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Home >> Toyota >> 2007 >> Highlander Base, 2.4 D, AWD >> Repair and Diagnosis >> Engine Performance >> Engine Control System (2AZ-FE) (Except Hybrid) >> SFI System >> Fuel Pump Control Circuit >> Inspection Procedure

Inspection Procedure

When using intelligent tester: 

  1. PERFORM ACTIVE TEST BY INTELLIGENT TESTER (OPERATE CIRCUIT OPENING RELAY) 
    1. Connect the intelligent tester to the DLC3.
    2. Turn the ignition switch to the ON position, 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 sub-assembly.
    2. Measure the resistance of the circuit opening relay.
      Fig 1: Inspecting Circuit Opening Relay
      G05245403Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard resistance 

      TESTER CONNECTION AND 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 

    OK: Go to Next Step 

  3. INSPECT ECM (FC VOLTAGE) 
    1. Turn the ignition switch to the ON position.
    2. Measure the voltage according to the value(s) in the table below.
      Fig 2: Identifying ECM Connectors
      G05245471Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard voltage 

      TESTER CONNECTION AND SPECIFIED CONDITION

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

    OK: REPLACE ECM 

    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 No. 1.
      3. Measure the resistance according to the value(s) in the table below.

        Standard resistance 

        TESTER CONNECTION AND SPECIFIED CONDITION

        Tester Connection Specified Condition
        E5-10 (FC) - R/B No. 1 circuit opening relay terminal 2 Below 1 Ω
        E5-10 (FC) or R/B No. 1 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 No. 1.
      3. Disconnect the I15 ignition switch connector.
      4. Measure the resistance according to the value(s) in the table below.
        Fig 3: Identifying Circuit Opening Relay In R/B No. 1
        G05245472Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Standard resistance 

        TESTER CONNECTION AND SPECIFIED CONDITION

        Tester Connection Specified Condition
        R/B No. 1 circuit opening relay terminal 1 - I15-6 (IG2) Below 1 Ω
        R/B No. 1 circuit opening relay terminal 1 or I15-6 (IG2) - Body ground 10 kΩ or higher

    NG: REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK: REPLACE ECM 

  5. INSPECT FUEL PUMP 
    1. Measure the resistance of the fuel pump.
      Fig 4: Identifying Fuel Pump Connector Terminals
      G05245473Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard resistance 

      TESTER CONNECTION AND 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 on the fuel pump side.

    NG: REPLACE FUEL PUMP 

    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 according to the value(s) in the table below.
        Fig 5: Identifying Circuit Opening Relay
        G05245474Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Standard resistance 

        TESTER CONNECTION AND SPECIFIED CONDITION

        Tester Connection Specified Condition
        R/B No. 1 circuit opening relay terminal 3 - F12-4 Below 1 Ω
        R/B No. 1 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 according to the value(s) in the table below.

        Standard resistance 

        TESTER CONNECTION AND SPECIFIED CONDITION

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

    OK: REPAIR OR REPLACE HARNESS OR CONNECTOR 

    NG: REPLACE ECM 

When Using OBD II Scan Tool: 

  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 IN 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.
      Fig 6: Identifying E5 ECM Connector Terminals
      G05245475Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard: 

      Noise can be heard from the circuit opening relay. 

    OK:  Go to step  6

    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.
      Fig 7: Inspecting Circuit Opening Relay
      G05245403Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard resistance 

      TESTER CONNECTION AND 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 

    OK: Go to Next Step 

  4. INSPECT ECM (FC VOLTAGE) 
    1. Turn the ignition switch to the ON position.
    2. Measure the voltage according to the value(s) in the table below.
      Fig 8: Identifying ECM Connectors
      G05245471Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard voltage 

      TESTER CONNECTION AND SPECIFIED CONDITION

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

    OK: REPLACE ECM 

    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 No. 1.
      3. Measure the resistance according to the value(s) in the table below.
        Fig 9: Identifying R/B No. 1 Circuit Opening Relay
        G05245472Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Standard resistance 

        TESTER CONNECTION AND SPECIFIED CONDITION

        Tester Connection Specified Condition
        E5-10 (FC) - R/B No. 1 circuit opening relay terminal 2 Below 1 Ω
        E5-10 (FC) or R/B No. 1 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 No. 1.
      3. Disconnect the I15 ignition switch connector.
      4. Measure the resistance according to the value(s) in the table below.

        Standard resistance 

        TESTER CONNECTION AND SPECIFIED CONDITION

        Tester Connection Specified Condition
        R/B No. 1 circuit opening relay terminal 1 - I15-6 (IG2) Below 1 Ω
        R/B No. 1 circuit opening relay terminal 1 or I15-6 (IG2) - Body ground 10 kΩ or higher

    NG: REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK: REPLACE ECM 

  6. INSPECT FUEL PUMP 
    1. Measure the resistance of the fuel pump.
      Fig 10: Identifying F2 Fuel Pump Connector Terminals
      G05245473Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard resistance 

      TESTER CONNECTION AND 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 on the fuel pump side.

    NG: REPLACE FUEL PUMP 

    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 according to the value(s) in the table below.
        Fig 11: Identifying R/B No. 1 Circuit Opening Relay
        G05245474Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Standard resistance 

        TESTER CONNECTION AND SPECIFIED CONDITION

        Tester Connection Specified Condition
        R/B No. 1 circuit opening relay terminal 3 - F12-4 Below 1 Ω
        R/B No. 1 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 according to the value(s) in the table below.

        Standard resistance 

        TESTER CONNECTION AND SPECIFIED CONDITION

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

    NG: REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK: REPLACE ECM 

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