Toyota Previa 1991-1997 Repair Information

Control Relays

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TESTING



1991-93 Models

See Figures 1 through 5



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Fig. Fig. 1: Control relays terminal identification-1991-93 models

  1. With the ignition switch OFF , remove the 2 control relays from the actuator. For identification, the solenoid relay has 5 terminals; the pump motor relay has 4 terminals.
  2.  
  3. Check the continuity of the pump motor relay. There should be continuity between terminals 1 and 2. There should be no continuity between terminals 3 and 4 or between terminals 1 and 4.
  4.  



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Fig. Fig. 2: Pump motor relay continuity testing-1991-93 models

  1. Apply battery voltage to terminal 1 and connect terminal 2 to battery ground. There should be continuity between terminals 3 and 4 but no continuity between terminals 1 and 4.
  2.  



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Fig. Fig. 3: Check the continuity with battery voltage for the pump motor relay-1991-93 models

  1. Check the continuity of the solenoid relay. There should be continuity between terminals 1 and 3 as well as between terminals 2 and 4. There should be no continuity between terminals 4 and 5.
  2.  



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Fig. Fig. 4: Inspect the solenoid relay continuity at these terminals-1991-93 models

  1. Apply battery voltage to terminal 3 and connect terminal 1 to battery ground. There should be continuity between terminals 4 and 5 but no continuity between terminals 2 and 4.
  2.  



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Fig. Fig. 5: Inspect the solenoid relay operation while applying battery voltage-1989-91 models

  1. All continuity checks must be met; if any check reveals a fault, the relay must be replaced.
  2.  

1994-97 Models

See Figures 6 through 10

  1. To inspect the motor relay circuit, turn the ignition switch OFF and remove the control relay from the actuator.
  2.  
  3. Inspect the continuity of the motor relay circuit. Check that there is continuity between terminals 3 and 4, and no continuity between terminals 1 and 2.
  4.  



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Fig. Fig. 6: Pump motor relay continuity testing-1994-97 models

  1. If continuity is not as specified above, replace the relay.
  2.  
  3. Connect a jumper wire from the positive battery terminal to terminal 4. Connect a jumper wire from the negative battery terminal to terminal 3 of the relay.
  4.  



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Fig. Fig. 7: Check the continuity with battery voltage for the pump motor relay-1994-97 models

  1. Using an ohm meter, check for continuity between terminals 1 and 2 of the relay. Replace the relay if the test results indicate no continuity.
  2.  
  3. To inspect the solenoid relay circuit, with the relay off of the actuator, check for continuity between terminals 1 and 6.
  4.  



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Fig. Fig. 8: Inspect the solenoid relay continuity at these terminals-1994-97 models



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Fig. Fig. 9: Connect the positive lead of the ohmmeter to terminal 5 and the negative to lead 4 of the solenoid relay-1994-97 models



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Fig. Fig. 10: Inspect the solenoid relay operation while applying battery voltage-1994-97 models

  1. Check that there is no continuity between terminals 2 and 5.
  2.  
  3. Check that there is continuity between terminals 3 and 5.
  4.  
  5. Connect the positive lead of an ohmmeter to terminal 5 and the negative lead to terminal 4 of the relay. There should be continuity. Reverse the leads of the ohm meter and observe the readings. There should be no continuity.
  6.  
  7. If continuity readings differ from specified results, replace the relay.
  8.  

REMOVAL & INSTALLATION



The control relays are located in the actuator. There is a plastic case surrounding them, remove this case and unplug the relays.

 
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