Part 1
FA20 ENGINE CONTROL: SFI SYSTEM: P1603; Engine Stall History; 2013 MY FR-S [03/2012 -]
P1603 - Engine Stall History
DESCRIPTION
After starting the engine, this DTC is stored when the engine stops without the ignition switch being operated.
Using the Techstream, the conditions present when the DTC was stored can be confirmed by referring to the freeze frame data. Freeze frame data records engine conditions when a malfunction occurs. This information can be useful when troubleshooting.
It is necessary to check if the vehicle has run out of fuel before performing troubleshooting, as this DTC is also stored when the engine stalls due to running out of fuel.
INSPECTION PROCEDURE
HINT
* In contrast to normal malfunction diagnosis for components, circuits and systems, DTCs P1603 is used to determine the malfunctioning area from the problem symptoms and freeze frame data when the user mentions problems such as engine stall.
As these DTCs can be stored as a result of certain user actions, even if these DTCs are output, if the customer makes no mention of problems, clear these DTCs without performing any troubleshooting and return the vehicle to the customer.
* If any other DTCs are output, perform troubleshooting for those DTCs first.
* Use any information from the customer problem analysis about the condition of the vehicle at the time when the problem occurred (how the engine stopped, conditions when the engine was restarted, etc.) as a reference.
* Read freeze frame data using the Techstream. Freeze frame data records engine conditions when a malfunction occurs. This information can be useful when troubleshooting.
* When confirming the freeze frame data, be sure to check all 5 sets of freeze frame data Freeze Frame Data.
* When confirming freeze frame data, if there are multiple items related to the cause of the malfunction, perform troubleshooting for all related items.
* Try to operate the vehicle under the conditions recorded in the freeze frame data which were present when the malfunction occurred. Confirm the data at this time and the data when the engine is idling (engine warmed up, no load, and shift lever in D, N or neutral) and compare these data with the freeze frame data.
* Inspections take into account the fact that the malfunction may not have reoccurred and place emphasis on checking the vehicle conditions present at the time when the malfunction occurred.
* When performing inspections, jiggle the relevant wire harnesses and connectors in an attempt to reproduce malfunctions that do not always occur.
Inspection flow:
Using freeze frame data, narrow down the parts to be inspected according to the vehicle conditions at the time when the malfunction occurred.
1:
* If the engine stalled when the intake air volume was low (during idling or deceleration), there may be a decrease in torque due to an incorrect air-fuel ratio, etc.
* If the engine stalled when the intake air volume was high (during driving or acceleration), there may be a major malfunction such as continuous misfire due to ignition stoppage, fuel injection stoppage, etc. and the torque drops to zero.
2:
* If the engine speed decreased slowly, there may have been a decrease in torque due to an air-fuel ratio that was incorrect (by approximately 20 to 30%), etc.
* If the engine speed decreased rapidly, there may have been a malfunction such as when the engine misfires almost continuously due to ignition stoppage, fuel injection stoppage, etc., or when the external load increases due to an external part malfunctioning.
3:
* If the air-fuel ratio is abnormal, there may have been an intake air leak, sensor malfunction, or fuel supply problem.
* If the vehicle was normal, the air volume may have been insufficient or the ignition timing may have been incorrect.
P1603 inspection flow: Narrow down the parts to be inspected according to the vehicle conditions at the time when the malfunction occurred (freeze frame data).
*: If the engine stalls immediately after the injection method is switched from port injection to direct injection, the injector driver (EDU) may be malfunctioning.
NOTICE:
Inspect the fuses for circuits related to this system before performing the following inspection procedure.
PROCEDURE
1. CHECK FOR ANY OTHER DTCS OUTPUT
(a) Connect the Techstream to the DLC3.
(b) Turn the ignition switch to ON.
(c) Read the DTCs Reading and Clearing Diagnostic Trouble Codes.
Result
HINT
If any DTCs other than P1603 are output, troubleshoot those DTCs first.
B -- GO TO DTC CHART SFI System
A -- Continue to next step.
2. CHECK 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.
OK:
Immobiliser Fuel Cut is OFF.
Result
B -- READ FREEZE FRAME DATA
A -- Continue to next step.
3. CHECK ENGINE IMMOBILISER SYSTEM
(a) Connect the Techstream to the DLC3.
(b) Start the engine.
(c) Idle the engine
(d) Enter the following menus: Powertrain / Engine / Data List / Immobiliser Communication and Immobiliser Fuel Cut.
(e) Check the Data List indication.
Result
NG -- CHECK ENGINE IMMOBILISER SYSTEM Initial Inspection and Diagnostic Overview
OK -- Continue to next step.
4. 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: A rapid decrease in engine speed may be caused by an electrical fault in the shared wiring of all or a number of cylinders, an increase in load from external parts, etc. The engine speed is considered to have decreased rapidly if either of the following conditions applies.
Otherwise, the engine speed is considered to have decreased slowly.
(1) In the freeze frame data, the decrease in engine speed from #3 to #5 is 400 rpm or more.
(2) In the freeze frame data, the engine speed at #5 is 120 rpm or less.
* If the vehicle speed is 30 km/h or less and the difference between Engine Speed and SPD (NT) is 100 rpm or less, inspect the automatic transmission. (Depending on the rate of vehicle deceleration, the engine speed may have decreased due to the A/T lock-up release being late.)
* *2: When a DTC is stored, feedback compensation increases because the air-fuel ratio is determined to be lean.
* *3: When a DTC is stored, feedback compensation decreases because the air-fuel ratio is determined to be rich.
B -- CHECK IGNITION SYSTEM
C -- CHECK IGNITION SYSTEM
D -- CHECK TERMINAL VOLTAGE (FUEL INJECTOR POWER SOURCE)
E -- CHECK FREEZE FRAME DATA
A -- Continue to next step.
5. CHECK INTAKE SYSTEM
(a) Check for air leakage in the intake system [vacuum hose disconnection, cracks, damaged gaskets, etc.] Intake System.
HINT
* If the accelerator pedal is released after racing the engine, the inspection is easier to perform because the vacuum inside the intake pipes increases and the air suction noise becomes louder.
* If Short FT and Long FT are largely different from the normal values when idling (the intake air volume is small) and almost the same as the normal values when racing the engine (the intake air volume is high), air leakage may be present.
OK:
There is no air leakage.
NG -- REPAIR OR REPLACE INTAKE SYSTEM
OK -- Continue to next step.
6. CHECK PURGE VALVE
(a) Disconnect the purge hose (on the canister side) of the purge valve.
(b) Start the engine.
(c) Idle the engine.
(d) Disconnect the connector of the purge valve.
(e) Check if air flows through the purge valve.
OK:
Air does not flow.
(f) Connect the connector of the purge valve.
(g) Connect the purge hose of the purge valve.
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 -- REPLACE PURGE VALVE Removal
OK -- Continue to next step.
7. 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
B -- CHECK IGNITION SYSTEM
A -- Continue to next step.
8. READ VALUE USING TECHSTREAM (SHORT FT)
(a) Connect the Techstream to the DLC3.
(b) Turn the ignition switch to ON.
(c) Start the engine and warm it up until the engine coolant temperature stabilizes.
HINT
The A/C switch and all accessory switches should be off.
(d) Idle the engine.
(e) Using the Techstream, read the value of Short FT #1 in the Data List while depressing the brake pedal.
Standard:
Short FT #1 changes by +10% or less.
HINT
When air leakage from the brake booster is present, the feedback compensation increases because the air-fuel ratio becomes lean.
NG -- INSPECT BRAKE BOOSTER ASSEMBLY Testing and Inspection
OK -- Continue to next step.
9. PERFORM DRIVE TEST
(a) Connect the Techstream to the DLC3.
(b) Start the engine and warm it up until the engine coolant temperature stabilizes.
HINT
The A/C switch and all accessory switches should be off.
(c) Idle the engine.
(d) Using the Techstream, read the value of Short FT #1 in the Data List.
Standard:
NG -- INSPECT BRAKE BOOSTER ASSEMBLY Testing and Inspection
OK -- Continue to next step.
10. CHECK IGNITION SYSTEM
(a) Perform ignition system On-vehicle Inspection Testing and Inspection.
NG -- REPAIR OR REPLACE MALFUNCTIONING PARTS, COMPONENT AND AREA
OK -- Continue to next step.
11. 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 mass air flow meter is malfunctioning and incorrectly measures the pressure to be less than the actual intake manifold pressure, the freeze frame data will show a low engine load value.
* *2: If the air fuel ratio sensor is malfunctioning and constantly outputs a value indicating the air-fuel ratio is lean, the actual air-fuel ratio will become rich and the engine may stall.
B -- PERFORM ACTIVE TEST USING TECHSTREAM (CONTROL THE INJECTION VOLUME FOR A/F SENSOR)
A -- Continue to next step.
12. CHECK MASS AIR FLOW METER
(a) Remove the mass air flow meter.
(b) Check for foreign matter in the airflow passage of the mass airflow meter.
Result
B -- REPLACE MASS AIR FLOW METER Removal
A -- Continue to next step.
13. CHECK HARNESS AND CONNECTOR (ECM - MASS AIR FLOW METER)
(a) Disconnect the ECM.
(b) Disconnect the mass air flow meter 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.
NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- Continue to next step.
14. PERFORM DRIVE TEST
(a) Connect the Techstream to the DLC3.
(b) Start the engine and warm it up until the engine coolant temperature stabilizes.
HINT
The A/C switch and all accessory switches should be off.
(c) Idle the engine.
(d) Using the Techstream, read the value of Calculate Load in the Data List.
Standard:
Result
B -- READ FREEZE FRAME DATA
A -- REPLACE MASS AIR FLOW METER Removal
15. PERFORM ACTIVE TEST USING TECHSTREAM (CONTROL THE INJECTION VOLUME FOR A/F SENSOR)
(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) Idle the engine.
(e) Enter the following menus: Powertrain / Engine / Active Test / Control the Injection Volume for A/F Sensor.
(f) Read the output voltage from the air fuel ratio sensor when increasing and decreasing the fuel injection volume.
Standard:
Result
HINT
The air fuel ratio sensor has an output delay of a few seconds and the heated oxygen sensor has a maximum output delay of approximately 20 seconds.
B -- READ FREEZE FRAME DATA
A -- Continue to next step.
16. CHECK TERMINAL VOLTAGE (AIR FUEL RATIO SENSOR POWER SOURCE)
(a) Disconnect the air fuel ratio sensor connector.
(b) Turn ignition switch to ON.
(c) Measure the voltage according to the value(s) in the table below.
Standard Voltage:
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 AIR FUEL RATIO SENSOR POWER SOURCE CIRCUIT
OK -- Continue to next step.
17. CHECK HARNESS AND CONNECTOR (AIR FUEL RATIO SENSOR - ECM)
(a) Disconnect the ECM.
(b) Disconnect the air fuel ratio sensor 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.
NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- Continue to next step.
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: A long time had elapsed after stopping the engine.
* *2: A long time had not elapsed after stopping the engine.
B -- READ FREEZE FRAME DATA
A -- Continue to next step.
19. 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
This step is not directly related to engine stall.
B -- INSPECT ENGINE COOLANT TEMPERATURE SENSOR
C -- READ FREEZE FRAME DATA
A -- Continue to next step.
20. INSPECT THERMOSTAT
HINT
For the thermostat inspection, refer to the following procedures Testing and Inspection.
Result
B -- INSPECT ENGINE COOLANT TEMPERATURE SENSOR
A -- REPLACE THERMOSTAT Removal