Part 4

1UR-FSE ENGINE CONTROL SYSTEM: SFI SYSTEM: P1604: Startability Malfunction
P1604 - Startability Malfunction

Continued

50. CHECK HARNESS AND CONNECTOR (FUEL INJECTOR FOR PORT INJECTION - ECM)

(a) Disconnect the fuel injector for port injection 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 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 for port injection connector.

NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR

OK -- REPLACE ECM Removal

51. INSPECT MASS AIR FLOW METER

(a) Inspect the mass air flow meter On-Vehicle Inspection.

NG -- CHECK HARNESS AND CONNECTOR (MASS AIR FLOW METER - ECM)
OK -- Continue to next step.

52. CHECK INTAKE SYSTEM

(a) Check for air suction in the intake system [vacuum hose disconnection, cracks, damaged gaskets, etc.].

HINT
- If the accelerator pedal is released after racing the engine, the inspection is easier to perform because the vacuum inside the intake manifold increases and the air suction noise becomes louder.
- If Short FT and Long FT are largely different from the normal values when idling (intake air volume is small) and almost the same as the normal values when racing the engine (intake air volume is high), air leakage may be present.

Standard:

There is no air suction.

NG -- REPAIR OR REPLACE INTAKE SYSTEM
OK -- Continue to next step.

53. CHECK THROTTLE BODY

(a) Disconnect the throttle body connector.

HINT
When the connector is disconnected, the vehicle enters fail-safe mode and the throttle valve opening angle is 4 to 7°.

(b) Crank the engine and check that it starts.

Result:

(c) Connect the throttle body connector.

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

B -- PERFORM ACTIVE TEST USING TECHSTREAM (CONTROL THE VVT-IE LINEAR)
A -- Continue to next step.

54. CHECK THROTTLE BODY

(a) Check if carbon is in the air flow passage.

Standard:

No carbon present.

NG -- REMOVE FOREIGN OBJECT AND CLEAN THROTTLE BODY
OK -- Continue to next step.

55. PERFORM ACTIVE TEST USING TECHSTREAM (CONTROL THE VVT-IE LINEAR)

(a) Connect the Techstream to the DLC3.

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

(c) Turn the Techstream on.

(d) Start the engine and warm it up.

(e) Enter the following menus: Powertrain / Engine / Active Test / Control the VVT-iE Linear (Bank 1) or Control the VVT-iE Linear (Bank 2).

(f) Monitor VVT-iE Aim Angle #1 and VVT Change Angle #1 or VVT-iE Aim Angle #2 and VVT Change Angle #2.

(g) Perform the Active Test operation with the engine speed at 1500 rpm.

OK:

HINT
- When viewed from the rear of the engine assembly, bank 1 is on the left side and bank 2 is on the right side.
- Juggle the wire harness and connector to increase the likelihood of detecting malfunctions that do not always occur.
NG -- CHECK VVT-IE SYSTEM
OK -- Continue to next step.

56. PERFORM ACTIVE TEST USING TECHSTREAM (CONTROL THE VVT EXHAUST LINEAR)

(a) Connect the Techstream to the DLC3.

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

(c) Turn the Techstream on.

(d) Start the engine and warm it up.

(e) Enter the following menus: Powertrain / Engine / Active Test / Control the VVT Exhaust Linear (Bank 1) or Control the VVT Exhaust Linear (Bank 2).

(f) Check the engine speed while operating the oil control valve using the Techstream.

OK*:

Result:

HINT
- *: From step 72, perform intake system troubleshooting (steps 89 to 91). If engine starting trouble still occurs, perform fuel system troubleshooting A (steps 92 to 99).
- Jiggle the wire harness and connector to increase the likelihood of detecting malfunctions that do not always occur.
- When the results of the inspection using the Active Test are normal but the camshaft timing oil control valve operating noise is abnormal, check the camshaft timing oil control valve for any signs of problems.
- If the camshaft timing oil control valve assembly is stuck on, the valve overlap increases and combustion worsens due to the internal EGR which may cause the engine to stall.
B -- CHECK MALFUNCTION CONDITION

A -- REPLACE CAMSHAFT TIMING OIL CONTROL VALVE Removal

57. CHECK HARNESS AND CONNECTOR (MASS AIR FLOW METER - ECM)

(a) Disconnect the mass air flow meter 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 malfunctions that do not always occur.
- Make sure there is not an excessive amount of force applied to the wire harness.
- If the wire harness is normal, after replacing the mass air flow meter, check if engine starting trouble occurs again. If engine starting trouble occurs again, proceed to step 72 and perform intake system troubleshooting (steps 89 to 91). If engine starting trouble still occurs, perform fuel system troubleshooting A (steps 92 to 99).
(d) Reconnect the ECM connector.

(e) Reconnect the mass air flow meter connector.

NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR

OK -- REPLACE MASS AIR FLOW METER

58. INSPECT ENGINE COOLANT TEMPERATURE SENSOR

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

HINT
If the engine coolant temperature sensor is malfunctioning, after replacing it, check if engine starting trouble occurs again. If engine starting trouble occurs, replace the ECM. If engine starting trouble still occurs, proceed to step 72 and perform fuel system troubleshooting A (steps 100 to 107), fuel system troubleshooting B (steps 108 to 110), intake system troubleshooting (steps 111 to 113), and ignition system troubleshooting (steps 114 to 123), in that order.

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

59. CHECK HARNESS AND CONNECTOR (ENGINE COOLANT TEMPERATURE SENSOR - ECM)

(a) Disconnect the engine coolant temperature 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 malfunctions that do not always occur.
- Make sure there is not an excessive amount of force applied to the wire harness.
- If the wire harness or connector is malfunctioning, after replacing or repairing it, check if engine starting trouble occurs again. If engine starting trouble occurs, replace the ECM. If engine starting trouble still occurs, proceed to step 72 and perform fuel system troubleshooting A (steps 100 to 107), fuel system troubleshooting B (steps 108 to 110), intake system troubleshooting (steps 111 to 113), and ignition system troubleshooting (steps 114 to 123), in that order.
(d) Reconnect the ECM connector.

(e) Reconnect the engine coolant temperature sensor connector.

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

60. INSPECT MASS AIR FLOW METER

(a) Inspect the mass air flow meter On-Vehicle Inspection.

HINT
If the mass air flow meter is malfunctioning, after replacing it, check if engine starting trouble occurs again. If engine starting trouble occurs, replace the ECM. If engine starting trouble still occurs, proceed to step 72 and perform fuel system troubleshooting A (steps 100 to 107), fuel system troubleshooting B (steps 108 to 110), intake system troubleshooting (steps 111 to 113), and ignition system troubleshooting (steps 114 to 123), in that order.

NG -- REPLACE MASS AIR FLOW METER
OK -- Continue to next step.

61. CHECK HARNESS AND CONNECTOR (MASS AIR FLOW METER - ECM)

(a) Disconnect the mass air flow meter 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):

B -- CHECK FUEL PRESSURE (LOW PRESSURE SIDE)
A -- Continue to next step.

63. PERFORM SIMULATION TEST

(a) Remove the EFI and ETCS fuses from the engine room relay block.

(b) After 60 seconds or more have elapsed, install the EFI and ETCS fuses.

(c) Check if the engine can be started.

Result

B -- CHECK FUEL PRESSURE (LOW PRESSURE SIDE)
A -- Continue to next step.

64. INSPECT AIR FUEL RATIO SENSOR

(a) Connect the Techstream to the DLC3.

(b) Start the engine.

(c) Turn the Techstream on.

(d) Enter the following menus: Powertrain / Engine / Data List / Fuel System Status #1 and Fuel System Status #2.

(e) Confirm that Fuel System Status #1 and Fuel System Status #2 are both CL.

(f) Enter the following menus: Powertrain / Engine / Data List / AF Lambda B1S1 and AF Lambda B2S1.

(g) Confirm that AF Lambda B1S1 and AF Lambda B2S1 are both within the range of 0.95 to 1.05 when idling.

(h) Enter the following menus: Powertrain / Engine / Active Test / Control the Injection Volume for A/F Sensor.

(i) Read the output voltage from the air fuel ratio sensor when increasing and decreasing the fuel injection volume.

Standard:

HINT
- The air fuel ratio sensor has an output delay of a few seconds and the heated oxygen sensor has a maximum output delay of approximately 20 seconds.
- If the air fuel ratio sensor is malfunctioning, after replacing it, check if engine starting trouble occurs again. If engine starting trouble occurs, replace the ECM. If engine starting trouble still occurs, proceed to step 72 and perform fuel system troubleshooting A (steps 100 to 107), fuel system troubleshooting B (steps 108 to 110), intake system troubleshooting (steps 111 to 113), and ignition system troubleshooting (steps 114 to 123), in that order.
NG -- REPLACE AIR FUEL RATIO SENSOR Removal
OK -- Continue to next step.

65. PERFORM SIMULATION TEST

(a) Check if the idle speed is stable after starting the engine.

OK:

Idle speed is stable.

HINT
After replacing the fuel injector for port injection or mass air flow meter, check if engine starting trouble occurs again. If engine starting trouble occurs, replace the ECM. If engine starting trouble still occurs, proceed to step 72 and perform fuel system troubleshooting A (steps 100 to 107), fuel system troubleshooting B (steps 108 to 110), intake system troubleshooting (steps 111 to 113), and ignition system troubleshooting (steps 114 to 123), in that order.

NG -- REPLACE FUEL INJECTOR FOR PORT INJECTION Removal

OK -- REPLACE MASS AIR FLOW METER

66. CHECK FUEL PRESSURE (LOW PRESSURE SIDE)

(a) Inspect the fuel pressure (low pressure side) Testing and Inspection.

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

67. CHECK SPARK PLUG

(a) Inspect the spark plugs Testing and Inspection.

Result

HINT
- *1: If one cylinder is abnormal, replace the spark plug of that cylinder and inspect the ignition and fuel system for that cylinder. After performing repairs, check if engine starting trouble occurs again. If engine starting trouble still occurs, proceed to step 72 and perform fuel system troubleshooting A (steps 100 to 107), fuel system troubleshooting B (steps 108 to 110), intake system troubleshooting (steps 111 to 113), and ignition system troubleshooting (steps 114 to 123), in that order.
- *2: If all cylinders are abnormal, replace the spark plugs of all cylinders and check if engine starting trouble occurs again. If engine starting trouble still occurs, proceed to step 72 and perform fuel system troubleshooting A (steps 100 to 107), fuel system troubleshooting B (steps 108 to 110), intake system troubleshooting (steps 111 to 113), and ignition system troubleshooting (steps 114 to 123), in that order.
- *3: Engine starting trouble may occur if the vehicle is driven extremely short distances repeatedly.
C -- REPLACE SPARK PLUG (ALL CYLINDER) Removal

B -- REPLACE SPARK PLUG (ABNORMAL CYLINDER) Removal
A -- Continue to next step.

68. CONFIRM VEHICLE CONDITION

(a) Confirm the conditions present when the malfunction occurred based on the customer problem analysis.

Result:

HINT
*1: The pressure regulator may be stuck open. Attach a fuel pressure gauge and check the ability to maintain fuel pressure after stopping the engine.

*2: Fuel may be leaking from a fuel injector for port injection.

*3: The pressure regulator may not be able to maintain the fuel pressure. Attach a fuel pressure gauge and check the ability to maintain fuel pressure after stopping the engine.

*4: From step 72, perform fuel system troubleshooting A (steps 100 to 107), fuel system troubleshooting B (steps 108 to 110), intake system troubleshooting (steps 111 to 113), and ignition system troubleshooting (steps 114 to 123), in that order.

C -- CHECK MALFUNCTION CONDITION

B -- CHECK FUEL INJECTOR FOR PORT INJECTION
A -- Continue to next step.

69. CHECK FUEL PRESSURE (LOW PRESSURE SIDE)

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:

HINT
- If the engine cannot be started, check the fuel pressure after cranking the engine.
- *: From step 72, perform fuel system troubleshooting A (steps 100 to 107), fuel system troubleshooting B (steps 108 to 110), intake system troubleshooting (steps 111 to 113), and ignition system troubleshooting (steps 114 to 123), in that order.
B -- CHECK MALFUNCTION CONDITION

A -- REPLACE PRESSURE REGULATOR

70. CHECK FUEL INJECTOR FOR PORT INJECTION

(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.
- *: From step 72, perform fuel system troubleshooting A (steps 100 to 107), fuel system troubleshooting B (steps 108 to 110), intake system troubleshooting (steps 111 to 113), and ignition system troubleshooting (steps 114 to 123), in that order.
B -- CHECK MALFUNCTION CONDITION

A -- REPLACE FUEL INJECTOR FOR PORT INJECTION Removal