Test Procedure

Description
Refer to FUEL SYSTEM - HYBRID for additional information on the fuel delivery system.
Inertia Fuel Shutoff (IFS) Switch Reset Instructions
WARNING: If you see or smell gasoline at any time other than during fueling, do not reset the inertia fuel shutoff (IFS) switch. Failure to follow these instructions may result in personal injury.
- Key in OFF position.
- Check for fuel leaks in the engine compartment.
- If no leak is present, reset the IFS switch by pushing the reset button on the top of the switch. Refer to the Owner's Literature for IFS switch location.
NOTE: In the closed position, the button can be pressed an additional 1.57 mm (0.06 in) against a spring.
- Key ON, engine OFF.
- Key in OFF position.
- Key ON, engine OFF.
- Key in OFF position.
- Check for leaking fuel.
HC1: CHECK THE SYSTEM INTEGRITY
- Visually inspect the complete fuel delivery system for damage and leakage.
  Check the following:
  - fuel lines and connections
  - relays
  - fuel tank
  - fuel pump
  - fuel pressure regulator
  - fuel pulse damper
  - fuel rail at injectors
  - damaged connector pins
  - electrical connectors not fully engaged
- Verify the vehicle has followed the maintenance schedule. A new fuel filter should have been installed within the last 48,280 km (30,000 miles).
- Verify the IFS switch is set (button pushed in). Refer to the Owner's Literature for location.
- Verify the fuse integrity.
- Verify the 12-volt battery is fully charged.
- Verify the fuel level, grade, and quality is sufficient to support normal operation of the engine.
- Are any of the above concerns present?
- Yes: REPAIR as necessary. CLEAR the DTCs. REPEAT the self-test.
- No: GO to HC2.
HC2: CHECK ALL SYSTEM RELATED DEVICES (SENSOR, DAMPER, OR REGULATOR) FOR LEAKAGE
- Key in OFF position.
- FP connector connected.
- Key ON, engine running.
- Check for manifold vacuum at each system related component with a vacuum line.
- Key in OFF position.
- Wait 10 seconds.
- Key ON, engine running.
- Run the engine for approximately 10 seconds.
- Key in OFF position.
- Remove the vacuum hose on each system device connected to the fuel rail.
- Inspect for the presence of fuel in the vacuum line of each device connected to the fuel rail.
- Are all vacuum lines for system related devices indicating no fuel present?
- Yes: GO to HC3.
- No: If the vacuum line connected to a component indicates that a fuel leak is present, INSTALL a new component.
  CLEAR the DTCs. REPEAT the self-test.
HC3: CHECK THE FUEL PRESSURE
NOTE: During output state control, the fuel pump stays commanded on for only about 5 seconds.
- Key in OFF position.
- Relieve the fuel pressure. Refer to the FUEL SYSTEM - HYBRID for the Fuel System Pressure Release procedure.
- Mechanical fuel pressure gauge connected.
- Pressurize the fuel system. Refer to the FUEL SYSTEM - HYBRID for the Fuel System Pressure Release procedure.
- Key ON, engine OFF.
- Access the PCM and control the FP PID.
- Control the FP ON.
- Is the fuel pressure between 275-485 kPa (40-70 psi)?
- Yes: GO to HC6.
- No: GO to HC4.

HC4: CHECK THE FUEL PUMP GROUND CIRCUIT FOR AN OPEN IN THE HARNESS

Key in OFF position.
FP connector disconnected.
Key ON, engine OFF.

Measure the voltage between:

(+) Vehicle Battery	(-) FP Connector, Harness Side
Positive terminal	FPGND

Is the voltage greater than 10 V?

Yes: GO to HC5.
No: REPAIR the open circuit. CLEAR the DTCs. REPEAT the self-test.

HC5: CHECK THE FUEL PUMP POWER CIRCUIT FOR AN OPEN IN THE HARNESS

NOTE: During output state control, the fuel pump stays commanded on for only about 5 seconds.

Verify the IFS switch is set (button pushed in). Refer to the Owner's Literature for location.
FP connector disconnected.
Key ON, engine OFF.
Access the PCM and control the FP PID.
Control the FP ON.

Measure the voltage between:

(+) FP Connector, Harness Side	(-) Vehicle Battery
FPPWR	Negative terminal

Is the voltage greater than 10 V?

Yes: GO to HC6.
No: REPAIR the open circuit. CLEAR the DTCs. REPEAT the self-test.

HC6: CHECK THE FUEL PRESSURE LEAKDOWN
NOTE: When the fuel pump is commanded off, the fuel pressure may substantially decrease and then stabilize.

NOTE: During output state control, the fuel pump stays commanded on for only about 5 seconds.
- Mechanical fuel pressure gauge connected.
- Key ON, engine OFF.
- Access the PCM and control the FP PID.
- Run the fuel pump to obtain maximum fuel pressure.
- Command the fuel pump off.
- Allow the fuel pressure to stabilize.
- Monitor the fuel pressure for 1 minute.
- Does the fuel pressure remain greater than 275 kPa (40 psi) after 1 minute?
- Yes: GO to HC8.
- No: GO to HC7.
HC7: CHECK FUEL INJECTOR FLOW AND LEAKAGE
NOTE: Observe the warnings, cautions, and notes at the beginning of this pinpoint test.
- Check the fuel injectors for leakage and flow rate using the injector flow tester.
- Are test results satisfactory?
- Yes: GO to HC8.
- No: INSTALL a new fuel injector as necessary. REFER to the FUEL CHARGING AND CONTROLS -- HYBRID .
  RESET the keep alive memory (KAM). REFER to RESETTING THE KEEP ALIVE MEMORY (KAM) . REPEAT the self-test.
HC8: COMPARE THE FRP PID TO THE MECHANICAL GAUGE
NOTE: Most mechanical gauges are referenced to atmospheric pressure. The fuel rail pressure and temperature (FRPT) sensor is referenced to manifold pressure. In order to make a valid comparison, the engine must be off.

NOTE: The vehicle may exhibit a long crank until the fuel system is pressurized.
- Key in OFF position.
- Relieve the fuel pressure. Refer to the FUEL SYSTEM - HYBRID for the Fuel System Pressure Release procedure.
- Disable the fuel pump.
- Key ON, engine OFF.
- Monitor the mechanical gauge.
- Access the PCM and monitor the FRP PID.
- Compare the FRP PID value to the mechanical gauge.
- Key in OFF position.
- Pressurize the fuel system. Refer to the FUEL SYSTEM - HYBRID for the Fuel System Pressure Release procedure.
- Key ON, engine running.
- Allow the fuel pressure to stabilize.
- Key in OFF position.
- Key ON, engine OFF.
- Compare the FRP PID value to the mechanical gauge.
- Are the FRP PID values within 34 kPa (5 psi) of the mechanical gauge readings?
- Yes: GO to HC9.
- No: INSTALL a new FRPT sensor. REFER to the FUEL SYSTEM - HYBRID at the beginning of this pinpoint test. REFER to the ELECTRONIC ENGINE CONTROLS .
  CLEAR the DTCs. REPEAT the self-test.
HC9: CHECK THE FUEL SUPPLY LINE FOR RESTRICTION
NOTE: Observe the warnings, cautions, and notes at the beginning of this pinpoint test.
- Disconnect the fuel supply line at the fuel rail.
- Disconnect the fuel supply line at the fuel pump.
- Check the fuel supply line for restriction.
- Apply 21 to 34 kPa (3 to 5 psi) air pressure to the fuel supply line.
- Does air flow freely through the line?
- Yes: For misfire DTC diagnosis, GO to HD8.
  For symptoms without DTCs, RETURN to SYMPTOM CHARTS for further direction.
  
  For all others, INSTALL a new FP module. REFER to the FUEL TANK REMOVAL/INSTALLATION -- HYBRID and FUEL LINES REMOVAL/INSTALLATION -- HYBRID .
  
  CLEAR the DTCs. REPEAT the self-test.
- No: REPAIR the cause of the restriction.
  CLEAR the DTCs. REPEAT the self-test.