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Fuel Pressure: Highlander

  1. Ensure battery is fully charged. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE . Disconnect negative battery cable.
  2. Purchase No. 1 fuel pipe Part No. (23801-20120) from local Toyota parts department. No. 1 fuel pipe is fuel pipe that attaches to fuel rail. Remove fuel pipe connector from end of NEW No. 1 fuel pipe. See Fig 1.
    Fig 1: Identifying Fuel Pipe Connector (Highlander)
    G99C52375Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Remove fuel pipe clamp from disconnect fitting at end of No. 1 fuel pipe. See Fig 2. Ensure area around No. 1 fuel pipe and disconnect fitting is clean.
    4. CAUTION: Use care when disconnecting No. 1 fuel pipe from fuel pipe fitting, as some residual fuel pressure may still exist in the fuel system.
  4. Depress both tabs and pull No. 1 fuel pipe with disconnect fitting from fuel pipe fitting. See Fig 2. Install Adapter (SST 09268-41250) and hose with fuel pressure gauge from Fuel Pressure Gauge Set (SST 09268-45014) with fuel pipe connector between No. 1 fuel pipe and fuel pipe fitting. See Fig 3. Ensure hose, No. 1 fuel pipe and fuel pipe connector are properly connected.
  5. Install negative battery cable. Connect Toyota hand-held tester to data link connector No. 3. See Figure. Turn ignition on. DO NOT start engine.
  6. Turn hand-held tester on. Select ACTIVE TEST MODE on hand-held tester. Using hand-held tester manufacturer's instructions, activate fuel pump and note fuel pressure. If hand-held tester is not available, fuel pump may also be activated by connecting battery voltage to specified terminals on fuel pump. See Figure. Fuel pressure should be 44-50 psi (3.1-3.5 kg/cm2 ).
  7. If fuel pressure is within specification, go to next step. If fuel pressure exceeds specification, replace fuel pressure regulator mounted on fuel pump in the fuel tank. See FUEL PRESSURE REGULATOR under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - V6 & V8 article. If fuel pressure is less than specified, check for leaking fuel hoses or connections, restricted fuel filter, defective fuel pump or defective fuel pressure regulator.
  8. Remove hand-held tester from data link connector No. 3. Start engine and note fuel pressure with engine idling. Fuel pressure should be 44-50 psi (3.1-3.5 kg/cm2 ). Shut engine off and note fuel pressure. Fuel pressure should remain at least 21 psi (1.5 kg/cm2 ) for a minimum of 5 minutes. If fuel pressure is within specification and holds as specified, go to next step. If fuel pressure is not within specification or does not hold as specified, check for defective fuel pump, fuel injector or fuel pressure regulator.
  9. Release fuel pressure. Disconnect negative battery cable. Remove adapter, hose, fuel pressure gauge and fuel pipe connector.
  10. Install No. 1 fuel pipe on fuel pipe fitting. Pull on No. 1 fuel pipe to ensure No. 1 fuel pipe is properly locked on fuel pipe fitting. Reinstall fuel pipe clamp. Install negative battery cable. Check for fuel leaks by activating the fuel pump by using hand-held tester or connecting battery voltage to fuel pump.
Fig 2: Locating Fuel Pipe Clamp & Disconnecting No. 1 Fuel Pipe From Fuel Pipe Fitting (Highlander)
G00023140Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 3: Installing Fuel Pressure Gauge (Highlander)
G00020815Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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