Part 2

1GR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: P1604: Startability Malfunction
P1604 - Startability Malfunction (Continued..)

26. INSPECT BATTERY

(a) Check the electrolyte quantity.

OK:

Electrolyte quantity is within the specified range.

(b) Inspect the specific gravity.

(1) Inspect the specific gravity of each cell.

Standard specific gravity:

1.25 to 1.29 (electrolyte is at 20°C (68°F))

HINT
* If the result is not as specified, recharge or replace the battery.
* It is not necessary to inspect a maintenance-free battery.

(c) Inspect the battery voltage.

(1) Turn the ignition switch off and turn on the headlights for 20 to 30 seconds. This will remove the surface charge from the battery.

(2) Measure the battery voltage.

Standard voltage:

12.5 to 12.9 V (electrolyte is at 20°C (68°F))

HINT
If the result is not as specified, recharge or replace the battery.

(3) Measure the battery voltage when cranking the engine.

Standard:

Approximately 6 V or higher (0°C (32°F) or higher)

HINT
When the battery is depleted, the horn becomes quieter.

NG -- CHARGE OR REPLACE BATTERY
OK -- Continue to next step.

27. CHECK ENGINE ASSEMBLY

(a) Check that the crankshaft rotates smoothly when rotating it by hand.

OK:

Crankshaft rotates smoothly.

HINT
Excess engine friction may have occurred temporarily. Remove the cylinder head cover and oil pan and check for foreign matter such as iron fragments. If there is a malfunction or signs of a malfunction present, perform a detailed inspection by disassembling all the parts.

NG -- REPAIR OR REPLACE ENGINE ASSEMBLY

OK -- INSPECT STARTER ASSEMBLY

28. CHECK STARTER ASSEMBLY

(a) Remove the starter assembly (for 1.4 kW Type) Removal.

(b) Remove the starter assembly (for 1.6 kW Type) Removal.

(c) Check for starter pinion gear wear and damage.

OK:

There is no wear or damage.

NG -- REPLACE STARTER ASSEMBLY

OK -- REPLACE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY Removal

29. INSPECT BATTERY

(a) Check the electrolyte quantity.

HINT
*: If the cranking speed is fast, there may be compression loss.

B -- CHECK AND REPAIR ENGINE ASSEMBLY
A -- Continue to next step.

32. INSPECT BATTERY

(a) Check the electrolyte quantity.

OK:

Electrolyte quantity is within the specified range.

(b) Inspect the specific gravity.

(1) Inspect the specific gravity of each cell.

Standard specific gravity:

1.25 to 1.29 (electrolyte is at 20°C (68°F))

HINT
* If the result is not as specified, recharge or replace the battery.
* It is not necessary to inspect a maintenance-free battery.

(c) Inspect the battery voltage.

(1) Turn the ignition switch off and turn on the headlights for 20 to 30 seconds. This will remove the surface charge from the battery.

(2) Measure the battery voltage.

Standard voltage:

12.5 to 12.9 V (electrolyte is at 20°C (68°F))

HINT
If the result is not as specified, recharge or replace the battery.

(3) Measure the battery voltage when cranking the engine.

Standard:

Approximately 6 V or higher (0°C (32°F) or higher)

HINT
When the battery is depleted, the horn becomes quieter.

NG -- CHARGE OR REPLACE BATTERY
OK -- Continue to next step.

33. CHECK ENGINE ASSEMBLY

(a) Check that the crankshaft rotates smoothly when rotating it by hand.

OK:

Crankshaft rotates smoothly.

HINT
Excess engine friction may have occurred temporarily. Remove the cylinder head cover and oil pan and check for foreign matter such as iron fragments. If there is a malfunction or signs of a malfunction present, perform a detailed inspection by disassembling all the parts.

NG -- REPAIR OR REPLACE ENGINE ASSEMBLY

OK -- INSPECT STARTER ASSEMBLY

34. CHECK FUEL INJECTOR ASSEMBLY

(a) Using a sound scope or screwdriver, check for fuel injector operating noise while cranking the engine.

OK:

Fuel injector operating noise is heard.

NG -- READ VALUE USING TECHSTREAM (ENGINE SPEED)
OK -- Continue to next step.

35. 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.

36. CHECK SPARK PLUG AND SPARK

(a) Check for sparks Testing and Inspection.

NG -- CHECK SPARK PLUG
OK -- Continue to next step.

37. CONFIRM VEHICLE CONDITION

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

Result

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

*2: Fuel may be leaking from a fuel injector assembly.

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

*4: From step 71, perform fuel system troubleshooting C (steps 72 to 76).

C -- CHECK MALFUNCTION CONDITION

B -- CHECK FUEL INJECTOR ASSEMBLY
A -- Continue to next step.

38. 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.

Result

HINT
* If the engine cannot be started, check the fuel pressure after cranking the engine.
* *: From step 71, perform fuel system troubleshooting C (steps 72 to 76).

B -- REPLACE FUEL PRESSURE REGULATOR ASSEMBLY Removal

A -- CHECK MALFUNCTION CONDITION

39. CHECK FUEL INJECTOR ASSEMBLY

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

Result

HINT
* If the concentration is 400 ppm or more, a fuel injector assembly may have a sealing problem.
* *: From step 71, perform fuel system troubleshooting C (steps 72 to 76).

B -- CHECK MALFUNCTION CONDITION

A -- REPLACE FUEL INJECTOR ASSEMBLY Removal

40. CHECK SPARK PLUG

(a) Inspect the spark plugs Testing and Inspection.

HINT
Even if the spark plug of only one cylinder is malfunctioning, replace the spark plugs of all cylinders.

NG -- REPLACE SPARK PLUG Removal
OK -- Continue to next step.

41. READ VALUE USING TECHSTREAM (ENGINE SPEED)

(a) Connect the Techstream to the DLC3.

(b) Turn the ignition switch to ON.

(c) Enter the following menus: Powertrain / Engine and ECT / Data List / Engine Speed.

(d) Start the engine.

(e) While running the engine, read the value of Engine Speed.

OK:

A value that matches the actual engine speed is constantly output.

HINT
* Check the engine speed using a line graph.
* If the engine cannot be started, check the engine speed while cranking the engine.
* If the engine speed is 0 rpm, the crankshaft position sensor may have an open or short circuit.

NG -- CHECK CRANKSHAFT POSITION SENSOR CIRCUIT P0335
OK -- Continue to next step.

42. CHECK TERMINAL VOLTAGE (IGNITION COIL POWER SOURCE)

(a) Disconnect the ignition coil assembly connectors.

(b) Turn the ignition switch to ON.

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

Standard Voltage:

Text in Illustration

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 IGNITION COIL POWER SOURCE CIRCUIT P0351
OK -- Continue to next step.

43. CHECK HARNESS AND CONNECTOR (IGNITION COIL ASSEMBLY - ECM)

(a) Disconnect the ignition coil assembly connector.

(b) Disconnect the ECM connector.

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

Standard Resistance:

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

44. CHECK HARNESS AND CONNECTOR (IGNITION COIL ASSEMBLY - ECM)

(a) Disconnect the ignition coil assembly connector.

(b) Disconnect the ECM connector.

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

Standard Resistance:

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 ignition coil assembly, check if engine starting trouble occurs again. If engine starting trouble occurs again, proceed to step 71 and perform troubleshooting for the ignition system (steps 77 to 82).

NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR

OK -- REPLACE IGNITION COIL ASSEMBLY Removal

45. 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) Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump / Speed.

(d) When performing the Active Test, check for an operating sound from the fuel pump.

OK:

HINT
Jiggle the wire harness and connector to increase the likelihood of detecting malfunctions that do not always occur.

NG -- CHECK FUEL PUMP CONTROL CIRCUIT Component Tests and General Diagnostics
OK -- Continue to next step.

46. 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) Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump / Speed.

(d) 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 circuit, check if engine starting trouble occurs again. If engine starting trouble occurs again, proceed to step 71 and perform fuel system troubleshooting (steps 72 to 76).

B -- CHECK FUEL PUMP CONTROL CIRCUIT Component Tests and General Diagnostics

A -- REPAIR OR REPLACE FUEL LINE

47. READ VALUE USING TECHSTREAM (ENGINE SPEED)

(a) Connect the Techstream to the DLC3.

(b) Turn the ignition switch to ON.

(c) Enter the following menus: Powertrain / Engine and ECT / Data List / Engine Speed.

(d) Start the engine.

(e) While running the engine, read the value of Engine Speed.

OK:

A value that matches the actual engine speed is constantly output.

HINT
* Check the engine speed using a line graph.
* If the engine cannot be started, check the engine speed while cranking the engine.
* If the engine speed is 0 rpm, the crankshaft position sensor may have an open or short circuit.

NG -- REPLACE CRANKSHAFT POSITION SENSOR Removal
OK -- Continue to next step.

48. CHECK TERMINAL VOLTAGE (FUEL INJECTOR POWER SOURCE)

(a) Disconnect the fuel injector assembly connectors.

(b) Turn the ignition switch to ON.

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

Standard Voltage:

Text in Illustration

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 -- REPAIR FUEL INJECTOR POWER SOURCE CIRCUIT Component Tests and General Diagnostics
OK -- Continue to next step.

49. CHECK HARNESS AND CONNECTOR (FUEL INJECTOR ASSEMBLY - ECM)

(a) Disconnect the fuel injector assembly connector.

(b) Disconnect the ECM connector.

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

Standard Resistance:

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 -- REPAIR OR REPLACE HARNESS OR CONNECTOR

OK -- REPLACE ECM Removal

50. CHECK MASS AIR FLOW METER

(a) Connect the Techstream to the DLC3.

(b) Start the engine and warm it up until the engine coolant temperature reaches 75°C (167°F) or higher.

HINT
The A/C switch and all accessory switches should be off, and the shift lever should be in N or P.

(c) Turn the Techstream on.

(d) Enter the following menus: Powertrain / Engine and ECT / Data List / MAF.

(e) Check MAF in the Data List during idling.

Standard:

2.5 to 4.7 gm/s

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