Toyota Venza manuals

Toyota Venza: Startability Malfunction (P1604)

Toyota Venza Service Manual / 1ar-fe Engine Control / Sfi System / Startability Malfunction (P1604)

DESCRIPTION

This DTC is stored when the engine does not start even though the STA signal is input or when the engine takes a long time to start, and when the engine speed is low or the engine stalls just after the engine starts.

Using the Techstream, the conditions present when the DTC was stored can be confirmed by referring to the freeze frame data. Freeze frame data records engine conditions when a malfunction occurs. This information can be useful when troubleshooting.

It is necessary to check if the vehicle ran out of fuel before performing troubleshooting, as this DTC is also stored when there is engine starting trouble due to running out of fuel.

DTC No.

DTC Detection Condition

Trouble Area

P1604

Either of the following condition is met (1 trip detection logic):

  • The engine speed is below 500 rpm with the STA signal on for a certain amount of time (refer to the illustration below).
  • After the engine starts (engine speed is 500 rpm or higher), the engine speed drops to 200 rpm or less within approximately 2 seconds.
  • Engine assembly (excess friction, compression loss)
  • Starter assembly
  • Crankshaft position sensor
  • Camshaft position sensor
  • Engine coolant temperature sensor
  • Fuel pump
  • Fuel pump control system
  • Fuel line (fuel filter, pipes and hoses)
  • Fuel injector assembly
  • Throttle body assembly
  • Fuel pressure regulator
  • Battery
  • Drive plate and ring gear sub-assembly
  • Spark plug
  • Ignition coil assembly circuit
  • Intake system
  • Camshaft timing oil control valve assembly
  • Mass air flow meter sub-assembly
  • Air fuel ratio sensor
  • Valve timing
  • Fuel
  • Purge VSV
  • Intake valve
  • Engine immobiliser system
  • ECM

1. Reference waveforms showing a normal cold engine start


2. Reference waveforms showing a normal warm engine start


3. Reference values when there is an air leak in the intake system during starting difficulty

Freeze Frame Data P1604 Startability Malfunction

Parameter

-3

-2

-1

0

1

Unit

Engine Speed

398

325

221

159

114

rpm

Calculate Load

43.1

42.7

43.1

87.4

87.4

%

Vehicle Load

28.2

26.2

26.6

17.2

15.0

%

MAF

3.01

2.28

1.59

0.75

0.48

gm/s

Atmosphere Pressure

14.5

14.5

14.5

14.5

14.5

psi (gauge)

Coolant Temp

85

85

85

85

85

°C

Intake Air

46

46

46

46

46

°C

Battery Voltage

12.460

12.382

12.324

12.324

12.343

V

Throttle Sensor Volt %

16.4

16.0

17.6

16.0

16.0

%

Throttl Sensor #2 Volt %

48.6

47.8

49.8

47.8

47.8

%

Throttle Sensor Position

0.0

0.0

0.0

0.0

0.0

%

Throttle Motor DUTY

17.6

16.0

16.0

16.0

16.0

%

Injector (Port)

4240

4302

4612

4612

7776

μs

Injection Volum (Cylinder 1)

0.274

0.274

0.187

0.187

0.187

ml

Fuel Pump/Speed Status

ON

ON

ON

ON

ON

 

EVAP (Purge) VSV

0.0

0.0

0.0

0.0

0.0

%

Evap Purge Flow

0.0

0.0

0.0

0.0

0.0

%

Purge Density Learn Value

0.000

0.000

0.000

0.000

0.000

 

EVAP Purge VSV

OFF

OFF

OFF

OFF

OFF

 

Target Air-Fuel Ratio

0.864

0.873

0.882

0.883

0.830

 

AF Lambda B1S1

0.999

0.999

1.001

1.002

1.005

 

AFS Voltage B1S1

3.298

3.298

3.307

3.312

3.327

V

O2S B1S2

0.015

0.015

0.015

0.015

0.015

V

Short FT #1

0.000

0.000

0.000

0.000

0.000

%

Long FT #1

3.906

3.906

3.906

3.906

3.906

%

Total FT #1

0.000

0.000

0.000

0.000

0.000

 

Fuel System Status #1

OL

OL

OL

OL

OL

 

IGN Advance

8.0

7.0

6.0

0.0

0.0

deg

Knock Feedback Value

-3.0

-3.0

-3.0

-3.0

-3.0

deg(CA)

Knock Correct Learn Value

19.0

19.0

19.0

19.0

19.0

deg(CA)

VVT Control Status #1

OFF

OFF

OFF

OFF

OFF

 

Starter Signal

OFF

OFF

OFF

OFF

OFF

 

WIRING DIAGRAM

Refer to DTC P0351 for the ignition coil circuit (See page ).


Refer to DTC P2195 for the air fuel ratio sensor circuit (See page ).


Refer to DTC P0451 for the EVAP system circuit (See page ).


Refer to Fuel Pump Control Circuit (See page ).


Refer to Fuel Injector Circuit (See page ).


CAUTION / NOTICE / HINT

HINT:

  • In contrast to normal malfunction diagnosis for components, circuits and systems, DTC P1604 is used to determine the malfunctioning area from the problem symptoms and freeze frame data when the user mentions problems such as starting difficulty.

    As the DTC can be stored as a result of certain user actions, even if the DTC is output, if the customer makes no mention of problems, clear the DTC without performing any troubleshooting and return the vehicle to the customer.

  • If any other DTCs are output, perform troubleshooting for those DTCs first.
  • When the Data List item "Immobiliser Fuel Cut" is ON, the engine cannot be started.
  • Read freeze frame data using the Techstream. Freeze frame data records engine conditions when a malfunction occurs. This information can be useful when troubleshooting.
  • When confirming the freeze frame data, be sure to check all 5 sets of freeze frame data (See page ).

  • When confirming the freeze frame data, if there are multiple items related to the cause of the malfunction, perform troubleshooting for all related items.
  • Try to start the vehicle under the conditions recorded in the freeze frame data which were present when the malfunction occurred. Confirm the data at this time and compare it with the freeze frame data.
  • If the malfunction does not reoccur, carefully check the vehicle conditions from when the malfunction occurred using freeze frame data.
  • When performing inspections, jiggle the relevant wire harnesses and connectors in an attempt to reproduce malfunctions that do not always occur.
  • If the same inspection or replacement procedure appears 2 times when performing an inspection procedure, it is not necessary to repeat the procedure the second time.

1. Malfunction Recurrence and Inspection Areas

(a) Freeze frame data exists, but the malfunction (starting difficulty) has not reoccurred and the malfunction conditions are unknown.

(1) The engine speed recorded in the freeze frame data is 0 rpm (the engine does not crank).

HINT:

One of the following problems may be present: battery depletion, excess engine friction, a starter malfunction or a crankshaft position sensor malfunction.

  • If the battery voltage is less than 6 V during cranking, there is a high probability that engine friction is abnormal.
  • If the battery voltage drops to 5 V or less when starting the engine, the battery may be malfunctioning.
  • If the battery voltage fluctuates while cranking the engine, it can be concluded that cranking is being performed. When the engine speed is 0 rpm, the crankshaft position sensor and/or an ECM may be malfunctioning.

(2) All engine speeds recorded in the freeze frame data are between 60 and 250 rpm (the engine cranks but there is no combustion).

HINT:

If the engine speed is between 60 and 250 rpm (no initial combustion), there may be a wiring problem or a complete failure of an ignition or fuel system part.

  • Due to an engine coolant temperature sensor malfunction, the fuel injection volume is extremely high or low and the engine may not be able to be started.

(3) The engine speed recorded in the freeze frame data is 250 rpm or higher (the initial combustion and starter turn off timing is too late).

HINT:

If the engine speed is 250 rpm or higher (combustion occurs but the initial combustion and starter turnoff timing is too late), the fuel injection volume is often incorrect (too low or too high) and determining the cause of the malfunction is often difficult.

  • Due to an engine coolant temperature sensor malfunction, the fuel injection volume is extremely high or low and engine starting trouble may occur.
  • If Long FT #1 is incorrect, there may be a fuel supply problem due to the injectors or fuel pump being clogged, etc.
  • If the engine cranking speed is too high, compression loss may have occurred due to carbon interfering with the valve operation.

(b) When the malfunction (starting difficulty) can be reproduced, or malfunction conditions are known, perform the following inspections ("Problem symptoms" and "Systems to inspect")

(1) Problem symptoms

  1. The engine does not crank.

    HINT:

    The starter is normal if a noise that indicates the starter pinion gear is extending is heard. The battery may be fully depleted or there may be excess engine friction.

  2. The engine cranking speed is abnormal.

    HINT:

    If the engine cranking speed is too high (for example, 300 rpm or higher with no combustion), compression loss may have occurred because carbon interfered with valve operation, etc.

  3. There is no initial combustion.

    HINT:

    If there is no initial combustion, there is probably a wiring problem or an ignition or fuel system part malfunction.

  4. The engine stalls after starter turn off.

    HINT:

    If the engine stalls after starter turn off, the air fuel ratio may be incorrect or the VVT may have a problem returning.

  5. The initial combustion and starter turn off occur late.

    HINT:

    If the initial combustion and starter turn off occur late, the fuel injection volume is probably incorrect (too low or too high).

    HINT:

    Causes of fuel system malfunctions according to conditions present at the time of the malfunction.

    • When 2 to 3 minutes have elapsed after stopping the engine: Fuel pressure loss due to the pressure regulator failing to maintain the fuel pressure.
    • When 15 to 120 minutes have elapsed after stopping the engine: Problem with injector fuel seal.
    • When a long time has elapsed after stopping the engine: Pressure regulator is stuck open.

(2) Systems to inspect.

  1. Intake system
  2. Ignition system
  3. Fuel system

2. INSPECTION FLOW

(a) Freeze frame data exists, but the malfunction (starting difficulty) has not reoccurred and the malfunction conditions are unknown.

Freeze Frame Data Item

Result

Suspected Area

Procedure

Engine Speed

0 rpm (no engine cranking at all)

  • Battery fully depleted
  • Engine assembly (excess friction)
  • Starter assembly
  • Engine immobiliser system
  • Crankshaft position sensor
  • ECM

4 to 9

60 to 250 rpm (engine cranks but no initial combustion*1)

  • Fuel pump control system
  • Ignition system
  • Engine coolant temperature sensor
  • Fuel injection system

10 to 14

250 rpm or higher (combustion occurs but initial combustion and starter turn off*2 occur late)

  • Engine assembly (compression loss)
  • Fuel injection system
  • Fuel pump control system

15 to 23

HINT:

  • *1: First combustion after cranking begins.
  • *2: Condition when engine speed increases and starter can be turned off.

(b) When the malfunction (starting difficulty) can be reproduced, or when malfunction conditions are known.

(1) Problem symptoms

Problem Symptom

Suspected Area

Suspected Component

Procedure

The engine does not crank

Battery malfunction

  • Battery fully depleted

26 to 31

Starting system

  • Starter assembly (includes pinion gear wear or tooth damage)
  • Starting system

Engine assembly

  • Engine assembly (excess friction)
  • Drive plate and ring gear sub-assembly wear or tooth damage

Cranking speed too low

Battery malfunction

  • Battery fully depleted

32 to 34

Starting system

  • Starter assembly

Engine assembly

  • Engine assembly (excess friction)

Cranking speed too high

Engine assembly

  • Engine assembly (compression loss)

There is no initial combustion

Fuel supply problem

  • Cannot maintain pressure due to pressure regulator malfunction
  • Fuel injector assembly leak
  • Fuel leak from fuel line
  • Fuel pump control system
  • Fuel pump

35 to 48

Ignition system malfunction

  • Spark plug
  • Crankshaft position sensor
  • Ignition coil assembly

Engine stalls after starter turnoff

Air suction

  • Intake system connections

49 to 54

Deposits in throttle body

  • Throttle body assembly

VVT valve does not return properly

  • Camshaft timing oil control valve assembly

Mass air flow meter sub-assembly malfunction

  • Mass air flow meter sub-assembly

The initial combustion and starter turnoff occur late

Engine coolant temperature sensor malfunction

  • Engine coolant temperature sensor

55 to 68

Mass air flow meter sub-assembly malfunction

  • Mass air flow meter sub-assembly

Abnormal air fuel learning value

  • Air fuel ratio sensor

Deviation from fuel injection characteristics

  • Fuel injector assembly

Wet-fouled or dry-fouled spark plug

  • Spark plug

Lack of fuel pressure

  • Pressure regulator
  • Fuel pump
  • Fuel pump control system

(2) Systems to inspect.

Troubleshooting by System

Suspected Area

Suspected Component

Procedure

Fuel system troubleshooting A

Abnormal air fuel ratio learning value

  • Fuel injector assembly

87 to 94

95 to 102

Rough idling

  • Crankshaft position sensor

Abnormal fuel pressure

  • Fuel
  • Fuel leak from fuel line
  • Fuel pump
  • Pressure regulator

Fuel system troubleshooting B

Abnormal concentration of HC in surge tank

  • Purge VSV system
  • Fuel injector assembly

103 to 105

Fuel system troubleshooting C

Injection signal system malfunction

  • Fuel injector assembly
  • Crankshaft position sensor
  • Camshaft position sensor
  • ECM

70 to 74

Intake system troubleshooting

Difference between ISC target value and opening angle when idling

  • Engine assembly (compression loss)
  • Valve timing
  • Engine coolant temperature sensor
  • ECM

84 to 86

106 to 108

Ignition system troubleshooting

Camshaft and/or crankshaft position sensor signal malfunction

  • Crankshaft position sensor system (including sensor installation)
  • Camshaft position sensor system (including sensor installation)
  • ECM

75 to 83

109 to 117

NOTICE:

  • Inspect the fuses for circuits related to this system before performing the following inspection procedure.
  • After turning ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work (See page ).

PROCEDURE

1.

CHECK ANY OTHER DTCS OUTPUT AND RECORD FREEZE FRAME DATA (IN ADDITION TO DTC P1604)

(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 / Trouble Codes.

(e) Read the DTCs and record the Freeze Frame Data.

HINT:

  • This freeze frame data shows the actual engine conditions when engine starting trouble occurred.
  • When confirming the freeze frame data, be sure to check all 5 data sets of freeze frame data.
  • The fourth set of freeze frame data is the data recorded when then the DTC is stored.
Result

Result

Proceed to

DTC P1604 is output

A

DTC P1604 and other DTCs are output

B



B

GO TO DTC CHART


A

2.

CHECK ENGINE IMMOBILISER SYSTEM

(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 / Primary / Immobiliser Fuel Cut.

(e) Read the value displayed on the Techstream.

OK:

Immobiliser Fuel Cut is OFF

HINT:

If the engine is cranked immediately after reconnecting the battery cable (key verification for engine immobiliser system not completed), the engine cannot be started. Key verification needs to wait for several seconds after turning the ignition switch to ON.

Result

Result

Proceed to

OK

A

NG (w/ smart key system)

B

NG (w/o smart key system)

C


B

REPAIR ENGINE IMMOBILISER SYSTEM


C

REPAIR ENGINE IMMOBILISER SYSTEM


A

3.

CHECK MALFUNCTION CONDITION

(a) Confirm the problem symptoms.

Result

Result

Proceed to

Freeze frame data exists, but the starting difficulty cannot be reproduced and it is unknown what kind of starting difficulty occurred

A

The problem symptoms can be reproduced, or the malfunction conditions are known

B


B

GO TO STEP 25


A

4.

READ FREEZE FRAME DATA

(a) Connect the Techstream to the DLC3.

(b) Turn the ignition switch to ON.

(c) Using the Techstream, confirm the vehicle conditions recorded in the freeze frame data which were present when the DTC was stored (See page ).


Result

Freeze Frame Data Item

Suspected Area

Proceed to

Engine Speed

Battery Voltage

All 5 sets of freeze frame data are 0 rpm (no engine cranking at all)

Minimum voltage is less than 5 V

Battery fully depleted

A

Minimum voltage is 5 V or higher

  • Starter assembly malfunction
  • Crankshaft position sensor system
  • Excess engine friction
  • ECM

B

60 to 250 rpm (engine cranks but no initial combustion)

-

  • Fuel pump control system
  • Ignition system
  • Engine coolant temperature sensor
  • Fuel injection system

C

250 rpm or higher (combustion occurs but initial combustion and starter turnoff occur late)

-

  • Engine assembly
  • Engine coolant temperature sensor
  • Fuel injection system
  • Fuel pump control system

D

Freeze Frame Data Item

Suspected Area

Proceed to

Low Rev for Eng Start

ON exists

  • Intake system connections
  • Throttle body
  • Camshaft timing oil control valve assembly
  • Mass air flow meter sub-assembly

E

HINT:

When DTC P1604 is stored, either "Engine Start Hesitation"*1 or "Low Rev for Eng Start"*2 in the Freeze Frame Data will be ON. If "Low Rev for Eng Start" is ON, proceed to E.

*1: This value turns ON when the engine speed does not reach a certain value for a certain period of time when starting the engine.

*2: This value turns ON when the engine stalls immediately after starting the engine. If "Low Rev for Eng Start" is ON, as there is a possibility that the low engine speed or engine stall was caused by the user, confirm the following freeze frame data items.

  • Immobiliser Fuel Cut
  • Engine Speed (Starter Off)
  • Shift SW Status (R, D Range)

A

CHARGE OR REPLACE BATTERY


C

GO TO STEP 10


D

GO TO STEP 15


E

GO TO STEP 49


B

5.

READ FREEZE FRAME DATA

(a) Connect the Techstream to the DLC3.

(b) Turn the ignition switch to ON.

(c) Using the Techstream, confirm the vehicle conditions recorded in the freeze frame data which were present when the DTC was stored (See page ).


Result

Freeze Frame Data Item

Result

Suspected Area

Proceed to

Battery Voltage

Minimum voltage is 6 V or higher and voltage does not fluctuate*1

Starter system

A

Minimum voltage is 6 V or higher and voltage fluctuates*2, *3

  • Crankshaft position sensor system
  • ECM

B

Minimum voltage is 5 to 6 V*4

  • Excess engine friction
  • Battery fully depleted

C

HINT:

  • *1: The 5 sets of freeze frame data show approximately the same battery voltage.

  • *2: The 5 sets of freeze frame data show different battery voltages.
  • *3: If the voltage fluctuates, it can be determined that cranking is being performed. When the engine speed is 0 rpm, the crankshaft position sensor system and/or the ECM may be malfunctioning.
  • *4: There may be excess engine friction. Make sure that the crankshaft rotates smoothly when turning it by hand. 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.
  • Perform "Inspection After Repair" after replacing the engine assembly (See page ).


A

CHECK STARTER SIGNAL CIRCUIT


C

CHECK AND REPAIR ENGINE ASSEMBLY OR BATTERY


B

6.

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

7.

INSPECT CRANKSHAFT POSITION SENSOR

(a) Disconnect the crankshaft position sensor connector.

(b) Check for oil on the connector terminals.

OK:

No oil on the terminals.


NG

REPLACE CRANKSHAFT POSITION SENSOR


OK

8.

CHECK HARNESS AND CONNECTOR (CRANKSHAFT POSITION SENSOR - ECM)

(a) Check the harnesses and connectors, referring to DTC P0335 inspection procedure (See page ).


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

9.

REPLACE CRANKSHAFT POSITION SENSOR

(a) Replace the crankshaft position sensor (See page ).


(b) Check the engine start operation.

OK:

Malfunction has been repaired successfully.


OK

END (CRANKSHAFT POSITION SENSOR IS DEFECTIVE)


NG

REPLACE ECM

10.

READ FREEZE FRAME DATA

(a) Connect the Techstream to the DLC3.

(b) Turn the ignition switch to ON.

(c) Using the Techstream, confirm the vehicle conditions recorded in the freeze frame data which were present when the DTC was stored (See page ).


Result

Freeze Frame Data Item

Suspected Area

Proceed to

Coolant Temp, Intake Air

Coolant Temp

Fuel Pump/Speed Status

Difference between Coolant Temp and Intake Air is 10°C (18°F) or higher*1

Coolant Temp is 125°C (257°F) or higher, or lower than outside temperature*3 by 15°C (27°F) or higher

-

Engine coolant temperature sensor

A

Other than above

All 5 sets of freeze frame data are ON

-

B

At least 1 of the 5 sets of freeze frame data is OFF

Fuel pump control system

C

Difference between Coolant Temp and Intake Air is less than 10°C (18°F) *2

-

At least 1 of the 5 sets of freeze frame data is OFF

Fuel pump control system

C

All 5 sets of freeze frame data are ON

-

B

HINT:

  • *1: A long time had not elapsed after stopping the engine.
  • *2: A long time had elapsed after stopping the engine.
  • *3: Use an actual outside temperature estimated from the Initial Intake Air, Ambient Temp for A/C, and (if possible) the weather when the DTC was detected.
  • Perform "Inspection After Repair" after replacing the engine coolant temperature sensor (See page ).


A

REPLACE ENGINE COOLANT TEMPERATURE SENSOR


C

CHECK FUEL PUMP CONTROL CIRCUIT


B

11.

PERFORM ACTIVE TEST USING TECHSTREAM (CONTROL THE FUEL PUMP / SPEED)

(a) Connect the Techstream to the DLC3.


(b) Disconnect the fuel pump connector.

(c) Turn the ignition switch to ON.

(d) Turn the Techstream on.

(e) Enter the following menus: Powertrain / Engine / Active Test / Control the Fuel Pump / Speed.

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

Standard Voltage:

Tester Connection

Condition

Specified Condition

L12-4 - Body ground

Active Test is being performed

11 to 14 V

Text in Illustration

*a

Front view of wire harness connector

(to Fuel Pump)

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 PUMP CONTROL CIRCUIT


OK

12.

CHECK TERMINAL VOLTAGE (FUEL INJECTOR CIRCUIT)

(a) Check the harnesses and connectors, referring to DTC P0300 inspection procedure (See page ).


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


OK

13.

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

Result

Proceed to

Fuel leakage or signs of fuel leakage are present

A

No fuel leakage or signs of fuel leakage

B

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.

A

REPAIR OR REPLACE FUEL LINE


B

14.

CHECK FUEL SYSTEM

(a) Check for foreign matter such as iron particles around the fuel pump (fuel pump, fuel pump filter and inside the fuel tank), and for signs that the fuel pump was stuck.

Result

Result

Proceed to

There is foreign matter or signs that fuel pump was stuck

A

There is no foreign matter and no signs that fuel pump was stuck

B

HINT:

If there is foreign matter such as iron particles on the fuel pump, fuel filter or fuel tank, remove the foreign matter.


A

REPAIR OR REPLACE FUEL SYSTEM


B

GO TO STEP 24

15.

READ FREEZE FRAME DATA

(a) Connect the Techstream to the DLC3.

(b) Turn the ignition switch to ON.

(c) Using the Techstream, confirm the vehicle conditions recorded in the freeze frame data which were present when the DTC was stored (See page ).


Result

Freeze Frame Data Item

Suspected Area

Proceed to

Coolant Temp, Intake Air

Coolant Temp

Long FT #1

Engine Speed

Difference between Coolant Temp and Intake Air is 10°C (18°F) or higher

Coolant Temp is 125°C (257°F) or higher, or lower than outside temperature*2 by 15°C (27°F) or higher

-

-

Engine coolant temperature sensor

A

Other than above

-15% or less, or +15% or higher

-

  • Fuel pump control system
  • Fuel injector assembly

B

-15 to +15%

Minimum speed is 300 rpm or higher*1

Engine assembly

C

Minimum speed is below 300 rpm

  • Fuel system
  • Intake air system

D

Difference between Coolant Temp and Intake Air is less than 10°C (18°F)

-

-15% or less, or +15% or higher

-

  • Fuel pump control system
  • Fuel injector assembly

B

-15 to +15%

Minimum speed is 300 rpm or higher*1

Engine assembly

C

Minimum speed is below 300 rpm

  • Fuel system
  • Intake air system

D

HINT:

  • *1: Compression loss may have occurred in the engine assembly.
  • *2: Use an actual outside temperature estimated from the Initial Intake Air, Ambient Temp for A/C, and (if possible) the weather when the DTC was detected.
  • Perform "Inspection After Repair" after replacing the engine assembly or engine coolant temperature sensor (See page ).


A

REPLACE ENGINE COOLANT TEMPERATURE SENSOR


C

CHECK AND REPAIR ENGINE ASSEMBLY


D

GO TO STEP 18


B

16.

INSPECT FUEL INJECTOR ASSEMBLY

(a) Check that no carbon is stuck to the fuel injector assembly.

OK:

No carbon present.

HINT:

Perform "Inspection After Repair" after replacing the fuel injector assembly (See page ).



NG

REPLACE FUEL INJECTOR ASSEMBLY


OK

17.

CHECK FUEL SYSTEM

(a) Check for foreign matter such as iron particles around the fuel pump (fuel pump, fuel pump filter and inside the fuel tank), and for signs that the fuel pump was stuck.

Result

Result

Proceed to

There is foreign matter or signs that fuel pump was stuck

A

There is no foreign matter and no signs that fuel pump was stuck

B

HINT:

If there is foreign matter such as iron particles on the fuel pump, fuel filter or fuel tank, remove the foreign matter.


A

REPAIR OR REPLACE FUEL SYSTEM


B

GO TO STEP 24

18.

READ FREEZE FRAME DATA

(a) Connect the Techstream to the DLC3.

(b) Turn the ignition switch to ON.

(c) Using the Techstream, confirm the vehicle conditions recorded in the freeze frame data which were present when the DTC was stored (See page ).


Result

Freeze Frame Data Item

Result

Suspected Area

Proceed to

Coolant Temp

Engine coolant temperature is 40°C (104°F) or less*1

Pressure regulator

A

Engine coolant temperature is 40 to 90°C (104 to 194°F)*2

Fuel injector assembly

B

Engine coolant temperature is 90°C (194°F) or higher*3

Pressure regulator

A

HINT:

*1: If the engine coolant temperature is 40°C [104°F] or less (after stopping the engine and the vehicle is not driven for a long period of time), 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: If the engine coolant temperature is 40 to 90°C [104 to 194°F] (15 to 120 minutes have passed after stopping the engine), there may be fuel leaking from a fuel injector.

*3: If the engine coolant temperature is 90°C [194°F] or higher (2 to 5 minutes have passed after stopping the engine), there may be a problem with the pressure regulator failing to maintain the fuel pressure. Attach a fuel pressure gauge and check the ability to maintain fuel pressure after stopping the engine.


B

GO TO STEP 20


A

19.

CHECK FUEL PRESSURE

HINT:

For the fuel pressure inspection, refer to the following procedures (See page ).


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

Standard:

147 kPa (1.5 kgf/cm2, 21 psi) or higher (5 minutes after stopping the engine)

HINT:

If the engine cannot be started, read the values after cranking the engine.

Result

Result

Proceed to

Abnormal

A

Normal

B


A

REPLACE FUEL PRESSURE REGULATOR


B

GO TO STEP 24

20.

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

Result

Proceed to

4000 ppm or higher

A

Less than 4000 ppm

B

HINT:

If the concentration is 4000 ppm or higher, a fuel injector assembly may have a sealing problem.


B

GO TO STEP 22


A

21.

INSPECT FUEL INJECTOR ASSEMBLY

(a) Inspect the fuel injector assemblies (See page ).


HINT:

Perform "Inspection After Repair" after replacing the fuel injector assembly (See page ).



NG

REPLACE FUEL INJECTOR ASSEMBLY


OK

22.

INSPECT THROTTLE BODY ASSEMBLY

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

Result

Result

Proceed to

No carbon present

A

Carbon in passage

B

HINT:

Perform "Inspection After Repair" after cleaning or replacing the throttle body assembly (See page ).



B

CLEAN OR REPLACE THROTTLE BODY ASSEMBLY


A

23.

CHECK INTAKE SYSTEM

(a) Check the intake system for vacuum leaks (See page ).


OK:

No leaks in intake system.

HINT:

Perform "Inspection After Repair" after repairing or replacing the intake system (See page ).



NG

REPAIR OR REPLACE INTAKE SYSTEM


OK

24.

PERFORM SIMULATION TEST

(a) Check if the engine can be started.

Result

Result

Proceed to

Engine cannot be started

A

Engine can be started

B


B

END


A

25.

CONFIRM PROBLEM SYMPTOM

(a) Confirm the problem symptoms.

HINT:

The problem symptoms below can be determined by reading the freeze frame data.

Result

Problem Symptom

Suspected Area

Proceed to

The engine does not crank

  • Battery fully depleted
  • Starter assembly (includes pinion gear wear or teeth damage)
  • Starter system
  • Engine assembly (excess friction)
  • Drive plate and ring gear sub-assembly wear or teeth damage

A

Abnormal cranking speed

  • Battery fully depleted
  • Starter assembly
  • Engine assembly (excess friction, compression loss)

B

There is no initial combustion (combustion does not occur even once)*1

  • Pressure regulator fuel pressure maintenance
  • Fuel injector assembly leak
  • Fuel leak from fuel line
  • Fuel pump control system
  • Fuel pump
  • Spark plug
  • Crankshaft position sensor system
  • Ignition coil assembly system

C

The engine stalls after starter turn off (engine stalls immediately after the first time the engine speed increases)*2

  • Intake system connections
  • Throttle body assembly
  • Camshaft timing oil control valve assembly
  • Mass air flow meter sub-assembly system

D

The initial combustion and starter turnoff occur late*3

  • Engine coolant temperature sensor
  • Mass air flow meter sub-assembly
  • Air fuel ratio sensor
  • Heated oxygen sensor
  • Fuel injector assembly
  • Spark plug
  • Pressure regulator
  • Fuel pump
  • Fuel pump control system

E

HINT:

  • If there is hesitation (cranking speed is slow and combustion occurs before passing TDC) during the initial cranking period, the battery charge may be insufficient or the starter may be malfunctioning.
  • *1: If there is no initial combustion, a wire harness may be malfunctioning, or the ignition or fuel system may be malfunctioning.
  • *2: If the engine stalls after starter turnoff, the air fuel ratio may be incorrect or the camshaft timing oil control valve may have a problem returning.
  • *3: If the initial combustion and starter turnoff occur late, the fuel injection volume may be incorrect (too low or too high).

B

GO TO STEP 32


C

GO TO STEP 35


D

GO TO STEP 49


E

GO TO STEP 55


A

26.

PERFORM SIMULATION TEST

(a) When cranking the engine, check for a noise indicating that the starter pinion gear is extending, and check that the starter pinion gear is not spinning freely.

Result

Problem Symptom

Suspected Area

Proceed to

A noise indicating that the starter pinion gear is extending is heard and the starter pinion gear is not spinning freely.*1

  • Battery
  • Excess engine friction
  • Starter assembly

A

A noise indicating that the starter pinion gear is extending is heard but the starter pinion gear is spinning freely.

  • Drive plate and ring gear sub-assembly
  • Starter assembly

B

A noise indicating that the starter pinion gear is extending is not heard

  • Battery
  • Starter assembly
  • Starter system

C

HINT:

*1: The battery may be fully depleted or there may be excess engine friction.


B

GO TO STEP 29


C

GO TO STEP 30


A

27.

INSPECT BATTERY

(a) Inspect the battery (See page ).



NG

CHARGE OR REPLACE BATTERY


OK

28.

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.
  • Perform "Inspection After Repair" after replacing the engine assembly (See page ).


OK

INSPECT STARTER ASSEMBLY


NG

REPAIR OR REPLACE ENGINE ASSEMBLY

29.

INSPECT STARTER ASSEMBLY (STARTER PINION GEAR)

(a) Remove the starter assembly (See page
).

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

OK:

There is no wear or damage.


OK

REPLACE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY


NG

REPLACE STARTER ASSEMBLY

30.

INSPECT BATTERY

(a) Inspect the battery (See page ).



NG

CHARGE OR REPLACE BATTERY


OK

31.

INSPECT STARTER ASSEMBLY

(a) Inspect the starter assembly (See page
).


OK

CHECK STARTER SIGNAL CIRCUIT


NG

REPLACE STARTER ASSEMBLY

32.

PERFORM SIMULATION TEST

(a) Check the cranking speed.

Result

Problem Symptom

Suspected Area

Proceed to

Cranking speed is slow (100 rpm or less)

  • Battery
  • Starter assembly
  • Excess engine friction

A

Cranking speed is fast (300 rpm or higher)*1

Engine compression loss

B

HINT:

  • *1: If the cranking speed is fast, there may be compression loss.
  • Perform "Inspection After Repair" after replacing the engine assembly (See page ).


B

CHECK AND REPAIR ENGINE ASSEMBLY


A

33.

INSPECT BATTERY

(a) Inspect the battery (See page ).



NG

CHARGE OR REPLACE BATTERY


OK

34.

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.
  • Perform "Inspection After Repair" after replacing the engine assembly (See page ).


OK

INSPECT STARTER ASSEMBLY


NG

CHECK AND REPAIR ENGINE ASSEMBLY

35.

INSPECT FUEL INJECTOR ASSEMBLY

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

OK:

Fuel injector assembly operating sound is heard.


NG

GO TO STEP 47


OK

36.

CHECK FUEL PRESSURE

(a) Check the fuel pressure (See page ).



NG

GO TO STEP 45


OK

37.

CHECK SPARK PLUG AND SPARK

(a) Check for sparks (See page ).



NG

GO TO STEP 41


OK

38.

CONFIRM VEHICLE CONDITION

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

Result

Problem Symptom

Suspected Area

Proceed to

When the engine is stopped and a long time has passed, engine starting trouble occurs*1

Pressure regulator is stuck open

A

When the engine is stopped and approximately 15 to 120 minutes have passed, engine starting trouble occurs*2

Fuel injector assembly leak

B

When the engine is stopped and approximately 2 to 3 minutes have passed, engine starting trouble occurs*3

Failure to maintain fuel pressure by pressure regulator

A

Condition other than above, or there is an inconsistency in the conditions present when engine starting trouble occurs

-

C*4

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 C (steps 70 to 74).


B

GO TO STEP 40


C

GO TO STEP 69


A

39.

CHECK FUEL PRESSURE

HINT:

For the fuel pressure inspection, refer to the following procedures (See page ).


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

Standard:

147 kPa (1.5 kgf/cm2, 21 psi) or higher (5 minutes after stopping the engine)

Result

Result

Proceed to

Abnormal

A

Normal

B*1

HINT:

  • If the engine cannot be started, read the values after cranking the engine.
  • *1: from step 69, perform fuel system troubleshooting C (steps 70 to 74).

A

REPLACE FUEL PRESSURE REGULATOR


B

GO TO STEP 69

40.

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

Result

Proceed to

4000 ppm or higher

A

Less than 4000 ppm

B*1

HINT:

  • If the concentration is 4000 ppm or higher, a fuel injector may have a sealing problem.
  • *1: From step 69, perform fuel system troubleshooting C (steps 70 to 74).
  • Perform "Inspection After Repair" after replacing the fuel injector assembly (See page ).


A

REPLACE FUEL INJECTOR ASSEMBLY


B

GO TO STEP 69

41.

INSPECT SPARK PLUG

(a) Inspect the spark plugs (See page ).


HINT:

  • Even if the spark plug of only one cylinder is malfunctioning, replace the spark plugs of all cylinders.
  • Perform "Inspection After Repair" after replacing the spark plug (See page ).


NG

REPLACE SPARK PLUG


OK

42.

READ VALUE USING TECHSTREAM (ENGINE 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 / Data List / Primary / Engine Speed.

(e) Start the engine.

(f) While running the engine, read the [Engine Speed] value.

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


OK

43.

CHECK TERMINAL VOLTAGE (POWER SOURCE OF IGNITION COIL ASSEMBLY)

(a) Check the harnesses and connectors, referring to DTC P0351 inspection procedure (See page ).


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


OK

44.

CHECK HARNESS AND CONNECTOR (IGNITION COIL ASSEMBLY - ECM)

(a) Check the harnesses and connectors, referring to DTC P0351 inspection procedure (See page ).


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 69 and perform troubleshooting for the ignition system (steps 75 to 83).
  • Perform "Inspection After Repair" after replacing the ignition coil assembly (See page ).


OK

REPLACE IGNITION COIL ASSEMBLY


NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

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 / Active Test / Control the Fuel Pump / Speed.

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

OK:

Control the Fuel Pump / Speed

Specified Condition

ON

Operating sound heard

OFF

Operating sound not heard

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


OK

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) 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

Result

Proceed to

Fuel leakage or signs of fuel leakage are present

A

No fuel leakage or signs of fuel leakage

B

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 occurs again, proceed to step 69 and perform fuel system troubleshooting C (steps 70 to 74).

A

REPAIR OR REPLACE FUEL LINE


B

CHECK FUEL PUMP CONTROL CIRCUIT

47.

READ VALUE USING TECHSTREAM (ENGINE 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 / Data List / Primary / Engine Speed.

(e) Start the engine.

(f) While running the engine, read the [Engine Speed] value.

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


OK

48.

CHECK TERMINAL VOLTAGE (FUEL INJECTOR CIRCUIT)

(a) Check the harnesses and connectors, referring to DTC P0300 inspection procedure (See page ).


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.

OK

REPLACE ECM


NG

CHECK FUEL INJECTOR CIRCUIT

49.

INSPECT MASS AIR FLOW METER SUB-ASSEMBLY

(a) Inspect the mass air flow meter sub-assembly (See page ).


HINT:

Perform "Inspection After Repair" after replacing the mass air flow meter sub-assembly (See page ).



NG

GO TO STEP 54


OK

50.

CHECK INTAKE SYSTEM

(a) Check for air leaks in the intake system (vacuum hose disconnection, cracks, damaged gaskets, etc.) (See page ).


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 #1 and Long FT #1 are largely different from the normal values (differ by higher than 15%) when idling (intake air volume is small) and almost the same as the normal values when racing the engine (for example, when maintaining a speed of 3000 rpm) (intake air volume is high), air leakage may be present.

OK:

There is no air leaks.

HINT:

Perform "Inspection After Repair" after repairing or replacing the intake system (See page ).



NG

REPAIR OR REPLACE INTAKE SYSTEM


OK

51.

INSPECT THROTTLE BODY ASSEMBLY

(a) Disconnect the throttle body assembly 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

Result

Proceed to

Engine starts

A

Engine does not start

B

HINT:

When this inspection is performed, the MIL may illuminate. After finishing the inspection, check and clear the DTCs (See page
).


B

GO TO STEP 53


A

52.

INSPECT THROTTLE BODY ASSEMBLY

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

OK:

No carbon present.

HINT:

Perform "Inspection After Repair" after cleaning the throttle body assembly (See page ).



NG

REMOVE FOREIGN OBJECT AND CLEAN THROTTLE BODY ASSEMBLY


OK

53.

PERFORM ACTIVE TEST USING TECHSTREAM (OPERATE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY)

(a) Operate the VVT system through the Active Test, and check if the VVT system is operating normally.

(1) Perform the Active Test, referring to DTC P0011 inspection procedure (VVT system for intake camshaft) (See page ).


(2) Perform the Active Test, referring to DTC P0014 inspection procedure (VVT system for exhaust camshaft) (See page ).


Result

Result

Proceed to

NG

A

OK

B*1

HINT:

  • 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 valve operating noise is abnormal, check the valve for any signs of problems.
  • *1: From step 69, perform intake system troubleshooting (steps 84 to 86). If engine starting trouble still occurs, perform fuel system troubleshooting A (steps 87 to 94).

A

REPLACE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (FOR INTAKE OR EXHAUST CAMSHAFT)


B

GO TO STEP 69

54.

CHECK HARNESS AND CONNECTOR (MASS AIR FLOW METER SUB-ASSEMBLY - ECM)

(a) Check the harnesses and connectors, referring to DTC P0102 inspection procedure (See page ).


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 sub-assembly, check if engine starting trouble occurs again. If engine starting trouble occurs again, proceed to step 69 and perform intake system troubleshooting (steps 84 to 86). If engine starting trouble still occurs, perform fuel system troubleshooting A (steps 87 to 94).
  • Perform "Inspection After Repair" after replacing the mass air flow meter sub-assembly (See page ).


OK

REPLACE MASS AIR FLOW METER SUB-ASSEMBLY


NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

55.

INSPECT ENGINE COOLANT TEMPERATURE SENSOR

(a) Inspect the engine coolant temperature sensor (See page ).


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.
  • Perform "Inspection After Repair" after replacing the engine coolant temperature sensor (See page ).


NG

REPLACE ENGINE COOLANT TEMPERATURE SENSOR


OK

56.

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

(a) Check the harnesses and connectors, referring to DTC P0115 inspection procedure (See page ).


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

57.

INSPECT MASS AIR FLOW METER SUB-ASSEMBLY

(a) Inspect the mass air flow meter sub-assembly (See page ).


HINT:

  • If the mass air flow meter sub-assembly 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.
  • Perform "Inspection After Repair" after replacing the mass air flow meter sub-assembly (See page ).


NG

REPLACE MASS AIR FLOW METER SUB-ASSEMBLY


OK

58.

CHECK HARNESS AND CONNECTOR (MASS AIR FLOW METER SUB-ASSEMBLY - ECM)

(a) Check the harnesses and connectors, referring to DTC P0102 inspection procedure (See page ).


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

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 / Gas AF Control / Long FT #1 and Atmosphere Pressure.

Result

Data List Item

Result

Suspected Area

Proceed to

Long FT #1

+25% or higher, or less than -25%

  • Air fuel ratio sensor (sensor 1)
  • Heated oxygen sensor (sensor 2)
  • Mass air flow meter sub-assembly
  • Fuel injector assembly
  • ECM

A

Atmosphere Pressure

80 kPa(abs) [600 mmHg(abs)] or less (when altitude is 0 m [0 ft.])

Both Data List items listed above

Values are other than above

-

B


B

GO TO STEP 63


A

60.

PERFORM SIMULATION TEST

(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 / Utility / Learning Value Reset.

(e) Confirm the following conditions as instructed on the screen.

  • - Ignition switch ON
  • - Engine stopped
  • - Battery voltage 9 V or higher

(f) After confirming, select "Next" and initialize the learn value.

HINT:

If a message indicating learned value initialization failure is displayed on the screen, confirm the execution conditions, and perform learned value initialization again.

(g) Check if the engine can be started.

Result

Result

Proceed to

Engine can be started

A

Engine cannot be started

B


B

GO TO STEP 63


A

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 / Gas AF Control / Fuel System Status #1.

(e) Confirm that Fuel System Status #1 is CL.

(f) Enter the following menus: Powertrain / Engine / Data List / Gas AF Control / 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 / Gas AF Control / AFS Voltage B1S1 and O2S B1S2.

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

Standard:

Techstream Display

Injection Volume

Specified Condition

AFS Voltage B1S1

+12%

Air fuel ratio sensor output voltage is below 3.1 V

-12%

Air fuel ratio sensor output voltage is higher than 3.4 V

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.
  • Perform "Inspection After Repair" after replacing the air fuel ratio sensor (See page ).


NG

REPLACE AIR FUEL RATIO SENSOR


OK

62.

PERFORM SIMULATION TEST

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

OK:

Engine speed is stable.

HINT:

  • After replacing the fuel injector assembly or mass air flow meter sub-assembly, 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.
  • Perform "Inspection After Repair" after replacing the fuel injector assembly or mass air flow meter sub-assembly (See page ).


OK

REPLACE MASS AIR FLOW METER SUB-ASSEMBLY


NG

REPLACE FUEL INJECTOR ASSEMBLY

63.

CHECK FUEL PRESSURE

(a) Check the fuel pressure (See page ).



NG

GO TO STEP 68


OK

64.

INSPECT SPARK PLUG

(a) Inspect the spark plugs (See page ).


Result

Result

Proceed to

All cylinders are normal

A

One cylinder is abnormal*1

B

All cylinders are abnormal*2, *3

C

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.
  • Perform "Inspection After Repair" after replacing the spark plug (See page ).


B

REPLACE SPARK PLUG (ABNORMAL CYLINDER)


C

REPLACE SPARK PLUG (ALL CYLINDER)


A

65.

CONFIRM VEHICLE CONDITION

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

Result

Problem Symptom

Suspected Area

Proceed to

When the engine is stopped and a long time has passed, engine starting trouble occurs*1

Pressure regulator is stuck open

A

When the engine is stopped and approximately 15 to 120 minutes have passed, engine starting trouble occurs*2

Fuel injector assembly leak

B

When the engine is stopped and approximately 2 to 3 minutes have passed, engine starting trouble occurs*3

Failure to maintain fuel pressure by pressure regulator

A

Condition other than above, or there is an inconsistency in the conditions present when engine starting trouble occurs

-

C*4

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.


B

GO TO STEP 67


C

GO TO STEP 69


A

66.

CHECK FUEL PRESSURE

HINT:

For the fuel pressure inspection, refer to the following procedures (See page ).


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

Standard:

147 kPa (1.5 kgf/cm2, 21 psi) or higher (5 minutes after stopping the engine)

Result

Result

Proceed to

Abnormal

A

Normal

B*1

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.

A

REPLACE FUEL PRESSURE REGULATOR


B

GO TO STEP 69

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

Result

Proceed to

4000 ppm or higher

A

Less than 4000 ppm

B*1

HINT:

  • If the concentration is 4000 ppm or higher, a fuel injector assembly 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.
  • Perform "Inspection After Repair" after replacing the fuel injector assembly (See page ).


A

REPLACE FUEL INJECTOR ASSEMBLY


B

GO TO STEP 69

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

Result

Proceed to

Fuel leakage or signs of fuel leakage are present

A

No fuel leakage or signs of fuel leakage

B

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.

A

REPAIR OR REPLACE FUEL LINE


B

CHECK FUEL PUMP CONTROL CIRCUIT

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 74).

Result

Performed Step

Troubleshooting by System

Procedure

Proceed to

Steps 38, 39, 40 and 46

Fuel system troubleshooting C

70 to 74

A

(b) If the malfunction could not be identified during the inspection in step 44, perform ignition system troubleshooting (steps 75 to 83).

Result

Performed Step

Troubleshooting by System

Procedure

Proceed to

Step 44

Ignition system troubleshooting

75 to 83

B

(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

Performed Step

Troubleshooting by System

Procedure

Proceed to

Step 53 and 54

Intake air system troubleshooting

84 to 86

C

Fuel system troubleshooting A

87 to 94

(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

Performed Step

Troubleshooting by System

Procedure

Proceed to

Steps 55, 56, 57, 58, 61, 62, 64, 65, 66, 67 and 68

Fuel system troubleshooting A

95 to 102

D

Fuel system troubleshooting B

103 to 105

Intake air system troubleshooting

106 to 108

Ignition system troubleshooting

109 to 117


B

GO TO STEP 75


C

GO TO STEP 84


D

GO TO STEP 95


A

70.

INSPECT FUEL INJECTOR ASSEMBLY

(a) Inspect the fuel injector assemblies (See page ).


HINT:

Perform "Inspection After Repair" after replacing the fuel injector assembly (See page ).



NG

REPLACE FUEL INJECTOR ASSEMBLY


OK

71.

CHECK TERMINAL VOLTAGE (FUEL INJECTOR CIRCUIT)

(a) Check the harnesses and connectors, referring to DTC P0300 inspection procedure (See page ).


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


OK

72.

REPLACE CRANKSHAFT POSITION SENSOR

(a) Replace the crankshaft position sensor (See page ).


(b) Check the engine start operation.

OK:

Malfunction has been repaired successfully.


OK

END (CRANKSHAFT POSITION SENSOR IS DEFECTIVE)


NG

73.

REPLACE CAMSHAFT POSITION SENSOR (FOR INTAKE CAMSHAFT)

(a) Replace the camshaft position sensor (for intake camshaft) (See page ).


(b) Check the engine start operation.

OK:

Malfunction has been repaired successfully.


OK

END (CAMSHAFT POSITION SENSOR (FOR INTAKE CAMSHAFT) IS DEFECTIVE)


NG

74.

REPLACE CAMSHAFT POSITION SENSOR (FOR EXHAUST CAMSHAFT)

(a) Replace the camshaft position sensor (for exhaust camshaft) (See page ).


(b) Check the engine start operation.

OK:

Malfunction has been repaired successfully.


OK

END (CAMSHAFT POSITION SENSOR (FOR EXHAUST CAMSHAFT) IS DEFECTIVE)


NG

REPLACE ECM

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

76.

CHECK SENSOR INSTALLATION (CAMSHAFT POSITION SENSOR (FOR INTAKE CAMSHAFT))

(a) Check the tightening and installation condition of the camshaft position sensor (for intake camshaft) bolt.

(b) Check the connection of the camshaft position sensor (for intake camshaft) connector.

OK:

Sensor is installed correctly.


NG

SECURELY REINSTALL SENSOR (FOR INTAKE CAMSHAFT)


OK

77.

CHECK SENSOR INSTALLATION (CAMSHAFT POSITION SENSOR (FOR EXHAUST CAMSHAFT))

(a) Check the tightening and installation condition of the camshaft position sensor (for exhaust camshaft) bolt.

(b) Check the connection of the camshaft position sensor (for exhaust camshaft) connector.

OK:

Sensor is installed correctly.


NG

SECURELY REINSTALL SENSOR (FOR EXHAUST CAMSHAFT)


OK

78.

CHECK HARNESS AND CONNECTOR (CRANKSHAFT POSITION SENSOR - ECM)

(a) Check the harnesses and connectors, referring to DTC P0335 inspection procedure (See page ).


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

79.

CHECK HARNESS AND CONNECTOR (CAMSHAFT POSITION SENSOR (FOR INTAKE CAMSHAFT) - ECM)

(a) Check the harnesses and connectors, referring to DTC P0340 inspection procedure (See page ).


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

80.

CHECK HARNESS AND CONNECTOR (CAMSHAFT POSITION SENSOR (FOR EXHAUST CAMSHAFT) - ECM)

(a) Check the harnesses and connectors, referring to DTC P0365 inspection procedure (See page ).


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

81.

REPLACE CRANKSHAFT POSITION SENSOR

(a) Replace the crankshaft position sensor (See page ).


(b) Check the engine start operation.

OK:

Malfunction has been repaired successfully.


OK

END (CRANKSHAFT POSITION SENSOR IS DEFECTIVE)


NG

82.

REPLACE CAMSHAFT POSITION SENSOR (FOR INTAKE CAMSHAFT)

(a) Replace the camshaft position sensor (for intake camshaft) (See page ).


(b) Check the engine start operation.

OK:

Malfunction has been repaired successfully.


OK

END (CAMSHAFT POSITION SENSOR (FOR INTAKE CAMSHAFT) IS DEFECTIVE)


NG

83.

REPLACE CAMSHAFT POSITION SENSOR (FOR EXHAUST CAMSHAFT)

(a) Replace the camshaft position sensor (for exhaust camshaft) (See page ).


(b) Check the engine start operation.

OK:

Malfunction has been repaired successfully.


OK

END (CAMSHAFT POSITION SENSOR (FOR EXHAUST CAMSHAFT) IS DEFECTIVE)


NG

REPLACE ECM

84.

READ VALUE USING TECHSTREAM (ISC LEARNING VALUE)

(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 / Primary / ISC Learning Valve.

(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

Data List Item

Result

Suspected Area

Proceed to

ISC Learning Value

(engine displacement (liters) x 0.9) or higher

  • Valve timing
  • Compression

A

Less than (engine displacement (liters) x 0.9)

-

B


B

GO TO STEP 86


A

85.

CHECK CYLINDER COMPRESSION PRESSURE

(a) Check the compression (See page ).


HINT:

Perform "Inspection After Repair" after replacing the engine assembly (See page ).



OK

CHECK VALVE TIMING


NG

CHECK AND REPAIR ENGINE ASSEMBLY

86.

INSPECT ENGINE COOLANT TEMPERATURE SENSOR

(a) Inspect the engine coolant temperature sensor (See page ).


HINT:

Perform "Inspection After Repair" after replacing the engine coolant temperature sensor (See page ).



NG

REPLACE ENGINE COOLANT TEMPERATURE SENSOR


OK

87.

CHECK FUEL PRESSURE

HINT:

For the fuel pressure inspection, refer to the following procedures (See page ).


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

Standard:

Vehicle State

Specified Condition

Cranking engine

304 kPa (3.1 kgf/cm2, 44 psi) to 343 kPa (3.5 kgf/cm2, 50 psi)

5 minutes after stopping engine

147 kPa (1.5 kgf/cm2, 21 psi) or higher


NG

GO TO STEP 93


OK

88.

READ VALUE USING TECHSTREAM (LONG FT #1)

(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 / Gas AF Control / Long FT #1.

Result

Data List Item

Result

Suspected Area

Proceed to

Long FT #1

-15 to +15%

  • Wire harness or connector
  • Fuel

A

+15% or higher, or less than -15%

Fuel injector assembly

B

HINT:

Perform "Inspection After Repair" after replacing the fuel injector assembly (See page ).



B

REPLACE FUEL INJECTOR ASSEMBLY


A

89.

PERFORM SIMULATION TEST

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

Result

Problem Symptom

Suspected Area

Proceed to

Current unstable idle speed or history of unstable idle speed

Crankshaft position sensor system

A

All current and past idle speeds are stable

Fuel

B

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

90.

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

91.

CHECK HARNESS AND CONNECTOR (CRANKSHAFT POSITION SENSOR - ECM)

(a) Check the harnesses and connectors, referring to DTC P0335 inspection procedure (See page ).


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

92.

REPLACE CRANKSHAFT POSITION SENSOR

(a) Replace the crankshaft position sensor (See page ).


(b) Check the engine start operation.

OK:

Malfunction has been repaired successfully.


OK

END (CRANKSHAFT POSITION SENSOR IS DEFECTIVE)


NG

REPLACE ECM

93.

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

Result

Proceed to

Fuel leakage or signs of fuel leakage are present

A

No fuel leakage or signs of fuel leakage

B

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.

A

REPAIR OR REPLACE FUEL LINE


B

94.

INSPECT FUEL PUMP

(a) Inspect the fuel pump (See page ).


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.
  • Perform "Inspection After Repair" after replacing the fuel pump (See page ).


OK

REPLACE FUEL PRESSURE REGULATOR


NG

REPLACE FUEL PUMP

95.

CHECK FUEL PRESSURE

HINT:

For the fuel pressure inspection, refer to the following procedures (See page ).


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

Standard:

147 kPa (1.5 kgf/cm2, 21 psi) or higher (5 minutes after stopping the engine)

HINT:

If the engine cannot be started, read the values after cranking the engine.


NG

GO TO STEP 101


OK

96.

READ VALUE USING TECHSTREAM (LONG FT #1)

(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 / Gas AF Control / Long FT #1.

Result

Data List Item

Result

Suspected Area

Proceed to

Long FT #1

-15 to +15%

  • Wire harness or connector
  • Fuel

A

+15% or higher, or less than -15%

Fuel injector assembly

B

HINT:

Perform "Inspection After Repair" after replacing the fuel injector assembly (See page ).



B

REPLACE FUEL INJECTOR ASSEMBLY


A

97.

PERFORM SIMULATION TEST

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

Result

Problem Symptom

Suspected Area

Proceed to

Current unstable idle speed or history of unstable idle speed

Crankshaft position sensor system

A

All current and past idle speeds are stable

Fuel

B

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

98.

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

99.

CHECK HARNESS AND CONNECTOR (CRANKSHAFT POSITION SENSOR - ECM)

(a) Check the harnesses and connectors, referring to DTC P0335 inspection procedure (See page ).


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

100.

REPLACE CRANKSHAFT POSITION SENSOR

(a) Replace the crankshaft position sensor (See page ).


(b) Check the engine start operation.

OK:

Malfunction has been repaired successfully.


OK

END (CRANKSHAFT POSITION SENSOR IS DEFECTIVE)


NG

REPLACE ECM

101.

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

Result

Proceed to

Fuel leakage or signs of fuel leakage are present

A

No fuel leakage or signs of fuel leakage

B

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.

A

REPAIR OR REPLACE FUEL LINE


B

102.

INSPECT FUEL PUMP

(a) Inspect the fuel pump (See page ).


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.
  • Perform "Inspection After Repair" after replacing the fuel pump (See page ).


NG

REPLACE FUEL PUMP


OK

103.

CHECK PURGE VSV

(a) Disconnect the fuel vapor feed hose (on the canister side) of the purge VSV.

Text in Illustration

*1

Fuel Vapor Feed Hose (to Canister)

*2

Connector

*3

Purge VSV


(b) Start the engine.

(c) Idle the engine.

(d) Disconnect the connector of the purge VSV.

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

OK:

Air does not flow

HINT:

When this inspection is performed, the MIL may illuminate. After finishing the inspection, check and clear the DTCs (See page
).


NG

INSPECT PURGE VSV


OK

104.

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

Result

Proceed to

4000 ppm or higher

A

Less than 4000 ppm

B

HINT:

  • If the concentration is 4000 ppm or higher, a fuel injector assembly may have a sealing problem.
  • Perform "Inspection After Repair" after replacing the fuel injector assembly (See page ).


A

REPLACE FUEL INJECTOR ASSEMBLY


B

105.

CHECK INTAKE VALVE

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

Result

Result

Proceed to

Carbon present

A

No carbon present

B


A

CLEAN INTAKE VALVE


B

106.

READ VALUE USING TECHSTREAM (ISC LEARNING VALUE)

(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 / Primary / ISC Learning Valve.

(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

Data List Item

Result

Suspected Area

Proceed to

ISC Learning Value

(engine displacement (liters) x 0.9) or more

  • Valve timing
  • Compression

A

Less than (engine displacement (liters) x 0.9)

-

B


B

GO TO STEP 108


A

107.

CHECK CYLINDER COMPRESSION PRESSURE

(a) Check the compression (See page ).


HINT:

Perform "Inspection After Repair" after replacing the engine assembly (See page ).



OK

CHECK VALVE TIMING


NG

CHECK AND REPAIR ENGINE ASSEMBLY

108.

INSPECT ENGINE COOLANT TEMPERATURE SENSOR

(a) Inspect the engine coolant temperature sensor (See page ).


HINT:

Perform "Inspection After Repair" after replacing the engine coolant temperature sensor (See page ).



NG

REPLACE ENGINE COOLANT TEMPERATURE SENSOR


OK

109.

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

110.

CHECK SENSOR INSTALLATION (CAMSHAFT POSITION SENSOR (FOR INTAKE CAMSHAFT))

(a) Check the tightening and installation condition of the camshaft position sensor (for intake camshaft) bolt.

(b) Check the connection of the camshaft position sensor (for intake camshaft) connector.

OK:

Sensor is installed correctly.


NG

SECURELY REINSTALL SENSOR (FOR INTAKE CAMSHAFT)


OK

111.

CHECK SENSOR INSTALLATION (CAMSHAFT POSITION SENSOR (FOR EXHAUST CAMSHAFT))

(a) Check the tightening and installation condition of the camshaft position sensor (for exhaust camshaft) bolt.

(b) Check the connection of the camshaft position sensor (for exhaust camshaft) connector.

OK:

Sensor is installed correctly.


NG

SECURELY REINSTALL SENSOR (FOR EXHAUST CAMSHAFT)


OK

112.

CHECK HARNESS AND CONNECTOR (CRANKSHAFT POSITION SENSOR - ECM)

(a) Check the harnesses and connectors, referring to DTC P0335 inspection procedure (See page ).


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

113.

CHECK HARNESS AND CONNECTOR (CAMSHAFT POSITION SENSOR (FOR INTAKE CAMSHAFT) - ECM)

(a) Check the harnesses and connectors, referring to DTC P0340 inspection procedure (See page ).


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

114.

CHECK HARNESS AND CONNECTOR (CAMSHAFT POSITION SENSOR (FOR EXHAUST CAMSHAFT) - ECM)

(a) Check the harnesses and connectors, referring to DTC P0365 inspection procedure (See page ).


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

115.

REPLACE CRANKSHAFT POSITION SENSOR

(a) Replace the crankshaft position sensor (See page ).


(b) Check the engine start operation.

OK:

Malfunction has been repaired successfully.


OK

END (CRANKSHAFT POSITION SENSOR IS DEFECTIVE)


NG

116.

REPLACE CAMSHAFT POSITION SENSOR (FOR INTAKE CAMSHAFT)

(a) Replace the camshaft position sensor (for intake camshaft) (See page ).


(b) Check the engine start operation.

OK:

Malfunction has been repaired successfully.


OK

END (CAMSHAFT POSITION SENSOR (FOR INTAKE CAMSHAFT) IS DEFECTIVE)


NG

117.

REPLACE CAMSHAFT POSITION SENSOR (FOR EXHAUST CAMSHAFT)

(a) Replace the camshaft position sensor (for exhaust camshaft) (See page ).


(b) Check the engine start operation.

OK:

Malfunction has been repaired successfully.


OK

END (CAMSHAFT POSITION SENSOR (FOR EXHAUST CAMSHAFT) IS DEFECTIVE)


NG

REPLACE ECM

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