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Inspection Procedure

  1. PERFORM ACTIVE TEST BY INTELLIGENT TESTER (OPERATE CIRCUIT OPENING RELAY)
    1. Connect the intelligent tester to the DLC3.
    2. Turn ON the ignition switch, push the intelligent tester or the OBD II scan tool main switch ON.
    3. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / FUEL PUMP / SPD.
    4. Check the relay operation while operating it using the intelligent tester.

      Standard: Operating noise can be heard from the relay.

    OK: Go to step  5

    NG: GO TO NEXT STEP

  2. INSPECT CIRCUIT OPENING RELAY
    1. Remove the circuit opening relay from the R/B subassembly.
    2. Measure the resistance of the circuit opening relay.

      Standard resistance

      TESTER CONNECTION SPECIFIED CONDITION

      Tester Connection Specified Condition
      3 - 5 10 kΩ or higher
      3 - 5 Below 1 Ω
      (when battery voltage is applied to terminals 1 and 2)

    NG: REPLACE CIRCUIT OPENING RELAY

    Fig 1: Inspecting Circuit Opening Relay
    G04424164Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    OK: GO TO NEXT STEP

  3. INSPECT ECM (FC VOLTAGE)
    1. Turn the ignition switch ON.
    2. Measure the voltage of the ECM connectors.

      Standard voltage

      TESTER CONNECTION SPECIFIED CONDITION

      Tester Connection Specified Condition
      E5-10 (FC) - E9-1 (E1) 9 to 14 V

    OK: REPLACE ECM

    Fig 2: Identifying ECM Connectors
    G04424165Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    NG: GO TO NEXT STEP

  4. CHECK HARNESS AND CONNECTOR (ECM - C/OPN RELAY, C/OPN RELAY - IGNITION SWITCH)
    1. Check the wire harness between the ECM and circuit opening relay.
      1. Disconnect the E5 ECM connector.
      2. Remove the circuit opening relay from the R/B subassembly.
      3. Measure the resistance of the wire harness side connectors.

        Standard resistance

        TESTER CONNECTION SPECIFIED CONDITION

        Tester Connection Specified Condition
        E5-10 (FC) - R/B sub-assembly circuit opening relay terminal 2 Below 1 Ω
        E5-10 (FC) or R/B sub-assembly circuit opening relay terminal 2 - Body ground 10 kΩ or higher
    2. Check the wire harness between the circuit opening relay and ignition switch.
      1. Check the IGN fuse.
        • Remove the IGN fuse from the instrument panel J/B assembly.
        • Measure the resistance of the IGN fuse.

          Standard resistance: Below 1 Ω

        • Reinstall the IGN fuse.
      2. Remove the circuit opening relay from the R/B subassembly.
      3. Disconnect the I15 ignition switch connector.
      4. Measure the resistance of the wire harness side connectors.

        Standard resistance

        TESTER CONNECTION SPECIFIED CONDITION

        Tester Connection Specified Condition
        R/B sub-assembly circuit opening relay terminal 1 - I15-6 (IG2) Below 1 Ω
        R/B sub-assembly circuit opening relay terminal 1 or I15-6 (IG2) - Body ground 10 kΩ or higher

    NG: REPAIR OR REPLACE HARNESS AND CONNECTOR

    Fig 3: Disconnecting E5 ECM Connector
    G04424166Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    OK: REPLACE ECM

  5. INSPECT FUEL PUMP
    1. Measure the resistance of the fuel pump.

      Standard resistance

      TESTER CONNECTION SPECIFIED CONDITION

      Tester Connection Condition Specified Condition
      4 - 5 20°C (68°F) 0.2 to 0.3 Ω
    2. Check operation of the fuel pump.
      1. Apply battery voltage to both terminals. Check that the pump operates.
        NOTE:
        • These tests must be done quickly (within 10 seconds) to prevent the coil from burning out.
        • Keep the fuel pump as far away from the battery as possible.
        • Always turn ON and OFF the voltage on the battery side, not the fuel pump side.

    NG: REPLACE FUEL PUMP

    Fig 4: Identifying Fuel Pump Connector Terminal
    G04424167Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    OK: GO TO NEXT STEP

  6. CHECK HARNESS AND CONNECTOR (CIRCUIT OPENING RELAY - FUEL PUMP, FUEL PUMP - BODY GROUND)
    1. Check the wire harness between the circuit opening relay and fuel pump.
      1. Remove the circuit opening relay from the R/B subassembly.
      2. Disconnect the F12 fuel pump connector.
      3. Measure the resistance of the wire harness side connectors.

        Standard resistance

        TESTER CONNECTION SPECIFIED CONDITION

        Tester Connection Specified Condition
        R/B sub-assembly circuit opening relay terminal 3 - F12-4 Below 1 Ω
        R/B sub-assembly circuit opening relay terminal 3 or F12-4 - Body ground 10 kΩ or higher
    2. Check the wire harness between the fuel pump and body ground.
      1. Disconnect the F12 fuel pump connector.
      2. Measure the resistance between the wire harness side connector and body ground.

        Standard resistance

        TESTER CONNECTION SPECIFIED CONDITION

        Tester Connection Specified Condition
        F12-5 - Body ground Below 1 Ω

    OK: REPAIR OR REPLACE HARNESS AND CONNECTOR

    Fig 5: Identifying F12 Fuel Pump Connector Terminal
    G04424168Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    NG: REPLACE ECM

  1. CHECK FUEL PUMP OPERATION
    1. Check if there is pressure in the fuel inlet hose.

      HINT:

      The pump has fuel pressure if the sound of flowing fuel can be heard.

    OK: PROCEED TO NEXT CIRCUIT INSPECTION SHOWN ON PROBLEM SYMPTOMS TABLE 

    NG: GO TO NEXT STEP

  2. CHECK CIRCUIT OPENING RELAY OPERATION
    1. Connect terminal FC of the ECM connector and body ground, and check relay operation.

      Standard: Noise can be heard from the circuit opening relay.

    OK: Go to step  6

    Fig 6: Identifying F5 ECM Connector
    G04424169Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    NG: GO TO NEXT STEP

  3. INSPECT CIRCUIT OPENING RELAY
    1. Remove the circuit opening relay from the R/B subassembly.
    2. Measure the resistance of the circuit opening relay.

      Standard resistance

      TESTER CONNECTION SPECIFIED CONDITION

      Tester Connection Specified Condition
      3 - 5 10 kΩ or higher
      3 - 5 Below 1 Ω
      (when battery voltage is applied to terminals 1 and 2)

    NG: REPLACE CIRCUIT OPENING RELAY

    Fig 7: Inspecting Circuit Opening Relay
    G04424170Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    OK: GO TO NEXT STEP

  4. INSPECT ECM (FC VOLTAGE)
    1. Turn the ignition switch ON.
    2. Measure the voltage of the ECM connectors.

      Standard voltage

      TESTER CONNECTION SPECIFIED CONDITION

      Tester Connection Specified Condition
      E5-10 (FC) - E9-1 (E1) 9 to 14 V

    OK: REPLACE ECM

    Fig 8: Inspecting ECM (FC Voltage)
    G04424171Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    NG: GO TO NEXT STEP

  5. CHECK HARNESS AND CONNECTOR (ECM - C/OPN RELAY, C/OPN RELAY - IGNITION SWITCH)
    1. Check the wire harness between the ECM and circuit opening relay.
      1. Disconnect the E5 ECM connector.
      2. Remove the circuit opening relay from the R/B subassembly.
      3. Measure the resistance of the wire harness side connectors.

        Standard resistance

        TESTER CONNECTION SPECIFIED CONDITION

        Tester Connection Specified Condition
        E5-10 (FC) - R/B sub-assembly circuit opening relay terminal 2 Below 1 Ω
        E5-10 (FC) or R/B sub-assembly circuit opening relay terminal 2 - Body ground 10 kΩ or higher
    2. Check the wire harness between the circuit opening relay and ignition switch.
      1. Check the IGN fuse.
        • Remove the IGN fuse from the instrument J/B assembly.
        • Measure the resistance of the IGN fuse.

          Standard resistance: Below 1 Ω

        • Reinstall the IGN fuse.
      2. Remove the circuit opening relay from the R/B subassembly.
      3. Disconnect the I15 ignition switch connector.
      4. Measure the resistance of the wire harness side connectors.

        Standard resistance

        TESTER CONNECTION SPECIFIED CONDITION

        Tester Connection Specified Condition
        R/B sub-assembly circuit opening relay terminal 1 - I15-6 (IG2) Below 1 Ω
        R/B sub-assembly circuit opening relay terminal 1 or I15-6 (IG2) - Body ground 10 kΩ or higher

    NG: REPAIR OR REPLACE HARNESS AND CONNECTOR

    Fig 9: Disconnecting E5 ECM Connector
    G04424172Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    OK: REPLACE ECM

  6. INSPECT FUEL PUMP
    1. Measure the resistance of the fuel pump.

      Standard resistance

      TESTER CONNECTION SPECIFIED CONDITION

      Tester Connection Condition Specified Condition
      4 - 5 20°C (68°F) 0.2 to 0.3 Ω
    2. Check operation of the fuel pump.
      1. Apply battery voltage to both the terminals. Check that the pump operates.
        NOTE:
        • These tests must be done quickly (within 10 seconds) to prevent the coil from burning out.
        • Keep the fuel pump as far away from the battery as possible.
        • Always turns ON and OFF the voltage on the battery side, not the fuel pump side.

    NG: REPLACE FUEL PUMP

    Fig 10: Identifying F12 Fuel Pump Connector Terminal
    G04424173Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    OK: GO TO NEXT STEP

  7. CHECK HARNESS AND CONNECTOR (CIRCUIT OPENING RELAY - FUEL PUMP, FUEL PUMP - BODY GROUND)
    1. Check the wire harness between the circuit opening relay and fuel pump.
      1. Remove the circuit opening relay from the R/B subassembly.
      2. Disconnect the F12 fuel pump connector.
      3. Measure the resistance of the wire harness side connectors.

        Standard resistance

        TESTER CONNECTION SPECIFIED CONDITION

        Tester Connection Specified Condition
        R/B sub-assembly circuit opening relay terminal 3 - F12-4 Below 1 Ω
        R/B sub-assembly circuit opening relay terminal 3 or F12-4 - Body ground 10 kΩ or higher
    2. Check the wire harness between the fuel pump and body ground.
      1. Disconnect the F12 fuel pump connector.
      2. Measure the resistance between the wire harness side connector and body ground.

        Standard resistance

        TESTER CONNECTION SPECIFIED CONDITION

        Tester Connection Specified Condition
        F12-5 - Body ground Below 1 Ω

    NG: REPAIR OR REPLACE HARNESS AND CONNECTOR

    Fig 11: Locating F12 Fuel Pump Connector Terminal
    G04424174Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    OK: REPLACE ECM

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