Inspection Procedure

1. Connect the intelligent tester to the DLC3.
2. Turn the ignition switch to the ON position and turn the intelligent tester ON.
3. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / FUEL PUMP / SPD.
4. Check the operation of the relay while operating it using the intelligent tester.

   OK: Operating noise can be heard from the relay. 

OK: GO TO step   6 

NG: Go to next step 

NG: REPAIR OR REPLACE POWER SOURCE CIRCUIT COMPONENTS 

OK: Go to next step 

1. Remove the IGCT No. 3 fuse from the R/B No. 3.
2. Measure the resistance in the IGCT No. 3 fuse.

   Standard resistance: 

   Below 1 Ω 

NG: CHECK FOR SHORT IN ALL HARNESS AND COMPONENTS CONNECTED TO FUSE 

Fig 1: Identifying IGCT No 3 Fuse

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

OK: Go to next step 

1. Remove the C/OPN relay from the engine room R/B.
2. Measure the C/OPN relay resistance.

   Standard resistance 

   TESTER CONNECTION AND SPECIFIED CONDITION
   
   

   Tester Connection	Specified Condition
   3 - 5	10 kΩ or higher
   3 - 5	Below 1 Ω (Apply battery voltage between terminals 1 and 2)

NG: REPLACE C/OPN RELAY 

Fig 2: Inspecting C/OPN Relay

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

OK: Go to next step 

1. Turn the ignition switch to the ON position.
2. Measure the voltage between the terminals of the H34 and H31 HV control ECU connectors.

   Standard voltage 

   TESTER CONNECTION AND SPECIFIED CONDITION
   
   

   Tester Connection	Specified Condition
   FC (H34-8) - E1 (H31-5)	9 to 14 V

OK: REPLACE HV CONTROL ECU 

Fig 3: Identifying H34 And H31 HV Control ECU Connectors

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NG: CHECK AND REPAIR HARNESS AND CONNECTOR (HV CONTROL ECU - CIRCUIT OPENING RELAY) 

1. Inspect fuel pump resistance.
   1. Measure the resistance between terminals 4 and 5.

      Standard resistance: 

      0.2 to 3.0 Ω at 20°C (68°F) 

2. Inspect fuel pump operation.
   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 fuel pump as far away from the battery as possible.
      • Always switch at the battery side.

NG: REPLACE FUEL PUMP 

Fig 4: Identifying Fuel Pump Connector Terminals

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

OK: Go to next step 

1. Check the harness and the connectors between the fuel pump and the C/OPN relay.
   1. Disconnect the fuel pump connector.
   2. Remove the C/OPN relay from the engine room R/ B.
   3. Measure the resistance according to the value(s) in the table below.

      Standard resistance (Check for open) 

      TESTER CONNECTION AND SPECIFIED CONDITION
      
      

      Tester Connection	Specified Condition
      Fuel pump (F16-4) - C/OPN relay (3)	Below 1 Ω

      Standard resistance (Check for short) 

      TESTER CONNECTION AND SPECIFIED CONDITION
      
      

      Tester Connection	Specified Condition
      Fuel pump (F16-4) or C/OPN (3) - Body ground	10 kΩ or higher

2. Check the harness and the connectors between the fuel pump and the body ground.
   1. Disconnect the fuel pump connector.
   2. Measure the resistance according to the value(s) in the table below.

      Standard resistance (Check for open) 

      TESTER CONNECTION AND SPECIFIED CONDITION
      
      

      Tester Connection	Specified Condition
      Fuel pump (F16-5) - Body ground	10 kΩ or higher

   NG: REPAIR OR REPLACE HARNESS OR CONNECTOR 

   Fig 5: Identifying C/OPN Relay From Engine Room R/ B

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   OK: REPLACE C/OPN RELAY