Part 7

2ZR-FE ENGINE CONTROL: SFI SYSTEM: P1604; Startability Malfunction; 2013 MY Corolla [07/2012 -]
P1604 - Startability Malfunction

70. 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:

HINT
* If the engine cannot be started, check the fuel pressure after cranking the engine.
* *: From step 73, perform fuel system troubleshooting A (steps 100 to 107), fuel system troubleshooting B (steps 108 to 110), intake system troubleshooting (steps 111 to 113), and ignition system troubleshooting (steps 114 to 122), in that order.

B -- CHECK MALFUNCTION CONDITION

A -- REPLACE PRESSURE REGULATOR Removal

71. 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 4000 ppm or higher, a fuel injector may have a sealing problem.
* *: From step 73, perform fuel system troubleshooting A (steps 100 to 107), fuel system troubleshooting B (steps 108 to 110), intake system troubleshooting (steps 111 to 113), and ignition system troubleshooting (steps 114 to 122), in that order.

B -- CHECK MALFUNCTION CONDITION

A -- REPLACE FUEL INJECTOR ASSEMBLY Removal

72. 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 and ECT / 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.
* 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 73 and perform fuel system troubleshooting A (steps 100 to 107), fuel system troubleshooting B (steps 108 to 110), intake system troubleshooting (steps 111 to 113), and ignition system troubleshooting (steps 114 to 122), in that order.

B -- CHECK FUEL PUMP CONTROL CIRCUIT Fuel Pump Control Circuit

A -- REPAIR OR REPLACE FUEL LINE

73. CHECK MALFUNCTION CONDITION

(a) If the malfunction could not be identified during the inspection in steps 38, 39, 40 and 47, perform fuel system troubleshooting C (steps 74 to 79).

Result:

(b) If the malfunction could not be identified during the inspection in step 45, perform ignition system troubleshooting (steps 80 to 88).

Result:

(c) If the malfunction could not be identified during the inspection in steps 55, 56 and 57, perform intake air system troubleshooting (steps 89 to 91). If engine starting trouble still occurs, perform fuel system troubleshooting A (steps 92 to 99).

Result:

(d) If the malfunction could not be identified during the inspection in steps 58, 59, 60, 61, 64, 65, 66, 68, 69, 70, 71, 72, perform fuel system troubleshooting A (steps 100 to 107), fuel system troubleshooting B (steps 108 to 110), intake air system troubleshooting (steps 111 to 113), and ignition system troubleshooting (steps 114 to 122), 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.

74. INSPECT FUEL INJECTOR ASSEMBLY

(a) Inspect the fuel injectors assembly Testing and Inspection.

NG -- REPLACE FUEL INJECTOR ASSEMBLY Removal
OK -- Continue to next step.

75. CHECK FUEL INJECTOR ASSEMBLY (POWER SOURCE VOLTAGE)

(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 -- CHECK FUEL INJECTOR CIRCUIT Fuel Injector Circuit
OK -- Continue to next step.

76. CHECK HARNESS AND CONNECTOR (FUEL INJECTOR ASSEMBLY - ECM)

(a) Disconnect the fuel injector assembly 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.

(d) Reconnect the ECM connector.

(e) Reconnect the fuel injector assembly connector.

NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- Continue to next step.

77. 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 (FOR INTAKE CAMSHAFT)

OK -- END (CRANKSHAFT POSITION SENSOR WAS DEFECTIVE)

78. CHECK CAMSHAFT POSITION SENSOR (FOR INTAKE CAMSHAFT)

(a) Replace the camshaft position sensor (for intake camshaft) Removal.

(b) Check the engine start operation.

OK:

Malfunction has been repaired successfully.

NG -- CHECK CAMSHAFT POSITION SENSOR (FOR EXHAUST CAMSHAFT)

OK -- END (CAMSHAFT POSITION SENSOR (FOR INTAKE CAMSHAFT) WAS DEFECTIVE)

79. CHECK CAMSHAFT POSITION SENSOR (FOR EXHAUST CAMSHAFT)

(a) Replace the camshaft position sensor (for exhaust camshaft) Removal.

(b) Check the engine start operation.

OK:

Malfunction has been repaired successfully.

NG -- REPLACE ECM Removal

OK -- END (CAMSHAFT POSITION SENSOR (FOR EXHAUST CAMSHAFT) IS DEFECTIVE)

80. 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 CRANKSHAFT POSITION SENSOR Installation
OK -- Continue to next step.

81. CHECK SENSOR INSTALLATION (CAMSHAFT POSITION SENSOR (FOR INTAKE CAMSHAFT))

(a) Check the tightening and installation condition of the camshaft position sensor (for intake camshaft) bolt.

(b) Check the connection of the camshaft position sensor (for intake camshaft) connector.

OK:

Sensor is installed correctly.

NG -- SECURELY REINSTALL CAMSHAFT POSITION SENSOR (FOR INTAKE CAMSHAFT) Installation
OK -- Continue to next step.

82. CHECK SENSOR INSTALLATION (CAMSHAFT POSITION SENSOR (FOR EXHAUST CAMSHAFT))

(a) Check the tightening and installation condition of the camshaft position sensor (for exhaust camshaft) bolt.

(b) Check the connection of the camshaft position sensor (for exhaust camshaft) connector.

OK:

Sensor is installed correctly.

NG -- SECURELY REINSTALL CAMSHAFT POSITION SENSOR (FOR EXHAUST CAMSHAFT) Installation
OK -- Continue to next step.

83. 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 malfunction that do not always occur.
* Make sure there is not an excessive amount of force applied to the wire harness.

(d) Reconnect the ECM connector.

(e) Reconnect the camshaft position sensor (for intake camshaft) connector.

NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- Continue to next step.

85. CHECK HARNESS AND CONNECTOR (CAMSHAFT POSITION SENSOR (FOR EXHAUST CAMSHAFT) - ECM)

(a) Disconnect the camshaft position sensor (for exhaust camshaft) 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 malfunction that do not always occur.
* Make sure there is not an excessive amount of force applied to the wire harness.

(d) Reconnect the ECM connector.

(e) Reconnect the camshaft position sensor (for exhaust camshaft) connector.

NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR
OK -- Continue to next step.

86. 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 (FOR INTAKE CAMSHAFT)

OK -- END (CRANKSHAFT POSITION SENSOR WAS DEFECTIVE)