Haima S5 1.5T. Service Manual - part 6

 

 

Electronic Fuel Injection Control System 1B

-

32 

 

sensor 

Yes Fault 

replacement

8 

Dismantle the fuel injector, and use the dedicated fuel injector 
cleaning analyzer to inspect if the fuel injector suffers leakage or 
blockage.  

No Next 

step 

Yes Fault 

replacement

9 

Step on the accelerator lightly and observe if the engine can be 
easily started. 

No Next 

step 

Yes Next 

step 

10 

Inspect if the engine’s ignition sequence and ignition timing 
accord with specification.   

No 

Overhaul the 
ignition system 

Yes Next 

step 

11 

Inspect if the exhaust pipe can efficiently exhaust the air. 

No 

Repair or replace 
the exhaust pipe 

 

14.  Idle start/stop function ineffective 

Ordinary faulted parts: 1. Engine compartment cover signal;2. Driver door signal;3. Clutch switch 
signal;4.Neutral position signal;5. Accelerator pedal;6. Brake vacuum degree signal;7. Accumulator sensor.   

Note: If the engine has been started, start/stop indicator blinks in yellow color and turns into yellow, 
indicating the system has located relevant part faults, and the faults shall be diagnosed and repaired in the 
repair factory.   

Ordinary Troubleshooting Flow: 

1.  Start/stop indicator is green, but the engine cannot stop automatically   

No. Operation 

Steps 

Test 

Results

Follow-up Steps 

Yes 

System is right staying in the 
normal “Automatic Stop 
Prohibited” condition.   

1 

If it is in green indicator blinking state or turns into 
yellow lamp now and then.   

No Next 

step 

Yes 

Inspect the accelerator pedal 

2 

Inspect if the idling speed is a little bit high after the 
accelerator has been released, and the normal idling 
speed should be 700 rpm(depending on specific 
project).  

No Next 

step 

Yes Next 

step 

3 

After the engine stops, the gearbox stays in the 
gear-engaging state, and then floor the clutch and turn 
the key to observe if the engine can be started.   

No 

Overhaul the clutch switch   

2.  After a period of driving (coolant temperature surpasses 75 ), start/stop indicator remains yellow, 

℃

and inspect if the accumulator temperature (ambient temperature) is excessively low (below 0 , specific 

℃

temperature) 

 

 

Electronic Fuel Injection Control System 1B

-

33 

 

 

5 Functional Requirements on ME7 System’s Diagnostic Unit   

Functions required: 

I. Self-diagnosis 

 

Mostly including: read fault code, and clear fault code; 

II.  System Parameter Display   

Mostly including: including: water temperature, air intake temperature, throttle opening, engine rotating 
speed, ignition angle, A/F ratio short-term modification, A/F ratio long-term plus and multiplication 
modification, intake pressure, intake flow, oxygen sensor signal, system voltage, and torque demand value 
etc; 

III. System Modes  

Mostly including: display of 10 modes like programming, cooling system, stable working condition, 
dynamic working condition, emission control, oxygen sensor, idling speed, fault indicator, emergency 
operation, and air conditioning etc.   

IV. Actuator Test 

Mostly including: six function tests on fault indicator, fuel pump, air conditioning relay, fan control, 
ignition test, and single-cylinder oil interruption; 

V.  System Initialization Resetting (self-adaption stop resetting) 

After being stalled, engine will send the initialization directive, and the system will stop resetting previous 
self-adaption.  

VI. Speedometer  

Mostly including: display of vehicle driving mileage and driving time; 

VII. Version Information   

Mainly including: display of car frame number (optional), ECU hardware number, and ECU software 
number  

5.1 Parts Mounting Torque Specification Table   

No. Part 

Name  Mounting Torque (N·m) 

1 

Intake air pressure and 

temperature sensor 

3.3 

2 Coolant 

temperature 

sensor 

20

 (Max) 

3 Knock 

sensor 

20±5 

4 Oxygen 

sensor 

50±10 

5 

Rotating speed sensor 

8±2 

6 Phase 

sensor 

8±0.5 

7 Magnetic 

fuel 

injector 

6 

 

 

 

 

Electronic Fuel Injection Control System 1B

-

34 

 

5.2 Electronic Fuel Injection System Maintenance Specification   

5.2.1 Family Vehicle   

Note: 

1.  This maintenance specification is only tailored to family vehicles; 

2.  Maintenance interval depends on the speedometer reading or time interval, and the one that expires first 

shall prevail.   

3.  Maintenance specification is based on the presumption that the automobile is used according to the 

normal design, and so it shall be strictly observed.   

Mileage 

x1000km 

10 20 30 40 50 60 70 80 

Items 

Month 

3  6  9  12 15 18 21 24 

Ignition 

Coil 

 I  I  I  I 

Ignition 

Cam 

 I  I  I  I 

Ignition 

Cap 

 I  I  I  I 

Ignition 

Wire 

 I  I  I  I 

Spark 

Plug 

 I  I  I  R 

Ignition 

Timing 

 I  I  I  I 

Engine 

Idling 

Speed 

 I  I  I  I 

Fuel Tank 

 

 

 

I 

 

 

 

C 

Fuel 

Filter 

 R  R  R  R 

Fuel 

Injector 

 C*  C*  C*  C* 

Air 

Filter 

 I  R  I  R 

EWD or Stepper Air Bypass 

 

C 

 

C 

 

C 

 

C 

Throttle 

Body 

 C  C  C  C 

Emission 

Check 

 I  I  I  I 

Check 

by 

Diagnostic 

Tool  I  I  I  I 

 

 

 

 

Electronic Fuel Injection Control System 1B

-

35 

 

5.2.2 Vehicle for Lease   

Explanation: 

1.  This maintenance specification is applicable to the vehicle for lease; 

2.  Maintenance interval depends on the speedometer reading or time interval, and the one that expires 

first shall prevail.   

3.  Maintenance specification is based on the presumption that the automobile is used according to the 

normal design, and so it shall be strictly observed.   

Mileage 

x1000km 

20 40 60 80 100 120 140 160 

Items 

Month 

3 6 9 12 15 18 21 24 

Ignition 

Coil 

I I I I I I I I 

Ignition 

Cam 

I I I I I I I I 

Ignition 

Cap 

I I I I I I I I 

Ignition 

Wire 

I I I I I I I I 

Spark 

Plug 

 I  R  I  R 

Ignition 

Timing 

 I  I  I  I 

Engine 

Idling 

Speed 

 I  I  I  I 

Fuel 

Tank 

   C    C 

Fuel 

Filter 

R R R R R R R R 

Fuel 

Injector 

C* C* C* C* C* C* C* C* 

Air 

Filter 

I R I R I R I R 

EWD or Stepper Air Bypass 

I 

C 

I 

C 

I 

C 

I 

C 

Throttle 

Body 

I C I C I C I C 

Emission 

Check 

 I  I  I  I 

Check 

by 

Diagnostic 

Tool 

 I  I  I  I 

Note:  R-Replace 

C-Clean 

I- Inspect (Replace the spare parts when find out failure in inspection.) 

C- The maintenance of fuel injector had better clean by a special tool -- fuel injector cleaner 

 

 

Fuel System 1C-1 

 

Chapter 3  Fuel System   

Table of Contents 

1. Fuel System ································································································1C-2 
  1.1 Preparatory Work before Repair ··································································· 1C-2 
     1.1.1 Work Safety Steps ············································································ 1C-2 
  1.2 Inspection to Fuel Leakage········································································· 1C-2 
     1.2.1Fuel Hose Mounting··········································································· 1C-2 
    1.3 Cylinder Dismantling /Mounting·································································· 1C-3 
     1.3.1Cylinder Air Tightness Test ·································································· 1C-4 
     1.3.2 Inspection of Check Valve ··································································· 1C-5 
     1.3.3 Inspection of Fuel Cylinder Pipeline Pressure ············································ 1C-5 
     1.3.4 Inspection of Fuel Pressure Maintenance·················································· 1C-6 
    1.4 Fuel Pump Assembly Dismantling /Mounting··················································· 1C-8 
     1.4.1 Fuel pump cover removal instructions····················································· 1C-8 
     1.4.2 

Fuel pump cover installation instructions

················································· 1C-8 

     1.4.3 Split fuel pump parts / assembly···························································· 1C-8 
    1.5 Spray Nozzle Dismantling /Mounting ···························································· 1C-11 
     1.5.1 Inspection of Spray Nozzle·································································· 1C-11 

2. Fuel Vaporation and Absorption System ·······························································1C-11 
    2.1 Inspection of Carbon Canister Assembly························································· 1C-11 
     2.1.1 Inspection of Carbon Canister’s Electromagnetic Valve ································ 1C-11 
  2.2 Inspection of Ventilation Condition ······························································· 1C-12 

2.3 Inspection of Open/Short Circuit·································································· 1C-12 

3.

 

Dismantling the fuel pump assembly diagram

····················································1C-12 

3.1 Demolition relief valve assembly

································································· 1C-12 

3.2

 

Demolition Fuel quantity sensor

·································································· 1C-13 

3.3 Demolition pump plug

·············································································· 1C-13 

3.4

 

Demolition of the fuel hose fixed widget

 ······················································· 1C-13 

3.5

 

Demolition fuel pump at the bottom case

························································ 1C-14 

3.6 Demolition prefilter, pump core, fine filter

······················································ 1C-14 

 

 

 

 

 

 

 

Fuel System 1C-2 

 

1. Fuel System   

1.1 Preparatory Work before Repair   

Warning 

  Fuel vapor is dangerous and combustible, 

which may lead to personnel injury and 
property loss. Due to this, avoid spark or naked 
flame at the place where there is fuel.   

  Fuel overflow or leakage is dangerous, and the 

fuel is combustible, which may lead to 
personnel injury and property loss. In addition, 
the fuel has side effect on the skin and eye. 
Due to this, work safety rules shall be observed 
during the working process.   

Notice: 

  Even if the engine does not run, fuel in the fuel 

system still stays within the high pressure 
state.  

1.1.1 Work Safety Steps   

1.  Dismantle the oil cylinder head, and release 

the pressure from the oil cylinder.   

2.  Pull out the fuel pump relay (located in the 

electrical box at the centre of the engine 
compartment).  

3. Start 

the 

engine. 

 

4.  Restart the engine several times after the 

engine stalls.   

5.  Turn the ignition switch to the “OFF” position.   

6.  Reload the fuel pump relay.   

1.2 Inspection Work after Maintenance   

Warning 

  Fuel overflow or leakage is dangerous, and 

also the fuel is combustible, which may lead to 
personnel injury and property loss. Due to this, 
follow the under-mentioned “Fuel Leakage 
Inspection” to conduct inspection after 
remounting the fuel hose.   

Inspection to Fuel Leakage   

Warning 

  Fuel overflow or leakage is dangerous, and 

also the fuel is combustible, which may lead to 
personnel injury and property loss. Due to this, 
fuel leakage shall be inspected frequently after 
the engine stops.   

Caution 

  Wrong connection with other wiring terminals 

may lead to fault, and so caution is needed 
during the connection process.   

1.  Connect the DLC’s wiring terminal F/P with 

the vehicle body (as the ground) with a 
jumper wire. 

 

2.  Turn the ignition switch to the “ON” position 

to run the oil pump.   

3.  Pressurize the oil circuit for at least five 

minutes according to preceding method, so as 
to inspect if there is leakage.   

4.  In the event that there is fuel leakage, inspect 

if fuel hose and fuel pipe’s sealing faces 
suffer damage. If necessary, replace them.   

5.  After the overhaul and remounting, repeat 

Step 1 to Step 3.   

1.2.1 Fuel Hose Mounting   

1.  Replace the damaged and distorted fuel hose, 

fuel pipe, and pipe clamp.   

2.  Fuel hose shall be mounted 25mm {0.98in} 

above the fuel pipe, and if the fuel pipe has 
limit device, mount the hose till it contacts the 
limit device.   

 

 

3.  Use the pipe clamp to clamp the hose within 

the mounting range (see the figure below), 
and prevent the clamp from nipping previous 
nipping place.   

Jumper Wire

Fuel Pipe

Limit Device

Fuel Hose 

 

Fuel System 1C-3 

 

   

Warning on Plastic Fuel Pipe (fuel supply 
pipe assembly, fuel supply pipe, and fuel 
return pipe assembly)   

Dismantling  

  When dismantling the fuel pipe, pressure in the 

fuel system will lead to ejection of fuel from 
the fuel pipeline, and so oil cylinder head shall 
be dismantled in advance according to 
requirements while dismantling the fuel 
pipeline, in order to release the pressure in the 
oil cylinder and avoid personnel injury and 
property loss.   

Caution 

  While dismantling the fuel pipeline, necessary 

sheltering measures shall be adopted, in order 
to avoid the fuel’s ejection onto your body.   

1.  If the quick plug assembly is equipped with 

double-lock mechanism, loosen the quick 
plug assembly’s double locks along the 
direction illustrated in the figure.   

 

2.  Pinch locking devices on both sides of the quick 

plug with fingers to remove the quick plug.   

3.  Repeat Step 1 and Step 2, and dismantle the 

quick plug at the other end of the fuel pipeline 
from the supporting pipeline.   

Explanations on Plastic Fuel Pipe (Fuel 
Supply Pipe Assembly, Fuel Supply Pipe, 
and Fuel Return Pipe) Mounting   

Notice 

When mounting the new fuel supply pipe 
assembly, assemble properly double locks on the 
quick plug assembly.   

 

1.  Inspect the fuel pipeline and supporting 

pipeline joint’s sealing faces and avoid their 
damage and distortion. If necessary, replace 
them.  

2.  If the quick plug O-ring is damaged or 

disengaged, mount the new fuel pipeline.   

3.  Push the fuel pipeline quick plug into the 

loading part till the pipe joint makes the 
“click” sound.    

4.  If the fuel pipeline quick plug is equipped 

with double-lock mechanism, mount the 
double locks till there is “click” sound.   

5.  Pull the quick plug with hands to confirm if it 

has been secured mounted.   

Explanations on fuel filter dismantling 
/mounting  

Warning : 

The fuel filter is integrated in the fuel pump 
assembly, disassembly, repair shop to replace 
HAIMA. 

1.3 Cylinder Dismantling /Mounting   

Warning 

  Unwashed cylinder is dangerous and may lead 

to combustion or explosion, which will further 
result in serious casualties. Due to this, 
cylinder shall be cleaned with vapor before the 
overhaul.  

  Fuel overflow or leakage is dangerous, and the 

fuel is combustible, which may lead to 
personnel injury and property loss. Due to this, 
do not damage the sealing face while 
dismantling/ mounting the oil pump assembly.   

Caution 

  Dismantling/mounting quick connector before 

cleaning will lead to damage of the fuel pipe 
and quick connector. Due to this, cleaning is a 
must before dismantling /mounting, in order to 
make sure that no foreign objects enter the fuel 
pipe and connector.   

1.  Park the vehicle stably on the lifting machine.   

2.  Complete preparatory work before repair (see 

Preparatory Work before Repair).   

3.  Loosen the accumulator’s negative cable.   

4. Dismantle 

the 

second-row seats (see Part S, 

Avoid nipping previous nipping place 

 

Fuel System 1C-4 

 

Seat, Second-row Seats Dismantling 
/Mounting).  

5.  Dismantle the cylinder repair cover plate.   

6.  Dismantle all fuel pipes that connect with the 

oil pump.   

7.  Drain fuel in the cylinder.   

8.  Life the vehicle with lifting machine and 

dismantle parts according to sequence 
illustrated in the figure.   

9.  Mount parts according to the sequence reverse 

to the dismantling process.   

10.  Complete inspection work after the repair (see 

Inspection Work after Repair) 

 

 

No.  Part name 

Part No. 

Torq
ue 

R
e
m
ar
k 

1 

Bolt HQ90786-1030 

36.3-
53.9 

 

2 

Fuelsupply pipe 

SA12-42-61X 

 

 

3 

Fuel pump 
gasket 

SA12-42-166    

4 

Fuel pump 

SA12-13-35Z 

 

 

5 

Fuel pump cover

SA12-42-161 

 

 

6 Hose 

clamp

 

S05B-42-239L1 

 

 

7 

Refueling hose 

SA12-42-231 

 

 

8 

Fuel tank straps 
(R) 

SA12-42-720    

9 

Refueling pipe 

SA12-42-211 

 

 

11 

Dust cover 

SA12-42-240 

 

 

10 

Cap-filler FA1A-42-250 

 

 

12 

Bolt HQ99786-0816 

20.0-
32.0 

 

13 

Elastical clamp 

HQ99283-1900 

 

 

14 

Breather hose 

SA12-42-232 

 

 

15 

Canister bracket 

SA12-13-960 

 

 

16 

Canister SA12-13-96Z 

 

 

17 

Bolt HQ99786-0820 

 

 

18 

Elastical clamp 

HQ99283-1100 

 

 

19 

Snorkel SA12-13-963 

 

 

20 

Desorption 
canister hose 

SA12-20-374    

21 

Pipe clip 

SA12-45-914 

 

 

22 

Fuel tank 

SA12-42-111 

 

 

23 

Fuel tank tie 
(left) 

SA12-42-710    

24 

Fuel tank 
insulation panels

SA12-42-741    

25 

Screw HQ99845-0510 

 

 

26 

Hose SA12-20-377 

 

 

27 

Fuel supply pipe 
assembly 

SA12-13-49X  

 

28 

Hose SA12-20-376 

 

 

29 

Clip SA12-45-911 

 

 

30 

Fuel hard tube 

SA12-45-110 

 

 

31 

Hard tube 
evaporator 

SA12-45-711    

32 

Elastical clamp 

HQ99283-1300 

 

 

 

 

Fuel System 1C-5 

 

1.3.1 Cylinder Air Tightness Test   

Notice 

  Cylinder air tightness test is used to test the 

welding quality between parts (like the upper oil 
filling port, exhaust port, and gravity valve) and 
the cylinder body.   

1.  Dismantle the cylinder mounting assembly 

(see the Cylinder Dismantling/Mounting).  

2.  Block the special blanking plug (dedicated to 

main fuel pipe) on the fuel pump assembly.   

3.  Use special blanking plug to block the gravity 

valve vapor hose’s joint on the cylinder body.   

4.  Connect the special air pressure test tool with 

the cylinder’s oil filling port and exhaust port.   

5.  Put the cylinder horizontally into the special 

water tank dedicated to cylinder test (the total 
cylinder shall be immersed 100mm below the 
water surface).   

6.  Charge compressed air into the cylinder’s oil 

filling port, and pressurize the cylinder to 
(30～50)kPa. Then, maintain the pressure for 
1min.  

7.  Inspect if there is air bubble between the parts 

(like oil filling port, exhaust port, and gravity 
valve) and the cylinder’s welding face.   

  If there is air bubble on the welding face, 

replace the cylinder (see Cylinder 
Dismantling/Mounting) 

 

 

 

1.3.2 Inspection of Check Valve   

1. Check the direction of welding welding 

direction ICV logo on the body with the fuel 
tank logo are aligned, if not aligned, then 
weld failed. 

2.    The role of the baffle is to prevent anti-jet fuel, 

while the pressure drop is not too large, to 
avoid early to jump the gun, and therefore 
whether the rebound pressure baffle is 
designed to reflect the performance by 
refueling. ICV welded to the tank, can not 
repair. 

1.3.3 Inspection of Fuel Cylinder Pipeline 

Pressure  

Warning 

  Fuel overflow or leakage is dangerous, and the 

fuel is combustible, which may lead to 
personnel injury and property loss. In addition, 
the fuel has side effect on the skin and eye.   

Caution 

  Dismantling/mounting quick connector before 

cleaning will lead to damage of the fuel pipe 
and quick connector. Due to this, cleaning to 
the quick connector’s contacting zone is a must 
before dismantling /mounting, in order to make 
sure that no foreign objects enter the fuel pipe 
and connector.   

Notice: 

  The following tests can be conducted if 

necessary  

1. Complete 

preparatory 

work before repair (see 

Preparatory Work before Repair) 

2.  Loosen the accumulator’s negative cable.   

Caution 

  To avoid the quick connector’s damage or oil 

leakage, follow the “Explanations on plastic 

 

Fuel System 1C-6 

 

fuel pipe dismantling” to complete the 
under-mentioned work (see the Fuel System, 
Explanations on Plastic Fuel Pipe Dismantling) 

3.  Dismantle the main fuel hose (fuel supply 

pipe assembly) from the main pipe (fuel rigid 
pipe).  

4.  Connect the special tool’s quick connector 

with the fuel distributor(fuel rail), and insert 
the fuel supply pipe assembly onto the special 
tool’s interface.   

 

5.  Remount the accumulator’s negative cable.   

Caution 

  Wrong connection with other wiring terminals 

may lead to fault, and so caution is needed 
during the connection process.   

6.  Connect the DLC’s wiring terminal F/P with 

the Vehicle body’s earthing point GND with a 
jumper wire. 

 

7.  Turn the ignition switch to “ON” position to 

make fuel pump run, and measure the 
pipeline’s maximum oil pressure.   

Standard value   

390～410kpa 

8.  Turn the ignition switch to the “OFF” 

position and loosen the jumper wire.   

  If the pressure is higher than the standard value, 

inspect the fuel pump’s maximum pressure   

  If the pressure is normal, inspect if the oil 

return pipe and pressure regulator suffer 
blockage.  

  If the pressure is lower than standard value, 

turn the switch handle and measure the oil 
pressure’s variation (see the figure).   

—If the oil pressure rises speedily, inspect the 
pressure regulator.   

—If the oil pressure rises slowly, inspect the oil 
pressure’s maximum value.   

  If the oil pump’s maximum pressure is normal, 

inspect if the oil circuit between the oil pump 
and pressure regulator suffers blockage.   

 

9.  Dismantle the special tool unit.   

Caution 

  To avoid the quick connector’s damage or oil 

leakage, follow the “Explanations on plastic 
fuel pipe dismantling” to complete the 
under-mentioned work (see the Cylinder 
Dismantling/Mounting, Explanations on 
Plastic Fuel Pipe Dismantling) 

10.  Connect the main fuel hose (fuel supply pipe 

assembly) and the main pipe (fuel rigid pipe)   

11.  Complete the inspection work after repair (see 

Inspection Work after Repair).   

1.3.4 Inspection of Fuel Pressure 
Maintenance  

Warning 

  Fuel overflow or leakage is dangerous, and 

the fuel is combustible, which may lead to 
personnel injury. In addition, the fuel has side 
effect on the skin and eye. 

Switch handle 

To main pipe 

Fuel distributor 

Earthing 
jumper 

Switch handle

To main pipe

Fuel distributor

 

Fuel System 1C-7 

 

Caution 

  Dismantling/mounting quick connector before 

cleaning will lead to damage of the fuel pipe 
and quick connector. Due to this, cleaning to 
the quick connector’s contacting zone is a 
must before dismantling /mounting, in order 
to make sure that no foreign objects enter the 
fuel pipe and connector.   

Notice: 

  The following tests can be conducted if 

necessary  

1. Complete 

preparatory 

work before repair (see 

Preparatory Work before Repair) 

2.  Loosen the accumulator’s negative cable.   

Caution 

  To avoid the quick connector’s damage or oil 

leakage, follow the “Explanations on plastic 
fuel pipe dismantling” to complete the 
under-mentioned work (see the Fuel System, 
Explanations on Plastic Fuel Pipe 
Dismantling) 

3.  Dismantle the main fuel hose (fuel supply pipe 

assembly) from the main pipe (fuel rigid pipe).   

4.  Connect the special tool’s quick connector 

with the fuel distributor (fuel rail), and insert 
the main fuel hose (fuel supply pipe assembly) 
onto the special tool’s interface.   

5.  Rotate the switch handle along the direction 

illustrated in the figure.   

 

6.  Remount the accumulator’s negative cable.     

Caution 

  Wrong connection with other wiring terminals 

may lead to fault, and so caution is needed 
during the connection process.   

7.  Connect the DLC’s wiring terminal F/P with 

the Vehicle body’s earthing point GND with a 
jumper wire. 

 

8.  Turn the ignition switch to the “ON” position 

for about 10s, in order to make the fuel pump 
run.  

9.  Turn the ignition switch to the “OFF” 

position and loosen the jumper wire.     

10.  Observe the oil pressure after 60 minutes.   

  If the oil pressure is lower than the standard 

value, observe the oil pressure’s variation 
while rotating the switch handle   

—If the oil pressure maintains unchanged, replace 
the pressure regulator (see Pressure Regulator 
Dismantling/Mounting) 

—If the oil pressure is changed, inspect if the oil 
circuit and spray nozzle suffer oil leakage.   

Standard value: 

≥250kpa(2.5kgf/cm2, 36psi) 

 

11.  Loosen the special tool unit.   

12.  Connect the main fuel hose with main fuel 

pipe.  

13.  Complete the inspection work after repair 

(see Inspection Work after Repair).   

Switch handle 

To main pipe 

Fuel distributor 

Earthing 
jumper 

Switch handle 

To main pipe

Fuel distributor

 

Fuel System 1C-8 

 

1.4 Fuel Pump Assembly Dismantling 
/Mounting  

Warning 
Fuel is a combustible liquid is very strong, and if 
the fuel spilled from the pressurized fuel system 
will result in serious injury or death, while also 
causing facilities were destroyed, oil can irritate 
the skin and eyes, in order to avoid this case, be 
sure to perform "Fuel pipeline safety program," 
while referring to "maintenance precautions." 
Fuel is a very strong combustible liquids, if spilled 
or leaked from the fuel pressure in the fuel system, 
it will cause serious injury or death, while also 
causing facilities were destroyed, oil can irritate 
the skin and eyes, in order to To avoid this 
situation, the fuel pump components prior removal 
/ installation, be sure to perform "After the 
installation of the fuel pump assembly fuel leak 
check." 
1.  Before performing any operations, comply 
with "maintenance before precautions" to avoid 
spilling fuel from the fuel system. 
2. Disconnect the negative battery cable. 
3. Remove the fuel tank. 
4. In the order shown in the table to be demolished. 

 

 

 

 

5. According to the order the demolition phase side 
installation. 

6. Through the implementation of 
"post-maintenance considerations" to check all 
relevant components. 

 1.4.1

 Fuel pump cover removal instructions

 

Notice: 

In using the SST time, if there is a gap between the 
fuel pump cover and SST, then the fuel pump 
cover may be damaged, the SST fixed so that the 
SST tabs with no gap between the fuel pump side 
cover.  

Removing the fuel pump cover using the SST.

 

   

 

1.4.2 

Fuel pump cover installation instructions

 

1.

 

Fuel tank and the fuel pump so that the 

alignment marks in the alignment member, as 
shown in Fig.

 

 

       

                                         

2.  As shown in FIG. Fixed SST. 

Using SST accordance with the provisions of the 
tightening torque to tighten the fuel pump cover, 
but can not move the alignment mark. 

4 .  If you can not achieve the required tightening 
torque, replace the fuel pump cover. 

5 .  If after replacing the fuel pump cover can not 
achieve the required tightening torque, replace the 
tank. 

1.4.3 Split fuel pump parts / assembly 

Explanation： 

  Can not be split fuel pump components. 

Inspection of Fuel Pump Assembly   

Simulation Test   

Inspect the fuel pump’s working condition (see 
Fault Diagnosis, Inspection of Engine Control 
System’s Working Condition, Inspection of Fuel 
Pump’s Working Condition).   

1 Quick 

release 

connectors 

2 Fuel 

pump 

cover 

3 Fuel 

pump 

parts 

 

Fuel System 1C-9 

 

  If the condition is abnormal, conduct further 

inspection to the fuel pump assembly.   

Inspection of Conducting/Non-conducting 
State  

Notice 

  Inspection below can be conducted if 

necessary  

1.  Loosen the accumulator’s negative cable.   

2.  Remove the second-row seats (see Seats, 

Second-row Seats Dismantling /Mounting).   

3.  Dismantle the oil tank’s repair cover plate.   

4.  Loosen the fuel pump assembly’s connector.   

5.  Inspect the conducting/non-conducting state 

between fuel pump or connector’s wiring 
terminal B and wiring terminal D. If it is in 
conducting state but the simulation test is 
abnormal, inspect if the circuit suffers 
short/open circuit. If it is in non-conducting 
state, replace the fuel pump assembly.   

 

Inspection of Open/Short Circuit   

1.  Inspect if there is open/short circuit on the 

following wiring harnesses. If there is, repair 
or replace corresponding wiring harness:   

Open Circuit   

  Earting circuit (between fuel pump assembly’s 

connector D and the vehicle body GND) 

  Power circuit (between the fuel pump relay 

connector A and fuel pump assembly 
connector B, and there is public connector) 

 

Short Circuit   

  The circuit between the fuel pump assembly 

connector B and fuel pump relay connector E, 
in which there is public connector and ground 
short circuit (electrical ground) 

2.  Remount the fuel pump assembly connector.   

3.  Remount the oil tank’s repair cover plate.   

4.  Remount the second-row seats (see Seats, 

Second-row Seats Dismantling /Mounting).   

5.  Remount the accumulator’s negative cable.   

Inspection of Fuel Pump’s Maximum 
Pressure  

Warning 

  Fuel overflow or leakage is dangerous, and the 

fuel is combustible, which may lead to personnel 
injury and property loss. Due to this, 
under-mentioned operations shall not be started 
until the engine stops.   

Caution 

  Dismantling/mounting quick connector before 

cleaning will lead to damage of the fuel pipe 
and quick connector. Due to this, cleaning to 
the quick connector’s contacting zone is a must 
before dismantling /mounting, in order to make 
sure that no foreign objects enter the oil pipe 
and connector. 

Notice 

  The following tests can be conducted if 

necessary  

1. Complete 

preparatory 

work before repair (see 

Preparatory Work before Repair) 

2.  Loosen the accumulator’s negative cable.   

Caution 

  To avoid the quick connector’s damage or oil 

leakage, follow the “Explanations on plastic 
fuel pipe dismantling/ mounting” to complete 
the under-mentioned work (see the Fuel 
System, Explanations on Plastic Fuel Pipe 
Dismantling) 

3.  Dismantle the main fuel hose (fuel supply 

pipe assembly) from the main pipe 
(vaporation rigid pipe).   

4.  Turn the switch handle to the position 

illustrated in the figure to block the special 
tool’s port.   

Fuel pump relay 

 

Fuel System 1C-10 

 

5.  Push the special tool’s quick connector into 

the main pipe (fuel rigid pipe) till there is a 
“click” sound.    

6.  Put the hose into a vessel in order to avoid the 

fuel overflow.   

 

7.  Remount the accumulator’s negative cable.   

Caution 

  Wrong connection with other wiring terminals 

may lead to fault, and so caution is needed 
during the connection process.   

8.  Connect the DLC’s wiring terminal F/P with 

the vehicle body’s earthing point GND with a 
jumper wire.   

 

9.  Turn the ignition switch to the “ON” position to 

make the fuel pump run, and measure the fuel 
pump’s maximum output oil pressure.   

Fuel pump’s maximum output oil pressure: 650～
900kpa 

10. Turn the ignition switch to the “OFF” 

position and loosen the jumper wire.   

If the maximum output oil pressure goes 
beyond the specified range, inspect items below:   

—Fuel pump relay (see Inspection of Fuel Pump 
Relay) 

—If the fuel filter (LV, HV) suffers blockage.   

—If the fuel pipeline suffers blockage or leakage.   

11.  Dismantle the special tool.   

Caution 

  To avoid the quick connector’s damage or oil 

leakage, follow the “Explanations on plastic 
fuel pipe dismantling” to complete the 
under-mentioned work (see the Fuel System, 
Explanations on Plastic Fuel Pipe Dismantling) 

12.  Remount the main fuel hose (fuel supply pipe 

assembly).  

13.  Complete the inspection work after repair (see 

Inspection Work after Repair) 

Inspection of Fuel Pump Oil Pressure 
Maintenance  

Warning 

  Fuel overflow or leakage is dangerous, and the 

fuel is combustible, which may lead to 
personnel injury and property loss. Due to this, 
under-mentioned operations shall not be 
started until the engine stops.   

Caution 

  Dismantling/mounting quick connector before 

cleaning will lead to damage of the fuel pipe 
and quick connector. Due to this, cleaning to 
the quick connector’s contacting zone is a must 
before dismantling /mounting, in order to make 
sure that no foreign objects enter the oil pipe 
and connector. 

Notice 

  The following tests can be conducted if 

necessary  

1. Complete 

preparatory 

work before repair (see 

Preparatory Work before Repair).   

2.  Loosen the accumulator’s negative cable.   

Caution 

  To avoid the quick connector’s damage or oil 

leakage, follow the “Explanations on plastic 
fuel pipe dismantling” to complete the 
under-mentioned work (see the Fuel System, 
Explanations on Plastic Fuel Pipe Dismantling) 

3.  Dismantle the main fuel hose (fuel supply 

pipe assembly) from the main pipe (fuel rigid 
pipe). 

4.  Turn the switch handle along the direction 

illustrated in the figure to block the special 
tool’s port. 

5.  Push the special tool’s quick connector into 

the main pipe (fuel rigid pipe) till there is a 
“click” sound.    

Jumper wire 

 

Fuel System 1C-11 

 

6.  Put the hose into a vessel in order to avoid the 

fuel overflow.   

   

7.  Remount the accumulator’s negative cable.   

Caution 

  Wrong connection with other wiring terminals 

may lead to fault, and so caution is needed 
during the connection process.   

8.  Connect the DLC’s wiring terminal F/P with 

the vehicle body’s earthing point GND with a 
jumper wire.   

 

9.  Turn the ignition switch to the “ON” position 

to make fuel pump run for 10s or so.   

10. Turn the ignition switch to the “OFF” 

position. After 5 minutes, inspect the fuel 
pump’s oil pressure maintenance.   

Fuel pump’s oil pressure maintenance: ＞
410kpa(4.1kgf/cm2, 59psi) 

11.  Loosen the jumper wire.   

12.  Remove the special tool.   

13.  Connect the main fuel hose (fuel supply pipe 

assembly) with the main pipe(fuel rigid pipe).   

If the oil pressure maintenance fails to accord 
with standard, replace the fuel pump assembly 
(see Fuel Pump Assembly 
Dismantling/Mounting) 

14.  Confirm if around the quick plug’s bonding 

zone there is not oil leakage.   

15. Complete the inspection work after 

repair(see Inspection Work after Repair) 

1.5 Spray Nozzle Dismantling /Mounting   

(see the Control System) 

1.5.1 Inspection of Spray Nozzle 

(see the Control System) 

2 Fuel Vaporation and Absorption 
System 

Location of Combustion Vaporation & 
Absorption System’s Components (in Engine 
Compartment) 

 

2.1 Inspection of Carbon Canister 
Assembly  

1.  Remove the carbon canister.   

2.  Block the interface on the carbon canister’s 

ventilation side and the interface on the 
carbon canister’s electromagnetic valve side.   

3.  Blow air into the carbon canister’s oil tank 

interface, and Confirm if there is no air 
leakage (If there is air leakage, replace carbon 
canister).  

2.1.1 Inspection of Carbon Canister’s 
Electromagnetic Valve   

Conduct simulation test   

Inspect the carbon canister’s electromagnetic 
valve (see Fault Diagnosis, Inspection of Engine 
Control System’s Working Condition, Inspection 
of Carbon Canister’s Electromagnetic Valve); if it 
is abnormal, conduct further inspection to the 
carbon canister’s electromagnetic valve.   

                 

Earthing 
jumper 

Air hose  Main fuel pipe 

Switch 
handle

 

Fuel System 1C-12 

 

 

2.2 Inspection of Ventilation Condition   

Notice 

  The following tests can be conducted if 

necessary  

1.  Loosen the accumulator’s negative cable.   

2. 

Dismantle the carbon canister’s 
electromagnetic valve .   

3.  Inspect ventilation condition of the carbon 

canister’s electromagnetic valve   

(If normal, inspect if there is open /short circuit, 
and if the vacuum hose is correctly arranged or 
suffers distortion and air leakage. If abnormal, 
replace the carbon canister’s electromagnetic 
valve ).   

 

 

2.3 Inspection of Open/Short Circuit   

1.  Inspect if there is open/short circuit on the 

following wiring harnesses (If there is, 
overhaul or replace corresponding wiring 
harness).  

Open Circuit   

  Earthing circuit (the circuit between the carbon 

canister’s electromagnetic valve connector 1 
and ECU connector terminal 46, in which there 
is public connector) 

  Power circuit (the circuit between the carbon 

canister’s electromagnetic valve connector 
terminal 2 and main circuit breaker connector 
terminal D, in which there is public connector) 

 

Short Circuit   

  Electrical ground between carbon canister’s 

electromagnetic valve connector terminal 2 and 
ECU connector terminal 46, in which there is 
public connector. 

2. 

Remount the carbon canister’s 
electromagnetic valve.   

3.  Remount the accumulator’s negative cable.   

 

3  Dismantling the fuel pump 

assembly diagram

 

3.1 Demolition relief valve assembly 

 

 

Main relay 

Connector on wiring harness’s side 

  (viewing from the electrode terminal side)

With a screwdriver 

inserted from here..