Part 3

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

Continued

27. CHECK ENGINE ASSEMBLY

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

OK:

Crankshaft rotates smoothly.

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

NG -- REPAIR OR REPLACE ENGINE ASSEMBLY

OK -- INSPECT STARTER Testing and Inspection

28. CHECK STARTER

(a) Remove the starter Removal.

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

Standard:

There is no wear or damage.

Result:

C -- REPLACE DRIVE PLATE AND RING GEAR

B -- REPLACE FLYWHEEL SUB-ASSEMBLY

A -- REPLACE STARTER Removal

29. INSPECT BATTERY

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

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

32. INSPECT BATTERY

(a) Check the electrolyte quantity.

OK:

Electrolyte quantity is within the specified range.

(b) Inspect the battery voltage.

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

(2) Measure the battery voltage.

Standard voltage:

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

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

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

Standard:

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

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

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

33. CHECK ENGINE ASSEMBLY

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

OK:

Crankshaft rotates smoothly.

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

NG -- REPAIR OR REPLACE ENGINE ASSEMBLY

OK -- INSPECT STARTER Testing and Inspection

34. CHECK FUEL INJECTOR

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

OK:

Fuel injector operating noise is heard.

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

35. CHECK FUEL PRESSURE

(a) Check the fuel pressure Testing and Inspection.

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

36. INSPECT SPARK PLUG AND SPARK

(a) Inspect for sparks Testing and Inspection.

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

37. CONFIRM VEHICLE CONDITION

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

Result:

HINT
*1: The 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.

*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 71, perform fuel system troubleshooting C (steps 72 to 76).

C -- CHECK MALFUNCTION CONDITION

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

38. 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.
- *1: From step 71, perform fuel system troubleshooting C (steps 72 to 76).
B -- CHECK MALFUNCTION CONDITION

A -- REPLACE PRESSURE REGULATOR

39. CHECK FUEL INJECTOR

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

Result:

HINT
- If he concentration is 400 ppm or higher, a fuel injector may have a sealing problem.
- *1: From step 71, perform fuel system troubleshooting C (steps 72 to 76).
B -- CHECK MALFUNCTION CONDITION

A -- REPLACE FUEL INJECTOR Removal

40. INSPECT SPARK PLUG

(a) Inspect the spark plugs Testing and Inspection.

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

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

41. READ VALUE USING TECHSTREAM (ENGINE SPEED)

(a) Connect the Techstream to the DLC3.

(b) Turn the ignition switch to ON.

(c) Turn the Techstream on.

(d) Enter the following menus: Powertrain / Engine and ECT / Data List / 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 -- Continue to next step.

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

(a) Disconnect the ignition coil 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 ignition coil connectors.

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

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

(a) Disconnect the ignition coil connectors.

(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 ignition coil connectors.

(e) Reconnect the ECM connector.

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

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

(a) Disconnect the ignition coil connectors.

(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 71 and perform troubleshooting for the ignition system (steps 77 to 83).
(d) Reconnect the ignition coil connectors.

(e) Reconnect the ECM connector.

NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR

OK -- REPLACE IGNITION COIL Removal

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

(a) Connect the Techstream to the DLC3.

(b) Turn the ignition switch to ON.

(c) 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 an operating sound from the fuel pump.

OK:

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

NG -- CHECK FUEL PUMP CONTROL SYSTEM
OK -- Continue to next step.