Hello all.

Well, i have a 1999 2.4ltr EFI Petrol Hiace that has been running perfect until one morning it just didn't start.

It would crank over fine / Removed No.1 Spark Plug and there is Spark / Tank has fuel, although i had been running it very low of late

Even though there is spark i have replace Plugs/Leads/Rotor Botton/Dizzy Cap all with new.

Same problem still exsists, thus you would think it is fuel..... Using the "Start you ****" spray, the engine will fire and run unitl all spray has been burnt.

I have checked all fuses, ok
Checked Relays, seem ok
I now suspect it to be either block fuel filter / broken fuel pump / AFM or ECU?

There is fuel at the fuel rail when you crack the fuel line nut (but i haven't tried turning the key when bolt is undone to see if fuel sprays out)

This is about where i am at.... and i am half way through pulling the fuel tank out to check the leads to the fuel pump for power and/or fuel pump operation.

This van has worked flawlessly up until one morning when it just did not fire again..... Does anyone have any suggestions or simple tests or checks i could do?
As pulling everything apart is a real pain.

I have been searching for Toyota Service Manuals on the net for a weeks with no luck at all..... in fact any info has been amazingly hard to find.

Can anyone tell me if taking the tank out is the correct way to access the fuel pump? (just seems a lot of work to get to a simple part)
Is the Fuel filter under the EFI intake? (in a very hard place to get too)

Cheers and Thank You for any help or suggestions.

Ok, first you need to determine that you have fuel pump pressure.

You can crack the nut you mentioned or just look at where the fuel enters the injection rail and drop the hose there (into a container).

Turn the key on - the pump will probably start (to give some pressure) then stop (because the engine hasn't started - safety measure).

If you get no fuel pressure at all, time to start looking at the fuel system. Most Toyotas with EFI have a fuel pump relay and a resistor that supplies power to the pump. Not uncommon for the resistor to go open circuit.

Get someone to lie down beside the vehicle at the rear, then you turn the key on. You should be able to hear the pump start. That's a pretty easy check.

If all this is in order, then you have an ECU issue. Pretty uncommon for an ECU to die - unless someone has jump started the vehicle using booster or jumper leads that have no surge protection on them. That can nuke an ECU pretty quick.

Related to the ECU are various sensors on the engine, but I am not aware of any one sensor that would stop the engine from at least starting.

If it gets to this point, your best bet is to wheel your vehicle to your nearest Toyota dealer and get them to put it on the diagnostics. This will save time and money as they will be able to determine very quickly what is at fault.

Oh, and by the way - don't take the spark plugs out and crank the engine over as you mentioned to "test for spark". With these new electronically controlled engine management systems, if the spark doesn't have a path to ground (as it does when the plug is in the head) then the energy travels back up into the ignitor and can find its way back to the ECU - POOF! I have seen several cases of fried ECUs due to this action.

Thank you very much for such a prompt and detailed reply Hiace4x4.
I did i have the spark plug earth to the head when i cranked, but i will take your advice on board :)

I will go check the pressure at Fuel Rail now (from memory i have had no pump noise at the tank end, so that resistor may be a place to look... if i can ever find it?) It seems so hard to find any kind of schematic diagram for these things.

Ok... i removed the fuel line from the fuel rail... fuel was trickling out, turned the key... still just trickling at same speed.... cranked the car... still trickling at same speed. You certainly would not say it was under any presure at any time.
Bolted the fuel line back to fuel rail.

Started re checking relays. This is where it gets a little harder, as the legend inside the relay cover doesn't really match the relays and fuses i have. Cover seems to support a Diesel more so, although it is probably the same cover. As it does mention some EFI stuff.


Relay set in foot well --------------->

(IMG:http://i37.tinypic.com/10h2hcz.jpg)
^^^^ Both Black Relays to the far left work, but only the Top one activates when key is turned.

Fuses ------------------>

(IMG:http://i35.tinypic.com/xayyo.jpg)
^^^^ All fuses are ok

Connection at rear of van, behind passanger rear wheel and leading into Fuel tank?? ----------->

(IMG:http://i34.tinypic.com/afa8mv.jpg)
^^^^ Is this a power connection for the pump? As when it is disconnected the fuel gauge still reads, so i take it it's not for that?

I am really stumped here, and worse it is my work vehicle, Doh! It seems i may have to take the fuel tank out now check if there is power to the pump?? Although i'd love to know an easier way to solve this problem.

Any advise would be greatly appreciated :)

Ooops. Sorry for my late reply!!

I've been ultra busy with work and stuff and haven't had much time on the net.

I'm guessing that since a month at least has gone by since you posted the photos and the request above that you've probably fixed it somehow by now, but in case you haven't, read on...

Ok, the relays you are looking at in the black box are not the ones you need to look at. The relay that controls the fuel pump will be in the engine bay somewhere - near the engine. The resistor will be next to it or not far away.

You need to determine if there is any voltage on the resistor. You may find there is +12 v one side of the resistor and nothing on the other - clear indication that the resistor is open circuit.

The lack of fuel pressure and the fact you can't hear the pump means it's pretty likely the pump isn't running.

Let me know where you are at with everything.