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 

   Fig 1: Identifying IGCT No 3 Fuse

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

OK: Go to Next Step 

1. Remove the C/OPN relay from the engine room R/B No. 2.
2. Measure the C/OPN relay resistance.
   Fig 2: Inspecting C/OPN Relay

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard resistance 

   RESISTANCE SPECIFICATION
   
   

   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 

OK: Go to Next Step 

1. Turn the ignition switch to the ON position.
2. Measure the voltage between the terminals of the H17 and H14 HV control ECU connectors.
   Fig 3: Identifying HV Control ECU Connector Terminals

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard voltage 

   VOLTAGE SPECIFICATION
   
   

   Tester Connection	Specified Condition
   FC (H17-8) - E1 (H14-5)	9 to 14 V

OK: REPLACE HV CONTROL ECU 

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) 

      Fig 4: Identifying Fuel Pump Connector Terminals

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 

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 No. 2.
      Fig 5: Identifying Fuel Pump And C/OPN RELAY Connector Terminals

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Measure the resistance according to the value(s) in the table below.

      Standard resistance (Check for open) 

      RESISTANCE SPECIFICATION
      
      

      Tester Connection	Specified Condition
      Fuel pump (F12-4) - C/OPN relay (3)	Below 1 Ω

      Standard resistance (Check for short) 

      RESISTANCE SPECIFICATION
      
      

      Tester Connection	Specified Condition
      Fuel pump (F12-4) or C/OPN relay (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) 

      RESISTANCE SPECIFICATION
      
      

      Tester Connection	Specified Condition
      Fuel pump (F12-5) - Body ground	10 kΩ or higher

NG: REPAIR OR REPLACE HARNESS OR CONNECTOR 

OK: REPLACE C/OPN RELAY