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Headlight Relay Circuit: Procedure

  1. PERFORM ACTIVE TEST USING TECHSTREAM 
    1. Connect the Techstream to the DLC3.
    2. Turn the ignition switch to ON.
    3. Turn the Techstream on.
    4. Enter the following menus: Body Electrical / Main Body / Active Test.
    5. Check that the relays operate.
      MAIN BODY

      Tester Display Test Part Control Range Diagnostic Note
      Headlight Relay Low beam headlight relay ON/OFF -

      OK

      Headlight relays operate. (Low beam headlights illuminate.)

    NG → See step   2 

    OK → See step   12 

  2. SYSTEM CHECK 
    1. Check the vehicle specifications.
      RESULT

      Result Proceed to
      w/o HID Headlight System A
      w/ HID Headlight System B

    B → See step   8 

    A: Go to next step 

  3. REPLACE INTEGRATION RELAY 
    1. Temporarily replace the integration relay with a new or normally functioning one.

    NEXT: Go to next step 

  4. PERFORM ACTIVE TEST USING TECHSTREAM 
    1. Connect the Techstream to the DLC3.
    2. Turn the ignition switch to ON.
    3. Turn the Techstream on.
    4. Enter the following menus: Body Electrical / Main Body / Active Test.
    5. Check that the relays operate.
      MAIN BODY

      Tester Display Test Part Control Range Diagnostic Note
      Headlight Relay Low beam headlight relay ON/OFF -

      OK

      Headlight relays operate. (Low beam headlights illuminate.)

    NG → See step   5 

    OK → END (INTEGRATION RELAY WAS DEFECTIVE) 

  5. CHECK HARNESS AND CONNECTOR (BATTERY - INTEGRATION RELAY) 
    1. Disconnect the 1D integration relay connector.
      Fig 1: Checking Harness And Connector (Battery - Integration Relay)
      GTY302712Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Measure the voltage according to the value(s) in the table below.

      Standard Voltage

      Tester Connector Condition Specified Condition
      1D-7 - Body ground Always 11 to 14 V
      TEXT IN ILLUSTRATION

      *a Front view of wire harness connector
      (to Integration Relay)

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK: Go to next step 

  6. CHECK HARNESS AND CONNECTOR (INTEGRATION RELAY - INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY) 
    1. Disconnect the 1C integration relay connector.
    2. Disconnect the 2F instrument panel junction block assembly connector.
    3. Measure the resistance according to the value(s) in the table below.

      Standard Resistance

      Tester Connection Condition Specified Condition
      1C-9 - 2F-21 Always Below 1 Ω
      1C-9 - Body ground Always 10 kΩ or higher

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK: Go to next step 

  7. INSPECT INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY 
    1. Remove the instrument panel junction block assembly.
      Fig 2: Inspecting Instrument Panel Junction Block Assembly
      GTY296297Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Measure the resistance according to the value(s) in the table below.

      Standard Resistance

      Tester Connection Condition Specified Condition
      2F-21 - 2I-15 (HRLY) Always Below 1 Ω
      2F-21 - Body ground Always 10 kΩ or higher
      TEXT IN ILLUSTRATION

      *a Component without harness connected
      (Instrument Panel Junction Block Assembly)

    NG → REPLACE INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY 

    OK → See step   13 

  8. INSPECT HEADLIGHT RELAY (H-LP RELAY) 
    1. Inspect the headlight relay. Refer to ON-VEHICLE INSPECTION .

    NG → REPLACE HEADLIGHT RELAY 

    OK: Go to next step 

  9. CHECK HARNESS AND CONNECTOR (BATTERY - HEADLIGHT RELAY) 
    Fig 3: Checking Harness And Connector (Battery - Headlight Relay)
    GTY294580Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the headlight relay.
    2. Measure the voltage according to the value(s) in the table below.

      Standard Voltage

      Tester Connection Condition Specified Condition
      2 - Body ground Always 11 to 14 V
      5 - Body ground Always 11 to 14 V
      TEXT IN ILLUSTRATION

      *a Engine Room Relay Block
      *b Headlight Relay Holder

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK: Go to next step 

  10. CHECK HARNESS AND CONNECTOR (HEADLIGHT RELAY - INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY) 
    1. Disconnect the 2F instrument panel junction block assembly connector.
    2. Measure the resistance according to the value(s) in the table below.

      Standard Resistance

      Tester Connection Condition Specified Condition
      1 - 2F-21 Always Below 1 Ω
      1 - Body ground Always 10 kΩ or higher

    NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK: Go to next step 

  11. INSPECT INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY 
    1. Remove the instrument panel junction block assembly.
      Fig 4: Inspecting Instrument Panel Junction Block Assembly
      GTY296297Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Measure the resistance according to the value(s) in the table below.

      Standard Resistance

      Tester Connection Condition Specified Condition
      2F-21 - 2I-15 (HRLY) Always Below 1 Ω
      2F-21 - Body ground Always 10 kΩ or higher
      TEXT IN ILLUSTRATION

      *a Component without harness connected
      (Instrument Panel Junction Block Assembly)

    NG → REPLACE INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY 

    OK → See step   13 

  12. PROCEED TO NEXT SUSPECTED AREA SHOWN IN PROBLEM SYMPTOMS TABLE. Refer to  PROBLEM SYMPTOMS TABLE 
  13. REPLACE MAIN BODY ECU. Refer to  REMOVAL 
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