Part 2
2AZ-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: P1604: Startability Malfunction
P1604 - Startability Malfunction
12. CHECK HARNESS AND CONNECTOR (FUEL INJECTOR CIRCUIT)
(a) Check the harnesses and connectors, referring to DTC P0300 inspection procedure P0300.
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 -- CHECK FUEL INJECTOR CIRCUIT Fuel Injector Circuit
OK -- Continue to next step.
13. 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) Using the Techstream, select the [Control the Fuel Pump / Speed] Active Test.
(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 -- CHECK FUEL SYSTEM
A -- REPAIR OR REPLACE FUEL LINE
14. 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
15. 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: Use an actual outside temperature estimated from the Initial Intake Air Temp, Ambient Temp for A/C, and (if possible) the weather when the DTC was detected.
- *2: Compression loss may have occurred in the engine assembly.
B -- INSPECT FUEL INJECTOR
C -- CHECK AND REPAIR ENGINE ASSEMBLY
D -- READ FREEZE FRAME DATA
A -- REPLACE ENGINE COOLANT TEMPERATURE SENSOR Removal
16. 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.
17. 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
18. 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 -- INSPECT FUEL INJECTOR
A -- Continue to next step.
19. 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.
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.
OK -- PERFORM SIMULATION TEST
NG -- REPLACE FUEL PRESSURE REGULATOR Removal
20. INSPECT 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 -- INSPECT THROTTLE BODY
A -- Continue to next step.
21. INSPECT FUEL INJECTOR
(a) Inspect the fuel injectors Testing and Inspection.
Result
B -- INSPECT THROTTLE BODY
A -- REPLACE FUEL INJECTOR Removal
22. INSPECT THROTTLE BODY
(a) Check if carbon is in the air flow passage.
Result
B -- CHECK INTAKE SYSTEM
A -- CLEAN OR REPLACE THROTTLE BODY Removal
23. CHECK INTAKE SYSTEM
(a) Check the intake system for vacuum leak Intake System.
OK:
No leak in intake system.
NG -- REPAIR OR REPLACE INTAKE SYSTEM
OK -- Continue to next step.
24. PERFORM SIMULATION TEST
(a) Check if the engine can be started.
Result
B -- CONFIRM PROBLEM SYMPTOM
A -- END
25. 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).
B -- PERFORM SIMULATION TEST
C -- INSPECT FUEL INJECTOR
D -- INSPECT MASS AIR FLOW METER
E -- INSPECT ENGINE COOLANT TEMPERATURE SENSOR
A -- Continue to next step.
26. 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.
B -- INSPECT STARTER (STARTER PINION GEAR)
C -- INSPECT BATTERY
A -- Continue to next step.
27. INSPECT BATTERY
(a) Inspect the battery Testing and Inspection.
NG -- CHARGE OR REPLACE BATTERY
OK -- Continue to next step.
28. 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
29. INSPECT STARTER (STARTER PINION GEAR)
(a) Remove the starter Removal.
(b) Check for starter pinion gear wear and damage.
OK:
There is no wear or damage.
NG -- REPLACE STARTER Removal
OK -- REPLACE FLYWHEEL SUB-ASSEMBLY OR DRIVE PLATE AND RING GEAR Removal
30. INSPECT BATTERY
(a) Inspect the battery Testing and Inspection.
NG -- CHARGE OR REPLACE BATTERY
OK -- Continue to next step.
31. INSPECT STARTER
(a) Inspect the starter Testing and Inspection.
NG -- REPLACE STARTER Removal
OK -- CHECK STARTER SIGNAL CIRCUIT Starter Signal Circuit
32. PERFORM SIMULATION TEST
(a) Check the cranking speed.
Result
HINT
*1: If the cranking speed is fast, there may be compression loss.
B -- CHECK AND REPAIR ENGINE ASSEMBLY
A -- Continue to next step.
33. INSPECT BATTERY
(a) Inspect the battery Testing and Inspection.
NG -- CHARGE OR REPLACE BATTERY
OK -- Continue to next step.
34. 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 -- CHECK AND REPAIR ENGINE ASSEMBLY
OK -- INSPECT STARTER Testing and Inspection
35. INSPECT FUEL INJECTOR
(a) Using a sound scope or screwdriver, check for an injector operating sound while cranking the engine.
OK:
Fuel injector operating sound is heard.
NG -- READ VALUE USING TECHSTREAM (ENGINE SPEED)
OK -- Continue to next step.
36. CHECK FUEL PRESSURE
(a) Inspect the fuel pressure Fuel System.
NG -- PERFORM ACTIVE TEST USING TECHSTREAM (CONTROL THE FUEL PUMP / SPEED)
OK -- Continue to next step.
37. CHECK SPARK PLUG AND SPARK
(a) Check for sparks Testing and Inspection.
NG -- INSPECT SPARK PLUG
OK -- Continue to next step.
38. 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 69, perform fuel system troubleshooting C (steps 70 to 73).
B -- INSPECT FUEL INJECTOR
C -- CHECK MALFUNCTION CONDITION
A -- Continue to next step.
39. 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
HINT
- If the engine cannot be started, check the fuel pressure after cranking the engine.
- *1: From step 69, perform fuel system troubleshooting C (steps 70 to 73).
A -- CHECK MALFUNCTION CONDITION
B -- REPLACE FUEL PRESSURE REGULATOR Removal
40. INSPECT FUEL INJECTOR
(a) 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.
- *1: From step 69, perform fuel system troubleshooting C (steps 70 to 73).
B -- CHECK MALFUNCTION CONDITION
A -- REPLACE FUEL INJECTOR Removal
41. 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.
42. READ VALUE USING TECHSTREAM (ENGINE SPEED)
(a) Connect the Techstream to the DLC3.
(b) Turn the ignition switch to ON.
(c) Using the Techstream, select [Engine Speed] of the Data List.
(d) Start the engine.
(e) 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 P0335
OK -- Continue to next step.