Troubleshooting

Basic Troubleshooting Procedures

Basic Troubleshooting Procedure

Customer Problem Analysis Check Sheet

Basic Inspection Procedure: Resistance Measurement Conditions of Electronic Parts. Measured resistance may be high or low when the vehicle is hot after driving. Therefore, all resistances must be measured at ambient temperature (20 °C, 68°F), unless otherwise specified.

Measured resistance values are reference values, except for ambient temperature (20 °C, 68°F).

Intermittent Problem Inspection Procedure: Sometimes the most difficult case in troubleshooting is when the problem symptom occurs but does not recur during testing. For example, if the problem occurs only when the vehicle is cold and did not appear when warm. In this case, the technician must carefully complete the Customer Problem Analysis Check Sheet and recreate (simulate) the environment and conditions present when the vehicle problem occurred.

1. 1
   Clear the Diagnostic Trouble Code (DTC).
2. 2
   Inspect the connector connection and check the terminal for poor contact. Check for loose connections, loose wires, bent, broken or corroded pins, then check that the connectors are always securely fastened.

   

3. 3
   Gently shake the connector and wire harness vertically and horizontally.
4. 4
   Repair or replace the faulty component.
5. 5
   Confirm that the problem is resolved by performing a road test.
6. 6
   Sensors and Actuators: Gently tap the sensors, actuators or relays with a finger.

   Strong vibration may damage sensors, actuators or relays.

7. 7
   Connectors and Harness: Lightly shake the connector and wiring harness in the vertical and then in the horizontal direction.
8. 8
   Heat the components suspected of causing the malfunction using a hair dryer or other heat source.

   DO NOT heat the components to the point where they may be damaged. DO NOT heat the ECM directly.

9. 9
   Spray water on the vehicle to simulate rainy or high humidity conditions.

   DO NOT spray water directly into the engine compartment or onto electrical components.

10. 10
    Turn on all electrical systems to simulate excessive electrical loads (radio, fans, lights, rear window defogger, etc.).
11. 11
    Connector Handling

    A.	Never pull on the wire harness when disconnecting connectors.

    B.	When disconnecting a connector with a lock, press or pull the locking lever.

    C.	Listen for a click when connectors lock. This sound indicates that they are securely locked.

    D.	When using a tester to check continuity or measure voltage, always insert the tester probe from the wire harness side.

    E.	Check waterproof connector terminals from the connector side. Waterproof connectors cannot be accessed from the wire harness side. Use a thin wire to avoid damaging the terminal. Do not damage the terminal when inserting the tester wire.

12. 12
    Connector Checkpoints

    A.	With the connector connected: While holding the connector, check the connection condition and locking efficiency.

    B.	With the connector disconnected: Check for a missing terminal, crimped terminal or broken core wire by gently pulling the wire harness. Visually check for rust, contamination, deformation and bending.

    C.	Check terminal tightness: Insert a spare male terminal into the female terminal, then check the terminal tightness condition.

    D.	Gently pull on each individual wire to confirm that each wire is secured in the terminal.

13. 13
    Connector Terminal Repair Method

    A.	Clean the contact points using compressed air and/or a cloth. Never use sandpaper to polish contact points, as this may damage the contact point.

    B.	If contact pressure is abnormal, replace the female terminal.

14. 14
    Before removing the wire harness, check the position and clamping of the wire harness to restore it correctly.
15. 15
    Check that the wire harness is not twisted, stretched or loose.
16. 16
    Check that the wire harness is not exposed to excessive temperature.
17. 17
    Check that the wire harness does not rotate, move or vibrate against sharp edges of components.
18. 18
    Check the connection between the wire harness and any installed part.
19. 19
    If the wire harness covering is damaged, secure, repair or replace the harness.
20. 20
    Open Circuit Procedures

    A.	Continuity Check

    B.	Voltage Check

    If an open circuit occurs (as shown in [FIG. 1]), it can be located by performing Step 2 (Continuity Check Method) or Step 3 (Voltage Check Method), as shown below.

    

21. 21
    Continuity Check Method

    When measuring resistance, gently shake the wire harness up and down or from side to side.

    Specification (resistance) 1 Ω or less > Normal circuit; 1 MΩ or more > Open circuit

    A.

    Disconnect connectors (A) and (C), and measure resistance between connectors (A) and (C), as shown in [FIG. 2]. In [FIG. 2], the measured resistance of lines 1 and 2 should be higher than 1 MΩ and lower than 1 Ω, respectively. Specifically, an open circuit is line 1 (line 2 is normal). To find the exact break point, inspect the sub-section of line 1 as described in the following step.

    B.

    Disconnect connector (B) and measure the resistance between connector (C) and (B1), and between (B2) and (A), as shown in [FIG. 3]. In this case, the measured resistance between connector (C) and (B1) is higher than 1 MΩ, and the open circuit is between terminal 1 of connector (C) and terminal 1 of connector (B1).

22. 22
    Voltage Check Method

    A.	With each connector still connected, measure the voltage between chassis ground and terminal 1 of each connector (A), (B) and (C), as shown in [FIG. 4]. The measured voltage of each connector is 5 V, 5 V and 0 V, respectively. Therefore, the circuit is open between connectors (C) and (B).

23. 23
    Short to Ground Check Method

    A.	Continuity Check with Chassis Ground

    If a short to ground occurs, as shown in [FIG. 5], the breakpoint can be located by performing Step 2 (Continuity Check Method with chassis ground), as shown below.

    

24. 24
    Continuity Check Method (with Chassis Ground)

    When measuring resistance, gently shake the wire harness up and down or from side to side.

    Specification (resistance) 1 Ω or less > Short to ground; 1 MΩ or more > Normal circuit

    A.

    Disconnect connectors (A) and (C), and measure the resistance between connector (A) and chassis ground, as shown in [FIG. 6]. In this example, the measured resistance of lines 1 and 2 is below 1 Ω and above 1 MΩ respectively. Specifically, line 1 is shorted to ground (line 2 is normal). To find the exact break point, check the sub-line of line 1 as described in the next step.

    B.

    Disconnect connector (B) and measure the resistance between connector (A) and chassis ground, and between (B1) and chassis ground, as shown in [FIG. 7]. The measured resistance between connector (B1) and chassis ground is 1 Ω or less. The short to ground is between terminal 1 of connector (C) and terminal 1 of connector (B1).

25. 25
    Connect the positive voltmeter lead to the wire end (or connector or switch side) closest to the battery.
26. 26
    Connect the negative lead to the other end of the wire (or the other side of the connector or switch).
27. 27
    Operate the circuit.
28. 28
    The voltmeter will show the voltage difference between the two points. A difference or drop of more than 0.1 V (50 mV in a 5 V circuit) may indicate a problem. Check the circuit for loose or dirty connections.

    

? Simulate Vibration ? Simulate Heat ? Simulate Water Spray ? Simulate Electrical Load. Connector Inspection Procedure. Wire Harness Inspection Procedure. Electrical Circuit Inspection Procedure: ? Check for Open Circuit ? Check for Short Circuit ? Voltage Drop Test. This test checks the voltage drop across a wire or through a connection or switch. Symptom Troubleshooting Table

Main Symptom	Diagnostic Procedure	Also check
Cannot Start (Engine does not crank)	1 Check the battery 2 Check the starter 3 Inhibitor switch (A/T) or clutch start switch (M/T)
Cannot Start (Incomplete combustion)	1 Check the battery 2 Check the fuel pressure 3 Check the ignition circuit 4 Immobilizer System Troubleshooting (If the immobilizer lamp flashes)	Trouble Code Low compression Intake air leaks Slipping or broken timing belt Contaminated Fuel
Hard to Start	1 Check the battery 2 Check the fuel pressure 3 Check ECTS and circuit (Check DTC) 4 Check the ignition circuit	Trouble Code Low compression Intake air leaks Contaminated Fuel Weak ignition spark
Poor Idling (Rough, unstable or incorrect idle)	1 Check the fuel pressure 2 Check the injector 3 Check the long-term fuel trim and short-term fuel trim. (See CUSTOMER DATA FLOW) 4 Check the idle air control circuit (check DTC). 5 Inspect and check the throttle body 6 Check ECTS and circuit (Check DTC)	Trouble Code Low compression Intake air leaks Contaminated Fuel Weak ignition spark
Engine Stalls	1 Check the battery 2 Check the fuel pressure 3 Check the idle air control circuit (check DTC). 4 Check the ignition circuit 5 Check the CKPS circuit (check DTC)	Trouble Code Intake air leaks Contaminated Fuel Weak ignition spark
Poor Driveability (Surging)	1 Check the fuel pressure 2 Inspect and check the throttle body 3 Check the ignition circuit 4 Check ECTS and circuit (Check DTC) 5 Check the exhaust system for possible blockage 6 Check the long-term fuel trim and short-term fuel trim (refer to CUSTOMER DATA FLOW).	Trouble Code Low compression Intake air leaks Contaminated Fuel Weak ignition spark
Knock	1 Check the fuel pressure 2 Inspect the engine coolant 3 Inspect the radiator and the electric cooling fan. 4 Check the spark plugs	Trouble Code Contaminated Fuel
Poor Fuel Economy	1 Check the customer's driving habits. · Is the A/C on continuously or the defroster mode on? · Is the tire pressure correct? · Is an excessively heavy load being carried? · Is acceleration too strong or too frequent? 2 Check the fuel pressure 3 Check the injector 4 Check the exhaust system for possible blockage 5 Check ECTS and circuit	Trouble Code Low compression Intake air leaks Contaminated Fuel Weak ignition spark
Hard to Refuel (Overflow during refueling)	1 Check the canister close valve 2 Inspect the fuel tank hose/tube. · Pinched, kinked or blocked? · Torn filler hose 3 Inspect the fuel tank vapor hose between the canister and the fuel tank air filter. 4 Check the canister	Gas station fuel nozzle malfunction (If this problem occurs at a specific gas station during refueling)