Part 4

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

76. CHECK CRANKSHAFT POSITION SENSOR

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

(b) Check the engine start operation.

OK:

Malfunction has been repaired successfully.

NG -- CHECK CAMSHAFT POSITION SENSOR (FOR INTAKE CAMSHAFT)

OK -- END (CRANKSHAFT POSITION SENSOR IS DEFECTIVE)

77. CHECK CAMSHAFT POSITION SENSOR (FOR INTAKE CAMSHAFT)

(a) Replace the camshaft position sensor (for intake camshaft) Removal.

(b) Check the engine start operation.

OK:

Malfunction has been repaired successfully.

NG -- CHECK CAMSHAFT POSITION SENSOR (FOR EXHAUST CAMSHAFT)

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

78. CHECK CAMSHAFT POSITION SENSOR (FOR EXHAUST CAMSHAFT)

(a) Replace the camshaft position sensor (for exhaust camshaft) Removal.

(b) Check the engine start operation.

OK:

Malfunction has been repaired successfully.

NG -- REPLACE ECM Removal

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

79. 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 CRANKSHAFT POSITION SENSOR Installation
OK -- Continue to next step.

80. 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 connector.

OK:

Sensor is installed correctly.

NG -- SECURELY REINSTALL CAMSHAFT POSITION SENSOR (FOR INTAKE CAMSHAFT) Installation
OK -- Continue to next step.

81. 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 connector.

OK:

Sensor is installed correctly.

NG -- SECURELY REINSTALL CAMSHAFT POSITION SENSOR (FOR EXHAUST CAMSHAFT) Installation
OK -- Continue to next step.

82. 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):

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.

85. CHECK CRANKSHAFT POSITION SENSOR

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

(b) Check the engine start operation.

OK:

Malfunction has been repaired successfully.

NG -- CHECK CAMSHAFT POSITION SENSOR (FOR INTAKE CAMSHAFT)

OK -- END (CRANKSHAFT POSITION SENSOR IS DEFECTIVE)

86. CHECK CAMSHAFT POSITION SENSOR (FOR INTAKE CAMSHAFT)

(a) Replace the camshaft position sensor (for intake camshaft) Removal.

(b) Check the engine start operation.

OK:

Malfunction has been repaired successfully.

NG -- CHECK CAMSHAFT POSITION SENSOR (FOR EXHAUST CAMSHAFT)

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

87. CHECK CAMSHAFT POSITION SENSOR (FOR EXHAUST CAMSHAFT)

(a) Replace the camshaft position sensor (for exhaust camshaft) Removal.

(b) Check the engine start operation.

OK:

Malfunction has been repaired successfully.

NG -- REPLACE ECM Removal

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

88. 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.

89. CHECK CYLINDER COMPRESSION PRESSURE

(a) Check the compression Engine.

NG -- CHECK AND REPAIR ENGINE ASSEMBLY

OK -- ADJUST VALVE TIMING

90. 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.

91. CHECK FUEL PRESSURE

HINT
For the fuel pressure inspection, refer to the following procedures Fuel System.

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

Standard:

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

92. 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.

93. 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.

94. 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 CRANKSHAFT POSITION SENSOR Installation
OK -- Continue to next step.

95. 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):

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

98. INSPECT FUEL PUMP

(a) Inspect the fuel pump Inspection.

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.

NG -- REPLACE FUEL PUMP Removal

OK -- REPLACE PRESSURE REGULATOR Removal

99. CHECK FUEL PRESSURE

HINT
For the fuel pressure inspection, refer to the following procedures Fuel System.

(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.

100. 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.

101. 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.

102. 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 CRANKSHAFT POSITION SENSOR Installation
OK -- Continue to next step.

103. 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):

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

106. INSPECT FUEL PUMP

(a) Inspect the fuel pump Inspection.

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.

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

107. CHECK PURGE VSV

(a) Disconnect the vacuum hose (on the canister side) of the 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

(f) Connect the connector of the purge VSV.

(g) Connect the vacuum hose of the purge VSV.

HINT
When this inspection is performed, the MIL may illuminate. After finishing the inspection, check and clear DTCs Reading and Clearing Diagnostic Trouble Codes.

NG -- INSPECT PURGE VSV Testing and Inspection
OK -- Continue to next step.

108. 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 INTAKE VALVE

A -- REPLACE FUEL INJECTOR Removal

109. CHECK INTAKE VALVE

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

Result

B -- READ VALUE USING TECHSTREAM (ISC LEARNING VALUE)

A -- CLEAN INTAKE VALVE

110. 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, turn off all accessory switches and warm up the engine until the engine coolant temperature stabilizes.

Result

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

111. CHECK CYLINDER COMPRESSION PRESSURE

(a) Check the compression Engine.

NG -- REPAIR OR REPLACE ENGINE ASSEMBLY

OK -- ADJUST VALVE TIMING

112. INSPECT ENGINE COOLANT TEMPERATURE SENSOR

(a) Inspect the engine coolant temperature sensor Removal.

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

113. 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 CRANKSHAFT POSITION SENSOR Installation
OK -- Continue to next step.

114. 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 CAMSHAFT POSITION SENSOR (FOR INTAKE CAMSHAFT) Installation
OK -- Continue to next step.

115. 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 CAMSHAFT POSITION SENSOR (FOR EXHAUST CAMSHAFT) Installation
OK -- Continue to next step.

116. 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):

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.

119. CHECK CRANKSHAFT POSITION SENSOR

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

(b) Check the engine start operation.

OK:

Malfunction has been repaired successfully.

NG -- CHECK CAMSHAFT POSITION SENSOR (FOR INTAKE CAMSHAFT)

OK -- END (CRANKSHAFT POSITION SENSOR IS DEFECTIVE)

120. CHECK CAMSHAFT POSITION SENSOR (FOR INTAKE CAMSHAFT)

(a) Replace the camshaft position sensor Removal.

(b) Check the engine start operation.

OK:

Malfunction has been repaired successfully.

NG -- CHECK CAMSHAFT POSITION SENSOR (FOR EXHAUST CAMSHAFT)

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

121. CHECK CAMSHAFT POSITION SENSOR (FOR EXHAUST CAMSHAFT)

(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 (FOR EXHAUST CAMSHAFT) IS DEFECTIVE)