Part 4

FA20 ENGINE CONTROL: SFI SYSTEM: P1604; Startability Malfunction; 2013 MY FR-S [03/2012 -]
P1604 - Startability Malfunction (Continued)

70. CHECK FUEL INJECTOR ASSEMBLY (FOR PORT INJECTION)

(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 4000 ppm or more, a fuel injector assembly may have a sealing problem.
* *1: From step 72, perform fuel system troubleshooting A (steps 95 to 102), fuel system troubleshooting B (steps 103 to 105), intake system troubleshooting (steps 106 to 108), and ignition system troubleshooting (steps 109 to 115), in that order.

B -- CHECK MALFUNCTION CONDITION

A -- REPLACE FUEL INJECTOR ASSEMBLY (FOR PORT INJECTION) Removal

71. 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) Enter the following menus: Powertrain / Engine / 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.
* 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 circuit, check if engine starting trouble occurs again. If engine starting trouble still occurs, proceed to step 72 and perform fuel system troubleshooting A (steps 95 to 102), fuel system troubleshooting B (steps 103 to 105), intake system troubleshooting (steps 106 to 108), and ignition system troubleshooting (steps 109 to 114), in that order.

B -- CHECK FUEL PUMP CONTROL CIRCUIT (LOW PRESSURE SIDE) Fuel Pump Control Circuit

A -- REPAIR OR REPLACE FUEL LINE

72. CHECK MALFUNCTION CONDITION

(a) If the malfunction could not be identified during the inspections in steps 38, 39, 40 and 47, perform fuel system troubleshooting C (steps 73 to 76).

Result

(b) If the malfunction could not be identified during the inspection in step 45, perform ignition system troubleshooting (steps 77 to 83).

Result

(c) If the malfunction could not be identified during the inspections in steps 55, 56 and 57, perform intake air system troubleshooting (steps 84 to 86). If engine starting trouble still occurs, perform fuel system troubleshooting A (steps 87 to 94).

Result

(d) If the malfunction could not be identified during the inspections in steps 58, 59, 60, 63, 64, 66, 67, 68, 70 and 71, perform fuel system troubleshooting A (steps 95 to 102), fuel system troubleshooting B (steps 103 to 105), intake air system troubleshooting (steps 106 to 108), and ignition system troubleshooting (steps 109 to 115), in that order.

Result

B -- CHECK CRANKSHAFT POSITION SENSOR

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

D -- CHECK FUEL PRESSURE (LOW PRESSURE SIDE)
A -- Continue to next step.

73. INSPECT FUEL INJECTOR ASSEMBLY (FOR PORT INJECTION)

(a) Inspect the fuel injector assemblies (for port injection) Fuel Injector (For Port Injection).

NG -- REPLACE FUEL INJECTOR ASSEMBLY (FOR PORT INJECTION) Removal
OK -- Continue to next step.

74. CHECK TERMINAL VOLTAGE (FUEL INJECTOR POWER SOURCE)

(a) Disconnect the fuel injector assembly connectors.

(b) Turn the 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 FUEL INJECTOR POWER SOURCE CIRCUIT
OK -- Continue to next step.

75. 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 VVT SENSOR

OK -- END (CRANKSHAFT POSITION SENSOR IS DEFECTIVE)

76. CHECK VVT SENSOR

(a) Replace the VVT sensor Removal.

(b) Check the engine start operation.

OK:

Malfunction has been repaired successfully.

NG -- REPLACE ECM Removal

OK -- END (VVT SENSOR IS DEFECTIVE)

77. CHECK 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.

78. CHECK VVT SENSOR

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

(b) Check the connection of the VVT sensor connector.

OK:

Sensor is installed correctly.

NG -- SECURELY REINSTALL SENSOR Installation
OK -- Continue to next step.

79. 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):

(b) Measure the voltage according to the value(s) in the table below.

Standard Voltage:

(c) Disconnect the ECM connector.

(d) Measure the resistance according to the value(s) in the table below.

Standard Resistance (Check for open):

Standard Resistance (Check for short):

(b) Measure the voltage according to the value(s) in the table below.

Standard Voltage:

(c) Disconnect the ECM connector.

(d) Measure the resistance according to the value(s) in the table below.

Standard Resistance (Check for open):

Standard Resistance (Check for short):

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

85. CHECK CYLINDER COMPRESSION PRESSURE

(a) Inspect the compression Engine.

NG -- REPAIR OR REPLACE ENGINE ASSEMBLY

OK -- ADJUST VALVE TIMING Installation

86. 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.

87. CHECK FUEL PRESSURE (LOW PRESSURE SIDE)

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.

Result

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

88. READ VALUE USING TECHSTREAM (LONG FT)

(a) Connect the Techstream to the DLC3.

(b) Turn the ignition switch to ON.

(c) Enter the following menus: Powertrain / Engine / Data List / Long FT.

Result

B -- REPLACE FUEL INJECTOR ASSEMBLY (FOR PORT INJECTION) Removal
A -- Continue to next step.

89. PERFORM SIMULATION TEST

(a) Check if the idling speed is stable after starting the engine and if an unstable idling speed has ever occurred 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.

90. CHECK 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 Removal
OK -- Continue to next step.

91. 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):