GR Yaris High Pressure (DI) Fuel Sensor Failed on Track

[ninjan00dles]

Just documenting this for others.

Our development car had a high pressure fuel sensor fail midcorner at high rpm on track (Sonoma Raceway) several weeks ago.
Ecutek / ECU did what it was supposed to do - it lost high pressure signal and instantly went into port injection only mode / limp mode and lowered the redline.

Installed a new sensor and all is good again.

CEL was P0190-11


2023 GR Corolla, 12+ track days, 44000 miles (~ 71000 km)
Ecutek w/ flex fuel. Stock fueling otherwise.

 

[Michael Knight]

any idea why did the sensor go? ethanol or just broke down?

 

[Orion]

My 2021 GRY, 102000km (3000 track km) did the exact same thing on a public road, luckily I wasnt overtaking.
CEL, same code, limp mode, hard cut at 2k RPM, those 30km limping home werent a joyride
Unfortunately wasnt allowed to open the sensor cover, as the workshop had to return it. Covered under warranty.
Could it be related to the increased boost/fuel demands of the Toyota remap done 2000km ago...?

 

[Sekred]

I would not say it's a common issue but its, say a known issue. I think there is a thread on this forum or the other about it.
Keeping one as a spare is not a bad idea. Google the part number to find the best price otherwise you may pay way too much.

 

[ninjan00dles]

any idea why did the sensor go? ethanol or just broke down?

No clue - our tuner said it's been happening with some 2nd gen GRZ86s as well. I didn't do any digging as to whether it's the same (sensor) manufacturer.

I also recall there being an issue with 1st gen GRY oil pressure sensors that led to Toyota relocating them to the current position.

 

[ninjan00dles]

I would not say it's a common issue but its, say a known issue. I think there is a thread on this forum or the other about it.
Keeping one as a spare is not a bad idea. Google the part number to find the best price otherwise you may pay way too much.

Ours was PN 89458-78030

If you attempt to do it at the track - try your best to completely depressurize the DI fuel rail. The DI rail seemed to have a ton of residual pressure when uninstalling the original sensor even with running the system dry and disconnecting the supply line.

1. Pull the fuel pump fuse in the main fuse box
2. Unplug the low pressure fuel pump under the rear seats (I assume GRY is the same)
3. Run car until it dies from no fuel
4. Disconnect Battery
5. Disconnect fuel line at the Y fitting before it splits between DI and PI
6. Remove sensor with 2 8mm bolts underneath throttle body area on front of block

TIS recommends doing an ECU relearn afterwards. Ecutek can now reset trims and learning in the app (our tuner had that as an open ticket for some time). If on a stock car you will have to use GTS+ to reset. In our experience disconnecting the battery (even for 24 hours and shorting the terminal) does not reset our fuel trims, but maybe you guys have more luck.

 

[Sekred]

Ours was PN 89458-78030

If you attempt to do it at the track - try your best to completely depressurize the DI fuel rail. The DI rail seemed to have a ton of residual pressure when uninstalling the original sensor even with running the system dry and disconnecting the supply line.

1. Pull the fuel pump fuse in the main fuse box
2. Unplug the low pressure fuel pump under the rear seats (I assume GRY is the same)
3. Run car until it dies from no fuel
4. Disconnect Battery
5. Disconnect fuel line at the Y fitting before it splits between DI and PI
6. Remove sensor with 2 8mm bolts underneath throttle body area on front of block

TIS recommends doing an ECU relearn afterwards. Ecutek can now reset trims and learning in the app (our tuner had that as an open ticket for some time). If on a stock car you will have to use GTS+ to reset. In our experience disconnecting the battery (even for 24 hours and shorting the terminal) does not reset our fuel trims, but maybe you guys have more luck.

Where is it located?

 

[Orion]

Oddly the GR Yaris part number is different, 89458-33030 but apparently they fail equally
Is located under the intake manifold
Image taken from 4turbo.pl

 

[Sekred]

Ours was PN 89458-78030

If you attempt to do it at the track - try your best to completely depressurize the DI fuel rail. The DI rail seemed to have a ton of residual pressure when uninstalling the original sensor even with running the system dry and disconnecting the supply line.

1. Pull the fuel pump fuse in the main fuse box
2. Unplug the low pressure fuel pump under the rear seats (I assume GRY is the same)
3. Run car until it dies from no fuel
4. Disconnect Battery
5. Disconnect fuel line at the Y fitting before it splits between DI and PI
6. Remove sensor with 2 8mm bolts underneath throttle body area on front of block

TIS recommends doing an ECU relearn afterwards. Ecutek can now reset trims and learning in the app (our tuner had that as an open ticket for some time). If on a stock car you will have to use GTS+ to reset. In our experience disconnecting the battery (even for 24 hours and shorting the terminal) does not reset our fuel trims, but maybe you guys have more luck.

Mmm. When I did mine and I was just checking the location to make sure we were talking about the same sensor, I didn't do any of that procedure I just pull it out after letting it cool over night. There was no residual pressure.

 

[Orion]

Mmm. When I did mine and I was just checking the location to make sure we were talking about the same sensor, I didn't do any of that procedure I just pull it out after letting it cool over night. There was no residual pressure.

I am trying to figure out the pids and equations for "fuel rail pressure high" target and actual
Just checked on my car, the sensor shows 3.7bars before starting the car (car last used 16 hours ago)
Started the car, value jumps to 140bars...

 

[Sekred]

 

[ninjan00dles]

Mmm. When I did mine and I was just checking the location to make sure we were talking about the same sensor, I didn't do any of that procedure I just pull it out after letting it cool over night. There was no residual pressure.

ok.