Part 2

2ZR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: P1604: Startability Malfunction
P1604 - Startability Malfunction

Continued

9. 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 Freeze Frame Data.

Result:

HINT
- *1: A long time had not elapsed after stopping the engine.
- *2: A long time had elapsed after stopping the engine.
C -- CHECK FUEL PUMP CONTROL SYSTEM

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

A -- REPLACE ENGINE COOLANT TEMPERATURE SENSOR Removal

10. 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 and ECT / Active Test / Control the Fuel Pump/Speed.

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

Standard Voltage:

(a) Disconnect the injector connectors.

(b) Turn the ignition switch to ON.

(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 injector connectors.

NG -- CHECK POWER SOURCE CIRCUIT
OK -- Continue to next step.

12. 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 and ECT / Active Test / Control the Fuel Pump/Speed.

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

Result:

HINT
- Jiggle the wire harness and connector to increase the likelihood of detecting malfunctions that do not always occur.
- 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.
B -- CHECK FUEL SYSTEM

A -- REPAIR OR REPLACE FUEL LINE

13. 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:

B -- PERFORM SIMULATION TEST

A -- REPAIR OR REPLACE FUEL SYSTEM

14. 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 Freeze Frame Data.

Result:

HINT
*1: Compression loss may have occurred in the engine assembly.

D -- READ FREEZE FRAME DATA

C -- CHECK AND REPAIR ENGINE ASSEMBLY

B -- INSPECT FUEL INJECTOR

A -- REPLACE ENGINE COOLANT TEMPERATURE SENSOR Removal

15. INSPECT FUEL INJECTOR

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

OK:

No carbon present.

NG -- REPLACE FUEL INJECTOR Removal
OK -- Continue to next step.

16. 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:

B -- PERFORM SIMULATION TEST

A -- REPAIR OR REPLACE FUEL SYSTEM

17. 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 Freeze Frame Data.

Result:

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 more (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 -- CHECK FUEL INJECTOR
A -- Continue to next step.

18. 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.

Standard:

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

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

Result:

B -- PERFORM SIMULATION TEST

A -- REPLACE PRESSURE REGULATOR

19. CHECK FUEL INJECTOR

(a) Clean the inside of the surge tank with compressed air.

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

Result:

HINT
If the concentration is 400 ppm or higher, a fuel injector may have a sealing problem.

B -- CHECK THROTTLE BODY
A -- Continue to next step.

20. INSPECT FUEL INJECTOR

(a) Inspect the fuel injectors Testing and Inspection.

Result:

B -- CHECK THROTTLE BODY

A -- REPLACE FUEL INJECTOR Removal

21. CHECK THROTTLE BODY

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

Result:

B -- CHECK INTAKE SYSTEM

A -- CLEAN OR REPLACE THROTTLE BODY Removal

22. CHECK INTAKE SYSTEM

(a) Check the intake system for vacuum leak Testing and Inspection.

OK:

No leak in intake system.

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

23. PERFORM SIMULATION TEST

(a) Check if the engine can be started.

Result:

B -- CONFIRM PROBLEM SYMPTOM

A -- END

24. CONFIRM PROBLEM SYMPTOM

(a) Confirm the problem symptoms.

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

Result:

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).
E -- INSPECT ENGINE COOLANT TEMPERATURE SENSOR

D -- INSPECT MASS AIR FLOW METER

C -- CHECK FUEL INJECTOR

B -- PERFORM SIMULATION TEST
A -- Continue to next step.

25. 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
*1: The battery may be fully depleted or there may be excess engine friction.

C -- INSPECT BATTERY

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

26. INSPECT BATTERY

(a) Check the electrolyte quantity.

OK:

Electrolyte quantity is within the specified range.

(b) Inspect the battery voltage.

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

(2) Measure the battery voltage.

Standard voltage:

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

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

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

Standard:

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

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

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