Symptom Simulation

The most difficult case in troubleshooting is when there are no problem symptoms occurring. In such case a thorough customer problem analysis must be carried out, then simulate the same or similar conditions at environment in which the problem occurred in the customer's vehicle. No matter how much experience a technician has, or how skilled he may be, if he proceeds to troubleshoot without confirming the problem symptoms he will tend to overlook something important in the repair operation and make a wrong guess somewhere, which will only lead to a standstill. For example, for a problem which only occurs when the engine is cold, or for a problem which occurs due to vibration caused by the road during driving, etc., the problem can never be determined so long as the symptoms are confirmed with the engine hot condition or the vehicle at a standstill. Since vibration, heat or water penetration (moisture) is likely cause for problem which is difficult to reproduce, the symptom simulation tests introduced here are effective measures in that the external causes are applied to the vehicle in a stopped condition.

Important Points in the Symptom Simulation Test:

In the symptom simulation test, the problem symptoms should of course be confirmed, but the problem area or parts must also be found out. To do this, narrow down the possible problem circuits according to the symptoms before starting this test and connect a tester beforehand. After that, carry out the symptom simulation test, judging whether the circuit being tested is defective or normal and also confirming the problem symptoms at the same time. Refer to .

1. VIBRATION METHOD: When vibration seems to be the major cause. 

   CONNECTORS 

   Slightly shake the connector vertically and horizontally.

   Fig 1: Vibration Test (Connector And Wire Harness)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   WIRE HARNESS 

   Slightly shake the wire harness vertically and horizontally. The connector joint, fulcrum of the vibration, and body through portion are the major areas to be checked thoroughly

   PARTS AND SENSOR 

   Apply slight vibration with a finger to the part of the sensor considered to be the problem cause and check that the malfunction occurs.

   HINT:

   Applying strong vibration to relays may result in open relays.

   Fig 2: Vibration Test (Parts And Sensor)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. HEAT METHOD: When the problem seems to occur when the suspect area is heated. 

   Heat the component that is the likely cause of the malfunction with a hair dryer or similar object.

   NOTE:

   1. Do not heat to more than 60 °C (140 °F). (Temperature is limited not to damage the components.)
   2. Do not apply heat directly to parts in the ECU.
      Fig 3: Heat Method: When Problem Seems To Occur When Suspect Area Is Heated

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. WATER SPRINKLING METHOD- When the malfunction seems to occur on a rainy day or in a high-humidity condition. 

   Sprinkle water onto the vehicle.

   NOTE:

   1. Never sprinkle water directly into the engine compartment, but Indirectly change the temperature and humidity by applying water spray onto the radiator front surface.
   2. Never apply water directly onto the electronic components.

      HINT:

      If a vehicle is subject to water leakage, the leaked water may contaminate the ECU. When testing a vehicle with a water leakage problem, special caution must be taken.

      Fig 4: Sprinkling Water Onto Vehicle

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. OTHER: When a malfunction seems to occur when electrical load is excessive, 

   Turn on all electrical loads including the heater blower, head lights, rear window defogger, etc.

   Fig 5: Turning On All Electrical Loads

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002