troubleshooting.pdf

C TROUBLESHOOTING

To Ignition SW

IG Terminal

VOLTAGE CHECK

(a) Establish conditions in which voltage is present at the check

point.

Example:

[A] – Ignition SW on

[B] – Ignition SW and SW 1 on

[C] – Ignition SW, SW 1 and Relay on (SW 2 off)

Fuse

[A]

SW 1

Voltmeter

(b) Using a voltmeter, connect the negative lead to a good ground

point or negative battery terminal, and the positive lead to the

connector or component terminal.

This check can be done with a test light instead of a voltmeter.

[B]

Relay

[C]

SW 2

Solenoid

Ohmmeter

CONTINUITY AND RESISTANCE CHECK

(a) Disconnect the battery terminal or wire so there is no voltage

between the check points.

(b) Contact the two leads of an ohmmeter to each of the check

points.

Ohmmeter

If the circuit has diodes, reverse the two leads and check

again.

When contacting the negative lead to the diode positive side

and the positive lead to the negative side, there should be

continuity.

When contacting the two leads in reverse, there should be no

continuity.

Diode

minimum) for troubleshooting of the electrical circuit.

Digital Type

Analog Type

2004 COROLLA (EWD533U)

To Ignition SW

IG Terminal

FINDING A SHORT CIRCUIT

(a) Remove the blown fuse and disconnect all loads of the fuse.

(b) Connect a test light in place of the fuse.

Example:

[A] – Ignition SW on

[B] – Ignition SW and SW 1 on

[C] – Ignition SW, SW 1 and Relay on (Connect the

Relay) and SW 2 off (or Disconnect SW 2)

Test Light

Fuse Case

Short [A]

SW 1

(d) Disconnect and reconnect the connectors while watching the

test light.

The short lies between the connector where the test light

stays lit and the connector where the light goes out.

(e) Find the exact location of the short by lightly shaking the

problem wire along the body.

Short [B]

Disconnect

Light

Relay

CAUTION:

(a) Do not open the cover or the case of the ECU unless

absolutely necessary. (If the IC terminals are touched,

the IC may be destroyed by static electricity.)

(b) When replacing the internal mechanism (ECU part) of

the digital meter, be careful that no part of your body or

clothing comes in contact with the terminals of leads

from the IC, etc. of the replacement part (spare part).

Short [C]

Disconnect

SW 2

Solenoid

DISCONNECTION OF MALE AND FEMALE

CONNECTORS

To pull apart the connectors, pull on the connector itself, not

the wire harness.

HINT : Check to see what kind of connector you are

disconnecting before pulling apart.

Pull Up

Press Down

2004 COROLLA (EWD533U)

C TROUBLESHOOTING

Reference:

HOW TO REPLACE TERMINAL

(with terminal retainer or secondary locking device)

1. PREPARE THE SPECIAL TOOL

HINT : To remove the terminal from the connector, please

construct and use the special tool or like object shown on

the left.

2. DISCONNECT CONNECTOR

0.2

(mm)

Example:

(Case 1)

Tool

3. DISENGAGE THE SECONDARY LOCKING DEVICE OR

TERMINAL RETAINER.

(a) Locking device must be disengaged before the terminal

locking clip can be released and the terminal removed from

the connector.

(b) Use a special tool or the terminal pick to unlock the secondary

locking device or terminal retainer.

NOTICE:

Do not remove the terminal retainer from connector body.

Terminal Retainer

[A] For Non–Waterproof Type Connector

Terminal Retainer

HINT : The needle insertion position varies according to the

connector’s shape (number of terminals etc.), so

check the position before inserting it.

[Retainer at Full Lock Position]

”Case 1”

Raise the terminal retainer up to the temporary lock

position.

Stopper

Terminal

Retainer

[Retainer at Temporary Lock Position]

Example:

(Case 2)

Secondary

Locking Device

”Case 2”

Open the secondary locking device.

2004 COROLLA (EWD533U)

Tool

Ta b

Example:

Terminal

Retainer

[B] For Waterproof Type Connector

(Case 1)

Tool

HINT : Terminal retainer color is different

according to connector body.

Example:

Terminal Retainer : Connector Body

Black or White

: Gray

Black or White

: Dark Gray

Tool

Access Hole

( Mark)

Gray or White

: Black

[Male]

[Female]

”Case 1”

Type where terminal retainer is pulled

up to the temporary lock position (Pull

Type).

Mark) and pull

the terminal retainer up to the

temporary lock position.

Retainer

at Full Lock Position

HINT : The needle insertion position varies

according to the connector’s shape

(Number of terminals etc.), so check

the position before inserting it.

Retainer

at Temporary Lock Position

[Male]

[Female]

Example:

(Case 2)

Terminal Retainer

”Case 2”

Type which cannot be pulled as far as

Power Lock insert the tool straight into

the access hole of terminal retainer as

shown.

Tool

[Male]

Press Down

2004 COROLLA (EWD533U)

Insert the special tool into the terminal

retainer access hole (

[Female]

C TROUBLESHOOTING

Push the terminal retainer down to the temporary lock position.

Retainer at

Full Lock Position

Retainer at

Temporary Lock Position

[Male]

[Female]

Locking Lug

from rear.

Tool

4. INSTALL TERMINAL TO CONNECTOR

(a) Insert the terminal.

HINT:

1. Make sure the terminal is positioned correctly.

2. Insert the terminal until the locking lug locks firmly.

3. Insert the terminal with terminal retainer in the temporary lock

position.

(b) Push the secondary locking device or terminal retainer in to

the full lock position.

5. CONNECT CONNECTOR

2004 COROLLA (EWD533U)

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