Part 2

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

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:

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

C -- INSPECT BATTERY

B -- CHECK STARTER ASSEMBLY
A -- Continue to next step.

27. INSPECT BATTERY

(a) Check the electrolyte quantity.

Standard:

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 engine switch off and turn on (IG) 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.

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.

NG -- REPAIR OR REPLACE ENGINE ASSEMBLY

OK -- INSPECT STARTER ASSEMBLY

29. CHECK STARTER ASSEMBLY

(a) Remove the starter assembly Removal.

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

Standard:

There is no wear or damage.

(c) Install the starter assembly.

NG -- REPLACE STARTER ASSEMBLY

OK -- REPLACE DRIVE PLATE AND RING GEAR

30. INSPECT BATTERY

(a) Check the electrolyte quantity.

B -- REPLACE STARTER ASSEMBLY

A -- CHECK CRANKING HOLDING FUNCTION CIRCUIT Cranking Holding Function Circuit

32. PERFORM SIMULATION TEST

(a) Check the cranking speed.

Result:

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

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

33. INSPECT BATTERY

(a) Check the electrolyte quantity.

Standard:

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 engine switch off and turn on (IG) 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.

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.

NG -- REPAIR OR REPLACE ENGINE ASSEMBLY

OK -- INSPECT STARTER ASSEMBLY

35. CHECK FUEL INJECTOR ASSEMBLY

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

OK:

Fuel injector assembly operating noise is heard.

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

36. CHECK FUEL PRESSURE

(a) Inspect the fuel pressure Testing and Inspection.

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

37. CHECK SPARK PLUG AND SPARK

(a) Check for sparks Testing and Inspection.

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

38. CONFIRM VEHICLE CONDITION

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

Result:

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

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

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

*4: From step 72, perform fuel system troubleshooting C (steps 73 to 77).

C -- CHECK MALFUNCTION CONDITION

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

39. CHECK FUEL PRESSURE

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

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

Result:

HINT
- If the engine cannot be started, check the fuel pressure after cranking the engine.
- *: From step 72, perform fuel system troubleshooting C (steps 73 to 77).
B -- CHECK MALFUNCTION CONDITION

A -- REPLACE PRESSURE REGULATOR

40. 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 higher, a fuel injector may have a sealing problem.
- *: From step 72, perform fuel system troubleshooting C (steps 73 to 77).
B -- CHECK MALFUNCTION CONDITION

A -- REPLACE FUEL INJECTOR ASSEMBLY Removal

41. 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.

42. READ VALUE USING TECHSTREAM (ENGINE SPEED)

(a) Connect the Techstream to the DLC3.

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

(c) Turn the Techstream on.

(d) Enter the following menus: Powertrain / Engine / Data List / Engine Speed.

(e) Start the engine.

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

Standard:

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.

43. CHECK HARNESS AND CONNECTOR (IGNITION COIL POWER SOURCE)

(a) Disconnect the ignition coil connector.

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

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

Standard Voltage:

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

NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR (IGNITION COIL - IG2 RELAY)
OK -- Continue to next step.

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

(a) Disconnect the ignition coil connector.

(b) Disconnect the ECM connector.

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

Standard Resistance (Check for Open):

Standard Resistance (Check for Short):

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

(e) Reconnect the ignition coil connector.

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

45. CHECK HARNESS AND CONNECTOR (IGNITION COIL - ECM)

(a) Disconnect the ignition coil connector.

(b) Disconnect the ECM connector.

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

Standard Resistance (Check for Open):

Standard Resistance (Check for Short):

HINT
- Jiggle the wire harness and connector to increase the likelihood of detecting malfunctions that do not always occur.
- Make sure there is not an excessive amount of force applied to the wire harness.
- If the wire harness is normal, after replacing the ignition coil, check if engine starting trouble occurs again. If engine starting trouble occurs again, proceed to step 72 and perform troubleshooting for the ignition system (steps 78 to 84).
(d) Reconnect the ECM connector.

(e) Reconnect the ignition coil connector.

NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR

OK -- REPLACE IGNITION COIL

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

(a) Connect the Techstream to the DLC3.

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

(c) Turn the Techstream on.

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

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

Standard:

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 -- Continue to next step.

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

(a) Connect the Techstream to the DLC3.

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

(c) Turn the Techstream on.

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

(e) When performing the Active Test, check for fuel leakage from the fuel pipes.

Result

Result:

HINT
- Jiggle the wire harness and connector to increase the likelihood of detecting malfunctions that do not always occur.
- Check if the vehicle ran out of fuel, as engine starting trouble due to running out of fuel is also detected.
- If there are no fuel leaks, after inspecting the fuel pump control system, check if engine starting trouble occurs again. If engine starting trouble occurs again, proceed to step 72 and perform fuel system troubleshooting (steps 73 to 77).
B -- CHECK FUEL PUMP CONTROL CIRCUIT

A -- REPAIR OR REPLACE FUEL LINE

48. READ VALUE USING TECHSTREAM (ENGINE SPEED)

(a) Connect the Techstream to the DLC3.

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

(c) Turn the Techstream on.

(d) Enter the following menus: Powertrain / Engine / Data List / Engine Speed.

(e) Start the engine.

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

Standard:

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.

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

(a) Disconnect the fuel injector assembly connector.

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

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

Standard Voltage:

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

NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR (FUEL INJECTOR - IG2 RELAY)
OK -- Continue to next step.

50. 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 (Check for Open):

Standard Resistance (Check for Short):

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

(e) Reconnect the fuel injector assembly connector.

NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR

OK -- REPLACE ECM Removal