Checking Cables and Wires

The most important point in troubleshooting is to determine "Probable Causes". Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only.





TROUBLESHOOTING STEPS
If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting.
Observe the symptom carefully. Check if there are also other problems.
In determining the probable causes, it is necessary to study the wiring diagram to understand the circuit as a system. Knowledge of switches, relays and other parts is necessary for accurate analysis. The causes of similar problems in the past must be taken into account.
Troubleshooting is carried out by making step-by-step checks until the true cause is found.
After the problems are corrected, be sure to check that the system operates correctly. Also check that new problems have not been caused by the repair.

INFORMATION FOR DIAGNOSIS
This information contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner:
1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path.
2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions.
3. Operational explanations include circuit drawings of voltage flow when the switch is operated and how the component operates in reaction.
4. Troubleshooting hints include numerous examples of problems which might occur, traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits.

NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant group which includes details of these components.

CABLE AND WIRE CHECK




1. Check connections for looseness, rust and stains.
2. Check terminals and wires for corrosion by battery electrolyte, etc.
3. Check terminals and wires for open circuit or impending open circuit.
4. Check wire insulation and coating for damage, cracks and wear.
5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts).
6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body.




7. Check for incorrect wiring.
8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.).
9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts.
10. Check that the harness between fixed parts such as the vehicle body and vibrating parts such as the engine are long enough to allow for vibration and movement.




BATTERY HANDLING
When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (-) battery terminal first and reconnect it last.