Part 6

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

Continued

79. CHECK HARNESS AND CONNECTOR (CRANKSHAFT POSITION SENSOR - ECM)

(a) Disconnect the crankshaft position sensor 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):

(a) Disconnect the camshaft position sensor (for intake camshaft) 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):

(a) Disconnect the camshaft position sensor (for exhaust camshaft) 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) Disconnect the camshaft position sensor (for exhaust camshaft) connector.

(e) Reconnect the ECM connector.

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

82. INSPECT CRANKSHAFT POSITION SENSOR

(a) Inspect the crankshaft position sensor Testing and Inspection.

NG -- REPLACE CRANKSHAFT POSITION SENSOR Testing and Inspection
OK -- Continue to next step.

83. REPLACE CAMSHAFT POSITION SENSOR

(a) Replace the camshaft position sensor Removal.

(b) Check the engine start operation.

OK:

Malfunction has been repaired successfully.

NG -- REPLACE ECM Removal

OK -- END (CAMSHAFT POSITION SENSOR IS DEFECTIVE)

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 and ECT / Data List / ISC Learning Value.

(e) Start the engine and warm it up until the engine coolant temperature stabilizes with the A/C switch and all the accessory switches should be off

Result:

B -- INSPECT ENGINE COOLANT TEMPERATURE SENSOR
A -- Continue to next step.

85. CHECK CYLINDER COMPRESSION PRESSURE

(a) Check the compression Engine.

NG -- REPAIR OR REPLACE ENGINE ASSEMBLY

OK -- CHECK VALVE TIMING

86. INSPECT ENGINE COOLANT TEMPERATURE SENSOR

(a) Inspect the engine coolant temperature sensor Testing and Inspection.

NG -- REPLACE ENGINE COOLANT TEMPERATURE SENSOR Removal
OK -- Continue to next step.

87. 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 when cranking the engine and after stopping the engine.

Result:

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

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 and ECT / Data List / Long FT #1.

Result:

B -- REPLACE FUEL INJECTOR Removal
A -- Continue to next step.

89. PERFORM SIMULATION TEST

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

Result:

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 -- Continue to next step.

90. CHECK 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 CRANKSHAFT POSITION SENSOR
OK -- Continue to next step.

91. INSPECT CRANKSHAFT POSITION SENSOR

(a) Inspect the crankshaft position sensor Testing and Inspection.

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

92. CHECK HARNESS AND CONNECTOR (CRANKSHAFT POSITION SENSOR - ECM)

Standard Resistance (Check for Short):

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 -- INSPECT FUEL PUMP

A -- REPAIR OR REPLACE FUEL LINE

94. INSPECT FUEL PUMP

(a) Disconnect the fuel pump connector.

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

Standard Resistance:

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.
(c) Reconnect the fuel pump connector.

NG -- REPLACE FUEL PUMP Removal

OK -- REPLACE PRESSURE REGULATOR

95. 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:

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

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 and ECT / Data List / Long FT #1.

Result:

B -- REPLACE FUEL INJECTOR Removal
A -- Continue to next step.

97. PERFORM SIMULATION TEST

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

Result:

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 -- Continue to next step.

98. CHECK 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 CRANKSHAFT POSITION SENSOR
OK -- Continue to next step.

99. INSPECT CRANKSHAFT POSITION SENSOR

(a) Inspect the crankshaft position sensor Testing and Inspection.

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