Part 4

1NZ-FE ENGINE CONTROL: SFI SYSTEM (for Hatchback): P1604: Startability Malfunction
P1604 - Startability Malfunction - (Continued)

86. 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 SENSOR Installation (from 07/2011)
OK -- Continue to next step.

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

(a) Check the harnesses and connectors, referring to DTC P0335 inspection procedure P0335.

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.

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

88. CHECK CRANKSHAFT POSITION SENSOR

(a) Replace the crankshaft position sensor Removal (from 07/2011).

(b) Check the engine start operation.

OK:

Malfunction has been repaired successfully.

NG -- REPLACE ECM Removal (from 07/2011)

OK -- END (CRANKSHAFT POSITION SENSOR IS DEFECTIVE)

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

(a) Connect the Techstream to the DLC3.

(b) Turn the ignition switch to ON and turn the Techstream on.

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

(d) 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 -- INSPECT FUEL PUMP

A -- REPAIR OR REPLACE FUEL LINE

90. INSPECT FUEL PUMP

(a) Inspect the fuel pump Testing and 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.
* Perform "Inspection After Repair" after replacing the fuel pump Programming and Relearning.

NG -- REPLACE FUEL PUMP Removal (from 07/2011)

OK -- REPLACE FUEL PRESSURE REGULATOR ASSEMBLY Removal (from 07/2011)

91. 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, read the values after cranking the engine.

B -- PERFORM ACTIVE TEST USING TECHSTREAM (CONTROL THE FUEL PUMP/SPEED)
A -- 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) Enter the following menus: Powertrain / Engine and ECT / Data List / Long FT #1.

Result





HINT
Perform "Inspection After Repair" after replacing the fuel injector assembly Programming and Relearning.

B -- REPLACE FUEL INJECTOR ASSEMBLY Removal (from 07/2011)
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 SENSOR Installation (from 07/2011)
OK -- Continue to next step.

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

(a) Check the harnesses and connectors, referring to DTC P0335 inspection procedure P0335.

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.

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

96. CHECK CRANKSHAFT POSITION SENSOR

(a) Replace the crankshaft position sensor Removal (from 07/2011).

(b) Check the engine start operation.

OK:

Malfunction has been repaired successfully.

NG -- REPLACE ECM Removal (from 07/2011)

OK -- END (CRANKSHAFT POSITION SENSOR IS DEFECTIVE)

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

(a) Connect the Techstream to the DLC3.

(b) Turn the ignition switch to ON and turn the Techstream on.

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

(d) 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 -- INSPECT FUEL PUMP

A -- REPAIR OR REPLACE FUEL LINE

98. INSPECT FUEL PUMP

(a) Inspect the fuel pump Testing and 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.
* Perform "Inspection After Repair" after replacing the fuel pump Programming and Relearning.

NG -- REPLACE FUEL PUMP Removal (from 07/2011)
OK -- Continue to next step.

99. CHECK PURGE VSV P1603

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

100. CHECK FUEL INJECTOR ASSEMBLY

(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.
* Perform "Inspection After Repair" after replacing the fuel injector assembly Programming and Relearning.

B -- CHECK INTAKE VALVE

A -- REPLACE FUEL INJECTOR ASSEMBLY Removal (from 07/2011)

101. 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

102. READ VALUE USING TECHSTREAM (ISC LEARNING VALUE)

(a) Connect the Techstream to the DLC3.

(b) Turn the ignition switch to ON.

(c) Start the engine, turn off all accessory switches and warm up the engine until the engine coolant temperature stabilizes.

(d) Enter the following menus: Powertrain / Engine and ECT / Data List / ISC Learning Value.

Result





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

103. CHECK CYLINDER COMPRESSION PRESSURE

(a) Inspect the compression Engine (for Hatchback).

HINT
Perform "Inspection After Repair" after replacing the engine assembly Programming and Relearning.

NG -- CHECK AND REPAIR ENGINE ASSEMBLY

OK -- CHECK VALVE TIMING P0011

104. INSPECT ENGINE COOLANT TEMPERATURE SENSOR

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

HINT
Perform "Inspection After Repair" after replacing the engine coolant temperature sensor Programming and Relearning.

NG -- REPLACE ENGINE COOLANT TEMPERATURE SENSOR Removal (from 07/2011)
OK -- Continue to next step.

105. 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 SENSOR Installation (from 07/2011)
OK -- Continue to next step.

106. CHECK SENSOR INSTALLATION (CAMSHAFT POSITION SENSOR)

(a) Check the tightening and installation condition of the camshaft position sensor bolt.

(b) Check the connection of the camshaft position sensor connector.

OK:

Sensor is installed correctly.

NG -- SECURELY REINSTALL SENSOR Installation (from 07/2011)
OK -- Continue to next step.

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

(a) Check the harnesses and connectors, referring to DTC P0335 inspection procedure P0335.

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.

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

108. CHECK HARNESS AND CONNECTOR (CAMSHAFT POSITION SENSOR - ECM)

(a) Check the harnesses and connectors, referring to DTC P0340 inspection procedure P0340.

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.

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

109. CHECK CRANKSHAFT POSITION SENSOR

(a) Replace the crankshaft position sensor Removal (from 07/2011).

(b) Check the engine start operation.

OK:

Malfunction has been repaired successfully.

NG -- CHECK CAMSHAFT POSITION SENSOR

OK -- END (CRANKSHAFT POSITION SENSOR IS DEFECTIVE)

110. CHECK CAMSHAFT POSITION SENSOR

(a) Replace the camshaft position sensor Removal (from 07/2011).

(b) Check the engine start operation.

OK:

Malfunction has been repaired successfully.

NG -- REPLACE ECM Removal (from 07/2011)

OK -- END (CAMSHAFT POSITION SENSOR IS DEFECTIVE)