Part 2
2GR-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: P1604: Startability Malfunction
P1604 - Startability Malfunction- (Continued)
12. CHECK HARNESS AND CONNECTOR (FUEL INJECTOR ASSEMBLY POWER SOURCE)
(a) Disconnect the fuel injector assembly connector.
(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.
(d) Reconnect the fuel injector assembly connector.
NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR (FUEL INJECTOR ASSEMBLY - IG2 RELAY)
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) Turn the Techstream on.
(d) Enter the following menus: Powertrain / Engine / Active Test / Control the Fuel Pump/Speed.
(e) 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
*: Compression loss may have occurred in the engine assembly.
B -- INSPECT FUEL INJECTOR ASSEMBLY
C -- CHECK AND REPAIR ENGINE ASSEMBLY
D -- READ FREEZE FRAME DATA
A -- REPLACE ENGINE COOLANT TEMPERATURE SENSOR
16. INSPECT FUEL INJECTOR ASSEMBLY
(a) Check that no carbon is stuck to the fuel injector assembly.
OK:
No carbon present.
NG -- REPLACE FUEL INJECTOR ASSEMBLY 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 assembly.
*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 -- CHECK FUEL INJECTOR ASSEMBLY
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, 21 psi) or higher (5 minutes after stopping the engine)
HINT
If the engine cannot be started, read the values after cranking the engine.
Result
B -- PERFORM SIMULATION TEST
A -- REPLACE PRESSURE REGULATOR
20. CHECK FUEL INJECTOR ASSEMBLY
(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 assembly may have a sealing problem.
B -- CHECK THROTTLE BODY
A -- Continue to next step.
21. CHECK FUEL INJECTOR ASSEMBLY
(a) Inspect the fuel injectors Testing and Inspection.
Result:
B -- CHECK THROTTLE BODY
A -- REPLACE FUEL INJECTOR ASSEMBLY Removal
22. CHECK 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.
OK:
No leaks 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 -- CHECK MALFUNCTION CONDITION
A -- END
25. CHECK MALFUNCTION CONDITION
(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 -- CHECK FUEL INJECTOR ASSEMBLY
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
*: The battery may be fully depleted or there may be excess engine friction.
B -- CHECK STARTER ASSEMBLY
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 ASSEMBLY Testing and Inspection
29. CHECK STARTER ASSEMBLY
(a) Remove the starter assembly Removal.
(b) Check for starter pinion gear wear and damage.
Standard:
There is no wear or damage.
(c) Install the starter assembly.
NG -- REPLACE STARTER ASSEMBLY Removal
OK -- REPLACE 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 ASSEMBLY
(a) Inspect the starter assembly Testing and Inspection.
Result:
B -- CHECK STARTER SIGNAL CIRCUIT SFI System
C -- REPLACE STARTER ASSEMBLY Removal
A -- CHECK CRANKING HOLDING FUNCTION CIRCUIT Cranking Holding Function Circuit
32. PERFORM SIMULATION TEST
(a) Check the cranking speed.
Result:
HINT
*: 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 -- REPAIR OR REPLACE ENGINE ASSEMBLY
OK -- INSPECT STARTER ASSEMBLY Testing and Inspection
35. CHECK FUEL INJECTOR ASSEMBLY
(a) Using a sound scope or screwdriver, check for an fuel injector assembly operating noise while cranking the engine.
OK:
Fuel injector assembly operating noise 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 On-Vehicle Inspection.
NG -- CHECK SPARK PLUG
OK -- Continue to next step.