EC-1688
[YD (WITHOUT EURO-OBD)]
FUEL TRANSPORT PUMP
10. CHECK TRANSPORT PUMP
Refer to EC-1689, "
Component Inspection" .
OK or NG
OK >> GO TO 14.
NG >> Replace fuel transport pump.
11 . CHECK FUEL LEVEL SWITCH POWER SUPPLY AND GROUND CIRCUIT FOR OPEN AND SHORT
1. Turn ignition switch OFF.
2. Disconnect ECM harness connector.
3. Disconnect sub fuel level sensor unit harness connector.
4. Check harness continuity between ECM terminal 14 and sub
fuel level sensor unit terminal 2, between sub fuel level sensor
unit terminal 4 and ground. Refer to Wiring Diagram.
5. Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 13.
NG >> GO TO 12.
12. DETECT MALFUNCTIONING PART
Check the following.
Harness connector F30, M63
Harness connector M78, B105 (LHD models)
Harness connectors M18, B2 (RHD models)
Harness for open or short between ECM and sub fuel level sensor unit
Harness for open or short between sub fuel level sensor unit and ground.
>> Repair open circuit or short to ground or short to power in harness or connectors.
13. CHECK FUEL LEVEL SWITCH
Refer to EC-1689, "
Component Inspection"
OK or NG
OK >> GO TO 14.
NG >> Replace sub fuel level sensor unit.
14. CHECK INTERMITTENT INCIDENT
Refer to EC-1414, "
TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT"
>>INSPECTION END Continuity should exist.
PBIB1944E
FUEL TRANSPORT PUMP
EC-1689
[YD (WITHOUT EURO-OBD)]
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EC
Component InspectionEBS0126K
FUEL TRANSPORT PUMP RELAY
Check continuity between terminals 3 and 5 under the following coni-
tions.
FUEL TRANSPORT PUMP
1. Remove fuel transport pump.
2. Apply battery voltage between fuel transport pump terminal 1 and 2.
3. Check operating sound of fuel transport pump under the following conditions.
4. Listen fuel transport pump operating sound.
FUEL LEVEL SWITCH
1. Confirm that the engine is cooled down and there are no fire hazards near the vehicle.
2. Check continuity between sub fuel level sensor unit terminal 2
and 4 under the following conditions.
Removal and InstallationEBS0126L
FUEL TRANSPORT PUMP
Refer to FL-23, "FUEL TANK" .
SUB FUEL LEVEL SENSOR UNIT
Refer to FL-19, "FUEL LEVEL SENSOR UNIT" .
Conditions Continuity
12V direct current supply between terminals 1 and 2 Yes
No current supply No
PBIB0098E
Conditions Operating sound
12V direct current supply between fuel transport pump
terminals 1 and 2Ye s
No current supply No
Conditions Continuity
Fuel level switch is soaked in fuel. Yes
Fuel level switch is not soaked in fuel. No
PBIB2015E
EC-1690
[YD (WITHOUT EURO-OBD)]
AUTOMATIC SPEED CONTROL DEVICE (ASCD)
AUTOMATIC SPEED CONTROL DEVICE (ASCD)PFP:18930
System DescriptionEBS01FEB
INPUT/OUTPUT SIGNAL CHART
BASIC ASCD SYSTEM
Refer to Owner's Manual for ASCD operating instructions.
Automatic Speed Control Device (ASCD) allows a driver to keep vehicle at predetermined constant speed
without depressing accelerator pedal. Driver can set vehicle speed in advance between approximately 40 km/
h (25 MPH) and 185 km/h (115 MPH).
ECM controls fuel injection value to regulate engine speed.
Operation status of ASCD is indicated by CRUISE indicator and SET indicator in combination meter. If any
malfunction occurs in ASCD system, it automatically deactivates control.
SET OPERATION
Press ASCD MAIN switch. (The CRUISE indicator in combination meter illuminates.)
When vehicle speed reaches a desired speed between approximately 40 km/h (25 MPH) and 185 km/h (115
MPH), press SET switch. (Then SET indicator in combination meter illuminates.)
ACCEL OPERATION
If the RESUME/ACCELERATE switch is depressed during cruise control driving, increase the vehicle speed
until the switch is released or vehicle speed reaches maximum speed controlled by the system.
And then ASCD will keep the new set speed.
CANCEL OPERATION
When any of following conditions exist, cruise operation will be canceled.
CANCEL switch is depressed
More than 2 switches at ASCD steering switch are depressed at the same time (Set speed will be
cleared.).
Brake pedal is depressed
Clutch pedal is depressed or gear position is changed to the neutral position
Vehicle speed increased to 13 km/h higher than the set speed
Vehicle speed decreased to 13 km/h lower than the set speed
ESP system is operated
When the ECM detects any of the following conditions, the ECM will cancel the cruise operation and inform
the driver by blinking indicator lamp.
Malfunction for some self-diagnoses regarding ASCD control: SET lamp will blink quickly.
If MAIN switch is turned to OFF during ASCD is activated, all of ASCD operations will be canceled and vehicle
speed memory will be erased.
COAST OPERATION
When the SET/COAST switch is depressed during cruise control driving, decrease vehicle set speed until the
switch is released. And then ASCD will keep the new set speed.
RESUME OPERATION
When the RESUME/ACCELERATE switch is depressed after cancel operation other than depressing MAIN
switch is performed, vehicle speed will return to last set speed. To resume vehicle set speed, vehicle condition
must meet following conditions.
Brake pedal is released
Clutch pedal is released
Vehicle speed is greater than 40 km/h (25 MPH) and less than 185 km/h (115 MPH)
Sensor Input signal to ECM ECM function Actuator
ASCD brake switch Brake pedal operation
ASCD vehicle speed control Fuel injector and Fuel pump Stop lamp switch Brake pedal operation
ASCD clutch switch Clutch pedal operation
ASCD steering switch ASCD steering switch operation
Combination meter Vehicle speed
SERVICE DATA AND SPECIFICATIONS (SDS)
EC-1701
[YD (WITHOUT EURO-OBD)]
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SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00100
General SpecificationsEBS0126P
Mass Air Flow SensorEBS0126Q
Engine Coolant Temperature SensorEBS0126R
Fuel Rail Pressure SensorEBS0126S
Glow PlugEBS0126T
EGR Volume Control ValveEBS0126U
Crankshaft Position Sensor EBS0126V
Refer to EC-1517, "Component Inspection" .
Camshaft Position Sensor EBS0126W
Refer to EC-1530, "Component Inspection" .
EngineYD22DDTi
Idle speed725 ± 25 rpm
Maximum engine speed 4,900 rpm
Supply voltageBattery voltage (11 - 14V)
Ignition switch ON (Engine stopped.) Approx. 0.4V
Idle (Engine is warmed up to normal operating temperature.) 1.5 - 2.0V
2,000 rpm (Engine is warmed up to normal operating tempera-
ture.)2.2 - 2.7V
Temperature °C (°F)Resistance kΩ
20 (68)2.1 - 2.9
50 (122)0.68 - 1.00
90 (194)0.236 - 0.260
Supply voltageApproximately 5V
Idle (Engine is warmed up to normal operating temperature.) 1.7 - 2.0V
2,000 rpm (Engine is warmed up to normal operating tempera-
ture.)2.0 - 2.3V
Resistance [at 25°C (77°F)] Ω Approximately 0.8
Resistance [at 25°C (77°F)] Ω13 - 17
FL-1
FUEL SYSTEM
B ENGINE
CONTENTS
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SECTION FL
A
FL
FUEL SYSTEM
QR
PREPARATION ........................................................... 2
Commercial Service Tools ........................................ 2
FUEL SYSTEM ........................................................... 3
Checking Fuel Lines ................................................. 3
General Precautions ................................................ 3
FUEL LEVEL SENSOR UNIT, FUEL FILTER AND
FUEL PUMP ASSEMBLY ........................................... 4
Removal and Installation .......................................... 4
REMOVAL ............................................................. 4
INSPECTION AFTER REMOVAL ......................... 7
INSTALLATION ..................................................... 7
INSPECTION AFTER INSTALLATION ................. 8
Disassembly and Assembly ..................................... 8
DISASSEMBLY ..................................................... 8
ASSEMBLY ........................................................... 9
FUEL TANK ...............................................................11
Removal and Installation ......................................... 11
REMOVAL ............................................................ 11
INSTALLATION ................................................... 12
INSPECTION AFTER INSTALLATION ............... 13
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 14
Standard and Limit ................................................. 14
FUEL TANK ......................................................... 14
Tightening Torque ................................................... 14
YD22DDTi
PREPARATION ......................................................... 15
Commercial Service Tools ...................................... 15
FUEL SYSTEM ......................................................... 16
Checking Fuel Lines ............................................... 16
General Precautions ............................................... 16
FUEL FILTER ............................................................ 17
Removal and Installation ........................................ 17
REMOVAL ........................................................... 17
INSTALLATION ................................................... 17
INSPECTION AFTER INSTALLATION ................ 17
Air Bleeding ............................................................ 18
Draining Water from Fuel Filter .............................. 18
FUEL LEVEL SENSOR UNIT ................................... 19
Removal and Installation ........................................ 19
REMOVAL ........................................................... 19
INSPECTION AFTER REMOVAL ....................... 22
INSTALLATION ................................................... 22
INSPECTION AFTER INSTALLATION ................ 22
FUEL TANK .............................................................. 23
Removal and Installation ........................................ 23
REMOVAL ........................................................... 23
INSTALLATION ................................................... 24
INSPECTION AFTER INSTALLATION ................ 25
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 26
Standard and Limit .................................................. 26
Tightening Torque ................................................... 26
FL-4
[QR]
FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLYPFP:17042
Removal and InstallationEBS00KOU
REMOVAL
WARNING:
Be sure to read “General Precautions” when working on the fuel system. Refer to FL-3, "
General Pre-
cautions" .
1. Check fuel level on fuel gauge. If gauge indicates more than the
level as shown in the figure (full or almost full), drain fuel from
fuel tank until gauge indicates level as shown in the figure or
below.
NOTE:
Fuel will be spilled when removing main and sub fuel level sen-
sor units for the top of the fuel is above the main and sub fuel
level sensor units installation surface.
As a guide, fuel level becomes the position as shown in the
figure or below when approximately 15 (3-1/4 Imp gal) of
fuel are drained from fuel tank.
In case fuel pump does not operate, perform the following
procedure.
a. Insert fuel tube of less than 25 mm (0.98 in) in diameter into fuel filler tube through fuel filler opening to
draw fuel from fuel filler tube.
b. Disconnect fuel filler hose from fuel filler tube. Refer to FL-11, "
FUEL TANK" .
c. Insert fuel tube into fuel tank through fuel filler hose to draw fuel from fuel tank.
2. Release the fuel pressure from the fuel lines. Refer to EC-49, "
FUEL PRESSURE RELEASE" (WITH
EURO-OBD) or EC-562, "
FUEL PRESSURE RELEASE" (WITHOUT EURO-OBD).
3. Open fuel filler lid.
4. Open fuel filler cap and release the pressure inside fuel tank.
5. Lift to hold rear seat cushion up. Refer to SE-32, "
REAR SEAT" .
1. Lock ring 2.Main fuel level sensor unit, fuel filter
and fuel pump assembly3.Jet pump, fuel hose and jet pump
inlet assembly
4. Chamber 5. Seal packing 6. Sub fuel level sensor unit
PBIC2257E
PBIC3641E
FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
FL-5
[QR]
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6. Remove inspection hole cover for main and sub fuel level sen-
sor units by turning clips clockwise by 90 degrees.
Remove cover by pushing it, then by turning clips clockwise
by 90 degrees and by matching both cover hole and clip
shape.
7. Disconnect harness connector and fuel feed hose.
Disconnect quick connector as follows:
–Hold the sides of connector, push in tabs and pull out fuel feed
hose.
–If quick connector sticks to tube of fuel level sensor unit, push
and pull quick connector several times until it starts to move.
Then disconnect quick connector by pulling.
PBIC2258E
KBIA0280E
SFE562A
FL-6
[QR]
FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
CAUTION:
Quick connector can be disconnected when the tabs
are completely depressed. Do not twist it more than
necessary.
Do not use any tools to disconnect quick connector.
Keep resin tube away from heat. Be especially careful
when welding near the resin tube.
Prevent acid liquid such as battery electrolyte, etc.
from getting on resin tube.
Do not bend or twist resin tube during installation and
disconnection.
Do not remove the remaining retainer on hard tube (or
the equivalent) except when resin tube or retainer is
replaced.
When resin tube or hard tube (or the equivalent) is
replaced, also replace retainer with a new one.
Replace same color retainer as before replacing.
To keep the connecting portion clean and to avoid
damage and foreign materials, cover them completely
with plastic bags or something similar.
8. Using a fuel tank lock ring wrench (commercial service tool),
remove lock ring.
9. Remove main fuel level sensor unit, fuel filter and fuel pump assembly, and sub fuel level sensor unit as
follows.
CAUTION:
Do not bend float arm during removal.
Avoid polluting the inside by residue fuel. Draw out with avoiding inclination by supporting with
a cloth.
Avoid impacts such as falling when handling components.Retainer color: Green
SBIA0504E
PBIC0163E
PBIC0240E