECU connector.


b.

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


c.

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

Standard Resistance:
Tester Connection Condition Specified Condition
N47-2 (FPU) - X5-3 (BLPU) Always Below 1 Ω
N47-3 (FPV) - X5-4 (BLPV) Always Below 1 Ω
N47-4 (FPW) - X5-2 (BLPW) Always Below 1 Ω
N47-2 (FPU) or X5-3 (BLPU) - Body ground and other terminals Always 10 kΩ or higher
N47-3 (FPV) or X5-4 (BLPV) - Body ground and other terminals Always 10 kΩ or higher
N47-4 (FPW) or X5-2 (BLPW) - Body ground and other terminals Always 10 kΩ or higher



Result:
Proceed to
OK
NG


HINT:

Perform "Inspection After Repair" after replacing the fuel pump (for low pressure side).

Click hereEngine / Hybrid System>7GR-FKS (ENGINE CONTROL)>SFI SYSTEM>INITIALIZATION



OK

REPLACE FUEL PUMP (FOR LOW PRESSURE SIDE)

Click hereEngine / Hybrid System>7GR-FKS (FUEL)>FUEL PUMP>REMOVAL


NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

6.INSPECT ECM (FPC TERMINAL)
A430912C05
0.563,1.104 0.969,1.375 0.406,0.271 1.719,1.823 1.719,1.365 true 0.208,0.292 0.521,0.448 0.313,0.156 10 false *a 0.625,1.146 1.083,1.344 0.458,0.198 10 false N46 1.604,1.823 2.063,2.021 0.458,0.198 10 false FPC
*a Front view of wire harness connector
(to Fuel Pump Control ECU)


a.

Disconnect the fuel pump control ECU connector.


b.

Connect the GTS to the DLC3.


c.

Turn the ignition switch to ON.


d.

Turn the GTS on.


e.

Enter the following menus: Powertrain / Engine / Active Test / Fuel Pump Single Phase Energization.

Powertrain > Engine > Active Test
Tester Display
Fuel Pump Single Phase Energization
50004 372 49

f.

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

Standard Resistance:
Tester Connection GTS Operation Specified Condition
N46-2 (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.



Result:
Proceed to
OK
NG



OK

REPLACE FUEL PUMP CONTROL ECU

Click hereEngine / Hybrid System>7GR-FKS (FUEL)>FUEL PUMP ECU>REMOVAL


NG

REPLACE ECM

Click hereEngine / Hybrid System>7GR-FKS (ENGINE CONTROL)>ECM>REMOVAL


7.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
N46-3 (GND) - Body ground Always Below 1 Ω



Result:
Proceed to
OK
NG



OK

8.INSPECT NO. 1 INTEGRATION RELAY (EFI MAIN NO. 2 RELAY)

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

8.INSPECT NO. 1 INTEGRATION RELAY (EFI MAIN NO. 2 RELAY)
a.

Inspect the EFI MAIN NO. 2 relay.

Click hereEngine / Hybrid System>7GR-FKS (ENGINE CONTROL)>RELAY>ON-VEHICLE INSPECTION


Result:
Proceed to
OK
NG



OK

9.CHECK HARNESS AND CONNECTOR (NO. 1 INTEGRATION RELAY - FUEL PUMP CONTROL ECU)

NG

REPLACE NO. 1 INTEGRATION RELAY

9.CHECK HARNESS AND CONNECTOR (NO. 1 INTEGRATION RELAY - FUEL PUMP CONTROL ECU)
a.

Remove the No. 1 integration relay from the No. 1 engine room relay block and junction 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
1D-6 - N46-1 (+B) Always Below 1 Ω
1D-6 or N46-1 (+B) - Body ground and other terminals Always 10 kΩ or higher



Result:
Proceed to
OK
NG



OK

GO TO ECM POWER SOURCE CIRCUIT

Click hereEngine / Hybrid System>7GR-FKS (ENGINE CONTROL)>SFI SYSTEM>ECM Power Source Circuit


NG

REPAIR OR REPLACE HARNESS OR CONNECTOR