Engine Control System & Component Testing - 4-CYLINDER: Overview

Engine Control System & Component Testing - 4-CYLINDER: Overview Toyota Highlander I

Fuel Pump Resistance & Operation (Camry)

Manufacturer lists checking fuel pump resistance and operation with fuel pump removed from fuel tank and fuel pump mounting bracket. For removal of fuel pump from fuel tank and fuel pump mounting bracket, see FUEL PUMP under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article.
To test fuel pump resistance, using ohmmeter, check resistance between electrical terminals on fuel pump. (Scheme 136) Replace fuel pump if resistance is not.20-3.00 ohms at 68°F (20°C). See FUEL PUMP under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article.
To test fuel pump operation, apply battery voltage and ground to (+) and (-) terminals on fuel pump. (Scheme 136) DO NOT apply battery voltage to fuel pump for more than 10 seconds. Replace fuel pump if fuel pump does not operate. See FUEL PUMP under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article.

Fuel Pump Resistance & Operation (Camry Solara, Celica, Corolla, ECHO, Highlander, MR2, Prius, RAV4 & Tacoma

WARNING

On Prius, read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS.

On Camry Solara, Celica, Corolla, ECHO and Prius, remove rear seat cushion, cover plate on floor panel and remaining necessary covers for access to electrical connector for fuel pump.
On Highlander, remove driver's side and passenger's side rear seats and cover plate on floor panel for access to electrical connector for fuel pump.
On MR2, remove luggage compartment lids, quarter trim covers, lower trim covers and luggage compartment boxes behind driver's and passenger's seats, and cover plate on floor panel for access to electrical connector for fuel pump. (Scheme 146) For additional information on removal of luggage compartment components, see «FUEL PUMP»(ref-133226-S07700574872002021900000) under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article.
On RAV4, remove driver's side rear seat and cover plate on floor panel for access to electrical connector for fuel pump.
On Tacoma, it may be necessary to lower fuel tank for access to electrical connector for fuel pump.
On all models, disconnect electrical connector for fuel pump. This is electrical connector for fuel pump and fuel gauge sending unit and is located on top of fuel tank, near fuel pump.
To test fuel pump resistance, using ohmmeter, check resistance between specified terminals on fuel pump electrical connector or fuel pump. (Scheme 137)- (Scheme 145). Replace fuel pump if resistance is not.20-3.00 ohms at 68°F (20°C). On Prius, it may be necessary to replace fuel pump and fuel tank as an assembly. Consult parts department for parts availability. See «FUEL PUMP»(ref-133226-S07700574872002021900000) under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article.
To test fuel pump operation, apply battery voltage and ground to (+) and (-) terminals on electrical connector or fuel pump. (Scheme 137)- (Scheme 145). DO NOT apply battery voltage to fuel pump for more than 10 seconds. Replace fuel pump and/or lead wire (if equipped) if fuel pump fails to operate. On Prius, it may be necessary to replace fuel pump and fuel tank as an assembly. Consult parts department for parts availability. See FUEL PUMP under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article.

Scheme 136

Scheme 137

Scheme 138

Scheme 139

Scheme 140

Scheme 141

Scheme 142

Scheme 143

Scheme 144

Scheme 145

Scheme 146

Scheme 146: Fuel Injectors (Camry)

Scheme 147

Scheme 148

Scheme 149

Scheme 150

To check for fuel injector operation, using stethoscope, listen for clicking sound at each fuel injector, or feel for fuel injector operation at fuel injector with engine cranking or with engine running. If fuel injector operation does not exist, check for loose connection at electrical connector for fuel injector. If electrical connector for fuel injector is okay, go to next step.
Ensure ignition is off. Disconnect electrical connector at fuel injector. Using ohmmeter, check resistance between electrical terminals on fuel injector. Replace fuel injector if resistance is not within specification. See «FUEL INJECTOR RESISTANCE»(ref-133221-S40320021852002021900000) table. See «FUEL RAILS & FUEL INJECTORS»(ref-133226-S05944270142002021900000) under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article.
If fuel injector operates and fuel injector resistance is within specification, go to next step. If fuel injector resistance is within specification but fuel injector does not operate, check wiring circuit to fuel injector. See «WIRING DIAGRAMS»(/toyota/highlander/i-2001-2003/remont/wiring-diagrams-engine-performance/#wiring-diagrams) article. If problem exists in fuel injector or wiring circuit and misfire exists, a Diagnostic Trouble Code (DTC) may be stored in Engine Control Module (ECM). See TESTING PROCEDURE under SELF-DIAGNOSTIC SYSTEM in appropriate SELF-DIAGNOSTICS article for retrieving of DTCs.
To check fuel injector volume, remove fuel injector. See «FUEL RAILS & FUEL INJECTORS»(ref-133226-S05944270142002021900000) under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article.
Remove fuel pipe clamp from end of fuel pipe at fuel pipe fitting if not previously done. (Scheme 147) Ensure area around fuel pipe and disconnect fitting is clean.
Depress both tabs and pull fuel pipe with disconnect fitting from fuel pipe fitting. (Scheme 147) Use care when disconnecting fuel pipe, as some residual fuel pressure may still exist in fuel system.
Purchase fuel pipe (part No. 23901-28130) from parts department. Remove fuel pipe connector from end of NEW fuel pipe. (Scheme 148)
Install fuel pipe connector on fuel pipe fitting. (Scheme 149) Ensure fuel pipe connector is securely attached on fuel pipe fitting is fully seated.
Connect delivery hose from Fuel Injector Measuring Set (SST 09268-41047) to fuel pipe connector. Check that "O" ring is installed on top of fuel injector. Using clamp and union from fuel injector measuring set, connect fuel injector to delivery hose. (Scheme 149)
Place vinyl tube on end of fuel injector to prevent fuel spillage. Place fuel injector into a clean graduated container.
Connect Toyota hand-held tester to data link connector No. 3 at driver's side of instrument panel. see scheme 8 Turn ignition on and then turn hand-held tester on. Select ACTIVE TEST MODE on hand-held tester. Using hand-held tester manufacturer's instructions, activate fuel pump. NOTE: If hand-held tester is not available, fuel pump may also be operated to pressurize fuel system by removing circuit opening relay from fuse/relay box and installing jumper wire between FP and +B terminals in fuse/relay box for circuit opening relay and then turning ignition on. (Scheme 150) Fuse/relay box is located at driver's side front corner of engine compartment.
Connect Fuel Injector Tester (09842-30080) to fuel injector for 15 seconds. (Scheme 151) Measure fuel injector volume. Test each fuel injector 2-3 times. Replace fuel injector if fuel injector volume is not within specification. See «FUEL INJECTOR VOLUME SPECIFICATIONS»(ref-133221-S38944995152002021900000) table. Ensure difference between fuel injector volume on all fuel injectors is within specification. See «FUEL INJECTOR VOLUME SPECIFICATIONS»(ref-133221-S38944995152002021900000) table.
Disconnect fuel injector tester. Ensure fuel leakage from end of fuel injector does not exceed one drop in 12 minutes. Replace fuel injector if leakage exceeds one drop in 12 minutes. Disconnect negative battery cable. Remove test equipment.
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 operating the fuel pump by using hand-held tester or connecting battery voltage to fuel pump. NOTE: It may be possible that power sun roof may not operate properly after battery was disconnected. If power sun roof does not operate properly, perform power sun roof reinitialization procedure. See appropriate «POWER SUN ROOF REINITIALIZATION PROCEDURE»(ref-133221-S15755059972002032500000) under PROGRAMMING.

Scheme 151

Scheme 151: Fuel Injectors (Camry Solara)

Scheme 152

Scheme 153

To check for fuel injector operation, using stethoscope, listen for clicking sound at each fuel injector, or feel for fuel injector operation at fuel injector with engine cranking or with engine running. If fuel injector operation does not exist, check for loose connection at electrical connector for fuel injector. If electrical connector for fuel injector is okay, go to next step.
Ensure ignition is off. Disconnect electrical connector at fuel injector. Using ohmmeter, check resistance between electrical terminals on fuel injector. Replace fuel injector if resistance is not within specification. See «FUEL INJECTOR RESISTANCE»(ref-133221-S40320021852002021900000) table. See «FUEL RAILS & FUEL INJECTORS»(ref-133226-S05944270142002021900000) under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article.
If fuel injector operates and fuel injector resistance is within specification, go to next step. If fuel injector resistance is within specification but fuel injector does not operate, check wiring circuit to fuel injector. See «WIRING DIAGRAMS»(/toyota/highlander/i-2001-2003/remont/wiring-diagrams-engine-performance/#wiring-diagrams) article. If problem exists in fuel injector or wiring circuit and misfire exists, a Diagnostic Trouble Code (DTC) may be stored in Engine Control Module (ECM). See TESTING PROCEDURE under SELF-DIAGNOSTIC SYSTEM in appropriate SELF-DIAGNOSTICS article for retrieving of DTCs.
To check fuel injector volume, remove fuel injector. See «FUEL RAILS & FUEL INJECTORS»(ref-133226-S05944270142002021900000) under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article.
Remove fuel pipe clamp from fuel pipe at fuel filter if not previously done. Perform STEP 1 in illustration. (Scheme 152) Ensure area around fuel pipe and fuel filter is clean.
Depress both sides of retainer and pull fuel pipe with disconnect fitting from fuel filter. Perform STEP 2 in illustration. (Scheme 152) Use care when disconnecting fuel pipe from fuel filter, as some residual fuel pressure may still exist in the fuel system.
Purchase fuel pipe (part No. 23901-22070) from parts department. Remove fuel pipe connector from end of NEW fuel pipe. (Scheme 153)
Install fuel pipe connector on fuel pipe fitting at fuel filter. see scheme 131 Ensure fuel pipe connector is securely attached on fuel pipe fitting.
Connect delivery hose from Fuel Injector Measuring Set (SST 09268-41047) to fuel pipe connector. Check that grommet and "O" ring are installed on top of fuel injector. Using clamp and union from fuel injector measuring set, connect fuel injector to delivery hose. see scheme 131
Place vinyl tube on end of fuel injector to prevent fuel spillage. Place fuel injector into a clean graduated container.
Connect Toyota hand-held tester to data link connector No. 3 at driver's side of instrument panel. see scheme 9 Turn ignition on and then turn hand-held tester on. Select ACTIVE TEST MODE on hand-held tester. Using hand-held tester manufacturer's instructions, activate fuel pump. NOTE: If hand-held tester is not available, fuel pump may also be operated to pressurize fuel system by applying battery voltage to electrical terminals on fuel pump. For operating of fuel pump, see appropriate «FUEL PUMP RESISTANCE & OPERATION»(ref-133221-S22385185732002021900000) procedure under FUEL DELIVERY under FUEL SYSTEMS.
Connect Fuel Injector Tester (09842-30070) to fuel injector for 15 seconds. (Scheme 151) Measure fuel injector volume. Test each fuel injector 2-3 times. Replace fuel injector if fuel injector volume is not within specification. See «FUEL INJECTOR VOLUME SPECIFICATIONS»(ref-133221-S38944995152002021900000) table. Ensure difference between fuel injector volume on all fuel injectors is within specification. See «FUEL INJECTOR VOLUME SPECIFICATIONS»(ref-133221-S38944995152002021900000) table.
Disconnect fuel injector tester. Ensure fuel leakage from end of fuel injector does not exceed one drop in 12 minutes. Replace fuel injector if leakage exceeds one drop in 12 minutes. Disconnect negative battery cable. Remove test equipment.
Apply light coat of engine oil on tip of fuel pipe fitting on fuel filter to allow for ease of disconnect fitting and fuel pipe installation. Using NEW retainer, install fuel pipe on fuel filter until "click" sound is heard. DO NOT reuse old retainer. Pull on fuel pipe to ensure fuel pipe is properly locked on fuel filter.
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.