Part 3
1AR-FE ENGINE CONTROL: SFI SYSTEM: P1604: Startability Malfunction
P1604 - Startability Malfunction - Continued
55. 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 69 and perform fuel system troubleshooting A (steps 95 to 102), fuel system troubleshooting B (steps 103 to 105), intake system troubleshooting (steps 106 to 108), and ignition system troubleshooting (steps 109 to 117), in that order.
NG -- REPLACE ENGINE COOLANT TEMPERATURE SENSOR Removal
OK -- Continue to next step.
56. CHECK HARNESS AND CONNECTOR (ENGINE COOLANT TEMPERATURE SENSOR - ECM)
(a) Check the harnesses and connectors, referring to DTC P0115 inspection procedure P0115.
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 69 and perform fuel system troubleshooting A (steps 95 to 102), fuel system troubleshooting B (steps 103 to 105), intake system troubleshooting (steps 106 to 108), and ignition system troubleshooting (steps 109 to 117), in that order.
NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- Continue to next step.
57. INSPECT MASS AIR FLOW METER
(a) Inspect the mass air flow meter 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 69 and perform fuel system troubleshooting A (steps 95 to 102), fuel system troubleshooting B (steps 103 to 105), intake system troubleshooting (steps 106 to 108), and ignition system troubleshooting (steps 109 to 117), in that order.
NG -- REPLACE MASS AIR FLOW METER Removal
OK -- Continue to next step.
58. CHECK HARNESS AND CONNECTOR (MASS AIR FLOW METER - ECM)
(a) Check the harnesses and connectors, referring to DTC P0102 inspection procedure P0102.
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 69 and perform fuel system troubleshooting A (steps 95 to 102), fuel system troubleshooting B (steps 103 to 105), intake system troubleshooting (steps 106 to 108), and ignition system troubleshooting (steps 109 to 117), in that order.
NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- Continue to next step.
59. READ VALUE USING TECHSTREAM
(a) Connect the Techstream to the DLC3.
(b) Turn the ignition switch to ON.
(c) Turn the Techstream on.
(d) Enter the following menus: Powertrain / Engine / Data List / Long FT # and Atmosphere Pressure.
Result
B -- CHECK FUEL PRESSURE
A -- Continue to next step.
60. PERFORM SIMULATION TEST
(a) Remove the EFI and ETCS fuses from the engine room relay block.
(b) After 60 seconds or more elapse, install the EFI and ETCS fuses.
(c) Check if the engine can be started.
Result
B -- CHECK FUEL PRESSURE
A -- Continue to next step.
61. 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.
(e) Confirm that Fuel System Status #1 is CL.
(f) Enter the following menus: Powertrain / Engine / Data List / AF Lambda B1S1.
(g) Confirm that AF Lambda B1S1 is 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:
Result
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 69 and perform fuel system troubleshooting A (steps 95 to 102), fuel system troubleshooting B (steps 103 to 105), intake system troubleshooting (steps 106 to 108), and ignition system troubleshooting (steps 109 to 117), in that order.
B -- REPLACE AIR FUEL RATIO SENSOR Removal
A -- Continue to next step.
62. PERFORM SIMULATION TEST
(a) Check if the idling speed is stable after starting the engine.
OK:
Engine speed is stable.
HINT
After replacing the fuel injector assembly 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 69 and perform fuel system troubleshooting A (steps 95 to 102), fuel system troubleshooting B (steps 103 to 105), intake system troubleshooting (steps 106 to 108), and ignition system troubleshooting (steps 109 to 117), in that order.
NG -- REPLACE FUEL INJECTOR ASSEMBLY Removal
OK -- REPLACE MASS AIR FLOW METER Removal
63. CHECK FUEL PRESSURE
(a) Inspect the fuel pressure Fuel System.
NG -- PERFORM ACTIVE TEST USING TECHSTREAM (CONTROL THE FUEL PUMP / SPEED)
OK -- Continue to next step.
64. INSPECT 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 69 and perform fuel system troubleshooting A (steps 95 to 102), fuel system troubleshooting B (steps 103 to 105), intake system troubleshooting (steps 106 to 108), and ignition system troubleshooting (steps 109 to 117), 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 69 and perform fuel system troubleshooting A (steps 95 to 102), fuel system troubleshooting B (steps 103 to 105), intake system troubleshooting (steps 106 to 108), and ignition system troubleshooting (steps 109 to 117), 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.
65. 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 assembly.
*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 69, perform fuel system troubleshooting A (steps 95 to 102), fuel system troubleshooting B (steps 103 to 105), intake system troubleshooting (steps 106 to 108), and ignition system troubleshooting (steps 109 to 117), in that order.
C -- CHECK MALFUNCTION CONDITION
B -- INSPECT FUEL INJECTOR ASSEMBLY
A -- Continue to next step.
66. CHECK FUEL PRESSURE
HINT
For the fuel pressure inspection, refer to the following procedures Fuel System.
(a) Attach a fuel pressure gauge and check the fuel pressure after stopping the engine.
Standard:
147 kPa (1.5 kgf/cm2) or higher (5 minutes after stopping the engine)
Result
HINT
* If the engine cannot be started, read the values after cranking the engine.
* *1: From step 69, perform fuel system troubleshooting A (steps 95 to 102), fuel system troubleshooting B (steps 103 to 105), intake system troubleshooting (steps 106 to 108), and ignition system troubleshooting (steps 109 to 117), in that order.
B -- CHECK MALFUNCTION CONDITION
A -- REPLACE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY Removal
67. INSPECT 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.
* *1: From step 69, perform fuel system troubleshooting A (steps 95 to 102), fuel system troubleshooting B (steps 103 to 105), intake system troubleshooting (steps 106 to 108), and ignition system troubleshooting (steps 109 to 117), in that order.
B -- CHECK MALFUNCTION CONDITION
A -- REPLACE FUEL INJECTOR ASSEMBLY Removal
68. PERFORM ACTIVE TEST USING TECHSTREAM (CONTROL THE FUEL PUMP / SPEED)
(a) Connect the Techstream to the DLC3.
(b) Turn the ignition switch to ON.
(c) Turn the Techstream on.
(d) Enter the following menus: Powertrain / Engine / Active Test / Control the Fuel Pump / Speed.
(e) When performing the Active Test, check for fuel leakage from the fuel pipes.
Result
HINT
* Jiggle the wire harness and connector to increase the likelihood of detecting malfunctions that do not always occur.
* Check if the vehicle ran out of fuel, as engine starting trouble due to running out of fuel is also detected.
* If there are no fuel leaks, after inspecting the fuel pump control system, check if engine starting trouble occurs again. If engine starting trouble still occurs, proceed to step 69 and perform fuel system troubleshooting A (steps 95 to 102), fuel system troubleshooting B (steps 103 to 105), intake system troubleshooting (steps 106 to 108), and ignition system troubleshooting (steps 109 to 117), in that order.
B -- CHECK FUEL PUMP CONTROL CIRCUIT Component Tests and General Diagnostics
A -- REPAIR OR REPLACE FUEL LINE
69. CHECK MALFUNCTION CONDITION
(a) If the malfunction could not be identified during the inspection in steps 38, 39, 40 and 46, perform fuel system troubleshooting C (steps 70 to 73).
Result
(b) If the malfunction could not be identified during the inspection in step 44, perform ignition system troubleshooting (steps 74 to 82).
Result
(c) If the malfunction could not be identified during the inspection in steps 53 and 54, perform intake air system troubleshooting (steps 84 to 86). If engine starting trouble still occurs, perform fuel system troubleshooting A (steps 87 to 94).
Result
(d) If the malfunction could not be identified during the inspection in steps 55, 56, 57, 58, 61, 62, 64, 65, 66, 67 and 68, perform fuel system troubleshooting A (steps 95 to 102), fuel system troubleshooting B (steps 103 to 105), intake air system troubleshooting (steps 106 to 108), and ignition system troubleshooting (steps 109 to 117), in that order.
Result
D -- CHECK FUEL PRESSURE
C -- READ VALUE USING TECHSTREAM (ISC LEARNING VALUE)
B -- CHECK SENSOR INSTALLATION (CRANKSHAFT POSITION SENSOR)
A -- Continue to next step.
70. INSPECT FUEL INJECTOR ASSEMBLY
(a) Inspect the fuel injector assemblies Testing and Inspection.
NG -- REPLACE FUEL INJECTOR ASSEMBLY Removal
OK -- Continue to next step.
71. CHECK TERMINAL VOLTAGE (POWER SOURCE OF FUEL INJECTOR ASSEMBLY)
(a) Check the harnesses and connectors, referring to Fuel Injector Circuit inspection procedure Component Tests and General Diagnostics.
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.
NG -- CHECK FUEL INJECTOR CIRCUIT Component Tests and General Diagnostics
OK -- Continue to next step.
72. 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 CAMSHAFT POSITION SENSOR (FOR INTAKE CAMSHAFT)
OK -- END (CRANKSHAFT POSITION SENSOR IS DEFECTIVE)
73. CHECK CAMSHAFT POSITION SENSOR (FOR INTAKE CAMSHAFT)
(a) Replace the camshaft position sensor (for intake camshaft) Removal.
(b) Check the engine start operation.
OK:
Malfunction has been repaired successfully.
NG -- CHECK CAMSHAFT POSITION SENSOR (FOR EXHAUST CAMSHAFT)
OK -- END (CAMSHAFT POSITION SENSOR (FOR INTAKE CAMSHAFT) IS DEFECTIVE)
74. CHECK CAMSHAFT POSITION SENSOR (FOR EXHAUST CAMSHAFT)
(a) Replace the camshaft position sensor (for exhaust camshaft) Removal.
(b) Check the engine start operation.
OK:
Malfunction has been repaired successfully.
NG -- REPLACE ECM Removal
OK -- END (CAMSHAFT POSITION SENSOR (FOR EXHAUST CAMSHAFT) IS DEFECTIVE)
75. CHECK SENSOR INSTALLATION (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 SENSOR
OK -- Continue to next step.