30,082021 Chapter 3 'SM_8 - Aulo Service Repair Manuals and Wiring Diagrams Rowdside Trouble Shooting | Roadside Trouble Shooting Contents RS ” Sane Sarg ahi : reat pass end Peculiar Gd ote Paupemchet : % Machen tem eas Description The ignition system inthis vehicles capable of producing dangerous voltages in the high tension circus. Extreme are must be used when working on or near the ignition System to prevent severe electrical shock. ‘This chapter deals with the common causes of failure of an engine to start. Roadside breakdowns other than engine failure ‘Gan be identified by reference to the Trouble Shooting heading inthe chapter on the particular component affected For an internal combustion engine to run, three basic require ments are ignition, fuel and compression. Failure to start can Usually be attributed toa fault one of these three systems, with Ignition or electrical faults the most common, followed by fuel system faults and lastly, mechanical or compression failure. Jump Starting a Vehicle dump stating a vehicle can be dangerous if the procedure destibed belo snot performed correctly. any doubt exits, ttrecommendd that the services ofa competent mechanic be obtained. ‘Te range of vhidles covered by this manual are equipped with Comples electronic crcuty which can be damaged by voltage Serge These voltage surges can be generated when jump ‘artng oF being jump started by another vehicle. tfavaabe use jumper leads equipped witha surge protection (deve ad follow the lead manufacturers instructions carefully, farcialyregerding the connection and disconnection of the leads 1 Ensure thatthe booster batter is 12 volts and the negative terminal isearthes 2 Ensure that the veices are not touching and thatthe Ign tion and all accesories on Both vehicles are switched Of 2 Ensure thatthe transmissions on both vehicles are in Patkor Neate apd the handBrakes are irmly appli «4 Remove the vert caps fom the battery and check the elec {lye level Replenish wth cstiled water as necessary. 5 Place the vet caps loosely over the call apertures. hitpsicardiagn.com/1996-1998-prado-roadside-trouble-shooting! stration of jumper lead connections. Connectinthe order shown and disconnect in the reverse sequence. {6 Connect one end of the red jumper lead to the positive (+) ‘battery terminal of the booster battery and the other end of the red lead to the positive (+) battery terminal of the discharged battery ‘The battery emits hydrogen gas which s explosive. Do rot expose the battery ro naked flames or sparks Do not lean ove the battery when connecting the Jumper leads. ‘Do nt allow the ends ofthe jumper leads to touch one ‘another or any part ofthe vehicle 7 Connect one end of the black jumper lead to the negative (-) battery terminal ofthe booster battery and the other end of the black lead to a good earthing point on the engine of the vehicle with the discharged battery seeioons ieee eaty claus Roa 8 Startthe engine on the vehicle with the booster battery and run the engine at a moderate speed for afew minutes '9 Start the engine on the vehicle with the discharged battery. 10 Leave the engines of both vehicles running for at least 10 ‘minutes. This will partially charge the discharged battery and reduce the risk of damage to electronic circuitry from voltage surges. "7 Ma30,082021 18 'SM_8 - Aulo Service Repair Manuals and Wiring Diagrams Roadside Trouble Shooting 11 Switch the engines of both vehicles Off and disconnect the jumper leads in the reverse order of the connecting sequence. 12 Attempt to start the engine of the vehicle with the discharged battery. 13 ifthe battery has not charged sufficiently to start the engine, reconnect the jumper leads as previously described and start the engines of both vehices. 114 Switch On the headlamps of the vehicle with the discharged battery 115 Disconnect the jumper leads in the reverse order of the connecting sequence. Switch the headlamps Off ignition and Electrical System Checks ‘veces covered by tis manual ore equipped witha securty System which reles n coded signals sent om the ition eich va te eave teehee mod to the engine oe tronic control unit ECU) to permit the vehicle to be started aut develops inthe engin immobiliser system the scutty lamp willcontinue to faster tee sinsetedin the non. 1 Inserthe key into the ignton and observe the secur lamp tn the insrument cuter I the lmp Sop fesing when thea tinsered proceed to sep & tthe lamp continues to fash, insert ancer key into the Ignition and cheek thatthe secu lamps stops flashing the acuity tmp soe Richie protien resco the fst hey. Refer tothe secuty system heading ln Body Eecal chapter 1. the sect amp continues to fash. afeutsndctedinthe Secuiy ayo Vang the wing gras atthe ero Body Bical (chapter 16) a0 guide, check the wing and onnectone between the Key reader, sci ECU ani the trgine EU for comtnaty an shorts to earth Aso check the poner supply and earth cuts for these components He faut canbe fund, fer to the scutty system heading in Body Eecrical (chapter 16) for procedure to check the aut sam orpeneres Artem fo stat the vehicle ¥ the tater motor will nt toate he engine orotate the engine sow oth on the headlamps and check for good hight intensty. Should the lames no uminate or te starter motor nt rotate the tre proceed os lows hitpsicardiagn.com/1996-1998-prado-roadside-trouble-shooting! a Onna ranamision made ens tahe Q reenter sinter: Disconnect the battery terminals and clean both terminals, and posts. Connect the terminals and where applicable, tighten firmly but not excessively. When disconnecting or connecting batter terminal, ‘ensure thatthe ignition sin the Off positon to prevent ‘damage othe electronic components and always disconnect the negative earth) terminal fst and connect icles. Check that the earth lead from the battery to the engine or ‘body frame is not broken and thatthe connections are clean and secute. (Check thatthe lead from the battery to the starter motor or starter solenoid is intact and has a clean and secure connec- Check the fusible links located in the engine compartment fuse and relay box. [Attempt to start the vehicle. Should the starter motor still not operate or the lamps not illuminate, one or more of the following faults may be the cause: No starter motor operation or lamps: Battery flat or defec- tive. Lamps illuminate but no starter operation: Starter motor drive jammed in mesh with flywheel ring gear Starter motor or solenoid defective. ignition switch faulty. Starter relay faulty. On automatic transmission models, faulty inhibitor swith att stare ypc ty ith Gp torrsonton Lamps dim and starter operation sluggish: Discharged battery or fault in starter motor. Battery flat due to broken dive belt or defective alternator. Faulty battery due to cell breakdown, If the battery and starter motor operation proves satisfactory but the engine stil fails to start, continue as follows: 2630,082021 ee A a oe Ce eee (ae EESE are 5 Open the electrode gap ofa serviceable sparkplug 3s much fs possible. Secutly earth the spark plug wing a jumper itaa'orby ying the plug toan earthed engine component. 6 Disconnect a high tension lead from a sparkplug an the passenger side cyinder head and connect tt the test spark ls, 7, Have an assistant operate the starter motorand checkthat ‘putkrepeatealy jumps the gapon the test spark lug 8 he sparks strong and blue, remove the spark plugs and heck thelr condition and the electrode gap as described in Engine (chapter 4 19 if there is no spark, check the EFI relay and fusible link AM2 located in the engine compartment fuse and relay box. Also check te ignition fuse inthe interior fuse and relay box. Aclick shouldbe audible rom the EFI relay ‘when the Ignition switched between the ‘Onand Off postions. 10 Check he high tension leads to ensure that they are dry and ‘hat the insulation is not racked or perished. Check the ends ofthe leads for burning or corrosion. Refer to Part 1 of Fuel and Engine Management (chapter 7) for further ignition system checks. 114. Ensure that all electrical connections and earth leads are clean and secure. a a Fuel System Checks ‘Due to the complex nature ofthe EFI system, itis recommended that should the following checks prove satisfactory but the tengine fails to start and the mechanical system is operational reference be made to Fuel and Engine Management (chapter 7) ‘ofthis manual or an authorised workshop be consulted. hitpsicardiagn.com/1996-1998-prado-roadside-trouble-shooting! 'SM_8 - Aulo Service Repair Manuals and Wiring Diagrams Roadside Trouble Shooting ‘The EFlrelay is located n the engine compartment fuse and relay box. 1 Check that at least one fuel tank contains a reasonable quan tity of fuel and that is the tank selected. 2. Check that all fuel hose connections are secure. 13. Check for a damaged vacuum hose or loose connections between the brake booster and the inlet manifold. A. Check for a loose or damaged air inlet hose between the ai cleaner and the throtie body. 5 Remove the fuel filer cap and while listening through the filler neck opening, have an assistant switch the ignition On. “The fuel pump should be heard to operate. Switch the igni- tion Off ifthe pump cannot be heard, squeeze the fuel return hose at the inlet manifold and switch the ignition On, Fuel should be felt flowing through the hose indicating correct fuel pump ‘operation, Ifthe pump is not operating, switch from the sub to main tank and vice versa and recheck operation of the fuel pump. If the pump is stil not operating, check the circuit opening relay located behind the passenger side of the dashboard, Refer to Fuel and Engine Management (chapter 7) 6 Ifthe engine stl fis to star and no faults found with the "mechanical or ignition systems, check the fuel pump and Injector circuits as descnbed in Part 1 of Fuel and Engine Management (chapter 7) 9 aia30,082021 'SM_8 - Aulo Service Repair Manuals and Wiring Diagrams 20, | Readside Trouble Shooting Mechanical Systems Checks Faults in the mechanical system that will prevent engine opera- tion can be caused by a broken timing belt, loss of cylinder ‘compression or internal component failure which prevents the crankshaft rating, 11 Remove the spark plugs and attempt to rotate the crank: shaft pulley manually. Ifthe crankshaft turns, remove the bolts retaining the upper timing belt cover and partially withdraw the cover to check the condition of the timing belt. Ifthe timing belts servicable proceed to step 4. Check the timing belt for breakage, stripped teeth et. 2 Ifthe crankshaft pulley cannot be turned, remove the starter motor and again attempt to tur the crankshaft pulley. ithe pulley now turns, it indicates thatthe fault is in the starter motor drive mechanism. pedal to disengage the transmission fom the engine to A ‘On manual transmission model, depress the clutch ‘eliminate the transmission os the problem source 3 ifthe crankshaft pulley cannot be turned, indicates engine seizure or broken internal components such as the connecting rods, pistons or crankshaft. Refer to the Engine Mechanical Trouble Shooting heading in Engine (chapter 4) Teakage. hitpsicardiagn.com/1996-1998-prado-roadside-trouble-shooting! 7 If any of the cylinders have low compressions, check the bhatt oa fe or eee, au 4 Check the radiator for loss of coolant. if coolant loss is ‘evident, check carefully for any signs of external leakage. Remove the engine ol dipstick and check for emulsification ofthe oil. When ol mixes with water itturns creamy and the oil level may increase. Ifthe oll is emulsified, it indicates internal coolant leakage, CCheck the following possible causes: Blown cylinder head gasket. Distorted cylinder head or cylinder block faces. Cracked cylinder head or block. '5_ Remove the EF relay from the engine compartment fuse and relay box and install one of the spark plugs. Operate the starter motor and listen to the sound that the engine makes asitis cranking. ac gt net x ti eee sans saloeuminy 6 Move the sparkplug to each ofthe eyliners and repeat the test. By performing the test onal cylinders, 3 rough compar kbon of compressions can be made to determine if there is any loss of compression in any cylinder. ‘A ofinder with normal compression wil ause a resistance ‘which in tum creates load on the engine when tis rotating However, ifthe compression is low, there wil be lite i ary resistance andthe engine wil otate easily and smoothly with litle change tothe sound when the spark plug is installed. ftom at ed Bi Secretar ce see ier inert tl ran following possible causes: Burnt or broken value(s) Broken piston(s) Broken timing bet. 4a