Part 4
2AZ-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: P1604: Startability Malfunction
P1604 - Startability Malfunction
68. 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.
- Check if the vehicle ran out of fuel, as engine starting trouble due to running out of fuel is also detected.
- If there are no fuel leaks, after inspecting the fuel pump control system, check if engine starting trouble occurs again. If engine starting trouble still occurs, proceed to step 69 and perform fuel system troubleshooting A (steps 91 to 98), fuel system troubleshooting B (steps 99 to 101), intake system troubleshooting (steps 102 to 104), and ignition system troubleshooting (steps 105 to 110), in that order.
B -- CHECK FUEL PUMP CONTROL CIRCUIT Fuel Pump Control Circuit
A -- REPAIR OR REPLACE FUEL LINE
69. CHECK MALFUNCTION CONDITION
(a) If the malfunction could not be identified during the inspection in steps 38, 39, 40 and 46, perform fuel system troubleshooting C (steps 70 to 73).
Result
(b) If the malfunction could not be identified during the inspection in step 44, perform ignition system troubleshooting (steps 74 to 79).
Result
(c) If the malfunction could not be identified during the inspection in steps 53 and 54, perform intake air system troubleshooting (steps 80 to 82). If engine starting trouble still occurs, perform fuel system troubleshooting A (steps 83 to 90).
Result
(d) If the malfunction could not be identified during the inspection in steps 55, 56, 57, 58, 61, 62, 64, 65, 66, 67 and 68, perform fuel system troubleshooting A (steps 91 to 98), fuel system troubleshooting B (steps 99 to 101), intake air system troubleshooting (steps 102 to 104), and ignition system troubleshooting (steps 105 to 110), in that order.
Result
B -- CHECK SENSOR INSTALLATION (CRANKSHAFT POSITION SENSOR)
C -- READ VALUE USING TECHSTREAM (ISC LEARNING VALUE)
D -- CHECK FUEL PRESSURE
A -- Continue to next step.
70. INSPECT FUEL INJECTOR
(a) Inspect the fuel injectors Testing and Inspection.
NG -- REPLACE FUEL INJECTOR Removal
OK -- Continue to next step.
71. 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.
72. CHECK CRANKSHAFT POSITION SENSOR
(a) Replace the crankshaft position sensor Removal.
(b) Check the engine start operation.
OK:
Malfunction has been repaired successfully.
NG -- CHECK CAMSHAFT POSITION SENSOR
OK -- END (CRANKSHAFT POSITION SENSOR IS DEFECTIVE)
73. CHECK 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)
74. 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
OK -- Continue to next step.
75. 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
OK -- Continue to next step.
76. 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.
77. 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.
78. CHECK CRANKSHAFT POSITION SENSOR
(a) Replace the crankshaft position sensor Removal.
(b) Check the engine start operation.
OK:
Malfunction has been repaired successfully.
NG -- CHECK CAMSHAFT POSITION SENSOR
OK -- END (CRANKSHAFT POSITION SENSOR IS DEFECTIVE)
79. CHECK 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)
80. READ VALUE USING TECHSTREAM (ISC LEARNING VALUE)
(a) Connect the Techstream to the DLC3.
(b) Turn the ignition switch to ON and turn the Techstream on.
(c) Start the engine and warm it up until the engine coolant temperature stabilizes with the A/C switch and all the accessory switches turned off
(d) Using the Techstream, select and read [ISC Learning Value] in the Data List.
Result
B -- INSPECT ENGINE COOLANT TEMPERATURE SENSOR
A -- Continue to next step.
81. CHECK CYLINDER COMPRESSION PRESSURE
(a) Inspect the compression On-Vehicle Inspection.
NG -- CHECK AND REPAIR ENGINE ASSEMBLY
OK -- CHECK VALVE TIMING P0011
82. 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.
83. 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.
84. READ VALUE USING TECHSTREAM (LONG FT #1)
(a) Connect the Techstream to the DLC3.
(b) Turn the ignition switch to ON.
(c) Using the Techstream, select and read [Long FT #1] in the Data List.
Result
B -- REPLACE FUEL INJECTOR Removal
A -- Continue to next step.
85. 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.
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
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.
(b) Check the engine start operation.
OK:
Malfunction has been repaired successfully.
NG -- REPLACE ECM Removal
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) 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 -- INSPECT FUEL PUMP
A -- REPAIR OR REPLACE FUEL LINE
90. 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 FUEL PRESSURE REGULATOR Removal
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 after stopping the engine.
Result
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) Using the Techstream, select and read [Long FT #1] in the Data List.
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 SENSOR Installation
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.
(b) Check the engine start operation.
OK:
Malfunction has been repaired successfully.
NG -- REPLACE ECM Removal
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) 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 -- 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 -- Continue to next step.
99. CHECK PURGE VSV
(a) Disconnect the vacuum hose (on the canister side) of the purge VSV.
Text in Illustration
(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.
100. 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
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) Using the Techstream, select and read [ISC Learning Value] in the Data List.
Result
B -- INSPECT ENGINE COOLANT TEMPERATURE SENSOR
A -- Continue to next step.
103. CHECK CYLINDER COMPRESSION PRESSURE
(a) Inspect the compression On-Vehicle Inspection.
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.
NG -- REPLACE ENGINE COOLANT TEMPERATURE SENSOR Removal
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
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
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.
(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.
(b) Check the engine start operation.
OK:
Malfunction has been repaired successfully.
NG -- REPLACE ECM Removal
OK -- END (CAMSHAFT POSITION SENSOR IS DEFECTIVE)