Maintenance precautions of IBS (IBS (RZ4E-TC))

1. Maintenance precautions of IBS

1. Using circuit test tools

Unless instructed in the diagnostic procedure, do not use a test lamp. When a probe connector is required in a diagnostic procedure, use connector test
adapter kit (5-8840-2835-0).

2. Commercial electronic equipment

Aftermarket electronic equipment refers to commercially available electronic equipment installed to the vehicle after it has been shipped from the factory.
Be careful, as such accessories are not taken into particular consideration at the vehicle design stage.
Aftermarket electronic equipment may cause malfunctions in the electronic control system, even if the equipment is properly installed. Aftermarket
electronic equipment includes devices not connected to the electronic control system of the vehicle, such as mobile phones or radios. Therefore, when
diagnosing electrical system problems, first check whether such aftermarket electronic equipment is installed. Remove it from the vehicle if installed. If the
problem has not been resolved after removing the equipment, perform the diagnosis using the regular procedure.

Caution
Make sure that both the power supply and ground of aftermarket electronic equipment are connected to a circuit that is not related to the
circuits of the electronic control system.

3. Damage caused by electrostatic discharge

Because the electronic components used in the electronic control system are designed to operate at extremely low voltages, they can easily be damaged
by electrostatic discharge, and some types of electronic components can be damaged by an electrostatic charge of 100 V or less, which cannot be felt by
humans. (A voltage of 4,000 V is required for a person to be able to detect an electrostatic discharge.)
There are various ways a person can build up an electrostatic charge. The most common way to build up an electrostatic charge is through friction or
induction. An example of when a person builds an electrostatic charge by friction is when they slide across the seat of the vehicle. A person wearing

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insulated shoes can build an electrostatic charge by induction if they momentarily touch the ground while standing near a highly charged object. A charge
of the same polarity flows out, and with a highly opposing polarity, that person becomes charged. Because static electricity can be damaging, take special
care when handling or testing electronic components.

Caution
To prevent damage caused by static electricity, do not touch the connector pins of the battery sensor or the electronic components
soldered onto the circuit board of the battery sensor.
To prevent damage caused by static electricity, do not open the packaging of a replacement part until the preparations for installation of the
part are completed.
To prevent damage caused by static electricity, connect the package to a properly working vehicle ground before removing the part from
the package.
To prevent damage caused by static electricity, touch a properly working ground before installing the part in such cases as when handling
the part while sliding across a seat, when sitting down from a standing position, or while walking a certain distance.

4. Tools to be used

When measuring the voltage and resistance, make sure to correctly use the tools, such as the scan tool, connector test adapter kit (5-8840-2835-0), and
digital multimeter [DMM] (5-8840-0285-3).

5. Digital multimeter (DMM)

6. Connector test adapter kit

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Function, structure, operation of IBS (IBS (RZ4E-TC))

1. IBS overview

The IBS is a system that effectively adjusts power generation levels based on vehicle operation conditions and battery status.
When engine load is high, it decreases fuel consumption by suppressing load increases caused by power generation.

1. Generation control

Use the charged battery power to restrict power generation by the generator during start-up or accelerating the vehicle.
Increase the amount of power generated by the generator to charge the battery during deceleration.

For the following condition, the generation control by IBS is stopped and switched to the normal charge by the regulator control built into the generator.

If battery protection is needed, such as at high or low battery temperature and insufficient battery capacity
When the headlight illuminates or when the wipers operate
If there is a malfunction in the charge control system
If periodical charge* is performed

Note
*: The battery sensor accumulates generation control time by the IBS, and performs periodical charge when 20 hours have passed. If the
power supply to the battery sensor is cut off, the accumulated time will be reset.

System schematic

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2. IBS controls components

1. Battery sensor

The battery sensor is installed to the battery negative terminal and calculates the amount of power generated according to the driving conditions from the
following information and controls the adjustment voltage of the generator via LIN communication.

Battery temperature, voltage and current

Information, such as vehicle speed and accelerator opening position, obtained from the ECM via CAN communication
Electrical load information by way of switch signals such as from the headlights and wipers

Caution
If the ground of electronic components, etc., is directly connected to the battery sensor, the difference between the amperage measured by
the battery sensor and the actual battery amperage may run down the battery due to control malfunction.
 2. Generator warning light

The generator warning light is located in the instrument panel cluster. The generator warning light illuminates when the ignition switch is turned ON for a
light check, and turns OFF after the engine is started.
The generator warning light illuminates when a malfunction has occurred in the charge control system and vehicle service is required.

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3. IBS controls component views

1. IBS control component layout

Description

1. Battery sensor

4. General circuit diagram

General circuit diagram

IBS outline view

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1 Ignition switch
2 CAN low signal
3 CAN high signal
4 Headlight switch
5 Battery voltage
6 Generator
7 -
8 Instrument panel cluster
9 Wiper switch
10 -
Introduction to the trouble diagnosis of IBS (IBS (RZ4E-TC))

1. Introduction to the trouble diagnosis of IBS

1. Description of diagnosis

Perform the Diagnostic system check-IBS.

Refer to "51.Engine Control 1A.Troubleshooting(IBS (RZ4E-TC)) diagnostic system check-IBS".

2. About self-diagnosis

The battery sensor has a self-diagnosing function, which always monitors the system when the charge control system is operating in order to determine
whether there are any system malfunctions and which areas are defective. If a malfunction is found, the generator warning light is illuminated and the DTC
information is sent via CAN communication.

3. Condition for clearing the DTC

The generator warning light is turned OFF when the diagnostic runs and does not fail. A current DTC is cleared when the diagnostic runs and passes.

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Intermittent conditions of IBS (IBS (RZ4E-TC))

1. Intermittent conditions of IBS

1. Important preliminary inspections before starting

Before using the symptom list, perform the Diagnostic system check-IBS and check all of the following items.

The generator warning light is functioning properly.

The scan tool data is within the normal range of operation values.

2. Visual inspection and actual inspection

Careful visual inspection and actual inspection are required for some symptom procedures. This procedure is extremely important. By conducting visual
and actual inspections, it is possible to save valuable time by fixing problems without performing further inspections. Check for the following items.

The battery sensor and battery ground cable are clean, properly tightened, and located in the correct position.
The battery sensor harness and terminals are properly connected without a pinching or open circuit.

3. Intermittent conditions

If an intermittent condition exists, inspect for improper installation of electronic equipment. Inspect whether there is any electronic equipment, light, or
mobile phone that was additionally installed. Verify that devices that were additionally installed are not connected to serial data circuits such as CAN.

Depending on the problem, the generator warning light may not illuminate, or a DTC may not be stored. An intermittent condition is often caused by an
improper electrical connection or wiring. Conduct a careful visual inspection, or conduct an actual inspection to see whether the following conditions exist
in the suspected connector.

Incomplete connection between connectors

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Terminal looseness
Damaged or deformed terminals

Repair or replace the connector terminal of the circuit with the problem, and appropriately connect. Remove the terminals from the connector body and
inspect the wires of the terminals for poor connections.

Connect the DMM to the suspected circuit and perform a vehicle road test. If an abnormal value is displayed when the malfunction occurs, it can be
determined that there is a problem in the monitored circuit. The scan tool is useful in detecting intermittent conditions. The scan tool has the following
convenient functions.

The snapshot function can be used to record the engine parameters.

The snapshot function can be used to review the recorded information and know the particular operation condition that resulted in the malfunction.
Freeze Frame/Failure Records are useful in identifying the locations of intermittent conditions.
Review the information recorded in the Freeze Frame/Failure Records, store the Freeze Frame/Failure Records, and operate the vehicle under the
DTC set conditions.
By using the plot function of the scan tool, it is possible to graph the selected data parameters.
The plot function of the scan tool can be used to review the recorded information and check the location of the intermittent condition.

In order to detect intermittent conditions, use the data recording function of the data recording module (DRM). The DRM includes a function for storing
engine log data when a DTC is set. If an entry exceeding the maximum storage count is set, the oldest log data is overwritten. The manual trigger switch
stores the log data when voluntarily operated by the driver on the occasion of an incorrect vehicle performance event, as opposed to when a DTC event
occurs. If the driver presses and releases the manual trigger switch once, that time becomes a trigger, and any log data after the trigger is stored in the
DRM memory. When there is available space in the DRM memory, the log data is stored in that space. However, if an entry exceeding the maximum
storage count is set, the oldest log data is overwritten.

Check for improper installation of optional electronic accessories such as lights or mobile phones. Under the following conditions, DTCs are not recorded,
and the generator warning light may illuminate intermittently.

The battery ground cable is improperly tightened or dirty.

The generator warning light circuit is intermittently shorted to ground.
The diode has an open circuit.

Note
A relay, ECM drive solenoid, or switch malfunction may cause the generation of a large surge voltage or surge current. Normally, this
problem will occur when the malfunctioning component is operating.

The following diagnosis shows possible causes for each symptom. There is no significance to the order of this procedure. If the value on the scan tool
does not indicate a malfunction, the next procedure to perform should be the one that can be most easily inspected or is most likely to be the cause.

There is no current problem, but a past DTC exists. Or, there is a complaint from the customer not related to a DTC, and that symptom cannot be
reproduced.

4. Preliminary inspection

Perform the Diagnostic system check-IBS.

5. Wire harness and connector

Intermittent open or short circuits may be caused by vibrations in the wire harnesses and connectors due to fluctuations in engine torque, bumps in the
road, etc. Perform the following inspections.

Shake the related connectors or wiring while monitoring the scan tool data.
Shake the related connectors or wiring and monitor component operation while turning the components ON and OFF using the scan tool.
Start the engine, and shake the related connectors and wiring while checking the operation status of the engine.

If moving the wire harness or connector affects the data displayed or the component or system operation, inspect the wire harness and connector as
necessary.

6. Electrical connections or wiring

Intermittent conditions are caused by poor wire harness connections, loose terminals, or problems in the wire harness. Check for the following conditions.
 Is there any improper mating of the connector halves or improper seating of the terminals in the connector body?
Are there any improperly formed, damaged, or loose terminals?
Are there any poor terminal-to-wire harness connections or bent terminals?
Is there any corrosion or water intrusion?
Are there any broken wire harnesses?
Is the wire harness pinched, cut, or damaged?
Is the wire harness coming in contact with hot exhaust components?

Note
Worn or damaged insulation can allow moisture to enter the wiring. The conductor can corrode inside the insulation, with little visible
evidence. Check for swollen or stiff sections of the wire harness in the suspected circuits.

7. Control module power supply and ground, and component power supply and ground

Various symptoms can occur due to poor connections at the power supply or ground.
Test all control module power supply circuits. In many vehicles, there are multiple circuits that supply power to the control module. Other components in the
system have separate power supply circuits that also need to be tested. Inspect the connections and fuses of the module and the component connectors,
as well as intermediate connections between the power supply, the module, and the components. A test lamp or a DMM may indicate that voltage is
present, but neither of them tests whether the circuit is carrying sufficient current. Check whether sufficient current necessary to operate the components is
flowing in the circuit.
Test all control module ground circuits and system ground circuits. Some control modules have multiple ground circuits. Other components in the system
have a separate ground that also needs to be tested. Inspect whether the ground is clean and is securely connected to the ground point. Inspect the
connections of the components and the splice pack. Check whether sufficient current necessary to operate the components is flowing in the circuit.

8. Effects caused by temperature

An intermittent condition may occur when a component or connection reaches its operating temperature. For intermittent conditions that may occur only
when the components or connections are cold or only when they are hot, failure records or snapshot data can be helpful, where possible.
If an intermittent condition is related to heat, review the data relating to the following items.

High ambient temperature

Heat generated under the hood and by the engine
Heat generated due to poor wire harness connections or a high electrical load
Higher than normal load conditions due to towing, etc.

If an intermittent condition is related to low temperatures, review the data relating to the following.

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Low ambient temperature
The symptom occurs only on a cold start.
The symptom goes away when the vehicle warms up.

Note
If the temperature is extremely low, a connection area or component may freeze. Inspect for water intrusion.

Based on the information from the customer, determine if the failure is caused by temperature.

9. Reproduction of failure conditions

If none of the previous tests are successful, attempt to duplicate or record the failure conditions.
An alternative method is to operate the vehicle with the DMM connected to the suspected circuit. If an abnormal value is displayed on the DMM when the
problem occurs, this can be helpful in identifying the defective area.

10. Scan tool snapshot

Snapshots can be taken using the scan tool. The snapshot function can be used to record ECU data in chronological order and analyze it. The scan tool
also has a graph function which can display graph data individually or in combination for comparison. The snapshot function can be used to set up the
manual trigger or automatic trigger when a DTC is set.
Analyzing the recorded data allows malfunctioning components to be identified.

11. DRM memory

Use the data stored in the DRM, or use the manual trigger switch. The DRM has the ability to store the engine log data at the time of a DTC event. The
manual trigger switch stores the log data by an arbitrary operation of the driver on the occurrence of a wrong vehicle performance event instead of a DTC
event. If the driver presses and releases the manual trigger switch once, that time becomes a trigger, and the log data after the trigger is stored in the DRM
memory.