2008 Toyota Prius BaseFACTORY OEM SERVICE PROCEDURE

Inspection Procedure

  1. PERFORM ACTIVE TEST BY TECHSTREAM (OPERATE CIRCUIT OPENING RELAY) 
    1. Connect Techstream to the DLC3.
    2. Turn the power switch ON (IG).
    3. Turn the tester ON.
    4. Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump / Speed.
    5. Check the relay operation while operating it with the tester.

      OK: 

      Operating noise can be heard from the relay. 

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

    NG: Go to next step. 

  2. INSPECT POWER SOURCE CIRCUIT 

    NG: REPAIR OR REPLACE POWER SOURCE CIRCUIT COMPONENTS 

    OK: Go to next step. 

  3. INSPECT INTEGRATION RELAY (C/OPN RELAY) 
    1. Remove the integration relay from the engine room relay block.
    2. Inspect the circuit opening relay.

      Standard resistance 

      TESTER CONNECTION SPECIFIED CONDITION

      Tester Connection Specified Condition
      3G-5 - 3G-8 10 kΩ or higher
      3G-5 - 3G-8 Below 1 Ω (Apply battery voltage to terminals 3G-6 and 3G-7)
    3. Reinstall the integration relay.

    NG: REPLACE INTEGRATION RELAY 

    Fig 1: Identifying Integration Relay Terminals
    G05188974Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    OK: Go to next step. 

  4. CHECK ECM (FC VOLTAGE) 
    1. Turn the power switch ON (IG).
    2. Measure the voltage between the specified terminals of the E5 and E6 ECM connectors.

      Standard voltage 

      TESTER CONNECTION SPECIFIED CONDITION

      Tester Connection Specified Condition
      E6-10 (FC) - E5-28 (E1) 9 to 14 V

    OK: Go to step 5 

    Fig 2: Identifying E5 And E6 ECM Connectors
    G05188975Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    NG: CHECK AND REPAIR HARNESS AND CONNECTOR 

  5. INSPECT FUEL PUMP 
    1. Disconnect the F14 fuel pump connector.
    2. Inspect the fuel pump resistance.
      1. Measure the resistance between terminals 3 and 7.

        Standard resistance 

        TESTER CONNECTION SPECIFIED CONDITION

        Tester Connection Specified Condition
        3 - 7 0.2 to 3.0 Ω at 20°C (68°F)
    3. Inspect the fuel pump operation.
      1. Apply battery voltage to the fuel pump terminals. Check that the pump operates.
        Fig 3: Identifying F14 Fuel Pump Connector
        G05674344Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Factory Service Tools

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.

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