Symptom simulation

The most difficult case in troubleshooting is when there are no problem symptoms occurring. In such cases, a thorough customer problem analysis must be carried out, then simulate the same or similar conditions and 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) are likely causes for problems which are 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 the matrix chart of problem symptoms for each system to narrow down the possible causes of the symptom.

1	VIBRATION METHOD: When vibration seems to be the major cause.
CONNECTORS Slightly shake the connector vertically and horizontally. WIRE HARNESS Slightly shake the connector vertically and horizontally. The connector joint, fulcrum of the vibration, and body through portion are the major areas to be checked thoroughly.
PARTS AND SENSORS Apply slight vibration with a finger to the part of the sensor considered to be the problem cause and check if the malfunction occurs. Applying strong vibration to relays may result in open relays.
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. Check to see if the malfunction occurs. Do not heat to more than 60°C (140°F). (Temperature limit that no damage is done to the component). Do not apply heat directly to parts in the ECU.
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 and check to see if the malfunction occurs. Never sprinkle water directly into the engine compartment, but indirectly change the temperature and humidity by applying water spray onto the radiator front surface. Never apply water directly onto the electronic components. (Service 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 used.
4	OTHER: When a malfunction seems to occur when electrical load is excessive.
Turn on all electrical loads including th3e heater blower, head lights, rear window defogger, etc. and check to see if the malfunction occurs.