Simulation (Reproduction) Test
- Troubleshooting is challenging the most when a faulty phenomenon is not reproduced. In such a case, a fault claimed by the customer must be analyzed thoroughly, and the same condition environment as of when the fault occurred on the customer's vehicle need to be reproduced. If troubleshooting is conducted without a faulty phenomenon checked, critical points on repair work may be overlooked, or misunderstanding may occur, resulting in causing problems.
- For instance, a fault cause cannot be identified, if the fault is checked while the engine is hot although the fault originally occurred with the engine cold, or if the vibration-based fault is checked with the vehicle stopped although the fault originally occurred due to road conditions during driving.
- Although fault causes such as vibrations, heat and intrusion of water (humidity) are not reproducible, the fault phenomenon reproduction methods introduced here are effective in terms of applying external factors to the stopped vehicle.
Important points for the faulty simulation test
In the fault phenomenon reproduction methods, not only fault phenomena should be checked, but a faulty range portion should also be identified. To perform these, narrow down the circuits where faults are included based on the faulty phenomenon before conducting the test, and connect to the tester in advance. Then, perform the fault reproduction method, and judge whether the circuit being tested is normal or faulty and also check the faulty phenomenon at the same time. To narrow down causes of the faulty phenomenon, see the list of a faulty phenomenon for each system. Also, to reproduce a DTC output, a reproduction method based on the detecting conditions detecting time for the relevant DTC is necessary.
- Vibration method: When estimated that vibrations are causing the fault
- Part and sensor
Apply vibrations by lightly tapping the parts of the probable cause by hand, and check for fault occurrence.
- Connector
Lightly shake the connector vertically and horizontally.
- Wire harness
Lightly shake Wire harness vertically and horizontally, and check for fault occurrence.
- Antenna cable
Lightly shake the antenna cable vertically and horizontally, and check for fault occurrence.
- Cooling/heating method: When estimated that the fault occurs during cold period or warm period
- Using a hair dryer and refrigerant, heat or cool the part of the probable defective cause, and check for fault occurrence.
- When heating the part, be sure that the temperature does not exceed 60°C (140°F) (touchable by hand).
- Do not heat or cool the electronic parts directly by opening the ECM lid and so on.
- Water spray method: When estimated that the fault occurs in the rain or at high temperature
- Spray the vehicle with water and check for fault occurrence.
- Do not spray water directly to the engine room, but mist the radiator front surface in order to change the temperature and humidity indirectly.
- Do not spray water to the electronic parts directly.
- Other: When estimated that the fault occurs when the electrical load is excessive
- Operate the electrical parts, such as the heater blower, headlight and rear defogger, to increase the electrical load, and check for fault occurrence.