RM3660EC _51 Engine / Hybrid System _080777 NR Series ENGINE CONTROL _0393969 SFI SYSTEM J

NR Series ENGINE CONTROL  SFI SYSTEM  Fuel Pump Control Circuit  


DESCRIPTION

The fuel pump circuit consists of the ECM, fuel pump (for low pressure side) and fuel pump control ECU assembly (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 assembly. Based on the signal sent from the ECM, the fuel pump control ECU assembly adjust the fuel pump operation speed.

WIRING DIAGRAM

A426496E03
0.75,0.615 0.906,0.813 0.156,0.198 10 false 2 0.76,1.135 0.917,1.333 0.156,0.198 10 false 1 1.344,0.271 1.5,0.469 0.156,0.198 10 false 4 1.344,1.323 1.5,1.521 0.156,0.198 10 false 5 0.271,1.719 0.781,1.969 0.51,0.25 10 false O44 3.219,2.344 5.406,2.688 2.188,0.344 10 false Fuel Pump Control ECU Assembly 2.938,3.875 4.208,4.125 1.271,0.25 10 false EFI-MAIN NO. 2 0.792,4.583 2.021,4.844 1.229,0.26 10 false EFI-MAIN NO. 1 0.271,1.865 1.5,2.229 1.229,0.365 10 false Fuel Pump (for Low Pressure Side) 3.115,5.813 3.802,6.052 0.688,0.24 10 false EFI-MAIN 2.76,6.427 5.969,6.625 3.208,0.198 10 false No. 1 Integration Relay 3.24,0.25 3.573,0.479 0.333,0.229 10 false 6 3.24,1.323 3.573,1.552 0.333,0.229 10 false 5 3.24,1.75 3.396,1.948 0.156,0.198 10 false 4 5.823,0.552 6.156,0.781 0.333,0.229 10 false 21 4.594,0.573 4.75,0.771 0.156,0.198 10 false 2 4.573,1.74 4.729,1.938 0.156,0.198 10 false 1 5.813,4.896 6.146,5.125 0.333,0.229 10 false 46 4.052,5.385 4.385,5.615 0.333,0.229 10 false 6 2.646,5.385 2.802,5.583 0.156,0.198 10 false 5 4.052,4.781 4.208,4.979 0.156,0.198 10 false 4 2.656,4.792 2.813,4.99 0.156,0.198 10 false 3 3.802,3.458 3.958,3.656 0.156,0.198 10 false 1 2.927,3.458 3.083,3.656 0.156,0.198 10 false 2 2.917,2.865 3.073,3.063 0.156,0.198 10 false 5 3.792,2.865 4.125,3.094 0.333,0.229 10 false 3 2.74,6.271 3.063,6.5 0.323,0.229 10 false 1B 6.344,5.604 6.677,5.833 0.333,0.229 10 false A46 6.333,5.75 6.667,5.979 0.333,0.229 10 false ECM 0.5,5.042 1.729,5.302 1.229,0.26 10 false BATT-MAIN 0.656,5.906 1.885,6.167 1.229,0.26 10 false Battery 1.24,3.115 2.51,3.365 1.271,0.25 10 false EFI-MAIN NO. 2 1.156,0.281 1.667,0.531 0.51,0.25 10 false B 1.156,1.323 1.667,1.573 0.51,0.25 10 false E 3.385,0.333 3.896,0.583 0.51,0.25 10 false FP 3.396,1.417 3.906,1.667 0.51,0.25 10 false FP- 3.396,1.823 3.906,2.073 0.51,0.25 10 false E 4.344,1.833 4.854,2.083 0.51,0.25 10 false +B 4.229,0.646 4.74,0.896 0.51,0.25 10 false FPC 6.042,0.552 6.552,0.802 0.51,0.25 10 false FPC 6.042,4.896 6.552,5.146 0.51,0.25 10 false MREL 3.229,2.167 3.74,2.417 0.51,0.25 10 false O65

CAUTION / NOTICE / HINT

NOTICE:

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


PROCEDURE

1.PERFORM ACTIVE TEST USING GTS (ACTIVATE THE CIRCUIT RELAY)
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 / Active Test / Activate the Circuit Relay.

Powertrain > Engine > Active Test
Tester Display
Activate the Circuit Relay
50004 372 24

e.

Check whether operating sounds can be heard while operating the fuel pump (for low pressure side) using the GTS.

OK:

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



Result:
Proceed to
OK
NG



OK

2.PERFORM ACTIVE TEST USING GTS (CONTROL THE FUEL PUMP DUTY RATIO, ACTIVATE THE CIRCUIT RELAY)

NG

7.CHECK TERMINAL VOLTAGE (POWER SOURCE OF FUEL PUMP CONTROL ECU ASSEMBLY)
2.PERFORM ACTIVE TEST USING GTS (CONTROL THE FUEL PUMP DUTY RATIO, ACTIVATE THE CIRCUIT RELAY)
A285444C10
1.031,1.719 1.552,0.833 false 2.469,1.75 1.865,0.833 false 0.281,0.219 0.646,0.573 0.365,0.354 10 false *a 2.479,1.813 2.802,2.021 0.323,0.208 10 false 2 0.958,1.781 1.25,1.99 0.292,0.208 10 false 1
*a Component with harness connected
(Fuel Pump (for Low Pressure Side))


a.

Remove the fuel pump (for low pressure side) from the fuel tank assembly.

Click hereEngine / Hybrid System>NR Series (FUEL)>FUEL PUMP>REMOVAL


b.

Clean the fuel pump to completely remove any remaining fuel.


c.

Connect the fuel pump connector.

CAUTION:

Make sure that there is no fuel remaining inside or on the outside of the fuel pump.



d.

Connect the GTS to the DLC3.


e.

Turn the ignition switch to ON.


f.

Turn the GTS on.


g.

Enter the following menus: Powertrain / Engine / Active Test / Control the Fuel Pump Duty Ratio.

Powertrain > Engine > Active Test
Tester Display
Control the Fuel Pump Duty Ratio
50004 372 10

h.

Operate the fuel pump (for low pressure side) 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
1 - 2 Fuel pump duty ratio: 25% 3.2 to 4.05 V
Fuel pump duty ratio: 80% 8.8 to 12.5 V



i.

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

Powertrain > Engine > Active Test
Tester Display
Activate the Circuit Relay
50004 372 24

j.

Operate the fuel pump (for low pressure side) 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
1 - 2 ON (Fuel pump duty ratio: 90%) 9.0 to 14.0 V


HINT:
·

Be sure to measure the voltage with all the connectors connected.

·

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




Result:
Proceed to
OK
NG



OK

3.INSPECT FUEL PUMP (FOR LOW PRESSURE SIDE)

NG

8.INSPECT FUEL PUMP (FOR LOW PRESSURE SIDE)
3.INSPECT FUEL PUMP (FOR LOW PRESSURE SIDE)
a.

Inspect the fuel pump (for low pressure side).

Click hereEngine / Hybrid System>NR Series (FUEL)>FUEL PUMP>INSPECTION


Result:
Proceed to
OK
NG



OK

END

NG

4.CHECK HARNESS AND CONNECTOR (FUEL PUMP CONTROL ECU ASSEMBLY - ECM)
4.CHECK HARNESS AND CONNECTOR (FUEL PUMP CONTROL ECU ASSEMBLY - ECM)
a.

Disconnect the fuel pump control ECU assembly 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
O65-2 (FPC) - A46-21 (FPC) Always Below 1 Ω
O65-2 (FPC) or A46-21 (FPC) - Body ground and other terminals Always 10 kΩ or higher



Result:
Proceed to
OK
NG



OK

5.REPLACE FUEL PUMP (FOR LOW PRESSURE SIDE)

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

5.REPLACE FUEL PUMP (FOR LOW PRESSURE SIDE)
a.

Replace the fuel pump (for low pressure side).

Click hereEngine / Hybrid System>NR Series (FUEL)>FUEL PUMP>REMOVAL

HINT:

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

Click hereEngine / Hybrid System>NR Series (ENGINE CONTROL)>SFI SYSTEM>INITIALIZATION



Result:
Proceed to
NEXT



NEXT

6.CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED
6.CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED
a.

Check the fuel pump operation.

Click hereEngine / Hybrid System>NR Series (FUEL)>FUEL SYSTEM>ON-VEHICLE INSPECTION

OK:

Malfunction has been repaired successfully.



Result:
Proceed to
OK
NG



OK

END

NG

PROCEED TO NEXT SUSPECTED AREA SHOWN IN PROBLEM SYMPTOMS TABLE

Click hereEngine / Hybrid System>NR Series (ENGINE CONTROL)>SFI SYSTEM>PROBLEM SYMPTOMS TABLE


7.CHECK TERMINAL VOLTAGE (POWER SOURCE OF FUEL PUMP CONTROL ECU ASSEMBLY)
A426620C02
0.333,1.021 0.802,1.271 0.469,0.25 0.958,1.76 1.146,1.292 true 2.021,1.792 1.875,1.313 true 0.135,0.115 0.448,0.313 0.313,0.198 10 false *a 0.438,1.073 0.75,1.271 0.313,0.198 10 false O65 0.833,1.792 1.146,1.99 0.313,0.198 10 false +B 2.01,1.813 2.323,2.01 0.313,0.198 10 false E
*a Front view of wire harness connector
(to Fuel Pump Control ECU Assembly)


a.

Disconnect the fuel pump control ECU assembly 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
O65-1 (+B) - O65-4 (E) Ignition switch ON 11 to 14 V



Result:
Proceed to
OK
NG



OK

8.INSPECT FUEL PUMP (FOR LOW PRESSURE SIDE)

NG

13.CHECK HARNESS AND CONNECTOR (FUEL PUMP CONTROL ECU ASSEMBLY - BODY GROUND)
8.INSPECT FUEL PUMP (FOR LOW PRESSURE SIDE)
a.

Inspect the fuel pump (for low pressure side).

Click hereEngine / Hybrid System>NR Series (FUEL)>FUEL PUMP>INSPECTION


HINT:

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

Click hereEngine / Hybrid System>NR Series (ENGINE CONTROL)>SFI SYSTEM>INITIALIZATION


Result:
Proceed to
OK
NG



OK

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

NG

REPLACE FUEL PUMP (FOR LOW PRESSURE SIDE)

Click hereEngine / Hybrid System>NR Series (FUEL)>FUEL PUMP>REMOVAL


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

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


b.

Disconnect the fuel pump control ECU assembly connector.


c.

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

Standard Resistance:
Tester Connection Condition Specified Condition
O44-4 (B) - O65-6 (FP) Always Below 1 Ω
O44-5 (E) - O65-5 (FP-) Always Below 1 Ω
O44-4 (B) or O65-6 (FP) - Body ground and other terminals Always 10 kΩ or higher
O44-5 (E) or O65-5 (FP-) - Body ground and other terminals Always 10 kΩ or higher



Result:
Proceed to
OK
NG



OK

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

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

10.CHECK HARNESS AND CONNECTOR (FUEL PUMP CONTROL ECU ASSEMBLY - ECM)
a.

Disconnect the fuel pump control ECU assembly 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
O65-2 (FPC) - A46-21 (FPC) Always Below 1 Ω
O65-2 (FPC) or A46-21 (FPC) - Body ground and other terminals Always 10 kΩ or higher



Result:
Proceed to
OK
NG



OK

11.REPLACE FUEL PUMP CONTROL ECU ASSEMBLY

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

11.REPLACE FUEL PUMP CONTROL ECU ASSEMBLY
a.

Replace the fuel pump control ECU assembly.

Click hereEngine / Hybrid System>NR Series (FUEL)>FUEL PUMP ECU>REMOVAL


Result:
Proceed to
NEXT



NEXT

12.CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED
13.CHECK HARNESS AND CONNECTOR (FUEL PUMP CONTROL ECU ASSEMBLY - BODY GROUND)
a.

Disconnect the fuel pump control ECU assembly connector.


b.

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

Standard Resistance:
Tester Connection Condition Specified Condition
O65-4 (E) - Body ground Always Below 1 Ω



Result:
Proceed to
OK
NG



OK

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

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

14.CHECK HARNESS AND CONNECTOR (FUEL PUMP CONTROL ECU ASSEMBLY - ECM)
a.

Disconnect the fuel pump control ECU assembly 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
O65-2 (FPC) - A46-21 (FPC) Always Below 1 Ω
O65-2 (FPC) or A46-21 (FPC) - Body ground and other terminals Always 10 kΩ or higher



Result:
Proceed to
OK
NG



OK

15.INSPECT EFI-MAIN NO. 2 RELAY

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

15.INSPECT EFI-MAIN NO. 2 RELAY
a.

Inspect the EFI-MAIN NO. 2 relay.

Click hereEngine / Hybrid System>NR Series (ENGINE CONTROL)>RELAY>ON-VEHICLE INSPECTION


Result:
Proceed to
OK
NG



OK

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

NG

REPLACE EFI-MAIN NO. 2 RELAY

16.CHECK HARNESS AND CONNECTOR (EFI-MAIN NO. 2 RELAY VOLTAGE)
a.

Remove the EFI-MAIN NO. 2 relay from the No. 1 engine room relay block and No. 1 junction block assembly.


b.

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

Standard Voltage:
Tester Connection Condition Specified Condition
5 (EFI-MAIN NO. 2 relay) - Body ground Always 11 to 14 V



Result:
Proceed to
OK
NG



OK

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

NG

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

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

Remove the EFI-MAIN NO. 2 relay from the No. 1 engine room relay block and No. 1 junction block assembly.


b.

Disconnect the fuel pump control ECU assembly connector.


c.

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

Standard Resistance:
Tester Connection Condition Specified Condition
3 (EFI-MAIN NO. 2 relay) - O65-1 (+B) Always Below 1 Ω
3 (EFI-MAIN NO. 2 relay) or O65-1 (+B) - Body ground and other terminals Always 10 kΩ or higher



Result:
Proceed to
OK
NG



OK

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

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

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

Disconnect the No. 1 integration relay connector.


b.

Remove the EFI-MAIN NO. 2 relay from the No. 1 engine room relay block and No. 1 junction block assembly.


c.

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

Standard Resistance:
Tester Connection Condition Specified Condition
1B-4 - 1 (EFI-MAIN NO. 2 relay) Always Below 1 Ω
1B-4 or 1 (EFI-MAIN NO. 2 relay) - Body ground and other terminals Always 10 kΩ or higher



Result:
Proceed to
OK
NG



OK

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

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

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

Remove the EFI-MAIN NO. 2 relay from the No. 1 engine room relay block and No. 1 junction block assembly.


b.

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

Standard Resistance:
Tester Connection Condition Specified Condition
2 (EFI-MAIN NO. 2 relay) - Body ground Always Below 1 Ω



Result:
Proceed to
OK
NG



OK

CHECK ECM POWER SOURCE CIRCUIT

Click hereEngine / Hybrid System>NR Series (ENGINE CONTROL)>SFI SYSTEM>ECM Power Source Circuit


NG

REPAIR OR REPLACE HARNESS OR CONNECTOR