Part 5

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

93. 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.
* 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 ASSEMBLY

A -- REPAIR OR REPLACE FUEL LINE

94. INSPECT FUEL PUMP ASSEMBLY

(a) Inspect the fuel pump assembly Inspection.

HINT
* Make sure there is no foreign matter such as iron particles on the fuel pump assembly 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 ASSEMBLY Removal

OK -- REPLACE FUEL PRESSURE REGULATOR ASSEMBLY Disassembly

95. 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 after stopping the engine.

Result

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

96. 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.

97. 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.

98. 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.

99. 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):

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.

100. 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)

101. 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.
* 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 ASSEMBLY

A -- REPAIR OR REPLACE FUEL LINE

102. INSPECT FUEL PUMP ASSEMBLY

(a) Inspect the fuel pump assembly Inspection.

HINT
* Make sure there is no foreign matter such as iron particles on the fuel pump assembly 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 ASSEMBLY Removal
OK -- Continue to next step.

103. CHECK PURGE VALVE

(a) Disconnect the vacuum 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 vacuum 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 -- INSPECT PURGE VALVE Testing and Inspection
OK -- Continue to next step.

104. 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.

B -- CHECK INTAKE VALVE

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

105. 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

106. 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 / Data List / ISC Learning Value.

Result

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

107. CHECK CYLINDER COMPRESSION PRESSURE

(a) Inspect the compression Engine.

NG -- REPAIR OR REPLACE ENGINE ASSEMBLY

OK -- ADJUST VALVE TIMING Installation

108. 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.

109. 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.

110. 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.

111. 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):

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.

114. 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)

115. 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)