SFI SYSTEM, Diagnostic DTC:P1604

DTC Code DTC Name
P1604 Startability Malfunction

DESCRIPTION

This DTC is stored when the engine does not start even though the STA signal is input or when the engine takes a long time to start, and when the engine speed is low or the engine stalls just after the engine starts.

Using the intelligent tester, 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 ran out of fuel before performing troubleshooting, as this DTC is also stored when there is engine starting trouble due to running out of fuel.

DTC No. DTC Detection Condition Trouble Area
P1604

Either of the following conditions is met.

(1 trip detection logic):


  • (a) The engine speed is below 500 rpm with the STA signal on for a certain amount of time (refer to the illustration below).*1

  • (b) After the engine starts (engine speed is 500 rpm or more), the engine speed drops to 200 rpm or less within approximately 2 seconds.*2

  • Engine immobiliser system

  • Engine assembly (excess friction, compression loss)

  • Starter assembly

  • Crankshaft position sensor

  • Engine coolant temperature sensor

  • Fuel pump

  • Fuel pump control system

  • Fuel line (fuel filter, pipes and hoses)

  • Fuel injector assembly

  • Throttle body with motor assembly

  • Fuel pressure regulator assembly

  • Battery

  • Drive plate and ring gear sub-assembly*3

  • Flywheel sub-assembly*4

  • Spark plug

  • Ignition coil circuit

  • Intake system

  • Camshaft timing oil control valve assembly

  • Mass air flow meter

  • Air fuel ratio sensor

  • Valve timing

  • Fuel

  • Purge VSV

  • EGR system

  • Intake valve

  • Exhaust valve

  • ECM

  • Wire harness or connector

A01VM02E01

  1. Reference waveforms showing a normal cold engine start

    A01VHD2

  2. Reference waveforms showing a normal warm engine start

    A01VKPQ

  3. Reference values when there is an air leak in the intake system during starting difficulty

    Freeze Frame Data P1604 Startability Malfunction
    Engine and ECT
    Current P1604: Startability Malfunction
    Time Freeze Frame Data
    Item Data1 Data2 Data3 Data4 Data5 Unit
    Engine Speed 1497 794 334 249 249 rpm
    Calculate Load 34.5 28.2 32.1 87.8 87.4 %
    Vehicle Load 8.6 21.9 15.6 7.4 5.8 %
    MAF 1.70 2.31 0.70 0.25 0.20 gm/sec
    Atmosphere Pressure 101 101 101 101 101 kPa
    MAP 73 90 98 99 99 kPa
    Coolant Temp 75 75 75 75 75 °C
    Intake Air 34 34 33 33 33 °C
    Ambient Temperature 19 19 19 19 19 °C
    Battery Voltage 13.222 13.015 12.343 12.343 12.343 V
    Throttle Sensor Volt % 16.0 17.6 17.2 15.6 15.6 %
    Throttle Sensor #2 Volt % 48.2 50.1 49.4 47.8 47.8 %
    Throttle Sensor Position 0.0 0.0 0.0 0.0 0.0 %
    Throttle Motor DUTY 16.0 17.6 17.6 15.6 15.6 %
    Injector (Port) 3206 2560 2560 2560 2560 μs
    Injection Volume (Cylinder 1) 0.152 0.152 0.152 0.152 0.152 ml
    Fuel Pump/Speed Status ON ON ON ON ON
    EVAP (Purge) VSV 0.0 0.0 0.0 0.0 0.0 %
    Evap Purge Flow 0.0 0.0 0.0 0.0 0.0 %
    Purge Density Learn Value 0.000 0.000 0.000 0.000 0.000
    EVAP Purge VSV OFF OFF OFF OFF OFF
    Target Air-Fuel Ratio 0.830 0.841 0.871 0.799 0.799
    AF Lambda B1 S1 1.014 1.016 1.021 1.022 1.027
    AFS Voltage B1 S1 3.368 3.385 3.403 3.417 3.422 V
    O2S B1 S2 0.823 0.315 0.070 0.055 0.035 V
    Short FT #1 0.000 0.000 0.000 0.000 0.000 %
    Long FT #1 0.000 -4.015 -4.687 -4.687 -4.687 %
    Total FT #1 -0.043 -0.043 -0.043 -0.043 -0.043
    Fuel System Status #1 OL OL OL OL OL
    IGN Advance -4.0 2.0 4.0 0.0 0.0 deg
    Knock Feedback Value -3.0 -3.0 -3.0 -3.0 -3.0 CA
    Knock Correct Learn Value 14.0 14.0 14.0 14.0 14.0 CA
    EGR Step Position 0 0 0 0 0 step
    VVT Control Status #1 OFF OFF OFF OFF OFF
    Starter Signal Close Close Close Close Close

WIRING DIAGRAM

Refer to DTC P0031 for the air fuel ratio sensor circuit Click here.

Refer to DTC P0102 for the mass air flow meter circuit Click here.

Refer to DTC P0115 for the engine coolant temperature sensor circuit Click here.

Refer to DTC P0335 for the crankshaft position sensor and camshaft position sensor circuit Click here.

Refer to Fuel Pump Control Circuit Click here.

Refer to Fuel Injector Circuit Click here.

Refer to Ignition Circuit Click here.

CAUTION / NOTICE / HINT

Tech Tips


  • In contrast to normal malfunction diagnosis for components, circuits and systems, DTC P1604 is used to determine the malfunctioning area from the problem symptoms and freeze frame data when the user mentions problems such as starting difficulty.

    As the DTC can be stored as a result of certain user actions, even if the DTC is output, if the customer makes no mention of problems, clear the DTC without performing any troubleshooting and return the vehicle to the customer.

  • If any other DTCs are output, perform troubleshooting for those DTCs first.

  • When the Data List item "Immobiliser Fuel Cut" is ON, the engine cannot be started.

  • Read freeze frame data using the intelligent tester. 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 Click here.

  • 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 start the engine under the conditions recorded in the freeze frame data which were present when the malfunction occurred. Confirm the data at this time and compare it with the freeze frame data.

  • If the malfunction does not reoccur, carefully check the vehicle conditions from when the malfunction occurred using freeze frame data.

  • When performing inspections, jiggle the relevant wire harness and connectors in an attempt to reproduce malfunctions that do not always occur.

  • If the same inspection or replacement procedure appears 2 times when performing an inspection procedure, it is not necessary to repeat the procedure the second time.


  1. Malfunction Recurrence and Inspection Areas


    1. Freeze frame data exists, but the malfunction has not reoccurred and the malfunction conditions are unknown.


      1. The engine speed recorded in the freeze frame data is 0 rpm (the engine does not crank).

        Tech Tips

        One of the following problems may be present: battery depletion, excess engine friction, a starter malfunction or a crankshaft position sensor malfunction.


        • If the battery voltage is less than 6 V during cranking, there is a high probability that engine friction is abnormal.

        • If the battery voltage drops to 5 V or less when starting the engine, the battery may be malfunctioning.

        • If the battery voltage fluctuates while cranking the engine, it can be concluded that cranking is being performed. When the engine speed is 0 rpm, the crankshaft position sensor and/or an ECM may be malfunctioning.

        A01VIHVE28

      2. All engine speeds recorded in the freeze frame data are between 100 and 250 rpm (the engine cranks but there is no combustion).

        Tech Tips

        If the engine speed is between 100 and 250 rpm (no initial combustion), there may be a wiring problem or a complete failure of an ignition or fuel system part.


        • Due to an engine coolant temperature sensor malfunction, the fuel injection volume is extremely high or low and the engine may not be able to be started.

          A01VFN9E56

      3. The engine speed recorded in the freeze frame data is 250 rpm or higher (the initial combustion and starter turnoff occur late).

        Tech Tips

        If the engine speed is 250 rpm or higher (combustion occurs but the initial combustion and starter turnoff timing is too late), the fuel injection volume is often incorrect (too low or too high) and determining the cause of the malfunction is often difficult.


        • Due to an engine coolant temperature sensor malfunction, the fuel injection volume is extremely high or low and engine starting trouble may occur.

        • If Long FT is incorrect, there may be a fuel supply problem due to the injectors or fuel pump being clogged, etc.

        • If the engine cranking speed is high, compression loss may have occurred due to carbon interfering with the valve operation.

          A01VIHVE98

    2. When the malfunction (starting difficulty) can be reproduced, or malfunction conditions are known, perform the following inspections ("Problem symptoms" and "Systems to inspect").


      1. Problem symptoms


        1. The engine does not crank

          Tech Tips

          The starter assembly is normal if a noise that indicates the starter pinion gear is extending is heard. The battery may be fully depleted or there may be excess engine friction.

        2. The engine cranking speed is abnormal.

          Tech Tips

          If the engine cranking speed is high (for example, 300 rpm or higher with no combustion), compression loss may have occurred because carbon interfered with valve operation, etc.

        3. There is no initial combustion

          Tech Tips

          If there is no initial combustion, there is probably a wiring problem or an ignition or fuel system part malfunction.

        4. The engine stalls after starter turnoff.

          Tech Tips

          If the engine stalls after starter turnoff, the airfuel ratio may be incorrect or the VVT may have a problem returning.

        5. The initial combustion and starter turnoff occur late

          Tech Tips


          • If the initial combustion and starter turnoff occur late, the fuel injection volume is probably incorrect (too low or too high).

          • Causes of fuel system malfunctions according to conditions present at the time of the malfunction.


            • When 2 to 3 minutes have elapsed after stopping the engine: Fuel pressure loss due to the pressure regulator failing to maintain the fuel pressure.

            • When 15 to 120 minutes have elapsed after stopping the engine: Problem with injector fuel seal.

            • When a long time has elapsed after stopping the engine: pressure regulator is stuck open.

      2. Systems to inspect.


        1. Intake system

        2. Ignition system

        3. Fuel system

  2. INSPECTION FLOW


    1. Freeze frame data exists, but the malfunction has not reoccurred and the malfunction conditions are unknown.

      Freeze Frame Data Item Result Suspected Area Procedure
      Engine Speed 0 rpm (no engine cranking at all)

      • Battery fully depleted

      • Engine assembly (excess friction)

      • Starter assembly

      • Crankshaft position sensor

      • ECM

      		 4 to 9
      100 to 250 rpm (engine cranks but no initial combustion*1)

      • Fuel pump control system

      • Ignition system

      • Engine coolant temperature sensor

      • Fuel injection system

      		 10 to 14
      250 rpm or higher (combustion occurs but initial combustion and starter turnoff*2 occur late)

      • Engine assembly (compression loss)

      • Fuel injection system

      • Fuel pump control system

      		 15 to 23

      Tech Tips


      • *1: First combustion after cranking begins.

      • *2: Condition when engine speed increases and starter can be turned off.

    2. When vehicle conditions can be reproduced, or when malfunction conditions are known.


      1. Problem symptoms

        Problem Symptom Suspected Area Suspected Component Procedure
        The engine does not crank Battery malfunction Battery fully depleted 26 to 31
        Starting system

        • Starter (includes pinion ring wear or tooth damage)

        • Starter assembly
        Engine assembly

        • Engine assembly (excess friction)

        • Drive plate and ring gear sub-assembly wear or tooth damage*1

        • Flywheel sub-assembly wear or tooth damage*2
        Cranking speed too low Battery malfunction Battery fully depleted 33 to 34
        Starting system Starter assembly
        Engine assembly Engine assembly (excess friction)
        Cranking speed too high Engine assembly Engine assembly (compression loss)
        There is no initial combustion Fuel supply problem

        • Maintenance of fuel pressure by fuel pressure regulator assembly

        • Fuel injector assembly leak

        • Fuel leak from fuel line

        • Fuel pump control system

        • Fuel pump

        		 35 to 48
        Ignition system malfunction

        • Spark plug

        • Crankshaft position sensor

        • No. 1 ignition coil
        Engine stalls after starter turnoff Air suction

        • Intake system connections

        		 49 to 57
        Deposits in throttle body with motor assembly

        • Throttle body with motor assembly
        VVT valve does not return properly

        • Camshaft timing oil control valve assembly
        Mass air flow meter malfunction

        • Mass air flow meter
        EGR valve does not close properly

        • EGR valve assembly
        The initial combustion and starter turnoff occur late Engine coolant temperature sensor malfunction

        • Engine coolant temperature sensor

        		 58 to 71
        Mass air flow meter malfunction

        • Mass air flow meter
        Abnormal A/F learning value

        • Air fuel ratio sensor
        Deviation from fuel injection characteristics

        • Fuel injector assembly
        Wet-fouled or dry-fouled spark plug

        • Spark plug
        Lack of fuel pressure

        • Fuel pressure regulator assembly

        • Fuel pump

        • Fuel pump control system

        • *1: for CVT

        • *2: for Manual Transaxle

      2. Systems to inspect

        Problem Symptom Suspected Area Suspected Components Procedure
        Fuel system troubleshooting A Abnormal air fuel ratio learning value

        • Fuel injector assembly

        90 to 97

        98 to 105
        Rough idling

        • Crankshaft position sensor
        Abnormal fuel pressure

        • Fuel

        • Fuel leak from fuel line

        • Fuel pump

        • Fuel pressure regulator assembly
        Fuel system troubleshooting B Abnormal concentration of HC in surge tank

        • Purge VSV system

        • Fuel injector assembly

        		 106 to 108
        Fuel system troubleshooting C Injection signal system malfunction

        • Fuel injector assembly

        • Crankshaft position sensor

        • Camshaft position sensor

        • ECM

        		 73 to 77
        Intake system troubleshooting Difference between ISC target value and opening angle when idling

        • Engine assembly (compression loss)

        • Valve timing

        • Engine coolant temperature sensor

        • ECM

        87 to 89

        109 to 111
        Ignition system troubleshooting Camshaft and/or crankshaft position sensor signal malfunction

        • Crankshaft position sensor system (including sensor installation)

        • Camshaft position sensor system (including sensor installation)

        • ECM

        78 to 86

        112 to 120

    Note


    • Inspect the fuses for circuits related to this system before performing the following inspection procedure.

    • After turning ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work Click here.

PROCEDURE


  1. CHECK ANY OTHER DTCS OUTPUT AND RECORD FREEZE FRAME DATA (IN ADDITION TO DTC P1604)


    1. Connect the intelligent tester to the DLC3.

    2. Turn the ignition switch to ON.

    3. Turn the tester on.

    4. Enter the following menus: Powertrain / Engine and ECT / DTC.

    5. A01VJLAE46
      *a DTC is stored
      *b 0.5 seconds
      *c Freeze frame data recorded point

      Read DTCs and record the Freeze Frame Data.

      Tech Tips


      • This freeze frame data shows the actual engine conditions when engine starting trouble occurred.

      • When confirming the freeze frame data, be sure to check all 5 data sets of freeze frame data.

      • The fourth set of freeze frame data is the data recorded when the DTC is stored.

      Result
      Result Proceed to
      Only DTC P1604 is output A
      DTCs other than P1604 are output B

    B

    GO TO DTC CHART Click here

    A

  2. CHECK ENGINE IMMOBILISER SYSTEM


    1. Connect the Intelligent tester to the DLC3.

    2. Turn the ignition switch to ON.

    3. Turn the tester on.

    4. Enter the following menus: Powertrain / Engine and ECT / Data List / Immobiliser Fuel Cut.

    5. Read the value displayed on the tester.

      OK
      Immobiliser Fuel Cut is OFF

      Tech Tips


      • If the engine is started immediately after reconnecting the battery terminal, the engine may stall immediately after it starts due to the intercommunication process between each ECU. For this reason, when starting the engine after reconnecting the battery terminal, first turn the ignition switch to ON and then wait several seconds for the communication process to complete before starting the engine.

      • When this operation causes DTC P1604 to be stored, this is due to normal operation of the engine immobiliser system and does not indicate a malfunction, so clear the DTC and return the vehicle to the customer.

      Result
      Result Proceed to
      OK A
      NG (w/ Entry and Start System) B
      NG (w/o Entry and Start System) C

    B

    GO TO ENGINE IMMOBILISER SYSTEM (W/ ENTRY AND START SYSTEM) Click here

    C

    GO TO ENGINE IMMOBILISER SYSTEM (W/O ENTRY AND START SYSTEM) Click here

    A

  3. CHECK MALFUNCTION CONDITION


    1. Confirm the problem symptoms.

      Result
      Result Proceed to
      Freeze frame data exists, but the problem symptoms cannot be reproduced and the malfunction conditions are unknown A
      The problem symptoms can be reproduced, or the malfunction conditions are known B

    B

    PERFORM SIMULATION TEST Click here

    A

  4. READ FREEZE FRAME DATA


    1. Connect the intelligent tester to the DLC3.

    2. Turn the ignition switch to ON.

    3. Turn the tester on.

    4. Using the tester, confirm the vehicle conditions recorded in the freeze frame data which were present when the DTC was stored Click here.

      Result
      Freeze Frame Data Item Suspected Area Proceed to
      Engine Speed Battery Voltage
      All 5 sets of freeze frame data are 0 rpm (no engine cranking at all) Minimum voltage is less than 5 V Battery fully depleted A
      Minimum voltage is 5 V or higher

      • Starter malfunction

      • Crankshaft position sensor system

      • Excess engine friction

      • ECM

      		 B
      100 to 250 rpm (engine cranks but no initial combustion) -

      • Fuel pump control system

      • Ignition system

      • Engine coolant temperature sensor

      • Fuel injection system

      		 C
      250 rpm or higher (combustion occurs but initial combustion and starter turnoff occur late) -

      • Engine assembly

      • Engine coolant temperature sensor

      • Fuel injection system

      • Fuel pump control system

      		 D
      Result
      Freeze Frame Data Item Suspected Area Proceed to
      Low Rev for Eng Start
      ON exists

      • Intake system connections

      • Throttle body with motor assembly

      • Camshaft timing oil control valve assembly

      • Mass air flow meter

      • EGR valve assembly

      		 E

      Tech Tips

      When DTC P1604 is stored, either "Engine Start Hesitation"*1 or "Low Rev for Eng Start"*2 in the Freeze Frame Data will be ON. If "Low Rev for Eng Start" is ON, Proceed to E.


      • *1: This value turns ON when the engine speed does not reach a certain value for a certain period of time when starting the engine.

      • *2: This value turns ON when the engine stalls immediately after starting the engine. If "Low Rev for Eng Start" is ON, as there is a possibility that the low engine speed or engine stall was caused by the user, confirm the following freeze frame data items.


        • Immobiliser Fuel Cut

        • Engine Speed (Starter OFF)

        • Shift SW Status (R, D Range)


    A

    CHARGE OR REPLACE BATTERY

    C

    READ FREEZE FRAME DATA Click here

    D

    READ FREEZE FRAME DATA Click here

    E

    INSPECT MASS AIR FLOW METER Click here

    B

  5. READ FREEZE FRAME DATA


    1. Connect the intelligent tester to the DLC3.

    2. Turn the ignition switch to ON.

    3. Turn the tester on.

    4. Using the tester, confirm the vehicle conditions recorded in the freeze frame data which were present when the DTC was stored Click here.

      Result
      Freeze Frame Data Item Result Suspected Area Proceed to
      Battery Voltage Minimum voltage is 6 V or higher and voltage does not fluctuate*3 Starter system

      A*1

      B*2
      Minimum voltage is 6 V or higher and voltage fluctuates*4, *5

      • Crankshaft position sensor system

      • ECM

      		 C
      Minimum voltage is 5 to 6 V*6

      • Excess engine friction

      • Battery fully depleted

      		 D

      • *1: w/ Entry and Start System

      • *2: w/o Entry and Start System

      Tech Tips


      • A01VE6YE01
        *1 Freeze Frame Data
        *2 Voltage does not Fluctuate
        *3 Voltage Fluctuates

        *3: The 5 sets of freeze frame data show approximately the same battery voltage.

      • *4: The 5 sets of freeze frame data show different battery voltages.

      • *5: If the voltage fluctuates, it can be determined that cranking is being performed normally. When the engine speed is 0 rpm, the crankshaft position sensor system and/or the ECM may be malfunctioning.

      • *6: There may be excess engine friction. Make sure that the crankshaft rotates smoothly when turning it by hand. Excess engine friction may have occurred temporarily. Remove the cylinder head cover sub-assembly 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.


    A

    CHECK CRANKING HOLDING FUNCTION CIRCUIT Click here

    B

    CHECK STARTER SIGNAL CIRCUIT Click here

    D

    CHECK AND REPAIR ENGINE OR BATTERY

    C

  6. CHECK SENSOR INSTALLATION (CRANKSHAFT POSITION SENSOR)


    1. Check the tightening and installation condition of the crankshaft position sensor bolt.

    2. Check the connection of the crankshaft position sensor connector.

      OK
      Sensor is installed correctly.

    NG

    SECURELY REINSTALL SENSOR Click here

    OK

  7. CHECK CRANKSHAFT POSITION SENSOR


    1. Disconnect the B24 crankshaft position sensor connector.

    2. Check for oil on the connector terminals.

      OK
      No oil on the terminals.

    NG

    REPLACE CRANKSHAFT POSITION SENSOR Click here

    OK

  8. CHECK HARNESS AND CONNECTOR (CRANKSHAFT POSITION SENSOR - ECM)


    1. Check the harnesses and connectors, referring to DTC P0335 inspection procedure.

      Tech Tips


      • 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

  9. CHECK CRANKSHAFT POSITION SENSOR


    1. Replace the crankshaft position sensor Click here.

    2. Check the engine start operation.

      OK
      Malfunction has been repaired successfully.

    OK

    END (CRANKSHAFT POSITION SENSOR IS DEFECTIVE)

    NG

    REPLACE ECM Click here

  10. READ FREEZE FRAME DATA


    1. Connect the intelligent tester to the DLC3.

    2. Turn the ignition switch to ON.

    3. Turn the tester on.

    4. Using the tester, confirm the vehicle conditions recorded in the freeze frame data which were present when the DTC was stored Click here.

      Result
      Freeze Frame Data Item Suspected Area Proceed to
      Coolant Temp, Ambient Temperature, Intake Air Coolant Temp, Ambient Temperature Fuel Pump/Speed Status
      Difference between Coolant Temp, Ambient Temperature and Intake Air is 10°C (18°F) or more*1 Coolant Temp is 125°C (257°F) or more, or lower than Ambient Temperature by 15°C (27°F) or more - Engine coolant temperature sensor A
      Other than above All 5 sets of freeze frame data are ON - B
      At least 1 of the 5 sets of freeze frame data is OFF Fuel pump control system C
      Difference between Coolant Temp, Ambient Temperature and Intake Air is less than 10°C (18°F)*2 - At least 1 of the 5 sets of freeze frame data is OFF Fuel pump control system C
      All 5 sets of freeze frame data are ON - B

      Tech Tips


      • *1: A long time had not elapsed after stopping the engine.

      • *2: A long time had elapsed after stopping the engine.

      • Perform "Inspection After Repairs" after replacing the engine coolant temperature sensor Click here.


    A

    REPLACE ENGINE COOLANT TEMPERATURE SENSOR Click here

    C

    CHECK FUEL PUMP CONTROL CIRCUIT Click here

    B

  11. PERFORM ACTIVE TEST USING INTELLIGENT TESTER (CONTROL THE FUEL PUMP/SPEED)


    1. Connect the intelligent tester to the DLC3.

    2. Disconnect the connector from the fuel suction tube.

    3. Turn the ignition switch to ON.

    4. Turn the tester on.

    5. Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump/Speed.

    6. A01VL98E02
      Text in Illustration
      *a

      Front view of wire harness connector

      (to Fuel Pump)

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

      Standard Voltage
      Tester Connection Condition Specified Condition
      K17-4 - Body ground Active Test is being performed 11 to 14 V

      Tech Tips


      • 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

    CHECK FUEL PUMP CONTROL CIRCUIT Click here

    OK

  12. CHECK TERMINAL VOLTAGE (#10, #20, #30 AND /OR #40)


    1. A01VJ46E02
      Text in Illustration
      *A for LHD
      *B for RHD
      *a

      Front view of wire harness connector

      (to ECM)

      Disconnect the ECM connector.

    2. Turn the ignition switch to ON.

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

      Standard Voltage
      for LHD
      Tester Connection Switch Condition Specified Condition
      B22-20 (#10) - B22-51 (E01) Ignition switch ON 11 to 14 V
      B22-17 (#20) - B22-51 (E01) Ignition switch ON 11 to 14 V
      B22-18 (#30) - B22-51 (E01) Ignition switch ON 11 to 14 V
      B22-19 (#40) - B22-51 (E01) Ignition switch ON 11 to 14 V
      for RHD
      Tester Connection Switch Condition Specified Condition
      B23-20 (#10) - B23-51 (E01) Ignition switch ON 11 to 14 V
      B23-17 (#20) - B23-51 (E01) Ignition switch ON 11 to 14 V
      B23-18 (#30) - B23-51 (E01) Ignition switch ON 11 to 14 V
      B23-19 (#40) - B23-51 (E01) Ignition switch ON 11 to 14 V

      Tech Tips


      • 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

    CHECK FUEL INJECTOR CIRCUIT Click here

    OK

  13. PERFORM ACTIVE TEST USING INTELLIGENT TESTER (CONTROL THE FUEL PUMP/SPEED)


    1. Connect the intelligent tester to the DLC3.

    2. Turn the ignition switch to ON.

    3. Turn the tester on.

    4. Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump/Speed.

    5. When performing the Active Test, check for fuel leakage from the fuel pipes.

      Result
      Result Proceed to
      Fuel leakage or signs of fuel leakage are present A
      No fuel leakage or signs of fuel leakage B

      Tech Tips


      • Jiggle the fuel hose 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.


    A

    REPAIR OR REPLACE FUEL LINE

    B

  14. CHECK FUEL SYSTEM


    1. 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
      Result Proceed to
      There is foreign matter or signs that fuel pump was stuck A
      There is no foreign matter and no signs that fuel pump was stuck B

    A

    REPAIR OR REPLACE FUEL SYSTEM

    B

    PERFORM SIMULATION TEST Click here

  15. READ FREEZE FRAME DATA


    1. Connect the intelligent tester to the DLC3.

    2. Turn the ignition switch to ON.

    3. Turn the tester on.

    4. Using the tester, confirm the vehicle conditions recorded in the freeze frame data which were present when the DTC was stored Click here.

      Result
      Freeze Frame Data Item Suspected Area Proceed to
      Coolant Temp, Ambient Temperature, Intake Air Coolant Temp, Ambient Temperature Long FT #1 Engine Speed
      Difference between Coolant Temp, Ambient Temperature and Intake Air is 10°C (18°F) or more*1 Coolant Temp is 125°C (257°F) or more, or lower than Ambient Temperature by 15°C (27°F) or more - - Engine coolant temperature sensor A
      Other than above -15% or less, or +15% or more -

      • Fuel pump control system

      • Fuel injector assembly

      		 B
      -15 to +15% Minimum speed is 300 rpm or more*3 Engine assembly C
      Minimum speed is below 300 rpm

      • Fuel system

      • Intake air system

      		 D
      Difference between Coolant Temp, Ambient Temperature and Intake Air is less than 10°C (18°F)*2 - -15% or less, or +15% or more -

      • Fuel pump control system

      • Fuel injector assembly

      		 B
      -15 to +15% Minimum speed is 300 rpm or more*3 Engine assembly C
      Minimum speed is below 300 rpm

      • Fuel system

      • Intake air system

      		 D

      Tech Tips


      • *1: A long time had not elapsed after stopping the engine.

      • *2: A long time had elapsed after stopping the engine.

      • *3: Compression loss may have occurred in the engine assembly.

      • Perform "Inspection After Repairs" after replacing the engine assembly or engine coolant temperature sensor Click here.


    A

    REPLACE ENGINE COOLANT TEMPERATURE SENSOR Click here

    C

    CHECK AND REPAIR ENGINE ASSEMBLY

    D

    READ FREEZE FRAME DATA Click here

    B

  16. CHECK FUEL INJECTOR ASSEMBLY


    1. Check that no carbon is stuck to the fuel injector assembly.

      OK
      No carbon present.

      Tech Tips

      Perform "Inspection After Repairs" after replacing the fuel injector assembly Click here.


    NG

    REPLACE FUEL INJECTOR ASSEMBLY Click here

    OK

  17. CHECK FUEL SYSTEM


    1. 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
      Result Proceed to
      There is foreign matter or signs that fuel pump was stuck A
      There is no foreign matter and no signs that fuel pump was stuck B

      Tech Tips

      If there is foreign matter such as iron particles on the fuel pump, fuel filter or fuel tank, remove the foreign matter.


    A

    REPAIR OR REPLACE FUEL SYSTEM

    B

    PERFORM SIMULATION TEST Click here

  18. READ FREEZE FRAME DATA


    1. Connect the intelligent tester to the DLC3.

    2. Turn the ignition switch to ON.

    3. Using the tester, confirm the vehicle conditions recorded in the freeze frame data which were present when the DTC was stored Click here.

      Result
      Freeze Frame Data Item Result Suspected Area Proceed to
      Coolant Temp Engine coolant temperature is 40°C (104°F) or less*1 Fuel pressure regulator assembly A
      Engine coolant temperature is 40 to 90°C (104 to 194°F)*2 Fuel injector assembly B
      Engine coolant temperature is 90°C (194°F) or more*3 Fuel pressure regulator assembly A

      Tech Tips

      *1: If the engine coolant temperature is 40°C (104°F) or less (after stopping engine and vehicle not driven for a long period of time), the fuel pressure regulator assembly 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 the 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 fuel pressure regulator assembly 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 Click here

    A

  19. CHECK FUEL PRESSURE

    Tech Tips

    For the fuel pressure inspection, refer to the following procedures Click here.


    1. Attach a fuel pressure gauge and check the fuel pressure after stopping the engine.

      Standard
      147 kPa (1.5 kgf/cm2) or higher (5 minutes after stopping the engine)

      Tech Tips

      If the engine cannot be started, read the values after cranking the engine.

      Result
      Result Proceed to
      NG A
      OK B

    A

    REPLACE FUEL PRESSURE REGULATOR ASSEMBLY Click here

    B

    PERFORM SIMULATION TEST Click here

  20. CHECK FUEL INJECTOR ASSEMBLY


    1. Clean the inside of the surge tank with compressed air.

    2. After stopping the engine, measure the HC concentration inside the surge tank for 15 minutes.

      Result
      Result Proceed to
      4000 ppm or higher A
      Less than 4000 ppm B

      Tech Tips

      If the concentration is 4000 ppm or higher, the fuel injector assembly may have a sealing problem.


    B

    CHECK THROTTLE BODY WITH MOTOR ASSEMBLY Click here

    A

  21. INSPECT FUEL INJECTOR ASSEMBLY


    1. Inspect the fuel injector assembly Click here.

      Tech Tips

      Perform "Inspection After Repairs" after replacing the fuel injector assembly Click here.


    NG

    REPLACE FUEL INJECTOR ASSEMBLY Click here

    OK

  22. CHECK THROTTLE BODY WITH MOTOR ASSEMBLY


    1. Check if carbon is in the air flow passage.

      Result
      Result Proceed to
      No carbon present A
      Carbon in passage B

      Tech Tips

      Perform "Inspection After Repairs" after replacing the throttle body with motor assembly Click here.


    B

    CLEAN OR REPLACE THROTTLE BODY WITH MOTOR ASSEMBLY Click here

    A

  23. CHECK INTAKE SYSTEM


    1. Check the intake system for vacuum leak Click here.

      OK
      No leak from intake system.

      Tech Tips

      Perform "Inspection After Repairs" after repairing or replacing the intake system Click here.


    NG

    REPAIR OR REPLACE INTAKE SYSTEM

    OK

  24. PERFORM SIMULATION TEST


    1. Check if the engine can be started.

      Result
      Result Proceed to
      Engine cannot be started A
      Engine can be started B

    B

    END

    A

  25. PERFORM SIMULATION TEST


    1. Confirm the problem symptoms.

      Tech Tips

      The problem symptoms below can be determined by reading the freeze frame data.

      Result
      Problem Symptom Suspected Area Proceed to
      The engine does not crank

      • Battery fully depleted

      • Starter (includes pinion ring wear or tooth damage)

      • Starter system

      • Engine assembly (excess friction)

      • Drive plate and ring gear sub-assembly wear or tooth damage*1

      • Flywheel sub-assembly wear or tooth damage*2

      		 A
      Abnormal cranking speed

      • Battery fully depleted

      • Starter assembly

      • Engine assembly (excess friction, compression loss)

      		 B
      There is no initial combustion (combustion does not occur even once)*3

      • Fuel pressure of fuel pressure regulator assembly maintained

      • Fuel injector leak

      • Fuel leak from fuel line

      • Fuel pump control system

      • Fuel pump

      • Spark plug

      • Crankshaft position sensor system

      • No. 1 ignition coil

      • EGR valve assembly

      		 C
      The engine stalls after starter turnoff (engine stalls immediately after the first time the engine speed increases)*4

      • Intake system connections

      • Throttle body with motor assembly

      • Camshaft timing oil control valve assembly

      • Mass air flow meter system

      • EGR valve assembly

      		 D
      The initial combustion and starter turnoff occur late*5

      • Engine coolant temperature sensor

      • Mass air flow meter

      • Air fuel ratio sensor

      • Heated oxygen sensor

      • Fuel injector assembly

      • Spark plug

      • Fuel pressure regulator assembly

      • Fuel pump

      • Fuel pump control system

      		 E

      • *1: for CVT

      • *2: for Manual Transaxle

      Tech Tips


      • 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.

      • *3: If there is no initial combustion, a wire harness may be malfunctioning, or the ignition or fuel system may be malfunctioning.

      • *4: If the engine stalls after starter turnoff, the airfuel ratio may be incorrect or the camshaft timing oil control valve may have a problem returning.

      • *5: 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 Click here

    C

    INSPECT FUEL INJECTOR ASSEMBLY Click here

    D

    INSPECT MASS AIR FLOW METER Click here

    E

    INSPECT ENGINE COOLANT TEMPERATURE SENSOR Click here

    A

  26. PERFORM SIMULATION TEST


    1. 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
      Problem Symptom Suspected Area Proceed to
      A noise indicating that the starter pinion gear is extending is heard and the starter pinion gear is not spinning freely*3

      • Battery

      • Excess engine friction

      • Starter assembly

      		 A
      A noise indicating that the starter pinion gear is extending is heard and the starter pinion gear is spinning freely*3

      • Drive plate and ring gear sub-assembly*1

      • Flywheel sub-assembly*2

      • Starter assembly

      		 B
      A noise indicating that the starter pinion gear is extending is not heard

      • Battery

      • Starter assembly

      • Starter system

      		 C

      • *1: for CVT

      • *2: for Manual Transaxle

      Tech Tips

      *3: The battery may be fully depleted or there may be excess engine friction.


    B

    INSPECT STARTER ASSEMBLY (STARTER PINION GEAR) Click here

    C

    INSPECT BATTERY Click here

    A

  27. INSPECT BATTERY


    1. Inspect the battery Click here


    NG

    CHARGE OR REPLACE BATTERY

    OK

  28. CHECK ENGINE ASSEMBLY


    1. Check that the crankshaft rotates smoothly when rotating it by hand.

      OK
      Crankshaft rotates smoothly.
      Result
      Result Proceed to
      NG A
      OK B

      Tech Tips


      • Excess engine friction may have occurred temporarily. Remove the cylinder head cover sub-assembly 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.

      • Perform "Inspection After Repairs" after replacing the engine assembly Click here.


    A

    REPAIR OR REPLACE ENGINE ASSEMBLY Click here

    B

    INSPECT STARTER ASSEMBLY

  29. INSPECT STARTER ASSEMBLY (STARTER PINION GEAR)


    1. Remove the starter assembly.

    2. Check for starter pinion gear wear and damage.

      OK
      There is no wear or damage.
      Result
      Result Proceed to
      NG A
      OK (for Manual Transaxle) B
      OK (for CVT) C

    A

    REPLACE STARTER ASSEMBLY

    B

    REPLACE FLYWHEEL SUB-ASSEMBLY

    C

    REPLACE DRIVE PLATE & RING GEAR SUB-ASSEMBLY

  30. INSPECT BATTERY


    1. Inspect the battery Click here.


    NG

    CHARGE OR REPLACE BATTERY

    OK

  31. INSPECT STARTER ASSEMBLY


    1. Inspect the starter assembly.

      Result
      Result Proceed to
      OK (w/ Entry and Start System) A
      OK (w/o Entry and Start System) B
      NG C

    A

    CHECK CRANKING HOLDING FUNCTION CIRCUIT Click here

    B

    CHECK STARTER SIGNAL CIRCUIT Click here

    C

    REPLACE STARTER ASSEMBLY

  32. PERFORM SIMULATION TEST


    1. Check the cranking speed.

      Result
      Problem Symptom Suspected Area Proceed to
      Cranking speed is slow (100 rpm or less)

      • Battery

      • Starter assembly

      • Excess engine friction

      		 A
      Cranking speed is fast (300 rpm or more)*1 Engine compression loss B

      Tech Tips

      *1: If the cranking speed is fast, there may be compression loss.


    B

    CHECK AND REPAIR ENGINE ASSEMBLY

    A

  33. INSPECT BATTERY


    1. Inspect the battery Click here.


    NG

    CHARGE OR REPLACE BATTERY

    OK

  34. CHECK ENGINE ASSEMBLY


    1. Check that the crankshaft rotates smoothly when rotating it by hand.

      OK
      Crankshaft rotates smoothly.
      Result
      Result Proceed to
      NG A
      OK B

      Tech Tips


      • Excess engine friction may have occurred temporarily. Remove the cylinder head cover sub-assembly 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.

      • Perform "Inspection After Repairs" after replacing the engine assembly Click here.


    A

    REPAIR OR REPLACE ENGINE ASSEMBLY

    B

    INSPECT STARTER ASSEMBLY

  35. INSPECT FUEL INJECTOR ASSEMBLY


    1. Using a sound scope or screwdriver, check for an injector operating noise while cranking the engine.

      OK
      Fuel injector operating noise is heard.

    NG

    READ VALUE USING INTELLIGENT TESTER (ENGINE SPEED) Click here

    OK

  36. CHECK FUEL PRESSURE


    1. Inspect the fuel pressure Click here.


    NG

    PERFORM ACTIVE TEST USING INTELLIGENT TESTER (CONTROL THE FUEL PUMP/SPEED) Click here

    OK

  37. CHECK SPARK PLUG AND SPARK


    1. Check for sparks Click here.


    NG

    INSPECT SPARK PLUG Click here

    OK

  38. PERFORM SIMULATION TEST


    1. Confirm the conditions present when the malfunction occurred based on the customer problem analysis.

      Result
      Problem Symptom Suspected Area Proceed to
      When the engine is stopped and a long time has passed, engine starting trouble occurs*1 Fuel pressure regulator assembly is stuck open A
      When the engine is stopped and approximately 15 to 120 minutes have passed, engine starting trouble occurs*2 Fuel injector leak B
      When the engine is stopped and approximately 2 to 3 minutes have passed, engine starting trouble occurs*3 Failure to maintain fuel pressure by fuel pressure regulator assembly A
      Condition other than above, or there is an inconsistency in the conditions present when engine starting trouble occurs - C*4

      Tech Tips

      *1: The fuel pressure regulator assembly may be stuck open. Attach a fuel pressure gauge and check the ability to maintain fuel pressure after stopping the engine.

      *2: Fuel may be leaking from the fuel injector assembly.

      *3: The fuel pressure regulator assembly may not be able to maintain the fuel pressure. Attach a fuel pressure gauge and check the ability to maintain fuel pressure after stopping the engine.

      *4: From step 72, perform fuel system troubleshooting C (steps 73 to 77).


    B

    CHECK FUEL INJECTOR ASSEMBLY Click here

    C

    CHECK MALFUNCTION CONDITION Click here

    A

  39. CHECK FUEL PRESSURE

    Tech Tips

    For the fuel pressure inspection, refer to the following procedures Click here.


    1. Attach a fuel pressure gauge and check the fuel pressure after stopping the engine.

      Standard
      147 kPa (1.5 kgf/cm2) or higher (5 minutes after stopping the engine)
      Result
      Result Proceed to
      NG A
      OK B*1

      Tech Tips


      • If the engine cannot be started, check the fuel pressure after cranking the engine.

      • *1: From step 72, perform fuel system troubleshooting C (steps 73 to 77).


    A

    REPLACE FUEL PRESSURE REGULATOR ASSEMBLY Click here

    B

    CHECK MALFUNCTION CONDITION Click here

  40. CHECK FUEL INJECTOR ASSEMBLY


    1. Clean the inside of the surge tank with compressed air.

    2. After stopping the engine, measure the HC concentration inside the surge tank for 15 minutes.

      Result
      Result Proceed to
      4000 ppm or higher A
      Less than 4000 ppm B*1

      Tech Tips


      • If the concentration is 4000 ppm or higher, the fuel injector assembly may have a sealing problem.

      • *1: From step 72, perform fuel system troubleshooting C (steps 73 to 77).

      • Perform "Inspection After Repairs" after replacing the fuel injector assembly Click here.


    A

    REPLACE FUEL INJECTOR ASSEMBLY Click here

    B

    CHECK MALFUNCTION CONDITION Click here

  41. INSPECT SPARK PLUG


    1. Inspect the spark plugs Click here.

      Tech Tips

      Even if the spark plug of only one cylinder is malfunctioning, replace the spark plugs of all cylinders.


    NG

    REPLACE SPARK PLUG Click here

    OK

  42. READ VALUE USING INTELLIGENT TESTER (ENGINE SPEED)


    1. Connect the intelligent tester to the DLC3.

    2. Turn the ignition switch to ON.

    3. Turn the tester on.

    4. Enter the following menus: Powertrain / Engine and ECT / Data List / Engine Speed.

    5. Start the engine.

    6. While running the engine, read the Engine Speed value.

      OK
      A value that matches the actual engine speed is constantly output.

      Tech Tips


      • Check the engine speed using a line graph.

      • If the engine cannot be started, check the engine speed while cranking the engine.

      • If the engine speed is 0 rpm, the crankshaft position sensor may have an open or short circuit.


    NG

    CHECK CRANKSHAFT POSITION SENSOR CIRCUIT Click here

    OK

  43. CHECK TERMINAL VOLTAGE (POWER SOURCE OF NO. 1 IGNITION COIL)


    1. Check the harness and connectors, referring to ignition circuit inspection procedure.

      Tech Tips


      • 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

    CHECK IGNITION CIRCUIT Click here

    OK

  44. CHECK HARNESS AND CONNECTOR (NO. 1 IGNITION COIL - ECM)


    1. Check the harness and connectors, referring to ignition circuit inspection procedure.

      Tech Tips


      • 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.

      • If the wire harness is normal, after replacing the ignition coil, check if engine starting trouble occurs again. If engine starting trouble occurs again, proceed to step 72 and perform troubleshooting for the ignition system (steps 78 to 86).

      • Perform "Inspection After Repairs" after replacing the No. 1 ignition coil Click here.


    OK

    REPLACE NO. 1 IGNITION COIL Click here

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

  45. PERFORM ACTIVE TEST USING INTELLIGENT TESTER (CONTROL THE FUEL PUMP/SPEED)


    1. Connect the intelligent tester to the DLC3.

    2. Turn the ignition switch to ON.

    3. Turn the tester on.

    4. Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump/Speed.

    5. When performing the Active Test, check for an operating sound from the fuel pump.

      OK
      Control the Fuel Pump/Speed Specified Condition
      ON Operating sound heard
      OFF Operating sound not heard

      Tech Tips

      Jiggle the wire harness and connector to increase the likelihood of detecting malfunctions that do not always occur.


    NG

    CHECK FUEL PUMP CONTROL CIRCUIT Click here

    OK

  46. PERFORM ACTIVE TEST USING INTELLIGENT TESTER (CONTROL THE FUEL PUMP/SPEED)


    1. Connect the intelligent tester to the DLC3.

    2. Turn the ignition switch to ON.

    3. Turn the tester on.

    4. Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump/Speed.

    5. When performing the Active Test, check for fuel leakage from the fuel pipes.

      Result
      Result Proceed to
      Fuel leakage or signs of fuel leakage are present A
      No fuel leakage or signs of fuel leakage B

      Tech Tips


      • Jiggle the fuel hose 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.

      • If there are no fuel leaks, after inspecting the fuel pump control system, check if engine starting trouble occurs again. If engine starting trouble occurs again, proceed to step 72 and perform fuel system troubleshooting (steps 73 to 77).


    A

    REPAIR OR REPLACE FUEL LINE

    B

    CHECK FUEL PUMP CONTROL CIRCUIT Click here

  47. READ VALUE USING INTELLIGENT TESTER (ENGINE SPEED)


    1. Connect the intelligent tester to the DLC3.

    2. Turn the ignition switch to ON.

    3. Turn the tester on.

    4. Enter the following menus: Powertrain / Engine and ECT / Data List / Engine Speed.

    5. Start the engine.

    6. While running the engine, read the Engine Speed value.

      OK
      A value that matches the actual engine speed is constantly output.

      Tech Tips


      • Check the engine speed using a line graph.

      • If the engine cannot be started, check the engine speed while cranking the engine.

      • If the engine speed is 0 rpm, the crankshaft position sensor may have an open or short circuit.


    NG

    REPLACE CRANKSHAFT POSITION SENSOR Click here

    OK

  48. CHECK TERMINAL VOLTAGE (#10, #20, #30 AND/OR #40)


    1. A01VJ46E02
      Text in Illustration
      *A for LHD
      *B for RHD
      *a

      Front view of wire harness connector

      (to ECM)

      Disconnect the ECM connector.

    2. Turn the ignition switch to ON.

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

      Standard Voltage
      for LHD
      Tester Connection Switch Condition Specified Condition
      B22-20 (#10) - B22-51 (E01) Ignition switch ON 11 to 14 V
      B22-17 (#20) - B22-51 (E01) Ignition switch ON 11 to 14 V
      B22-18 (#30) - B22-51 (E01) Ignition switch ON 11 to 14 V
      B22-19 (#40) - B22-51 (E01) Ignition switch ON 11 to 14 V
      for RHD
      Tester Connection Switch Condition Specified Condition
      B23-20 (#10) - B23-51 (E01) Ignition switch ON 11 to 14 V
      B23-17 (#20) - B23-51 (E01) Ignition switch ON 11 to 14 V
      B23-18 (#30) - B23-51 (E01) Ignition switch ON 11 to 14 V
      B23-19 (#40) - B23-51 (E01) Ignition switch ON 11 to 14 V

      Tech Tips


      • 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.


    OK

    REPLACE ECM Click here

    NG

    CHECK FUEL INJECTOR CIRCUIT Click here

  49. INSPECT MASS AIR FLOW METER


    1. Inspect the mass air flow meter Click here.


    NG

    CHECK HARNESS AND CONNECTOR (MASS AIR FLOW METER - ECM) Click here

    OK

  50. CHECK INTAKE SYSTEM


    1. Check for air suction in the intake system [vacuum hose disconnection, cracks, gaskets, etc.] Click here.

      Tech Tips


      • 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 #1 and Long FT #1 are largely different from the normal values when idling (intake air volume is small) and almost the same as the normal values when racing the engine (intake air volume is high), air suction may be present.

      OK
      There is no air suction.

      Tech Tips

      Perform "Inspection After Repairs" after repairing or replacing the intake system Click here.


    NG

    REPAIR OR REPLACE INTAKE SYSTEM

    OK

  51. INSPECT THROTTLE BODY WITH MOTOR ASSEMBLY


    1. Disconnect the B29 throttle body with motor assembly connector.

      Tech Tips

      When the connector is disconnected, the vehicle enters fail-safe mode and the throttle valve opening angle is 5.5°.

    2. Crank the engine and check that it starts.

      Result
      Result Proceed to
      Engine starts A
      Engine does not start B

      Tech Tips

      When this inspection is performed, the MIL may illuminate. After finishing the inspection, check and clear DTCs Click here.


    B

    PERFORM ACTIVE TEST USING INTELLIGENT TESTER (CONTROL THE VVT LINEAR (BANK 1)) Click here

    A

  52. INSPECT THROTTLE BODY WITH MOTOR ASSEMBLY


    1. Check if carbon is in the air flow passage.

      OK
      No carbon present.

      Tech Tips

      Perform "Inspection After Repairs" after cleaning the throttle body with motor assembly Click here.


    NG

    REMOVE FOREIGN OBJECT AND CLEAN THROTTLE BODY WITH MOTOR ASSEMBLY

    OK

  53. PERFORM ACTIVE TEST USING INTELLIGENT TESTER (CONTROL THE VVT LINEAR (BANK 1))


    1. Perform the Active Test, referring to DTC P0011 inspection procedure Click here.

      Tech Tips


      • Jiggle the wire harness and connector to increase the likelihood of detecting malfunctions that do not always occur.

      • When the results of the inspection using the Active Test are normal but the valve operating noise is abnormal, check the valve for any signs of problems.

      • If the camshaft timing oil control valve assembly is stuck ON, the valve overlap increases and combustion worsens due to the internal EGR which may cause the engine to stall.

      • From step 72, perform intake system troubleshooting (steps 87 to 89). If engine starting trouble still occurs, perform fuel system troubleshooting A (steps 90 to 97).


    NG

    REPLACE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (FOR INTAKE CAMSHAFT) Click here

    OK

  54. PERFORM ACTIVE TEST USING INTELLIGENT TESTER (CONTROL THE VVT EXHAUST LINEAR (BANK 1))


    1. Perform the Active Test, referring to DTC P0014 inspection procedure Click here.

      Tech Tips


      • Jiggle the wire harness and connector to increase the likelihood of detecting malfunctions that do not always occur.

      • When the results of the inspection using the Active Test are normal but the valve operating noise is abnormal, check the valve for any signs of problems.

      • If the camshaft timing oil control valve assembly is stuck ON, the valve overlap increases and combustion worsens due to the internal EGR which may cause the engine to stall.

      • From step 72, perform intake system troubleshooting (steps 87 to 89). If engine starting trouble still occurs, perform fuel system troubleshooting A (steps 90 to 97).


    NG

    REPLACE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (FOR EXHAUST CAMSHAFT) Click here

    OK

  55. PERFORM ACTIVE TEST USING INTELLIGENT TESTER (CONTROL THE EGR STEP POSITION)


    1. Connect the intelligent tester to the DLC3.

    2. Turn the ignition switch to ON.

    3. Turn the tester on.

    4. Start the engine and warm it up until the engine coolant temperature reaches 75°C (167°F) or more.

      Tech Tips


      • When performing the Active Test, make sure the shift lever is in P or N (neutral).

      • The air conditioning switch and all accessory switches should be off.

    5. Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the EGR Step Position.

    6. Check the MAP and Engine Speed in Data List at the idling condition while performing Active Test.

      OK
      MAP and idling condition change in response to EGR step position.
      - EGR Step Position (Active Test)
      0 Steps 0 to 30 Steps
      Idling condition Steady idling Idling changes from steady to rough idling

      MAP

      (Data List)

      MAP value is 20 to 48 kPa

      (150 to 360 mmHg)

      (EGR valve is fully closed)

      		 MAP value is at least +10 kPa (75 mmHg) higher than when EGR valve is fully closed
      Result
      Result Proceed to
      NG A
      OK B*1

      Tech Tips


      • Do not leave the EGR valve open for 10 seconds or more during the Active Test.

      • Be sure to return the EGR valve to step 0 when Active Test is completed.

      • *1: From step 72, perform intake system troubleshooting (steps 87 to 89. If engine starting trouble still occurs, perform fuel system troubleshooting A (steps 90 to 97).


    B

    CHECK MALFUNCTION CONDITION Click here

    A

  56. INSPECT EGR VALVE ASSEMBLY


    1. Remove the EGR valve assembly Click here.

    2. Check if the EGR valve is stuck open.

      OK
      EGR valve is tightly closed (It is not stuck open)
      Result
      Result Proceed to
      NG A
      OK B*1

      Tech Tips


      • Perform "Inspection After Repairs" after replacing the EGR valve assembly Click here.

      • *1: From step 72, perform intake system troubleshooting (steps 87 to 89). If engine starting trouble still occurs, perform fuel system troubleshooting A (steps 90 to 97).


    A

    REPLACE EGR VALVE ASSEMBLY Click here

    B

    CHECK MALFUNCTION CONDITION Click here

  57. CHECK HARNESS AND CONNECTOR (MASS AIR FLOW METER - ECM)


    1. Disconnect the B73 mass air flow meter connector.

    2. Disconnect the B22 ECM connector (for LHD).

    3. Disconnect the B23 ECM connector (for RHD).

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

      Standard Resistance
      for LHD
      Tester Connection Condition Specified Condition
      B73-5 (VG) - B22-91 (VG) Always Below 1 Ω
      B73-4 (E2G) - B22-92 (E2G) Always Below 1 Ω
      B73-5 (VG) or B22-91 (VG) - Body ground Always 10 kΩ or higher
      for RHD
      Tester Connection Condition Specified Condition
      B73-5 (VG) - B23-91 (VG) Always Below 1 Ω
      B73-4 (E2G) - B23-92 (E2G) Always Below 1 Ω
      B73-5 (VG) or B23-91 (VG) - Body ground Always 10 kΩ or higher

      Tech Tips


      • 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.

      • If the wire harness is normal, after replacing the mass air flow meter, check if engine starting trouble occurs again. If engine starting trouble occurs again, proceed to step 72 and perform intake system troubleshooting (steps 87 to 89). If engine starting trouble still occurs, perform fuel system troubleshooting A (steps 90 to 97).

      Tech Tips

      Perform "Inspection After Repairs" after replacing the mass air flow meter Click here.


    OK

    REPLACE MASS AIR FLOW METER Click here

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

  58. INSPECT ENGINE COOLANT TEMPERATURE SENSOR


    1. Inspect the engine coolant temperature sensor Click here.

      Tech Tips


      • If the engine coolant temperature sensor is malfunctioning, after replacing it, check if engine starting trouble occurs again. If engine starting trouble occurs, replace the ECM. If engine starting trouble still occurs, proceed to step 72 and perform fuel system troubleshooting A (steps 98 to 105), fuel system troubleshooting B (steps 106 to 108), intake system troubleshooting (steps 109 to 111), and ignition system troubleshooting (steps 112 to 120), in that order.

      • Perform "Inspection After Repairs" after replacing the engine coolant temperature sensor Click here.


    NG

    REPLACE ENGINE COOLANT TEMPERATURE SENSOR Click here

    OK

  59. CHECK HARNESS AND CONNECTOR (ENGINE COOLANT TEMPERATURE SENSOR - ECM)


    1. Disconnect the B33 engine coolant temperature sensor connector.

    2. Disconnect the B22 ECM connector (for LHD).

    3. Disconnect the B23 ECM connector (for RHD).

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

      Standard Resistance
      for LHD
      Tester Connection Condition Specified Condition
      B33-1 - B22-93 (THW) Always Below 1 Ω
      B33-2 - B22-94 (ETHW) Always Below 1 Ω
      B33-1 - B22-93 (THW) - Body ground Always 10 kΩ or higher
      for RHD
      Tester Connection Condition Specified Condition
      B33-1 - B23-93 (THW) Always Below 1 Ω
      B33-2 - B23-94 (ETHW) Always Below 1 Ω
      B33-1 - B23-93 (THW) - Body ground Always 10 kΩ or higher

      Tech Tips


      • 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.

      • If the wire harness or connector is malfunctioning, after replacing or repairing it, check if engine starting trouble occurs again. If engine starting trouble occurs, replace the ECM. If engine starting trouble still occurs, proceed to step 72 and perform fuel system troubleshooting A (steps 98 to 105), fuel system troubleshooting B (steps 106 to 108), intake system troubleshooting (steps 109 to 111), and ignition system troubleshooting (steps 112 to 120), in that order.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  60. INSPECT MASS AIR FLOW METER


    1. Inspect the mass air flow meter Click here.

      Tech Tips


      • If the mass air flow meter is malfunctioning, after replacing it, check if engine starting trouble occurs again. If engine starting trouble occurs, replace the ECM. If engine starting trouble still occurs, proceed to step 72 and perform fuel system troubleshooting A (steps 98 to 105), fuel system troubleshooting B (steps 106 to 108), intake system troubleshooting (steps 109 to 111), and ignition system troubleshooting (steps 112 to 120), in that order.

      • Perform "Inspection After Repairs" after replacing the mass air flow meter Click here.


    NG

    REPLACE MASS AIR FLOW METER Click here

    OK

  61. CHECK HARNESS AND CONNECTOR (MASS AIR FLOW METER - ECM)


    1. Disconnect the B73 mass air flow meter connector.

    2. Disconnect the B22 ECM connector (for LHD).

    3. Disconnect the B23 ECM connector (for RHD).

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

      Standard Resistance
      for LHD
      Tester Connection Condition Specified Condition
      B73-5 (VG) - B22-91 (VG) Always Below 1 Ω
      B73-4 (E2G) - B22-92 (E2G) Always Below 1 Ω
      B73-5 (VG) or B22-91 (VG) - Body ground Always 10 kΩ or higher
      for RHD
      Tester Connection Condition Specified Condition
      B73-5 (VG) - B23-91 (VG) Always Below 1 Ω
      B73-4 (E2G) - B23-92 (E2G) Always Below 1 Ω
      B73-5 (VG) or B23-91 (VG) - Body ground Always 10 kΩ or higher

      Tech Tips


      • 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.

      • If the wire harness or connector is malfunctioning, after replacing or repairing it, check if engine starting trouble occurs again. If engine starting trouble occurs, replace the ECM. If engine starting trouble still occurs, proceed to step 72 and perform fuel system troubleshooting A (steps 98 to 105), fuel system troubleshooting B (steps 106 to 108), intake system troubleshooting (steps 109 to 111), and ignition system troubleshooting (steps 112 to 120), in that order.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  62. READ VALUE USING INTELLIGENT TESTER (ATMOSPHERE PRESSURE, LONG FT #1)


    1. Connect the intelligent tester to the DLC3.

    2. Turn the ignition switch to ON.

    3. Turn the tester on.

    4. Enter the following menus: Powertrain / Engine and ECT / Data List / Atmosphere Pressure and Long FT #1.

      Result
      Data List Item Result Suspected Area Proceed to
      Atmosphere Pressure 80 kPa (abs) [600 mmHg (abs)] or less (when altitude is 0 m)

      • Air fuel ratio sensor

      • Heated oxygen sensor

      • Mass air flow meter

      • Fuel injector assembly

      • ECM

      		 A
      Long FT #1 25% or more or less than -25%
      Both Data List items listed above Values are other than above - B

    B

    CHECK FUEL PRESSURE Click here

    A

  63. PERFORM SIMULATION TEST


    1. Connect the intelligent tester to the DLC3.

    2. Turn the ignition switch to ON.

    3. Turn the tester on.

    4. Enter the following menus: Powertrain / Engine and ECT / Utility / Learning Value Reset.

    5. Confirm the following conditions as instructed on the screen.


      • - Ignition switch ON

      • - Engine stopped

      • - Battery voltage 9 V or more

    6. After confirming, select "Next" and initialize the learn value.

      Tech Tips

      If a message indicating learned value initialization failure is displayed on the screen, confirm the execution conditions, and perform learned value initialization again.

    7. Check if the engine can be started.

      Result
      Result Proceed to
      Engine can be started A
      Engine cannot be started B

    B

    CHECK FUEL PRESSURE Click here

    A

  64. INSPECT AIR FUEL RATIO SENSOR

    Note

    If a message indicating learned value initialization failure is displayed on the screen, confirm the execution conditions, and perform learned value initialization again.


    1. Connect the intelligent tester to the DLC3.

      A01VKPXE06

    2. Turn the ignition switch to ON.

    3. Turn the tester on.

    4. Enter the following menus: Powertrain / Engine and ECT / Data List / Fuel System Status #1.

    5. Confirm that Fuel System Status #1 is CL.

    6. Enter the following menus: Powertrain / Engine and ECT / Data List / AF Lambda B1S1.

    7. Confirm that AF Lambda B1S1 is within the range of 0.95 to 1.05 when idling.

    8. Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Injection Volume for A/F Sensor / AFS Voltage B1S1 and O2S B1S2.

    9. Read the output voltage from the air fuel ratio sensor when increasing and decreasing the fuel injection volume.

      Standard
      Tester Display Injection Volume Specified Condition
      AFS voltage B1S1 12.5% Air fuel ratio sensor output voltage is below 3.1 V
      -12.5% Air fuel ratio sensor output voltage is higher than 3.4 V

      Note

      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.

      Tech Tips


      • If the air fuel ratio sensor is malfunctioning, after replacing it, check if engine starting trouble occurs again. If engine starting trouble occurs, replace the ECM. If engine starting trouble still occurs, proceed to step 72 and perform fuel system troubleshooting A (steps 98 to 105), fuel system troubleshooting B (steps 106 to 108), intake system troubleshooting (steps 109 to 111), and ignition system troubleshooting (steps 112 to 120), in that order.

      • Perform "Inspection After Repairs" after replacing the air fuel ratio sensor Click here.


    NG

    REPLACE AIR FUEL RATIO SENSOR Click here

    OK

  65. PERFORM SIMULATION TEST


    1. Check if the idling speed is stable after starting the engine.

      OK
      Speed is stable.

      Tech Tips


      • After replacing the fuel injector assembly or mass air flow meter, check if engine starting trouble occurs again. If engine starting trouble occurs, replace the ECM. If engine starting trouble still occurs, proceed to step 72 and perform fuel system troubleshooting A (steps 98 to 105), fuel system troubleshooting B (steps 106 to 108), intake system troubleshooting (steps 109 to 111), and ignition system troubleshooting (steps 112 to 120), in that order.

      • Perform "Inspection After Repairs" after replacing the fuel injector assembly or mass air flow meter Click here.


    OK

    REPLACE MASS AIR FLOW METER Click here

    NG

    REPLACE FUEL INJECTOR ASSEMBLY Click here

  66. CHECK FUEL PRESSURE


    1. Check the fuel pressure Click here.


    NG

    PERFORM ACTIVE TEST USING INTELLIGENT TESTER (CONTROL THE FUEL PUMP/SPEED) Click here

    OK

  67. INSPECT SPARK PLUG


    1. Inspect the spark plugs Click here.

      Result
      Result Proceed to
      All cylinders are normal A
      One cylinder is abnormal*1 B
      All cylinders are abnormal*2, *3 C

      Tech Tips


      • *1: If one cylinder is abnormal, replace the spark plug of that cylinder and inspect the ignition and fuel system for that cylinder. After performing repairs, check if engine starting trouble occurs again. If engine starting trouble still occurs, proceed to step 72 and perform fuel system troubleshooting A (steps 98 to 105), fuel system troubleshooting B (steps 106 to 108), intake system troubleshooting (steps 109 to 111), and ignition system troubleshooting (steps 112 to 120), in that order.

      • *2: If all cylinders are abnormal, replace the spark plugs of all cylinders and check if engine starting trouble occurs again. If engine starting trouble still occurs, proceed to step 72 and perform fuel system troubleshooting A (steps 98 to 105), fuel system troubleshooting B (steps 106 to 108), intake system troubleshooting (steps 109 to 111), and ignition system troubleshooting (steps 112 to 120), in that order.

      • *3: Engine starting trouble may occur if the vehicle is driven extremely short distances repeatedly.

      • Perform "Inspection After Repairs" after replacing the spark plug Click here.


    B

    REPLACE SPARK PLUG (ABNORMAL CYLINDER) Click here

    C

    REPLACE SPARK PLUG (ALL CYLINDER) Click here

    A

  68. PERFORM SIMULATION TEST


    1. Confirm the conditions present when the malfunction occurred based on the customer problem analysis.

      Result
      Problem Symptom Suspected Area Proceed to
      When the engine is stopped and a long time has passed, engine starting trouble occurs*1 Fuel pressure regulator assembly is stuck open A
      When the engine is stopped and approximately 15 to 120 minutes have passed, engine starting trouble occurs*2 Fuel injector leak B
      When the engine is stopped and approximately 2 to 3 minutes have passed, engine starting trouble occurs*3 Failure to maintain fuel pressure by fuel pressure regulator assembly A
      Condition other than above, or there is an inconsistency in the conditions present when engine starting trouble occurs - C*4

      Tech Tips

      *1: The fuel pressure regulator assembly may be stuck open. Attach a fuel pressure gauge and check the ability to maintain fuel pressure after stopping the engine.

      *2: Fuel may be leaking from the fuel injector assembly.

      *3: The fuel pressure regulator assembly may not be able to maintain the fuel pressure. Attach a fuel pressure gauge and check the ability to maintain fuel pressure after stopping the engine.

      *4: From step 72, perform fuel system troubleshooting A (steps 98 to 105), fuel system troubleshooting B (steps 106 to 108), intake system troubleshooting (steps 109 to 111), and ignition system troubleshooting (steps 112 to 120), in that order.


    B

    CHECK FUEL INJECTOR ASSEMBLY Click here

    C

    CHECK MALFUNCTION CONDITION Click here

    A

  69. CHECK FUEL PRESSURE

    Tech Tips

    For the fuel pressure inspection, refer to the following procedures Click here.


    1. Attach a fuel pressure gauge and check the fuel pressure after stopping the engine.

      Standard
      147 kPa (1.5 kgf/cm2) or higher (5 minutes after stopping the engine)
      Result
      Result Proceed to
      NG A
      OK B*1

      Tech Tips


      • If the engine cannot be started, check the fuel pressure after cranking the engine.

      • *1: From step 72, perform fuel system troubleshooting A (steps 98 to 105), fuel system troubleshooting B (steps 106 to 108), intake system troubleshooting (steps 109 to 111), and ignition system troubleshooting (steps 112 to 120), in that order.


    A

    REPLACE FUEL PRESSURE REGULATOR ASSEMBLY Click here

    B

    CHECK MALFUNCTION CONDITION Click here

  70. CHECK FUEL INJECTOR ASSEMBLY


    1. Clean the inside of the surge tank with compressed air.

    2. After stopping the engine, measure the HC concentration inside the surge tank for 15 minutes.

      Result
      Result Proceed to
      4000 ppm or higher A
      Less than 4000 ppm B*1

      Tech Tips


      • If the concentration is 4000 ppm or higher, the fuel injector assembly may have a sealing problem.

      • *1: From step 72, perform fuel system troubleshooting A (steps 98 to 105), fuel system troubleshooting B (steps 106 to 108), intake system troubleshooting (steps 109 to 111), and ignition system troubleshooting (steps 112 to 120), in that order.

      • Perform "Inspection After Repairs" after replacing the fuel injector assembly Click here.


    A

    REPLACE FUEL INJECTOR ASSEMBLY Click here

    B

    CHECK MALFUNCTION CONDITION Click here

  71. PERFORM ACTIVE TEST USING INTELLIGENT TESTER (CONTROL THE FUEL PUMP/SPEED)


    1. Connect the intelligent tester to the DLC3.

    2. Turn the ignition switch to ON.

    3. Turn the tester on.

    4. Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump/Speed.

    5. When performing the Active Test, check for fuel leakage from the fuel pipes.

      Result
      Result Proceed to
      Fuel leakage or signs of fuel leakage are present A
      No fuel leakage or signs of fuel leakage B

      Tech Tips


      • 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 72 and perform fuel system troubleshooting A (steps 98 to 105), fuel system troubleshooting B (steps 106 to 108), intake system troubleshooting (steps 109 to 111), and ignition system troubleshooting (steps 112 to 120), in that order.


    A

    REPLACE FUEL LINE

    B

    CHECK FUEL PUMP CONTROL CIRCUIT Click here

  72. CHECK MALFUNCTION CONDITION


    1. If the malfunction could not be identified during the inspection in steps 38, 39, 40 and 46, perform fuel system troubleshooting C (steps 73 to 77).

      Result
      Performed Step Troubleshooting by System Procedure Proceed to
      Steps 38, 39, 40 and 46 Fuel system troubleshooting C 73 to 77 A

    2. If the malfunction could not be identified during the inspection in step 44, perform ignition system troubleshooting (steps 78 to 86).

      Result
      Performed Step Troubleshooting by System Procedure Proceed to
      Step 44 Ignition system troubleshooting 78 to 86 B

    3. If the malfunction could not be identified during the inspection in steps 53, 54, 55, 56 and 57, perform intake air system troubleshooting (steps 87 to 89). If engine starting trouble still occurs, perform fuel intake system troubleshooting A (steps 90 to 97).

      Result
      Performed Step Troubleshooting by System Procedure Proceed to
      Step 53, 54, 55, 56 and 57 Intake air system troubleshooting 87 to 89 C
      Fuel system troubleshooting A 90 to 97

    4. If the malfunction could not be identified during the inspection in steps 58, 59, 60, 61, 64, 65, 67, 68, 69, 70 and 71, perform fuel system troubleshooting A (steps 98 to 105), fuel system troubleshooting B (steps 106 to 108), intake air system troubleshooting (steps 109 to 111), and ignition system troubleshooting (steps 112 to 120), in that order.

      Result
      Performed Step Troubleshooting by System Procedure Proceed to
      Steps 58, 59, 60, 61, 64, 65, 67, 68, 69, 70 and 71 Fuel system troubleshooting A 98 to 105 D
      Fuel system troubleshooting B 106 to 108
      Intake air system troubleshooting 109 to 111
      Ignition system troubleshooting 112 to 120

    B

    CHECK SENSOR INSTALLATION (CRANKSHAFT POSITION SENSOR) Click here

    C

    READ VALUE USING INTELLIGENT TESTER (ISC FEEDBACK LEARNING TORQUE) Click here

    D

    CHECK FUEL PRESSURE Click here

    A

  73. INSPECT FUEL INJECTOR ASSEMBLY


    1. Inspect the fuel injector assembly Click here.

      Tech Tips

      Perform "Inspection After Repairs" after replacing the fuel injector assembly Click here.


    NG

    REPLACE FUEL INJECTOR ASSEMBLY Click here

    OK

  74. CHECK TERMINAL VOLTAGE (#10, #20, #30 AND/OR #40)


    1. A01VJ46E02
      Text in Illustration
      *A for LHD
      *B for RHD
      *a

      Front view of wire harness connector

      (to ECM)

      Disconnect the ECM connector.

    2. Turn the ignition switch to ON.

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

      Standard Voltage
      for LHD
      Tester Connection Switch Condition Specified Condition
      B22-20 (#10) - B22-51 (E01) Ignition switch ON 11 to 14 V
      B22-17 (#20) - B22-51 (E01) Ignition switch ON 11 to 14 V
      B22-18 (#30) - B22-51 (E01) Ignition switch ON 11 to 14 V
      B22-19 (#40) - B22-51 (E01) Ignition switch ON 11 to 14 V
      for RHD
      Tester Connection Switch Condition Specified Condition
      B23-20 (#10) - B23-51 (E01) Ignition switch ON 11 to 14 V
      B23-17 (#20) - B23-51 (E01) Ignition switch ON 11 to 14 V
      B23-18 (#30) - B23-51 (E01) Ignition switch ON 11 to 14 V
      B23-19 (#40) - B23-51 (E01) Ignition switch ON 11 to 14 V

      Tech Tips


      • 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

    CHECK FUEL INJECTOR CIRCUIT Click here

    OK

  75. CHECK CRANKSHAFT POSITION SENSOR


    1. Replace the crankshaft position sensor Click here.

    2. Check the engine start operation.

      OK
      Malfunction has been repaired successfully.

    OK

    END (CRANKSHAFT POSITION SENSOR IS DEFECTIVE)

    NG

  76. CHECK CAMSHAFT POSITION SENSOR (FOR INTAKE CAMSHAFT)


    1. Replace the camshaft position sensor (for intake camshaft) Click here.

    2. Check the engine start operation.

      OK
      Malfunction has been repaired successfully.

    OK

    END (CAMSHAFT POSITION SENSOR (FOR INTAKE CAMSHAFT) IS DEFECTIVE)

    NG

  77. CHECK CAMSHAFT POSITION SENSOR (FOR EXHAUST CAMSHAFT)


    1. Replace the camshaft position sensor Click here.

    2. Check the engine start operation.

      OK
      Malfunction has been repaired successfully.

    OK

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

    NG

    REPLACE ECM Click here

  78. CHECK SENSOR INSTALLATION (CRANKSHAFT POSITION SENSOR)


    1. Check the tightening and installation condition of the crankshaft position sensor bolt.

    2. Check the connection of the crankshaft position sensor connector.

      OK
      Sensor is installed correctly.

    NG

    SECURELY REINSTALL SENSOR

    OK

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


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

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

      OK
      Sensor is installed correctly.

    NG

    SECURELY REINSTALL SENSOR

    OK

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


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

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

      OK
      Sensor is installed correctly.

    NG

    SECURELY REINSTALL SENSOR

    OK

  81. CHECK HARNESS AND CONNECTOR (CRANKSHAFT POSITION SENSOR - ECM)


    1. Check the harness and connectors, referring to DTC P0335 inspection procedure.

      Tech Tips


      • 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

  82. CHECK HARNESS AND CONNECTOR (CAMSHAFT POSITION SENSOR (FOR INTAKE CAMSHAFT) - ECM)


    1. Check the harness and connectors, referring to DTC P0340 inspection procedure.

      Tech Tips


      • 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

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


    1. Check the harness and connectors, referring to DTC P0365 inspection procedure.

      Tech Tips


      • 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

  84. CHECK CRANKSHAFT POSITION SENSOR


    1. Replace the crankshaft position sensor Click here.

    2. Check the engine start operation.

      OK
      Malfunction has been repaired successfully.

    OK

    END (CRANKSHAFT POSITION SENSOR IS DEFECTIVE)

    NG

  85. CHECK CAMSHAFT POSITION SENSOR (FOR INTAKE CAMSHAFT)


    1. Replace the camshaft position sensor (for intake camshaft) Click here.

    2. Check the engine start operation.

      OK
      Malfunction has been repaired successfully.

    OK

    END (CAMSHAFT POSITION SENSOR (FOR INTAKE CAMSHAFT) IS DEFECTIVE)

    NG

  86. CHECK CAMSHAFT POSITION SENSOR (FOR EXHAUST CAMSHAFT)


    1. Replace the camshaft position sensor (for exhaust camshaft) Click here.

    2. Check the engine start operation.

      OK
      Malfunction has been repaired successfully.

    OK

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

    NG

    REPLACE ECM Click here

  87. READ VALUE USING INTELLIGENT TESTER (ISC FEEDBACK LEARNING TORQUE)


    1. Connect the intelligent tester to the DLC3.

    2. Turn the ignition switch to ON.

    3. Turn the tester on.

    4. Enter the following menus: Powertrain / Engine and ECT / Data List / ISC Feedback Learning Torque.

    5. Start the engine, turn off all accessory switches and warm up the engine until the engine coolant temperature stabilizes.

      Result
      Data List Item Result Suspected Area Proceed to
      ISC Feedback Learning Torque 5 Nm or more

      • Valve timing

      • Compression

      		 A
      Below 5 Nm - B

    B

    INSPECT ENGINE COOLANT TEMPERATURE SENSOR Click here

    A

  88. CHECK CYLINDER COMPRESSION PRESSURE


    1. Check the compression Click here.

      Tech Tips

      Perform "Inspection After Repairs" after replacing the engine assembly Click here.


    OK

    CHECK VALVE TIMING Click here

    NG

    REPAIR OR REPLACE ENGINE ASSEMBLY

  89. INSPECT ENGINE COOLANT TEMPERATURE SENSOR


    1. Inspect the engine coolant temperature sensor Click here.

      Tech Tips

      Perform "Inspection After Repairs" after replacing the engine coolant temperature sensor Click here.


    NG

    REPLACE ENGINE COOLANT TEMPERATURE SENSOR Click here

    OK

  90. CHECK FUEL PRESSURE

    Tech Tips

    For the fuel pressure inspection, refer to the following procedures Click here.


    1. Attach a fuel pressure gauge and check the fuel pressure when cranking the engine and after stopping the engine.

      Standard
      Vehicle State Specified Condition
      Cranking engine

      304 to 343 kPa (3.1 to 3.5 kgf/cm2)
      5 minutes after stopping engine

      147 kPa (1.5 kgf/cm2) or more

    NG

    PERFORM ACTIVE TEST USING INTELLIGENT TESTER (CONTROL THE FUEL PUMP/SPEED) Click here

    OK

  91. READ VALUE USING INTELLIGENT TESTER (LONG FT #1)


    1. Connect the intelligent tester to the DLC3.

    2. Turn the ignition switch to ON.

    3. Turn the tester on.

    4. Enter the following menus: Powertrain / Engine and ECT / Data List / Long FT #1.

      Result
      Data List Item Result Suspected Area Proceed to
      Long FT #1 -15 to 15%

      • Wire harness or connector

      • Fuel

      		 A
      15% or more, or less than -15% Fuel injector assembly B

      Tech Tips

      Perform "Inspection After Repairs" after replacing the fuel injector assembly Click here.


    B

    REPLACE FUEL INJECTOR ASSEMBLY Click here

    A

  92. PERFORM SIMULATION TEST


    1. Check if the idling speed after starting the engine is currently stable and has always been stable in the past.

      Result
      Problem Symptom Suspected Area Proceed to
      Current unstable idling speed or history of unstable idling speed Crankshaft position sensor system A
      All current and past idling speeds are stable Fuel B

      Tech Tips

      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

  93. CHECK SENSOR INSTALLATION (CRANKSHAFT POSITION SENSOR)


    1. Check the tightening and installation condition of the crankshaft position sensor bolt.

    2. Check the connection of the crankshaft position sensor connector.

      OK
      Sensor is installed correctly.

    NG

    SECURELY REINSTALL SENSOR

    OK

  94. CHECK HARNESS AND CONNECTOR (CRANKSHAFT POSITION SENSOR - ECM)


    1. Check harness and connectors, referring to DTC P0335 inspection procedure.

      Tech Tips


      • 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

  95. CHECK CRANKSHAFT POSITION SENSOR


    1. Replace the crankshaft position sensor Click here.

    2. Check the engine start operation.

      OK
      Malfunction has been repaired successfully.

    OK

    END (CRANKSHAFT POSITION SENSOR IS DEFECTIVE)

    NG

    REPLACE ECM Click here

  96. PERFORM ACTIVE TEST USING INTELLIGENT TESTER (CONTROL THE FUEL PUMP/SPEED)


    1. Connect the intelligent tester to the DLC3.

    2. Turn the ignition switch to ON.

    3. Turn the tester on.

    4. Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump/Speed.

    5. When performing the Active Test, check for fuel leakage from the fuel pipes.

      Result
      Result Proceed to
      Fuel leakage or signs of fuel leakage are present A
      No fuel leakage or signs of fuel leakage B

      Tech Tips


      • 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.


    A

    REPAIR OR REPLACE FUEL LINE

    B

  97. INSPECT FUEL PUMP


    1. Inspect the fuel pump Click here.

      Tech Tips


      • Make sure there is no foreign matter such as iron particles on the fuel pump 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.

      • Perform "Inspection After Repairs" after replacing the fuel pump Click here.


    OK

    REPLACE FUEL PRESSURE REGULATOR ASSEMBLY Click here

    NG

    REPLACE FUEL PUMP Click here

  98. CHECK FUEL PRESSURE

    Tech Tips

    For the fuel pressure inspection, refer to the following procedures Click here.


    1. Attach a fuel pressure gauge and check the fuel pressure when cranking the engine and after stopping the engine.

      Standard
      Vehicle State Specified Condition
      Cranking engine

      304 to 343 kPa (3.1 to 3.5 kgf/cm2)
      5 minutes after stopping engine

      147 kPa (1.5 kgf/cm2) or more

    NG

    PERFORM ACTIVE TEST USING INTELLIGENT TESTER (CONTROL THE FUEL PUMP/SPEED) Click here

    OK

  99. READ VALUE USING INTELLIGENT TESTER (LONG FT #1)


    1. Connect the intelligent tester to the DLC3.

    2. Turn the ignition switch to ON.

    3. Turn the tester on.

    4. Enter the following menus: Powertrain / Engine and ECT / Data List / Long FT #1.

      Result
      Data List Item Result Suspected Area Proceed to
      Long FT #1 -15 to 15%

      • Wire harness or connector

      • Fuel

      		 A
      15% or more, or less than -15% Fuel injector assembly B

      Tech Tips

      Perform "Inspection After Repairs" after replacing the fuel injector assembly Click here.


    B

    REPLACE FUEL INJECTOR ASSEMBLY Click here

    A

  100. PERFORM SIMULATION TEST


    1. Check if the idling speed after starting the engine is currently stable and has always been stable in the past.

      Result
      Problem Symptom Suspected Area Proceed to
      Current unstable idling speed or history of unstable idling speed Crankshaft position sensor system A
      All current and past idling speeds are stable Fuel B

      Tech Tips

      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

  101. CHECK SENSOR INSTALLATION (CRANKSHAFT POSITION SENSOR)


    1. Check the tightening and installation condition of the crankshaft position sensor bolt.

    2. Check the connection of the crankshaft position sensor connector.

      OK
      Sensor is installed correctly.

    NG

    SECURELY REINSTALL SENSOR

    OK

  102. CHECK HARNESS AND CONNECTOR (CRANKSHAFT POSITION SENSOR - ECM)


    1. Check harness and connectors, referring to DTC P0335 inspection procedure.

      Tech Tips


      • 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

  103. CHECK CRANKSHAFT POSITION SENSOR


    1. Replace the crankshaft position sensor Click here.

    2. Check the engine start operation.

      OK
      Malfunction has been repaired successfully.

    OK

    END (CRANKSHAFT POSITION SENSOR IS DEFECTIVE)

    NG

    REPLACE ECM Click here

  104. PERFORM ACTIVE TEST USING INTELLIGENT TESTER (CONTROL THE FUEL PUMP/SPEED)


    1. Connect the intelligent tester to the DLC3.

    2. Turn the ignition switch to ON.

    3. Turn the tester on.

    4. Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump/Speed.

    5. When performing the Active Test, check for fuel leakage from the fuel pipes.

      Result
      Result Proceed to
      No fuel leakage or signs of fuel leakage A
      Fuel leakage or signs of fuel leakage are present B

      Tech Tips


      • 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

    REPAIR OR REPLACE FUEL LINE

    A

  105. INSPECT FUEL PUMP (RESISTANCE)


    1. Inspect the fuel pump Click here.

      Tech Tips

      Perform "Inspection After Repairs" after replacing the fuel pump Click here.


    NG

    REPLACE FUEL PUMP Click here

    OK

  106. CHECK PURGE VSV


    1. A01VKWW

      Disconnect the vacuum hose (on the canister side) of the purge VSV.

    2. Start the engine.

    3. Idle the engine.

    4. Disconnect the B102 purge VSV connector.

    5. Check if air flows through the purge VSV.

      OK
      Air does not flow

      Tech Tips

      When this inspection is performed, the MIL may illuminate. After finishing the inspection, check and clear DTCs Click here.


    NG

    INSPECT PURGE VSV Click here

    OK

  107. CHECK FUEL INJECTOR ASSEMBLY


    1. Clean the inside of the surge tank with compressed air.

    2. After stopping the engine, measure the HC concentration inside the surge tank for 15 minutes.

      Result
      Result Proceed to
      Less than 4000 ppm A
      4000 ppm or higher B

      Tech Tips


      • If the concentration is 4000 ppm or higher, the fuel injector assembly may have a sealing problem.

      • Perform "Inspection After Repairs" after replacing the fuel injector assembly Click here.


    B

    REPLACE FUEL INJECTOR ASSEMBLY Click here

    A

  108. INSPECT INTAKE VALVE


    1. Inspect if carbon is on the intake valve.

      Result
      Result Proceed to
      No carbon present A
      Carbon present B

    B

    CLEAN INTAKE VALVE

    A

  109. READ VALUE USING INTELLIGENT TESTER (ISC FEEDBACK LEARNING TORQUE)


    1. Connect the intelligent tester to the DLC3.

    2. Turn the ignition switch to ON.

    3. Turn the tester on.

    4. Enter the following menus: Powertrain / Engine and ECT / Data List / ISC Feedback Learning Torque.

    5. Start the engine, turn off all accessory switches and warm up the engine until the engine coolant temperature stabilizes.

      Result
      Data List Item Result Suspected Area Proceed to
      ISC Feedback Learning Torque 5 Nm or more

      • Valve timing

      • Compression

      		 A
      Below 5 Nm - B

    B

    INSPECT ENGINE COOLANT TEMPERATURE SENSOR Click here

    A

  110. CHECK CYLINDER COMPRESSION PRESSURE


    1. Check the compression Click here.

      Tech Tips

      Perform "Inspection After Repairs" after replacing the engine assembly Click here.


    OK

    CHECK VALVE TIMING Click here

    NG

    REPAIR OR REPLACE ENGINE ASSEMBLY

  111. INSPECT ENGINE COOLANT TEMPERATURE SENSOR


    1. Inspect the engine coolant temperature sensor Click here.

      Tech Tips

      Perform "Inspection After Repairs" after replacing the engine coolant temperature sensor Click here.


    NG

    REPLACE ENGINE COOLANT TEMPERATURE SENSOR Click here

    OK

  112. CHECK SENSOR INSTALLATION (CRANKSHAFT POSITION SENSOR)


    1. Check the tightening and installation condition of the crankshaft position sensor bolt.

    2. Check the connection of the crankshaft position sensor connector.

      OK
      Sensor is installed correctly.

    NG

    SECURELY REINSTALL SENSOR

    OK

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


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

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

      OK
      Sensor is installed correctly.

    NG

    SECURELY REINSTALL SENSOR

    OK

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


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

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

      OK
      Sensor is installed correctly.

    NG

    SECURELY REINSTALL SENSOR

    OK

  115. CHECK HARNESS AND CONNECTOR (CRANKSHAFT POSITION SENSOR - ECM)


    1. Check harness and connectors, referring to DTC P0335 inspection procedure.

      Tech Tips


      • 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

  116. CHECK HARNESS AND CONNECTOR (CAMSHAFT POSITION SENSOR (FOR INTAKE CAMSHAFT) - ECM)


    1. Check harness and connectors, referring to DTC P0340 inspection procedure.

      Tech Tips


      • 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

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


    1. Check harness and connectors, referring to DTC P0365 inspection procedure.

      Tech Tips


      • 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

  118. CHECK CRANKSHAFT POSITION SENSOR


    1. Replace the crankshaft position sensor Click here.

    2. Check the engine start operation.

      OK
      Malfunction has been repaired successfully.

    OK

    END (CRANKSHAFT POSITION SENSOR IS DEFECTIVE)

    NG

  119. CHECK CAMSHAFT POSITION SENSOR (FOR INTAKE CAMSHAFT)


    1. Replace the camshaft position sensor (for intake camshaft) Click here.

    2. Check the engine start operation.

      OK
      Malfunction has been repaired successfully.

    OK

    END (CAMSHAFT POSITION SENSOR (FOR INTAKE CAMSHAFT) IS DEFECTIVE)

    NG

  120. CHECK CAMSHAFT POSITION SENSOR (FOR EXHAUST CAMSHAFT)


    1. Replace the camshaft position sensor (for exhaust camshaft) Click here.

    2. Check the engine start operation.

      OK
      Malfunction has been repaired successfully.

    OK

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

    NG

    REPLACE ECM Click here