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Highlander & RAV4

  1. Ensure battery is fully charged. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE . Disconnect negative battery cable.
  2. Purchase fuel pipe (part No. 23901-28070 for Highlander or 23901-22110 for RAV4) from parts department. Remove fuel pipe connector from end of NEW fuel pipe. See Figure and Fig 1 .
  3. Remove fuel pipe clamp from end of fuel pipe at fuel pipe fitting. See Fig 3 and Fig 4 . Ensure area around fuel pipe and disconnect fitting is clean.
    4. CAUTION: Use care when disconnecting fuel pipe, as some residual fuel pressure may still exist in the fuel system.
  4. Depress both tabs and pull fuel pipe with disconnect fitting from fuel pipe fitting. See Fig 3 and Fig 4 . Install Fuel Pressure Gauge Set (SST 09268-45012 for Highlander and SST 09268-45014 for RAV4) by using Injection Measuring Tool Set (SST 09268-41047) and fuel pipe connector between fuel pipe and fuel pipe fitting. See Figure and Fig 2 . Ensure hose, fuel pipe and fuel pipe connector are properly connected. Install fuel pipe clamp.
  5. Install negative battery cable. Connect Toyota hand-held tester to data link connector No. 3 at driver's side of instrument panel. See Figure and 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, operate 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 and 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 & INSTALLATION - 4-CYLINDER 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. Turn ignition off. Remove hand-held tester. Start engine and allow engine to idle. Note fuel pressure with engine idling. Fuel pressure should be 44-50 psi (3.1-3.5 kg/cm2 ).
  9. 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.
  10. Release fuel pressure. Disconnect negative battery cable. Remove adapter, hose, fuel pressure gauge and fuel pipe connector.
  11. Install fuel pipe on fuel pipe fitting. Pull on fuel pipe to ensure 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 1: Identifying Fuel Pipe Connector (RAV4)
    G00251585Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 2: Installing Fuel Pressure Gauge (RAV4)
    G00251586Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 3: Locating Fuel Pipe Clamp & Disconnecting Fuel Pipe From Fuel Pipe Fitting (Highlander)
    G00020894Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 4: Locating Fuel Pipe Clamp & Disconnecting Fuel Pipe From Fuel Pipe Fitting (RAV4)
    G00011392Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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