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INTRODUCTION - HOW TO TROUBLESHOOT ECU CONTROLLED IN-29
SYSTEMS
IN05X-20
HOW TO USE THE DIAGNOSTIC
CHART AND INSPECTION
PROCEDURE
1. CONNECTOR CONNECTION AND TERMINAL IN-
SPECTION
S For troubleshooting, diagnostic trouble code charts or
problem symptom table are provided for each circuit with
FI0046 detailed inspection procedures on the following pages.
S When all the component parts, wire harnesses and con-
nectors 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 per-
formed without the problem symptoms occurring, refer to
Step 8 to replace the ECU. So always confirm that the
problem symptoms are occurring, or proceed with inspec-
tion while using the symptom simulation method.
S The instructions "Check wire harness and connector" and
FI0047 "Check and replace ECU" which appear in the inspection
procedure, are common and applicable to all diagnostic
trouble codes. Follow the procedure outlined below
whenever these instructions appear.
OPEN CIRCUIT:
This could be due to a disconnected wire harness, faulty con-
tact in the connector, and a connector terminal pulled out, etc.
HINT:
S It is rarely the case that a wire is broken in the middle of
it. Most cases occur at the connector. In particular, care-
FI0048 fully check the connectors of sensors and actuators
S Faulty contact could be due to rusting of the connector
terminals, to foreign materials entering terminals or a de-
formation of connector terminals. 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 ab-
normality 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 con-
nectors.
SHORT CIRCUIT:
This could be due to a contact between wire harness and the
body ground or to a short circuit occurred inside the switch, etc.
HINT:
When there is a short circuit between the wire harness and body
ground, check thoroughly whether the wire harness is caught
in the body or is clamped properly.
2002 ECHO (RM884U)
Author : Date : 29
IN-30 INTRODUCTION - HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
2. CONNECTOR HANDLING
When inserting tester probes into a connector, insert them from
the rear of the connector. When necessary, use mini test leads.
For water resistant connectors which cannot be accessed from
behind, take good care not to deform the connector terminals.
FI7187
Sensor Side 3. CONTINUITY CHECK (OPEN CIRCUIT CHECK)
ECU Side (a) Disconnect the connectors at both ECU and sensor
sides.
IN0379
ECU Side (b) Measure the resistance between the applicable terminals
of the connectors.
Resistance: 1 or less
Sensor Side
HINT:
Measure the resistance while lightly shaking the wire harness
vertically and horizontally.
IN0378
ECU Side 4. RESISTANCE CHECK (SHORT CIRCUIT CHECK)
(a) Disconnect the connectors on both ends.
(b) Measure the resistance between the applicable terminals
Sensor Side 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
IN0380 vertically and horizontally.
5. VISUAL CHECK AND CONTACT PRESSURE CHECK
(a) Disconnect the connectors at both ends.
(b) Check for rust or foreign material, etc. in the terminals of
the connectors.
Pull Lightly (c) Check crimped portions for looseness or damage and
check that the terminals are secured in lock portion.
Looseness of Crimping
HINT:
The terminals should not come out when pulled lightly from the
IN0381 back.
2002 ECHO (RM884U)
Author : Date : 30
INTRODUCTION - HOW TO TROUBLESHOOT ECU CONTROLLED IN-31
SYSTEMS
(d) Prepare a test male terminal and insert it in the female ter-
minal, then pull it out.
NOTICE:
When testing a gold-plated female terminal, always use a
gold-plated male terminal.
HINT:
When the test terminal is pulled out more easily than others,
there may be poor contact in that section.
Fig. 1 6. CHECK OPEN CIRCUIT
ECU For the open circuit in the wire harness in Fig. 1, perform "(a)
C OPEN B A Continuity Check" or "(b) Voltage Check" to locate the section.
Sensor
1 1 1 1
2 2 2 2
Z17004
Fig. 2 (a) Check the continuity.
(1) Disconnect connectors "A" and "C" and measure
the resistance between them.
ECU
In the case of Fig. 2:
C A
Sensor B Between terminal 1 of connector "A" and terminal 1
1 1 1
2 2 2 of connector "C" No continuity (open)
Between terminal 2 of connector "A" and terminal 2
of connector "C" Continuity
Z17005 Therefore, it is found out that there is an open circuit
between terminal 1 of connector "A" and terminal 1
Fig. 3 of connector "C".
(2) Disconnect connector "B" and measure the resis-
ECU tance between the connectors.
In the case of Fig. 3:
Sensor
Between terminal 1 of connector "A" and terminal 1
C B2 B1 A of connector "B1" Continuity
1 1 1 1 Between terminal 1 of connector "B2" and terminal
2 2 2 2 1 of connector "C" No continuity (open)
B04722 Therefore, it is found out that there is an open circuit
between terminal 1 of connector "B2" and terminal
1 of connector "C".
2002 ECHO (RM884U)
Author : Date : 31
IN-32 INTRODUCTION - HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
Fig. 4 (b) Check the voltage.
In a circuit in which voltage is applied (to the ECU connec-
tor terminal), an open circuit can be checked for by con-
0V 5V ducting a voltage check.
Sensor A
C 5V B 5V As shown in Fig. 4, with each connector still con-
1 1 1 nected, measure the voltage between body ground
2 2 2
and terminal 1 of connector "A" at the ECU 5V out-
put terminal, terminal 1 of connector "B", and termi-
Z17007 nal 1 of connector "C", in that order.
If the results are:
5V: Between Terminal 1 of connector "A" and Body Ground
5V: Between Terminal 1 of connector "B" and Body Ground
0V: Between Terminal 1 of connector "C" and Body Ground
Then it is found out that there is an open circuit in the wire har-
ness between terminal 1 of "B" and terminal 1 of "C".
Fig. 5 7. CHECK SHORT CIRCUIT
If the wire harness is ground shorted as in Fig. 5, locate the sec-
C SHORT B A tion by conducting a "continuity check with ground".
1 1 1
2 2 2
Z17008
Fig. 6 Check the continuity with ground.
(1) Disconnect connectors "A" and "C" and measure
the resistance between terminal 1 and 2 of connec-
ECU tor "A" and body ground.
C B A In the case of Fig. 6:
Sensor
1 1 1 Between terminal 1 of connector "A" and body
2 2 2
ground Continuity (short)
Between terminal 2 of connector "A" and body
Z17009 ground No continuity
Therefore, it is found out that there is a short circuit
between terminal 1 of connector "A" and terminal 1
of connector "C".
2002 ECHO (RM884U)
Author : Date : 32
INTRODUCTION - HOW TO TROUBLESHOOT ECU CONTROLLED IN-33
SYSTEMS
Fig. 7 (2) Disconnect connector "B" and measure the resis-
tance between terminal 1 of connector "A" and body
ground, and terminal 1 of connector "B2" and body
ground.
ECU
C B2 B1 A Between terminal 1 of connector "A" and body
Sensor
1 1 1 1 ground No continuity
2 2 2 2 Between terminal 1 of connector "B2" and body
ground Continuity (short)
Z17808 Therefore, it is found out that there is a short circuit
between terminal 1 of connector "B2" and terminal
1 of connector "C".
8. CHECK AND REPLACE ECU
First check the ECU ground circuit. If it is faulty, repair it. If it is
normal, the ECU could be faulty, so replace the ECU with a nor-
mal functioning one and check that the symptoms appear.
(1) Measure the resistance between the ECU ground
Example
terminal and the body ground.
Resistance: 1 or less
Ground
IN0383
(2) Disconnect the ECU connector, check the ground
ECU Side
terminals on the ECU side and the wire harness
side for bend and check the contact pressure.
Ground
W/H Side
Ground
IN0384
2002 ECHO (RM884U)
Author : Date : 33
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