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[4] DIAGNOSTIC TROUBLE CODE CHART
The inspection procedure is shown in the table below. This table permits efficient and accurate troubleshooting
using the diagnostic trouble codes displayed in the diagnostic trouble code check. Proceed with troubleshooting
in accordance with the inspection procedure given in the diagnostic chart corresponding to the diagnostic
trouble codes displayed. The engine diagnostic trouble code chart is shown below as an example.
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[5] MATRIX CHART OF PROBLEM SYMPTOMS
The suspect circuits or parts for each problem symptom are shown in the table below. Use this table to trouble-
shoot the problem when a ºNormalº code is displayed in the diagnostic trouble code check but the problem is
still occurring. Numbers in the table indicate the inspection order in which the circuits or parts should be checked.
HINT: When the problem is not detected by the diagnostic system even though the problem symptom is present,
it is considered that the problem is occurring outside the detection range of the diagnostic system, or that the
problem is occurring in a system other than the diagnostic system.
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HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION
PROCEDURE
1. For troubleshooting, diagnostic trouble code charts or problem symptom charts are provided for each
circuit with detailed inspection procedures on the following pages.
2. When all the component parts, wire harnesses and connectors of each circuit except the ECU are found
to be normal in troubleshooting, then it is determined that the problem is in the ECU.
Accordingly, if diagnosis is performed without the problem symptoms occurring, the instruction will be to
check and replace the ECU, even if the problem is not in the ECU. So, always confirm that the problem
symptoms are occurring, or proceed with inspection while using the symptom simulation method.
3. The instructions ºCheck wire harness and connectorº and ºCheck and replace ECUº which appear in the
inspection procedure, are common and applicable to all diagnostic trouble codes. Follow the procedure
outlined below whenever these instructions appear.
Check Wire Harness and Connector
The problem in the wire harness or connector is an open circuit or a short circuit.
OPEN CIRCUIT:
This could be due to a disconnected wire harness, faulty contact in the connector, a connector terminal pulled
out, etc.
HINT:
1. It is rarely the case that a wire is broken in the middle of it. Most cases occur at the connector. In particular,
carefully check the connectors of sensors and actuators.
2. Faulty contact could be due to rusting of the connector terminals, to foreign materials entering terminals
or a drop in the contact pressure between the male and female terminals of the connector. Simply
disconnecting and reconnecting the connectors once changes the condition of the connection and may
result in a return to normal operation.
Therefore, in troubleshooting, if no abnormality is found in the wire harness and connector check, but the
problem disappears after the check, then the cause is considered to be in the wire harness or connectors.
SHORT CIRCUIT:
This could be due to a short circuit between the wire harness and the body ground or to a short inside the switch,
etc.
HINT:
wWhen there is a short between the wire harness and body ground, check thoroughly whether the wire
harness is caught in the body or is clamped properly. IN±30
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1. CONTINUITY CHECK (OPEN CIRCUIT CHECK)
(1) Disconnect the connectors at both ECU and sensor sides.
(2) Measure the resistance between the applicable terminals of
the connectors.
Resistance: 1 or less
HINT:
wMeasure the resistance while lightly shaking the wire
harness vertically and horizontally.
wWhen tester probes are inserted into a connector, insert
the probes from the back. For waterproof connectors in
which the probes cannot be inserted from the back, be
careful not to bend the terminals when inserting the
tester probes.
2. RESISTANCE CHECK (SHORT CIRCUIT CHECK)
(1) Disconnect the connectors at both ends.
(2) Measure the resistance between the applicable terminals of
the connectors and body ground. Be sure to carry out this
check on the connectors on both ends.
Resistance: 1 M or higher
HINT: Measure the resistance while lightly shaking the wire
harness vertically and horizontally.
3. VISUAL CHECK AND CONTACT PRESSURE CHECK
(a) Disconnect the connectors at both ends.
(b) Check for rust or foreign material, etc. on the terminals of the
connectors.
(c) Check crimped portions for looseness or damage and check
if the terminals are secured in the lock position.
HINT: The terminals should not come out when pulled lightly.
(d) Prepare a test male terminal and insert it in the female
terminal, then pull it out.
HINT: When the test terminal is pulled out more easily than
others, there may be poor contact in that section.
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Actual examples of the inspection method for open circuit and short circuit are explained below.
1. OPEN CIRCUIT CHECK
For the open circuit in the wire harness in Fig. 1, perform º(a) Continuity Checkº or º(b) Voltage Checkº to
locate the section.
(a) Continuity Check
(1) Disconnect connectors (A) and (C) and measure the resistance between them.
In the case of Fig. 2,
Between terminal 1 of connector (A) and terminal 1 of connector (C) " No continuity (open)
Between terminal 2 of connector (A) and terminal 2 of connector (C) " Continuity
Therefore, it is found out that there is an open circuit between terminal 1 of connector (A) and terminal 1
of connector (C).
(2) Disconnect connector (B) and measure the resistance between connectors (A) and (B), (B) and (C).
In the case of Fig. 3,
Between terminal 1 of connector (A) and terminal 1 of connector (B) " Continuity
Between terminal 1 of connector (B) and terminal 1 of connector (C) " No Continuity (open)
Therefore, it is found out that there is an open circuit between terminal 1 of connector (B) and terminal 1
of connector (C).
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(b) Voltage Check
In a circuit in which voltage is applied (to the ECU connector terminal), an open circuit can be checked for
by conducting a voltage check.
(1) As shown in Fig. 4, with each connector still connected, measure the voltage between body ground
and terminal 1 of connector (A) at the ECU 5V output terminal, terminal 1 of connector (B), and terminal
1 of connector (C), in that order.
If the results are:
5 V: Between Terminal 1 of connector (A) and Body Ground
5 V: Between Terminal 1 of connector (B) and Body Ground
0 V: Between Terminal 1 of connector (C) and Body Ground
then it is found out that there is an open circuit in the wire harness between terminal 1 of (B) and termi-
nal 1 of (C).
2. SHORT CIRCUIT CHECK
If the wire harness is ground shorted as in Fig. 5, locate the section by conducting a ºcontinuity check with
groundº.
± INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMSIN±33