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Home >> Toyota >> 2006 >> Highlander Limited, FWD >> Repair and Diagnosis >> Engine Performance >> System >> Engine Control System (3MZ-FE) (Except Hybrid) >> SFI System >> Fuel Pump Control Circuit >> Inspection Procedure

Inspection Procedure

  1. PERFORM ACTIVE TEST BY INTELLIGENT TESTER (OPERATE C/OPN 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 No. 1.
    2. Measure the resistance of the circuit opening relay.

      Standard resistance

      TESTER CONNECTION AND SPECIFIED CONDITION

      Tester Connection Specified Condition
      1 - 2 Below 1 Ω
      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: Identifying Relay Test Terminals
    G04044792Courtesy 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 AND SPECIFIED CONDITION

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

    OK: REPLACE ECM

    Fig 2: Inspecting ECM (FC Voltage)
    G04427366Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    NG: GO TO NEXT STEP

  4. CHECK HARNESS AND CONNECTOR (ECM, IGNITION - CIRCUIT OPENING RELAY)
    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 No. 1.
      3. Measure the resistance of the wire harness side connectors.

        Standard resistance

        TESTER CONNECTION AND SPECIFIED CONDITION

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

          Standard resistance: Below 1 Ω

        • Reinstall the IG2 fuse.
      2. Remove the circuit opening relay from the R/B No. 1.
      3. Disconnect the I15 ignition switch connector.
      4. Measure the resistance of the wire harness side connectors.

        Standard resistance

        TESTER CONNECTION AND SPECIFIED CONDITION

        Terminal Connections Specified Condition
        Circuit opening relay terminal 1 - I15-6 Below 1 Ω
        Circuit opening relay terminal 1 or I15-6 - Body ground 10 kΩ or higher
    3. Install the circuit opening relay.
    4. Reconnect the ECM connector and ignition switch connector.

    NG: REPAIR OR REPLACE HARNESS OR CONNECTOR

    Fig 3: Identifying E5 ECM Connector
    G04427367Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    OK: REPLACE ECM

  5. INSPECT FUEL PUMP ASSEMBLY
    1. Measure the resistance of the fuel pump.
      1. Measure the resistance between terminals 4 and 5.

        Standard resistance

        TESTER CONNECTION AND SPECIFIED CONDITION

        Terminal Connections Condition Specified Condition
        4-5 20°C (68°F) 0.2 to 3.0 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.
        Fig 4: Measuring Resistance Between Terminals 4 And 5
        G04427368Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    NG: REPLACE FUEL PUMP ASSEMBLY

    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 No. 1.
      2. Disconnect the F12 fuel pump connector.
      3. Measure the resistance of the wire harness side connectors.

        Standard resistance

        TESTER CONNECTION AND SPECIFIED CONDITION

        Tester Connection Specified Condition
        Circuit opening relay terminal 3 - F12-4 Below 1 Ω
        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 of the wire harness side connector and body ground.

        Standard resistance

        TESTER CONNECTION AND SPECIFIED CONDITION

        Tester Connection Specified Condition
        F12-5 (Fuel pump) - Body ground Below 1 Ω

    NG: REPAIR OR REPLACE HARNESS OR CONNECTOR

    Fig 5: Identifying F12 Fuel Pump Connector
    G04427369Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    OK: 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 fuel flowing can be heard.

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

    NG: GO TO NEXT STEP

  2. CHECK RELAY OPERATION (CIRCUIT OPENING)
    1. Connect terminal FC of the E5 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: Connecting Terminal FC Of E5 ECM Connector And Body Ground
    G04427370Courtesy 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 No. 1.
    2. Measure the resistance of the circuit opening relay.

      Standard resistance

      TESTER CONNECTION AND SPECIFIED CONDITION

      Tester Connection Specified Condition
      1 - 2 Below 1 Ω
      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: Identifying Relay Test Terminals
    G04044792Courtesy 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 AND SPECIFIED CONDITION

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

    NG: REPLACE ECM

    Fig 8: Inspecting ECM (FC Voltage)
    G04427372Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    OK: GO TO NEXT STEP

  5. CHECK HARNESS AND CONNECTOR (ECM, IGNITION - CIRCUIT OPENING RELAY)
    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 No. 1.
      3. Measure the resistance of the wire harness side connectors.

        Standard resistance

        TESTER CONNECTION AND SPECIFIED CONDITION

        Tester Connection Specified Condition
        E5-10 (FC) - circuit opening relay terminal 2 Below 1 Ω
        E5-10 (FC) or 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.
        • 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 No. 1.
      3. Disconnect the I15 ignition switch connector.
      4. Measure the resistance of the wire harness side connectors.

        Standard resistance

        TESTER CONNECTION AND SPECIFIED CONDITION

        Tester Connection Specified Condition
        Circuit opening relay terminal 1 - I15-6 (Ignition switch) Below 1 Ω
        Circuit opening relay terminal 1 or I15-6 (Ignition switch) - Body ground 10 kΩ or higher
    3. Install the circuit opening relay.
      Fig 9: Identifying E5 ECM Connector
      G04427373Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Reconnect the ECM connector and ignition switch connector.

    NG: REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK: REPLACE ECM

  6. INSPECT FUEL PUMP ASSEMBLY
    1. Measure the resistance of the fuel pump.
      1. Measure the resistance between terminals 4 and 5.

        Standard resistance

        TESTER CONNECTION AND SPECIFIED CONDITION

        Tester Connection Condition Specified Condition
        4-5 20°C (68°F) 0.2 to 3.0 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.
        Fig 10: Measuring Resistance Between Terminals 4 And 5
        G04427374Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    NG: REPLACE FUEL PUMP ASSEMBLY

    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 No. 1.
      2. Disconnect the F12 fuel pump connector.
      3. Measure the resistance of the wire harness side connectors.

        Standard resistance

        TESTER CONNECTION AND SPECIFIED CONDITION

        Tester Connection Specified Condition
        Circuit opening relay terminal 3 - F12-4 Below 1 Ω
        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 of the wire harness side connector.

        Standard resistance

        TESTER CONNECTION AND SPECIFIED CONDITION

        Tester Connection Specified Condition
        F12-5 - Body ground Below 1 Ω
        Fig 11: Identifying F12 Fuel Pump Connector
        G04427375Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    NG: REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK: REPLACE ECM

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