LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Toyota >> 2005 >> MR2 C65M >> Repair and Diagnosis >> Engine Performance >> System >> Engine Control System (SFI) >> Fuel Pump >> On-Vehicle Inspection
April 5, 2026: LEMON Manuals is launched! Read the announcement.

On-Vehicle Inspection

  1. CHECK FUEL PUMP OPERATION 
    1. Connect a hand-held tester to the DLC3.
      1. Connect the hand-held tester to the DLC3.
      2. Turn the ignition switch ON, and push the hand-held tester main switch ON.
        Fig 1: Connecting Hand-Held Tester To DLC3
        G02630964Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE: Do not start the engine.
      3. Select the following menu items: DIAGNOSIS/ENHANCED OBD II / ACTIVE TEST / FUEL PUMP / SPD.
      4. Please refer to the hand-held tester operator's manual for further details.

      If you have no hand-held tester, connect the positive (+) and negative (-) leads from the battery to the fuel pump connector (See step  3).

    2. Check that there is pressure in the fuel inlet tube from the fuel line.

      HINT:

      If there is fuel pressure, you will hear the sound of fuel flowing. If there is no pressure, check the fusible link, fuses, EFI Main relay, fuel pump, ECM and wiring connector.

    3. Turn the ignition switch OFF.
    4. Disconnect the hand-held tester from the DLC3.
    Fig 2: Checking For Pressure In Fuel Inlet Tube
    G02630965Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. CHECK FUEL PRESSURE 
    1. Check the battery positive voltage is above 12 V.
    2. Disconnect the negative (-) terminal cable from the battery.
    3. Purchase a new fuel tube and remove the fuel tube connector from its pipe.

      Fuel tube: Part No. 23901-22070

      Fig 3: Identifying Fuel Tube Connector
      G02630966Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect the fuel tube clamp from the fuel tube connector.
      Fig 4: Disconnecting Fuel Tube Clamp From Fuel Tube Connector
      G02630967Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Disconnect the fuel inlet tube (fuel tube connector) from the fuel pipe.
      CAUTION:
      • Disconnect the fuel tube connector (quick type) observing the precaution (See SFI SYSTEM ).
      • As there is retained pressure in the fuel line, prevent if from splashing inside the engine compartment.
      Fig 5: Disconnecting Fuel Tube Connector
      G02630968Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Install SST (pressure gauge) as shown in the illustration by using SST and fuel tube connector.

      SST 09268-41047, 09268-45014 (09268-41250)

    7. Wipe off any splattered gasoline.
    8. Reconnect the negative (-) terminal cable to the battery.
    9. Connect the hand-held tester to the DLC3 (See step  1).
    10. Measure the fuel pressure.

      Fuel pressure: 

      301 - 347 kPa (3.1 - 3.5 kgf/cm 2  , 44 - 50 psi) 

      If the pressure is high, replace the fuel pressure regulator.

      If the pressure is low, check the fuel hoses and connections, fuel pump, fuel filter and fuel pressure regulator.

    11. Disconnect the hand-held tester from the DLC3.
    12. Start the engine.
    13. Measure the fuel pressure at idle.

      Fuel pressure: 

      301 - 347 kPa (3.1 - 3.5 kgf/cm 2  , 44 - 50 psi) 

    14. Stop the engine.
    15. Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped.

      Fuel pressure: 147 kPa (1.5 kgf/cm 2  , 21 psi) or more 

      If the pressure is not as specified, check the fuel pump, pressure regulator and/or injectors.

    16. After checking the fuel pressure, disconnect the negative (-) terminal cable from the battery and carefully remove the SST and fuel tube connector to prevent gasoline from splashing.

      SST 09268-41047, 09268-45014

      Fig 6: Checking Fuel Pressure
      G02630969Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    17. Reconnect the fuel inlet tube (fuel tube connector).
      CAUTION: Connect the fuel tube connector (quick type) observing the precaution (See SFI SYSTEM ).
      Fig 7: Reconnecting Fuel Inlet Tube
      G02630970Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    18. Install the fuel tube clamp to the fuel tube connector.
    19. Reconnect the negative (-) terminal cable to the battery.
    20. Check for fuel leaks (See SFI SYSTEM ).
    Fig 8: Installing Fuel Tube Clamp To Fuel Tube Connector
    G02630971Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSPECT FUEL PUMP 
    1. Remove the luggage compartment.
    2. Remove the floor service hole cover.
    3. Disconnect the fuel pump & sender gauge connector.
    4. Using an ohmmeter, measure the resistance between terminals 4 and 5.

      Resistance: 0.2 - 3.0 Ω at 20°C (68°F) 

      If the resistance is not as specified, replace the fuel pump.

      Fig 9: Measuring Resistance Between Terminals 4 And 5 Using An Ohmmeter
      G02630972Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Inspect the fuel pump operation.

      Connect the positive (+) lead to terminal 4 and the negative (-) lead to terminal 5 of the connectors from the battery.

      NOTE:
      • These tests must be done quickly (within 10 seconds) to prevent the coil from burning out.
      • Keep the fuel pump as far away from the battery as possible.
      • Always do the switching on the battery side.
      Fig 10: Connecting Battery Positive Lead To Terminal 4 And Negative Lead To Terminal 5
      G02630973Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      If the operation is not as specified, replace the fuel pump.

    6. Reconnect the fuel pump & sender gauge connector.
    7. Reinstall the floor service hole cover.
    8. Reinstall the luggage compartment.
scientia non olet · About LEMON Manuals