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Electronic Circuit Inspection Procedure

  1. BASIC INSPECTION 
    1. WHEN MEASURING RESISTANCE OF ELECTRONIC PARTS
      1. Unless otherwise stated, all resistance measurements should be made at an ambient temperature of 20°C (68°F). Resistance measurements may be inaccurate if measured at high temperatures, i.e. immediately after the vehicle has been running. Measurements should be made after the engine has cooled down.
    2. HANDLING CONNECTORS
      1. When disconnecting a connector, first squeeze the mating connector housing halves tightly together to release the lock, and then press the lock claw and separate the connector.
      2. When disconnecting a connector, do not pull on the harnesses. Grasp the connector directly and separate it.
      3. Before connecting a connector, check that there are no deformations, damage, looseness or missing terminals.
      4. When connecting a connector, press firmly until it locks with a "click" sound.
      5. If checking a connector with a TOYOTA electrical tester, check the connector from the backside (harness side) using a mini test lead.
        NOTE:
        • As a waterproof connector cannot be checked from the backside, check it by connecting a sub-harness.
        • Do not damage the terminals by moving the inserted tester needle.
          Fig 1: Precaution For Handling Connector And Backprobing Terminals
          G04440802Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. CHECKING CONNECTORS
      1. Checking when a connectors is disconnected:

        Squeeze the connector together to confirm that they are fully connected and locked.

      2. Checking when a connector is disconnected:

        Check by pulling the wire harness lightly from the backside of the connector. Look for unlatched terminals, missing terminals, loose crimps or broken conductor wires. Check visually for corrosion, metallic or foreign matter and water, and bent, rusted, overheated, contaminated, or deformed terminals.

        Fig 2: Checking For Terminal Deformation And Looseness
        G04506082Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Checking the contact pressure of the terminal:

        Prepare a spare male terminal. Insert it into a female terminal, and check for ample tension when inserting and after full engagement.

        NOTE: When testing a gold-plated female terminal, always use a gold-plated male terminal.
        Fig 3: Checking Connectors (2 Of 2)
        G04458888Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. REPAIR METHOD OF CONNECTOR TERMINAL
      1. If there is any foreign matter on the terminal, clean the contact point with compressed air or a cloth. Never rub the contact point using sandpaper as the plating may come off.
      2. If there is abnormal contact pressure, replace the female terminal. If the male terminal is gold-plated (gold color), use a gold-plated female terminal; if it is silver-plated (silver color), use a silver-plated female terminal.
        Fig 4: Identifying Proper Method Of Cleaning Connector Terminal
        G04376131Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Damaged, deformed, or corroded terminals should be replaced. If the terminal does not lock into the housing, the housing may have to be replaced.
    5. HANDLING OF WIRE HARNESS
      1. If removing a wire harness, check the wiring and clamping before proceeding so that it can be restored in the same way.
      2. Never twist, pull or slacken the wire harness more than necessary.
      3. The wire harness should never come into contact with a high temperature part, or rotating, moving, vibrating or sharp-edged parts. Avoid contact with panel edges, screw tips and other sharp items.
        Fig 5: Precaution For Handling Of Wire Harness
        G04381266Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      4. When installing parts, never pinch the wire harness.
      5. Never cut or break the cover of the wire harness.

        If it is cut or broken, replace it or repair it with vinyl tape.

  2. CHECK FOR OPEN CIRCUIT 
    1. For an open circuit in the wire harness in Fig 6, the resistance or voltage, as described below.
      Fig 6: Identifying Open Circuit In Wire Harness
      G04458891Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Check the resistance.
      1. Disconnect connectors A and C and measure the resistance between the terminals of the connectors.
        Fig 7: Checking Harness Resistance
        G04458892Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Standard resistance ( Fig 7 ) 

        TESTER CONNECTION AND SPECIFIED CONDITION (1 OF 5)

        Tester Connection Specified Condition
        Connector A terminal 1 - Connector C terminal 1 10 kΩ or higher
        Connector A terminal 2 - Connector C terminal 2 Below 1Ω

        HINT:

        Measure the resistance while lightly shaking the wire harness vertically and horizontally. If the results match the examples above, an open circuit exists between terminal 1 of connector A and terminal 1 of connector C.

      2. Disconnect connector B and measure the resistance between the terminals of the connectors.
        Fig 8: Measuring Connector Terminal Resistance
        G04492885Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Standard resistance ( Fig 8 ) 

        TESTER CONNECTION AND SPECIFIED CONDITION (2 OF 5)

        Tester connection Specified Condition
        Connector A terminal 1 - Connector B1 terminal 1 Below 1 Ω
        Connector B2 terminal 2 - Connector C terminal 2 10 kΩ or higher

        If the results match the examples above, an open circuit exists between terminal 1 of connector B2 and terminal 1 of connector C.

    3. Check the voltage.
      1. In a circuit in which voltage is applied to the ECU connector terminal, an open circuit can be checked by conducting a voltage check. With each connector still connected, measure the voltage between the body ground and these terminals (in this order): 1) terminal 1 of connector A, 2) terminal 1 of connector B, and 3) terminal 1 of connector C.
        Fig 9: Checking Voltage
        G04458894Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Standard voltage ( Fig 9 ) 

        TESTER CONNECTION AND SPECIFIED CONDITION (3 OF 5)

        Tester Connection Specified Condition
        Connector A terminal 1 - Body ground 5 V
        Connector B terminal 1 - Body ground 5 V
        Connector C terminal 1 - Body ground Below 1 V

        If the results match the examples above, an open circuit exists in the wire harness between terminal 1 of connector B and terminal 1 of connector C.

  3. CHECK FOR SHORT CIRCUIT 
    1. If the wire harness is ground shorted (Fig 10), locate the section by conducting a resistance check with the body ground (below).
      Fig 10: Checking For Short Circuit
      G04458895Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Check the resistance with the body ground.
      1. Disconnect connectors A and C and measure the resistance.
        Fig 11: Measuring Resistance Between Ground and Harness Connector Terminals
        G04458896Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Standard resistance ( Fig 11 ) 

        TESTER CONNECTION AND SPECIFIED CONDITION (4 OF 5)

        Tester Connection Specified Condition
        Connector A terminal 1 - Body ground Below 1 Ω
        Connector A terminal 2 - Body ground 10 kΩ or higher

        HINT:

        Measure the resistance while lightly shaking the wire harness vertically and horizontally. If your results match the examples above, an open circuit exists between terminal 1 of connector A and terminal 1 of connector C.

      2. Disconnect connector B and measure the resistance.
        Fig 12: Checking Resistance Between Ground And Individual Harness Connector Terminals
        G04458897Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Standard resistance ( Fig 12 ) 

        TESTER CONNECTION AND SPECIFIED CONDITION (5 OF 5)

        Tester Connection Specified Condition
        Connector A terminal 1 - Body ground 10 kΩ or higher
        Connector B2 terminal 2 - Body ground Below 1 Ω

        If the results match the examples above, a short circuit exists between terminal 1 of connector B2 and terminal 1 of connector C.

  4. CHECK AND REPLACE ECU 
    NOTE:
    • The connector should not be disconnected from the ECU. Perform the inspection from the backside of the connector on the wire harness side.
    • When no measuring condition is specified, perform the inspection with the engine stopped and the ignition switch on.
    • Check that the connectors are fully seated. Check for loose, corroded or broken wires.
    1. First, check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be faulty. Temporarily replace the ECU with a normally functioning one and check if the symptoms occur. If the trouble symptoms disappear, replace the original ECU.
      Fig 13: Measuring Resistance Between ECU Ground Terminal & Body Ground
      G04434632Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Measure the resistance between the ECU ground terminal and body ground.

        Standard resistance: Below 1 Ω 

      2. Disconnect the ECU connector. Check the ground terminal on the ECU side and wire harness side for bending, corrosion or foreign matter. Lastly, check the contact pressure of the female terminals.
        Fig 14: Identifying ECU and Harness Ground Terminal
        G04423028Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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