Part 4

2GR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: P1604: Startability Malfunction - Continued
P1604 - Startability Malfunction

72. CHECK MALFUNCTION CONDITION

(a) If the malfunction could not be identified during the inspection in steps 38, 39, 40 and 47, perform fuel system troubleshooting C (steps 73 to 77).

Result:

(b) If the malfunction could not be identified during the inspection in step 45, perform ignition system troubleshooting (steps 78 to 84).

Result:

(c) If the malfunction could not be identified during the inspection in steps 55, 56 and 57, perform intake air system troubleshooting (steps 85 to 87). If engine starting trouble still occurs, perform fuel system troubleshooting A (steps 88 to 95).

Result:

(d) If the malfunction could not be identified during the inspection in steps 58, 59, 60, 61, 64, 65, 67, 68, 69, 70 and 71, perform fuel system troubleshooting A (steps 96 to 103), fuel system troubleshooting B (steps 104 to 106), intake air system troubleshooting (steps 107 to 109), and ignition system troubleshooting (steps 110 to 116), in that order.

Result:

D -- CHECK FUEL PRESSURE

C -- READ VALUE USING TECHSTREAM (ISC LEARNING VALUE)

B -- CHECK CRANKSHAFT POSITION SENSOR
A -- Continue to next step.

73. INSPECT FUEL INJECTOR ASSEMBLY

(a) Inspect the fuel injectors assembly Testing and Inspection.

NG -- REPLACE FUEL INJECTOR ASSEMBLY Removal
OK -- Continue to next step.

74. CHECK HARNESS AND CONNECTOR (FUEL INJECTOR ASSEMBLY POWER SOURCE)

(a) Disconnect the fuel injector assembly connector.

(b) Turn the engine switch on (IG).

(c) Measure the voltage according to the value(s) in the table below.

Standard Voltage:

Standard Resistance (Check for Short):

HINT
- Jiggle the wire harness and connector to increase the likelihood of detecting malfunctions that do not always occur.
- Make sure there is not an excessive amount of force applied to the wire harness.
(d) Reconnect the ECM connector.

(e) Reconnect the fuel injector assembly connector.

NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- Continue to next step.

76. CHECK CRANKSHAFT POSITION SENSOR

(a) Replace the crankshaft position sensor Removal.

(b) Check the engine start operation.

OK:

Malfunction has been repaired successfully.

NG -- CHECK VVT SENSOR

OK -- END (CRANKSHAFT POSITION SENSOR WAS DEFECTIVE)

77. CHECK VVT SENSOR

(a) Replace the VVT sensor Removal.

(b) Check the engine start operation.

OK:

Malfunction has been repaired successfully.

NG -- REPLACE ECM Removal

OK -- END (VVT SENSOR WAS DEFECTIVE)

78. CHECK CRANKSHAFT POSITION SENSOR

(a) Check the tightening and installation condition of the crankshaft position sensor bolt.

(b) Check the connection of the crankshaft position sensor connector.

OK:

Sensor is installed correctly.

NG -- SECURELY REINSTALL CRANKSHAFT POSITION SENSOR
OK -- Continue to next step.

79. CHECK VVT SENSOR

(a) Check the tightening and installation condition of the VVT sensor bolt.

(b) Check the connection of the VVT sensor connector.

OK:

Sensor is installed correctly.

NG -- SECURELY REINSTALL VVT SENSOR
OK -- Continue to next step.

80. CHECK HARNESS AND CONNECTOR (CRANKSHAFT POSITION SENSOR - ECM)

(a) Disconnect the crankshaft position sensor connector.

(b) Disconnect the ECM connector.

(c) Measure the resistance according to the value(s) in the table below.

Standard Resistance (Check for Open):

Standard Resistance (Check for Short):

HINT
- Jiggle the wire harness and connector to increase the likelihood of detecting malfunction that do not always occur.
- Make sure there is not an excessive amount of force applied to the wire harness.
(d) Reconnect the ECM connector.

(e) Reconnect the VVT sensor for exhaust side connector.

NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- Continue to next step.

83. CHECK CRANKSHAFT POSITION SENSOR

(a) Replace the crankshaft position sensor Removal.

(b) Check the engine start operation.

OK:

Malfunction has been repaired successfully.

NG -- CHECK VVT SENSOR

OK -- END (CRANKSHAFT POSITION SENSOR WAS DEFECTIVE)

84. CHECK VVT SENSOR

(a) Replace the VVT sensor Removal.

(b) Check the engine start operation.

OK:

Malfunction has been repaired successfully.

NG -- REPLACE ECM Removal

OK -- END (VVT SENSOR WAS DEFECTIVE)

85. READ VALUE USING TECHSTREAM (ISC LEARNING VALUE)

(a) Connect the Techstream to the DLC3.

(b) Turn the engine switch on (IG).

(c) Turn the Techstream on.

(d) Enter the following menus: Powertrain / Engine / Data List / ISC Learning Value.

(e) Start the engine and warm it up until the engine coolant temperature stabilizes with the A/C switch and all the accessory switches off.

Result:

B -- INSPECT ENGINE COOLANT TEMPERATURE SENSOR
A -- Continue to next step.

86. CHECK CYLINDER COMPRESSION PRESSURE

(a) Inspect the compression Engine.

NG -- REPAIR OR REPLACE ENGINE ASSEMBLY

OK -- CHECK VALVE TIMING

87. INSPECT ENGINE COOLANT TEMPERATURE SENSOR

(a) Inspect the engine coolant temperature sensor Testing and Inspection.

NG -- REPLACE ENGINE COOLANT TEMPERATURE SENSOR
OK -- Continue to next step.

88. CHECK FUEL PRESSURE

HINT
For the fuel pressure inspection, refer to the following procedures Testing and Inspection.

(a) Attach a fuel pressure gauge and check the fuel pressure when cranking the engine and after stopping the engine.

Result:

NG -- PERFORM ACTIVE TEST USING TECHSTREAM (CONTROL THE FUEL PUMP / SPEED)
OK -- Continue to next step.

89. READ VALUE USING TECHSTREAM (LONG FT #1 AND LONG FT #2)

(a) Connect the Techstream to the DLC3.

(b) Turn the engine switch on (IG).

(c) Turn the Techstream on.

(d) Enter the following menus: Powertrain / Engine / Data List / Long FT #1 and Long FT #2.

Result:

B -- REPLACE FUEL INJECTOR ASSEMBLY Removal
A -- Continue to next step.

90. PERFORM SIMULATION TEST

(a) Check if the idling speed after starting the engine is currently stable and has always been stable in the past.

Result:

HINT
Through the customer problem analysis, confirm the fuel being used and the location at which the fuel was added to check if the malfunction is caused by the fuel in the vehicle.

B -- REPLACE FUEL
A -- Continue to next step.

91. CHECK CRANKSHAFT POSITION SENSOR

(a) Check the tightening and installation condition of the crankshaft position sensor bolt.

(b) Check the connection of the crankshaft position sensor connector.

OK:

Sensor is installed correctly.

NG -- SECURELY REINSTALL CRANKSHAFT POSITION SENSOR
OK -- Continue to next step.

92. CHECK HARNESS AND CONNECTOR (CRANKSHAFT POSITION SENSOR - ECM)

(a) Disconnect the crankshaft position sensor connector.

(b) Disconnect the ECM connector.

(c) Measure the resistance according to the value(s) in the table below.

Standard Resistance (Check for Open):

Standard Resistance (Check for Short):

Result:

HINT
- Jiggle the wire harness and connector to increase the likelihood of detecting malfunctions that do not always occur.
- When performing the Active Test, if there is no operating noise from the fuel pump, the fuel pump system may be malfunctioning.
- Check if the vehicle ran out of fuel, as engine starting trouble due to running out of fuel is also detected.
B -- INSPECT FUEL PUMP

A -- REPAIR OR REPLACE FUEL LINE

95. INSPECT FUEL PUMP

(a) Disconnect the fuel pump connector.

(b) Measure the resistance according to the value(s) in the table below.

Standard Resistance:

HINT
- Make sure there is no foreign matter such as iron particles on the fuel pump and no signs that the fuel pump was stuck.
- Make sure the internal connector is securely connected.
- Make sure the fuel pump filter is not clogged.
(c) Reconnect the fuel pump connector.

NG -- REPLACE FUEL PUMP Removal

OK -- REPLACE PRESSURE REGULATOR

96. CHECK FUEL PRESSURE

HINT
For the fuel pressure inspection, refer to the following procedures Testing and Inspection.

(a) Attach a fuel pressure gauge and check the fuel pressure after stopping the engine.

Result:

B -- PERFORM ACTIVE TEST USING TECHSTREAM (CONTROL THE FUEL PUMP / SPEED)
A -- Continue to next step.

97. READ VALUE USING TECHSTREAM (LONG FT #1 AND LONG FT #2)

(a) Connect the Techstream to the DLC3.

(b) Turn the engine switch on (IG).

(c) Turn the Techstream on.

(d) Enter the following menus: Powertrain / Engine / Data List / Long FT #1 and Long FT #2.

Result:

B -- REPLACE FUEL INJECTOR ASSEMBLY Removal
A -- Continue to next step.

98. PERFORM SIMULATION TEST

(a) Check if the idling speed after starting the engine is currently stable and has always been stable in the past.

Result

Result:

HINT
Through the customer problem analysis, confirm the fuel being used and the location at which the fuel was added to check if the malfunction is caused by the fuel in the vehicle.

B -- REPLACE FUEL
A -- Continue to next step.

99. CHECK CRANKSHAFT POSITION SENSOR

(a) Check the tightening and installation condition of the crankshaft position sensor bolt.

(b) Check the connection of the crankshaft position sensor connector.

OK:

Sensor is installed correctly.

NG -- SECURELY REINSTALL CRANKSHAFT POSITION SENSOR
OK -- Continue to next step.

100. CHECK HARNESS AND CONNECTOR (CRANKSHAFT POSITION SENSOR - ECM)

(a) Disconnect the crankshaft position sensor connector.

(b) Disconnect the ECM connector.

(c) Measure the resistance according to the value(s) in the table below.

Standard Resistance (Check for Open):

Standard Resistance (Check for Short):

Result:

HINT
- Jiggle the wire harness and connector to increase the likelihood of detecting malfunctions that do not always occur.
- When performing the Active Test, if there is no operating noise from the fuel pump, the fuel pump system may be malfunctioning.
- Check if the vehicle ran out of fuel, as engine starting trouble due to running out of fuel is also detected.
B -- INSPECT FUEL PUMP

A -- REPAIR OR REPLACE FUEL LINE

103. INSPECT FUEL PUMP

(a) Disconnect the fuel pump connector.

(b) Measure the resistance according to the value(s) in the table below.

Standard Resistance:

HINT
- Make sure there is no foreign matter such as iron particles on the fuel pump and no signs that the fuel pump was stuck.
- Make sure the internal connector is securely connected.
- Make sure the fuel pump filter is not clogged.
(c) Reconnect the fuel pump connector.

NG -- REPLACE FUEL PUMP Removal
OK -- Continue to next step.

104. CHECK PURGE VSV

(a) Disconnect the vacuum hose (on the canister side) of the purge VSV.

(b) Start the engine.

(c) Idle the engine.

(d) Disconnect the purge VSV connector.

(e) Check if air flows through the purge VSV.

Standard:

Air does not flow

(f) Reconnect the purge VSV connector.

(g) Reconnect the vacuum hose.

HINT
When this inspection is performed, the MIL may illuminate. After finishing the inspection, check and clear DTCs DTC Check / Clear.

NG -- INSPECT PURGE VSV
OK -- Continue to next step.

105. CHECK FUEL INJECTOR ASSEMBLY

(a) Clean the inside of the surge tank with compressed air.

(b) After stopping the engine, measure the HC concentration inside the surge tank for 15 minutes.

Result:

HINT
If the concentration is 400 ppm or higher, a fuel injector may have a sealing problem.

B -- CHECK INTAKE VALVE

A -- REPLACE FUEL INJECTOR ASSEMBLY Removal

106. CHECK INTAKE VALVE

(a) Check if carbon is on the intake valves.

Result:

B -- READ VALUE USING TECHSTREAM (ISC LEARNING VALUE)

A -- CLEAN INTAKE VALVE

107. READ VALUE USING TECHSTREAM (ISC LEARNING VALUE)

(a) Connect the Techstream to the DLC3.

(b) Turn the engine switch on (IG).

(c) Turn the Techstream on.

(d) Enter the following menus: Powertrain / Engine / Data List / ISC Learning Value.

(e) Start the engine, turn off all accessory switches and warm up the engine until the engine coolant temperature stabilizes.

Result:

B -- INSPECT ENGINE COOLANT TEMPERATURE SENSOR
A -- Continue to next step.

108. CHECK CYLINDER COMPRESSION PRESSURE

(a) Inspect the compression Engine.

NG -- REPAIR OR REPLACE ENGINE ASSEMBLY

OK -- ADJUST VALVE TIMING Reassembly

109. INSPECT ENGINE COOLANT TEMPERATURE SENSOR

(a) Inspect the engine coolant temperature sensor Testing and Inspection.

NG -- REPLACE ENGINE COOLANT TEMPERATURE SENSOR
OK -- Continue to next step.

110. CHECK CRANKSHAFT POSITION SENSOR

(a) Check the tightening and installation condition of the crankshaft position sensor bolt.

(b) Check the connection of the crankshaft position sensor connector.

OK:

Sensor is installed correctly.

NG -- SECURELY REINSTALL CRANKSHAFT POSITION SENSOR
OK -- Continue to next step.

111. CHECK VVT SENSOR

(a) Check the tightening and installation condition of the VVT sensor bolt.

(b) Check the connection of the VVT sensor connector.

OK:

Sensor is installed correctly.

NG -- SECURELY REINSTALL VVT SENSOR
OK -- Continue to next step.

112. CHECK HARNESS AND CONNECTOR (CRANKSHAFT POSITION SENSOR - ECM)

(a) Disconnect the crankshaft position sensor connector.

(b) Disconnect the ECM connector.

(c) Measure the resistance according to the value(s) in the table below.

Standard Resistance (Check for Open):

Standard Resistance (Check for Short):