Fuel System - Check Fuel System Pressure 3-15

Chapter 3 Fuel System

Section 1 Check Fuel System Pressure
On-board inspection
1. Check the operation of the fuel pump.
(1) Connect the positive and the negative of the battery to
appropriate connector sockets of the fuel pump (see Figure 3-1).
Attention: Do not start the engine.
If there is pressure present, you will hear that the fuel is flowing.
If there is no pressure present, check the fusible cutout, fuse, EFI
open-circuit relay, fuel pump, ECM (Electronic Control Module) and
circuit joint. Battery
(2) Turn the ignition switch to "OFF". Figure 3-1
2. Check the pressure of the fuel.
(1) Check whether the battery voltage is more than 12V. T conector
(2) Disconnect the negative wiring cable from the battery.
(3) Mount a pressure gauge on the fuel input pipe
Hose
(see Figure 3-2).
Hose
(4) Connect the negative terminal of the battery.
(5) Measure the fuel pressure.
Fuel oil pressure: 265-304kPa
If the pressure is low, check the fuel pipe and connection, Fuel Inlet Pipe
fuel pump, and fuel filter. If the pressure is too high,
replace the regulator.
Fuel Pipe
(6) Start the engine. Measure the fuel pressure at idle speed. The Conector
fuel pressure is 265-304KPa. If the pressure is unsatisfactory, check
Figure 3-2
the fuel pump, pressure regulator, and injector, and replace if necessary.
(7) After shutting down the engine, check the fuel pressure and
keep the specified pressure for about 5 minutes. The fuel pressure is:
147KPa.
3. The fuel oil pressure regulator (DR) (see Figure 3-3).
Mounting position: On the distributing pipe for fuel.
Faults: Too low or too high fuel pressure, or hard to start.
General causes: Using poor fuel for a long time results in: 1.
strainer blocked; 2. serious leakage caused by particles and impurities. Figure 3-3
Other reasons: Man-made mechanical damage, etc.
Maintenance precautions: During maintenance: 1. Never impact the diaphragm element with high pressure
gas; 2. Never clean it with aggressively corrosive liquid; 3. No distortion caused by external force.
Easy measuring method: For the system with oil return, connect a pressure gauge for the fuel on the suction
pipe, start the engine, and run at idle speed. Now, the fuel pressure in the engine should be about 260KPa; pull out
the vacuum pipe of the fuel pressure regulator, and the pressure should be 300KPa approximately.
3-16 Fuel System - Fuel Pump Inspection

Section 2 Fuel Pump Inspection

1. Fuel pump
(1) Check whether the resistance of the fuel pump is 0.2~3.0 ohm¸ at 20°C. If not, replace the fuel pump (see Figure
3-4).
(2) Fuel oil pump running:
Switch on the fuel pump with a battery and check. If the operation is unsatisfactory, replace the fuel pump or
wires (see Figure 3-5).
The test should be done within 10s to protect the coil from burning out.
2. Fuel injector assembly
Oil injecting quantity: 40~50cm 3 /s.
Tolerance of each injector: not more than 10 cm 3.
If the fuel injecting quantity is not up to the specification, replace the injector.
Check leakage: Under above conditions, disconnect the wire from the battery, the fuel should not drip one per
minute.

Ohm
meter

Battery

Figure 3-4 Figure 3-5

 Fuel System - Fuel Pump Replacement 3-17

Section 3 Fuel Pump Replacement

Component View

Fuel tank cap

Fuel oil hose

Fuel pump with fuel sensor as-

sembly

O-ring
Fuel return hose

Fuel tank assembly

Figure 3-6

Replace
1. Operations avoiding petrol overflowing.
2. Disconnect the fuel oil hose from the oil tank.
3. Disconnect the oil return hose from the oil tank.
4. Disconnect the vapor discharge pipe from the oil tank.
5. Remove the fuel oil pump assembly with a filter (see Figure 3-7)
Loosen the oil tank cap with a tailored tool. Take care not to bend
the arm of the oil quantity sensor when taking the fuel oil pump out Figure 3-7

snap ring
6. Mount the fuel oil pump assembly (see Figure 3-8).Replace the
sealing ring. Align the boss on the oil pump with the nick on the oil
tank port; tighten the oil tank cap with special tool.
Torque: 40N.m
7. Mount the vapor discharge pipe.
(1) Mount the oil return hose;
(2) Mount the fuel oil hose; Figure 3-8
(3) Check leakage of the fuel oil.
3-18 Fuel System - Fuel Emission Control System

Section 4 Fuel Emission Control System

On-board Inspection
1. Check the operation when disconnecting the fuel supply.
(1) Warm the engine up to 2,500r/min at least, and check the noise of the injector with a sound level meter
(see Figure 3-9).
(2) When the throttle releases, the noise from the injector should stop immediately; repeat several times.
2. Check the fuel vapor discharge control system (see Figure 3-10).
(1) After starting the engine, disconnect the vacuum pipe.
(2) Make sure that there is vacuum present at the canister control valve (TEV) port when selecting ”ACTIVE
TEST" and "PURGE TEV" based on the display on the fault diagnosis instrument.
(3) After "ACTIVE TEST", connect the vacuum pipe.
(4) Carry out "ECM DATA MONITOR" on the fault diagnosis instrument, and then select "PURGE TEV"
for operation inspection.
(5) Start up the car after the engine warms up, and make sure the TEV ON from OFF (see Figure 3-11).
3. Check whether there is any distortion or damage on the filling cap and the washer (see Figure 3-12).

Sound level meter

Figure 3-9 Figure 3-10

Gasket

Figure 3-11 Figure 3-12

 Fuel System - Carbon Canister Replacement 3-19

Section 5 Carbon Canister Replacement

1. Check and replace the canister.

(1) Check for crack or damage on the canister visually (see Figure 3-13).
(2) Check the operation of the canister.
a. Plug the discharge port (see Figure 3-14).
b. Blow air (4.71KPa, 48kgf/cm 2 ) into the absorption port when keeping the discharge port closed, and the
air should flow out from the exit port.
If the operation is unsatisfactory, replace the canister.
c.Blow air into the absorption port, the air should flow from other ports without any resistance.
If the operation is unsatisfactory, replace the canister.
(3) Clean the canister: Block the desorption port, blow air (4.71KPa, 48kgf/cm 2 ) into the absorption port, and
the air should flow from the discharge port (see Figure 3-15).

Absorption port
Absorption port
Discharge port
Discharge port

Exit port
Exit port

Plug up

Figure 3-13 Figure 3-14 Figure 3-15

2. Canister control valve (TEV) (see Figure 3-16)

Mounting position: On the vacuum pipeline of the canister - suction manifold.
Faults: Bad idle speed, malfunction, etc.
General cause: Ingress of foreign materials into inside of the valve results in corrosion and Poor tightness.
Maintenance precautions: During maintenance:
1. Air flowing direction must conform to specifications;
2. If the control valve fails due to black particles in the valve body, and it is necessary to replace the control
valve, please check the condition of the canister;
3. Avoid liquid such as water and oil entering into the valve during maintaining as possible;
4. It is advisable to mount the canister control valve on the hose hanging in the air or fasten with soft rubber
to avoid transmission of solid borne noise.
3-20 Fuel System - Carbon Canister Replacement

Easy measuring method: (disconnect the connector) Set the digital multi-meter to ohm position, with two leads
connecting to two pins of the canister control valve respectively, rated resistance 22-30 ohm at 20°C

Figure 3-16

3. Vent valve (PCV) sub-assembly

Air should flow through the cylinder cap side freely.
Attention:
Do not suction air through the valve.
Never put anything into the valve. If the operation is unsatisfactory, replace PCV.
Blow air into from the suction side, and the air should be hard to flow through. If the operation is
unsatisfactory, replace PCV (see Figure 3-17).

Cylinder head side Manifold side

Cleaning pipe

Easy Hard

Figure 3-17