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).

  • (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.

  • Immobiliser system

  • Engine assembly (excess friction, compression loss)

  • Starter

  • Crankshaft position sensor

  • Engine coolant temperature sensor

  • Fuel pump

  • Fuel pump control system

  • Fuel pipes

  • Fuel injector assembly

  • Throttle body

  • Pressure regulator

  • Battery

  • Drive plate*1

  • Flywheel*2

  • Spark plug

  • Ignition coil circuit

  • Intake system

  • Camshaft timing oil control valve

  • Manifold absolute pressure sensor

  • Air fuel ratio sensor

  • Valve timing

  • Fuel

  • Purge VSV

  • EGR system

  • Intake valve

  • Exhaust valve

  • ECM

A011A1QE01

WIRING DIAGRAM

Refer to DTC P0107 for the manifold absolute pressure sensor 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 DTC P0351 for the ignition coil circuit Click here.

Refer to DTC P0443 for the purge VSV circuit Click here.

Refer to DTC P2195 for the air fuel ratio sensor circuit Click here.

Refer to Fuel Injector Circuit for the fuel injector circuit Click here.

INSPECTION PROCEDURE

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.

        A011AZOE25

      2. All engine speeds recorded in the freeze frame data are between 60 and 250 rpm (the engine cranks but there is no combustion).

        Tech Tips

        If the engine speed is between 60 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 a engine coolant temperature sensor malfunction, the fuel injection volume is extremely high or low and the engine may not be able to be started.

          A011AH7E12

      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.

          A011AZOE26

    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 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, 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 air-fuel 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

      • Immobiliser system

      • Crankshaft position sensor

      • ECM

      		 4 to 9
      60 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 gear wear or tooth damage)

        • Starter
        Immobiliser system

        • Immobiliser system
        Engine assembly

        • Engine assembly (excess friction)

        • Drive plate wear or tooth damage*1

        • Flywheel wear or tooth damage*2
        Cranking speed too low Battery malfunction

        • Battery fully depleted

        		 32 to 34
        Starting system

        • Starter
        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 pressure regulator

        • Fuel injector leak

        • Fuel leak from fuel line

        • Fuel pump control system

        • Fuel pump

        		 35 to 50
        Ignition system malfunction

        • Spark plug

        • Crankshaft position sensor

        • Ignition coil
        Engine stalls after starter turnoff Air suction

        • Intake system connections

        		 51 to 58
        Deposits in throttle body

        • Throttle body
        VVT valve does not return properly

        • Camshaft timing oil control valve assembly
        Manifold absolute pressure sensor malfunction

        • Manifold absolute pressure sensor
        EGR valve does not close properly

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

        • Engine coolant temperature sensor

        		 59 to 72
        Manifold absolute pressure sensor malfunction

        • Manifold absolute pressure sensor
        Abnormal A/F learning value

        • Air fuel ratio sensor
        Deviation from fuel injection characteristics

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

        • Spark plug
        Lack of fuel pressure

        • Pressure regulator

        • 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 A/F learning value

        • Fuel injector

        88 to 95

        96 to 103
        Rough idling

        • Crankshaft position sensor
        Abnormal fuel pressure

        • Fuel

        • Fuel leak from fuel line

        • Fuel pump

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

        • Purge VSV system

        • Fuel injector

        		 104 to 106
        Fuel system troubleshooting C Injection signal system malfunction

        • Fuel injector

        • Crankshaft position sensor

        • Camshaft position sensor

        • ECM

        		 74 to 78
        Intake system troubleshooting Difference between ISC target value and opening angle when idling

        • Engine assembly (compression loss)

        • Valve timing

        • Engine coolant temperature sensor

        • ECM

        85 to 87

        107 to 109
        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

        79 to 84

        110 to 115

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

    4. A0117BHE46

      Read the 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 then the DTC is stored.

        Result
        Result Proceed to
        Only DTC P1604 is output A
        DTC P1604 and other DTCs 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 intelligent tester.

      OK
      Immobiliser Fuel Cut is OFF

      Tech Tips

      If the engine is cranked immediately after reconnecting the battery cable (key verification for immobiliser system not completed), the engine cannot be started. Key verification needs to wait for several seconds after turning the ignition switch to ON.

      Result
      Result Proceed to
      OK A
      NG (w/ entry and start system) B
      NG (w/o entry and start system) C

    B

    REPAIR ENGINE IMMOBILISER SYSTEM Click here

    C

    REPAIR ENGINE IMMOBILISER 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

    CONFIRM PROBLEM SYMPTOM Click here

    A

  4. READ FREEZE FRAME DATA


    1. Connect the intelligent tester to the DLC3.

    2. Turn the ignition switch to ON.

    3. Using the intelligent 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 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

      • Immobiliser system

      • ECM

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

      • Fuel pump control system

      • Ignition system

      • Engine coolant temperature sensor

      • Immobiliser system

      • Fuel injection system

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

      • Engine assembly

      • Fuel injection system

      • Fuel pump control system

      		 D

      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.


        • Immobilizer Fuel Cut

        • Engine Speed (Starter OFF)

        • Shift SW Status (R, D Range)


    B

    READ FREEZE FRAME DATA Click here

    C

    READ FREEZE FRAME DATA Click here

    D

    READ FREEZE FRAME DATA Click here

    E

    INSPECT MANIFOLD ABSOLUTE PRESSURE SENSOR Click here

    A

    CHARGE OR REPLACE BATTERY

  5. READ FREEZE FRAME DATA


    1. Connect the intelligent tester to the DLC3.

    2. Turn the ignition switch to ON.

    3. Using the intelligent 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*1 Starter system

      A*5

      B*6
      Minimum voltage is 6 V or higher and voltage fluctuates*2, *3

      • Crankshaft position sensor system

      • ECM

      		 C
      Minimum voltage is 5 to 6 V*4

      • Excess engine friction

      • Battery fully depleted

      		 D

      Tech Tips


      • A01176NE01

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

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

      • *3: 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.

      • *4: 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 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.

      • *5: w/o Entry and start system

      • *6: w/ Entry and start system


    B

    CHECK CRANKING HOLDING FUNCTION CIRCUIT Click here

    C

    CHECK CRANKSHAFT POSITION SENSOR INSTALLATION Click here

    D

    CHECK AND REPAIR ENGINE ASSEMBLY OR BATTERY

    A

    CHECK STARTER SIGNAL CIRCUIT Click here

  6. CHECK CRANKSHAFT POSITION SENSOR INSTALLATION


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

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


    NG

    SECURELY REINSTALL CRANKSHAFT POSITION SENSOR Click here

    OK

  7. CHECK CRANKSHAFT POSITION SENSOR


    1. Disconnect the crankshaft position sensor connector.

    2. Check for oil on the connector terminals.

      OK
      No oil on the terminals.

    3. Reconnect the crankshaft position sensor connector.


    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 Click here.

      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.

    NG

    REPLACE ECM Click here

    OK

    END (CRANKSHAFT POSITION SENSOR IS DEFECTIVE)

  10. READ FREEZE FRAME DATA


    1. Connect the intelligent tester to the DLC3.

    2. Turn the ignition switch to ON.

    3. Using the intelligent 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.


    B

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

    C

    CHECK FUEL PUMP CONTROL CIRCUIT Click here

    A

    REPLACE ENGINE COOLANT TEMPERATURE SENSOR Click here

  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. A0117DZE02
      Text in Illustration
      *1

      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
      L1-4 - 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 HARNESS AND CONNECTOR (FUEL INJECTOR CIRCUIT)


    1. Check the harnesses and connectors, referring to DTC P0300 inspection procedure Click here.

      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.


    B

    CHECK FUEL SYSTEM Click here

    A

    REPAIR OR REPLACE FUEL LINE

  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

    B

    PERFORM SIMULATION TEST Click here

    A

    REPAIR OR REPLACE FUEL SYSTEM

  15. READ FREEZE FRAME DATA


    1. Connect the intelligent tester to the DLC3.

    2. Turn the ignition switch to ON.

    3. Using the intelligent 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 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

      		 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

      		 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.


    B

    INSPECT FUEL INJECTOR ASSEMBLY Click here

    C

    CHECK AND REPAIR ENGINE ASSEMBLY

    D

    READ FREEZE FRAME DATA Click here

    A

    REPLACE ENGINE COOLANT TEMPERATURE SENSOR Click here

  16. INSPECT FUEL INJECTOR ASSEMBLY


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

      OK
      No carbon present

    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

    B

    PERFORM SIMULATION TEST Click here

    A

    REPAIR OR REPLACE FUEL SYSTEM

  18. READ FREEZE FRAME DATA


    1. Connect the intelligent tester to the DLC3.

    2. Turn the ignition switch to ON.

    3. Using the intelligent 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 Pressure regulator A
      Engine coolant temperature is 40 to 90°C (104 to 194°F)*2 Fuel injector B
      Engine coolant temperature is 90°C (194°F) or more*3 Pressure regulator 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 pressure regulator may be stuck open. Attach a fuel pressure gauge and check the ability to maintain fuel pressure after stopping the engine.

      *2: If the engine coolant temperature is 40 to 90°C (104 to 194°F) (15 to 120 minutes have passed after stopping the engine), there may be fuel leaking from the fuel injector.

      *3: If the engine coolant temperature is 90°C (194°F) or more (2 to 5 minutes have passed after stopping the engine), there may be a problem with the pressure regulator failing to maintain the fuel pressure. Attach a fuel pressure gauge and check the ability to maintain fuel pressure after stopping the engine.


    B

    CHECK FUEL INJECTOR ASSEMBLY 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
      Abnormal A
      Normal B

    B

    PERFORM SIMULATION TEST Click here

    A

    REPLACE FUEL PRESSURE REGULATOR ASSEMBLY 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
      400 ppm or higher A
      Less than 400 ppm B

      Tech Tips

      If the concentration is 400 ppm or higher, the fuel injector may have a sealing problem.


    B

    CHECK THROTTLE BODY ASSEMBLY Click here

    A

  21. INSPECT FUEL INJECTOR ASSEMBLY


    1. Inspect the fuel injector Click here.

      Result
      Result Proceed to
      Abnormal A
      Normal B

    B

    CHECK THROTTLE BODY ASSEMBLY Click here

    A

    REPLACE FUEL INJECTOR ASSEMBLY Click here

  22. CHECK THROTTLE BODY ASSEMBLY


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

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

    B

    CHECK INTAKE SYSTEM Click here

    A

    REPLACE THROTTLE BODY ASSEMBLY Click here

  23. CHECK INTAKE SYSTEM


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

      OK
      No leak in intake system.

    NG

    REPAIR OR REPLACE INTAKE SYSTEM

    OK

  24. PERFORM SIMULATION TEST


    1. Check if the engine can be started.

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

    B

    CONFIRM PROBLEM SYMPTOM Click here

    A

    END

  25. CONFIRM PROBLEM SYMPTOM


    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 gear wear or teeth damage)

      • Starter system

      • Engine assembly (excess friction)

      • Drive plate wear or teeth damage

      		 A
      Abnormal cranking speed

      • Battery fully depleted

      • Starter

      • Engine assembly (excess friction, compression loss)

      		 B
      There is no initial combustion (combustion does not occur even once)*1

      • Fuel pressure of pressure regulator maintained

      • Fuel injector leak

      • Fuel leak from fuel line

      • Fuel pump control system

      • Fuel pump

      • Spark plug

      • Crankshaft position sensor system

      • Ignition coil system

      • EGR valve

      		 C
      The engine stalls after starter turnoff (engine stalls immediately after the first time the engine speed increases)*2

      • Intake system connections

      • Throttle body

      • Camshaft timing oil control valve

      • Manifold absolute pressure sensor

      • EGR valve

      		 D
      The initial combustion and starter turnoff occur late*3

      • Engine coolant temperature sensor

      • Manifold absolute pressure sensor

      • Air fuel ratio sensor

      • Heated oxygen sensor

      • Fuel injector

      • Spark plug

      • Pressure regulator

      • Fuel pump

      • Fuel pump control system

      		 E

      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.

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

      • *2: If the engine stalls after starter turnoff, the air-fuel ratio may be incorrect or the Camshaft timing oil control valve may have a problem returning.

      • *3: If the initial combustion and starter turnoff occur late, the fuel injection volume may be incorrect (too low or too high).


    B

    PERFORM SIMULATION TEST Click here

    C

    INSPECT FUEL INJECTOR ASSEMBLY Click here

    D

    INSPECT MANIFOLD ABSOLUTE PRESSURE SENSOR 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*1

      • Battery

      • Excess engine friction

      • Starter

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

      • Drive plate*2

      • Flywheel*3

      • Starter

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

      • Battery

      • Starter

      • Starter system

      		 C

      Tech Tips


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

      • *2: for CVT

      • *3: for Manual Transaxle


    B

    INSPECT STARTER ASSEMBLY 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

      (Models w/ 0.8 kW type starter)

      		 B

      OK

      (Models w/ 1.0 kW type starter)

      		 C

      Tech Tips

      Excess engine friction may have occurred temporarily. Remove the cylinder head cover and oil pan, and check for foreign matter such as iron fragments. If there is a malfunction or signs of a malfunction present, perform a detailed inspection by disassembling all the parts.


    B

    INSPECT STARTER ASSEMBLY (FOR 0.8 KW TYPE) Click here

    C

    INSPECT STARTER ASSEMBLY (FOR 1.0 KW TYPE) Click here

    A

    CHECK AND REPAIR ENGINE ASSEMBLY

  29. INSPECT STARTER ASSEMBLY


    1. Remove the starter.

      Starter See page
      0.8 kW Type

      Click here

      1.0 kW Type

      Click here

    2. Check for starter pinion gear wear and damage.

      Standard
      There is no wear or damage.
      Result
      Result Proceed to
      NG A

      OK

      (for Manual Transaxle)

      		 B

      OK

      (for CVT)

      		 C

    3. Install the starter.

      Starter See page
      0.8 kW Type

      Click here

      1.0 kW Type

      Click here


    B

    REPLACE FLYWHEEL SUB-ASSEMBLY Click here

    C

    REPLACE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY Click here

    A

    REPLACE STARTER ASSEMBLY

  30. INSPECT BATTERY


    1. Inspect the battery Click here.


    NG

    CHARGE OR REPLACE BATTERY

    OK

  31. INSPECT STARTER ASSEMBLY


    1. Inspect the starter.

      Starter See page
      0.8 kW Type Starter

      Click here

      1.0 kW Type Starter

      Click here

      Result
      Result Proceed to
      NG A

      OK

      (w/o Entry and start system)

      		 B

      OK

      (w/ Entry and start system)

      		 C

    B

    CHECK STARTER SIGNAL CIRCUIT Click here

    C

    CHECK CRANKING HOLDING FUNCTION CIRCUIT Click here

    A

    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

      • 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

      (Models w/ 0.8 kW type starter)

      		 B

      OK

      (Models w/ 1.0 kW type starter)

      		 C

      Tech Tips

      Excess engine friction may have occurred temporarily. Remove the cylinder head cover and oil pan, and check for foreign matter such as iron fragments. If there is a malfunction or signs of a malfunction present, perform a detailed inspection by disassembling all the parts.


    B

    INSPECT STARTER ASSEMBLY (FOR 0.8 KW TYPE) Click here

    C

    INSPECT STARTER ASSEMBLY (FOR 1.0 KW TYPE) Click here

    A

    CHECK AND REPAIR ENGINE 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. CONFIRM VEHICLE CONDITION


    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 Pressure regulator 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 Pressure regulator 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 pressure regulator 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.

      *3: The pressure regulator 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 73, perform fuel system troubleshooting C (steps 74 to 78).


    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.

      Result
      Result Proceed to

      Less than 147 kPa (1.5 kgf/cm2) (5 minutes after stopping the engine)

      		 A

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

      		 B*1

      Tech Tips


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

      • *1: From step 73, perform fuel system troubleshooting C (steps 74 to 78).


    B

    CHECK MALFUNCTION CONDITION Click here

    A

    REPLACE FUEL PRESSURE REGULATOR ASSEMBLY Click here

  40. CHECK FUEL INJECTOR ASSEMBLY


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

      Result
      Result Proceed to
      400 ppm or higher A
      Less than 400 ppm B*1

      Tech Tips


      • If the concentration is 400 ppm or higher, the fuel injector may have a sealing problem.

      • *1: From step 73, perform fuel system troubleshooting C (steps 74 to 78).


    B

    CHECK MALFUNCTION CONDITION Click here

    A

    REPLACE FUEL INJECTOR ASSEMBLY 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 HARNESS AND CONNECTOR (IGNITION COIL POWER SOURCE)


    1. Check the harnesses and connectors, referring to DTC P0351 inspection procedure Click here.

      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 POWER SOURCE CIRCUIT (IGNITION COIL POWER SOURCE) Click here

    OK

  44. CHECK HARNESS AND CONNECTOR (IGNITION COIL - ECM)


    1. Check the harnesses and connectors, referring to DTC P0351 inspection procedure Click here.

      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

  45. CHECK HARNESS AND CONNECTOR (IGNITION COIL - ECM)


    1. Check the harnesses and connectors, referring to DTC P0351 inspection procedure Click here.

      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 73 and perform troubleshooting for the ignition system (steps 79 to 84).


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

    REPLACE IGNITION COIL Click here

  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 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

  47. 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 73 and perform fuel system troubleshooting (steps 74 to 78).


    B

    CHECK FUEL PUMP CONTROL CIRCUIT Click here

    A

    REPAIR OR REPLACE FUEL LINE

  48. 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

  49. CHECK HARNESS AND CONNECTOR (FUEL INJECTOR POWER SOURCE)


    1. Check the harnesses and connectors, referring to Fuel Injector Circuit inspection procedure Click here.

      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

  50. CHECK HARNESS AND CONNECTOR (FUEL INJECTOR - ECM)


    1. Check the harnesses and connectors, referring to Fuel Injector Circuit inspection procedure Click here.

      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

    REPLACE ECM Click here

  51. INSPECT MANIFOLD ABSOLUTE PRESSURE SENSOR


    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 / MAP.

    5. Read the MAP value.

      Standard
      Same as actual atmospheric pressure.

      Tech Tips

      Reference MAP value:

      Engine Condition Specified Condition
      Idling with warm engine 28 to 48 kPa
      IG ON, engine stopped 80 to 110 kPa*

      *: varies with weather condition.


    NG

    CHECK HARNESS AND CONNECTOR (MANIFOLD ABSOLUTE PRESSURE SENSOR - ECM) Click here

    OK

  52. 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.

      OK
      There is no air suction.

    NG

    REPAIR OR REPLACE INTAKE SYSTEM

    OK

  53. INSPECT THROTTLE BODY ASSEMBLY


    1. Disconnect the throttle body connector.

      Tech Tips

      When the connector is disconnected, the vehicle enters fail-safe mode and the throttle valve opening angle is 4 to 7°.

    2. Crank the engine and check that it starts.

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

    3. Connect the throttle body connector.

      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 SYSTEM) Click here

    A

  54. INSPECT THROTTLE BODY ASSEMBLY


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

      OK
      No carbon present.

    NG

    REMOVE FOREIGN OBJECT AND CLEAN THROTTLE BODY

    OK

  55. PERFORM ACTIVE TEST USING INTELLIGENT TESTER (CONTROL THE VVT SYSTEM)


    1. A0118X7E01

      Connect the intelligent tester to the DLC3.

    2. Turn the tester on.

    3. Warm up the engine.

    4. Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the VVT system (Bank 1).

      Tech Tips

      When performing the Active Test, make sure the A/C is on and the shift lever is in N (neutral).

    5. Check the engine speed while operating the Oil Control Valve (OCV) using the intelligent tester.

      OK*1
      Tester Operation Specified Condition
      OFF Normal engine speed
      ON Engine idles roughly or stalls
      Result
      Result Proceed to
      NG A
      OK B

      Tech Tips


      • *1: From step 73, perform intake system troubleshooting (steps 85 to 87). If engine starting trouble still occurs, perform fuel system troubleshooting A (steps 88 to 95).

      • 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.


    B

    PERFORM ACTIVE TEST USING INTELLIGENT TESTER (CONTROL THE EGR STEP POSITION) Click here

    A

    REPLACE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY Click here

  56. 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 N or 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 Date List at the idling condition while performing Active Test.

      OK
      MAP and idling condition change in response to EGR step position.
      Standard
      - 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 28 to 48 kPa (210 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

      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.

      Result
      Result Proceed to
      NG A
      OK B

    B

    CHECK MALFUNCTION CONDITION Click here

    A

  57. 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

    3. Reinstall the EGR valve assembly Click here.


    B

    CHECK MALFUNCTION CONDITION Click here

    A

    REPLACE EGR VALVE ASSEMBLY Click here

  58. CHECK HARNESS AND CONNECTOR (MANIFOLD ABSOLUTE PRESSURE SENSOR - ECM)


    1. Check the harnesses and connectors, referring to DTC P0107 inspection procedure Click here.

      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 manifold absolute pressure sensor, check if engine starting trouble occurs again. If engine starting trouble occurs again, proceed to step 73 and perform intake system troubleshooting (steps 85 to 87). If engine starting trouble still occurs, perform fuel system troubleshooting A (steps 88 to 95).


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

    REPLACE MANIFOLD ABSOLUTE PRESSURE SENSOR Click here

  59. 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 73 and perform fuel system troubleshooting A (steps 96 to 103), fuel system troubleshooting B (steps 104 to 106), intake system troubleshooting (steps 107 to 109), and ignition system troubleshooting (steps 110 to 115), in that order.


    NG

    REPLACE ENGINE COOLANT TEMPERATURE SENSOR Click here

    OK

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


    1. Check the harnesses and connectors, referring to DTC P0115 inspection procedure Click here.

      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 73 and perform fuel system troubleshooting A (steps 96 to 103), fuel system troubleshooting B (steps 104 to 106), intake system troubleshooting (steps 107 to 109), and ignition system troubleshooting (steps 110 to 115), in that order.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  61. INSPECT MANIFOLD ABSOLUTE PRESSURE SENSOR


    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 / MAP.

    5. Read the MAP value.

      Standard
      Same as actual atmospheric pressure.

      Tech Tips

      Reference MAP value:

      Engine Condition Specified Condition
      Idling with warm engine 28 to 48 kPa
      IG ON, engine stopped 80 to 110 kPa*

      *: Varies with weather condition.

      Tech Tips

      If the manifold absolute pressure 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 73 and perform fuel system troubleshooting A (steps 96 to 103), fuel system troubleshooting B (steps 104 to 106), intake system troubleshooting (steps 107 to 109), and ignition system troubleshooting (steps 110 to 115), in that order.


    NG

    REPLACE MANIFOLD ABSOLUTE PRESSURE SENSOR Click here

    OK

  62. CHECK HARNESS AND CONNECTOR (MANIFOLD ABSOLUTE PRESSURE SENSOR - ECM)


    1. Check the harnesses and connectors, referring to DTC P0107 inspection procedure Click here.

      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 73 and perform fuel system troubleshooting A (steps 96 to 103), fuel system troubleshooting B (steps 104 to 106), intake system troubleshooting (steps 107 to 109), and ignition system troubleshooting (steps 110 to 115), in that order.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

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


    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 (600 mmHg) or less (when altitude is 0 m)

      • Air fuel ratio sensor

      • Heated oxygen sensor

      • Manifold absolute pressure sensor

      • Fuel injector

      • 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

  64. PERFORM SIMULATION TEST


    1. Remove the EFI MAIN fuse and ETCS fuse from the engine room relay block.

    2. After 60 seconds or more elapse, install the EFI MAIN fuse and ETCS fuse.

    3. 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

  65. INSPECT AIR FUEL RATIO SENSOR


    1. A011AEDE01

      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 / 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.

    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
      Air fuel ratio sensor voltage +25% 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

      Tech Tips


      • 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.

      • 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 73 and perform fuel system troubleshooting A (steps 96 to 103), fuel system troubleshooting B (steps 104 to 106), intake system troubleshooting (steps 107 to 109), and ignition system troubleshooting (steps 110 to 115), in that order.


    NG

    REPLACE AIR FUEL RATIO SENSOR Click here

    OK

  66. 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 or manifold absolute pressure sensor, check if engine starting trouble occurs again. If engine starting trouble occurs, replace the ECM. If engine starting trouble still occurs, proceed to step 73 and perform fuel system troubleshooting A (steps 96 to 103), fuel system troubleshooting B (steps 104 to 106), intake system troubleshooting (steps 107 to 109), and ignition system troubleshooting (steps 110 to 115), in that order.


    NG

    REPLACE FUEL INJECTOR ASSEMBLY Click here

    OK

    REPLACE MANIFOLD ABSOLUTE PRESSURE SENSOR Click here

  67. 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

  68. 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 73 and perform fuel system troubleshooting A (steps 96 to 103), fuel system troubleshooting B (steps 104 to 106), intake system troubleshooting (steps 107 to 109), and ignition system troubleshooting (steps 110 to 115), 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 73 and perform fuel system troubleshooting A (steps 96 to 103), fuel system troubleshooting B (steps 104 to 106), intake system troubleshooting (steps 107 to 109), and ignition system troubleshooting (steps 110 to 115), in that order.

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


    B

    REPLACE SPARK PLUG (ABNORMAL CYLINDER) Click here

    C

    REPLACE SPARK PLUG (ALL CYLINDER) Click here

    A

  69. 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 Pressure regulator 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 pressure regulator 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 pressure regulator 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.

      *3: The pressure regulator 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 73, perform fuel system troubleshooting A (steps 96 to 103), fuel system troubleshooting B (steps 104 to 106), intake system troubleshooting (steps 107 to 109), and ignition system troubleshooting (steps 110 to 115), in that order.


    B

    CHECK FUEL INJECTOR ASSEMBLY Click here

    C

    CHECK MALFUNCTION CONDITION Click here

    A

  70. 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.

      Result
      Result Proceed to

      Less than 147 kPa (1.5 kgf/cm2) (5 minutes after stopping the engine)

      		 A

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

      		 B*1

      Tech Tips


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

      • *1: From step 73, perform fuel system troubleshooting A (steps 96 to 103), fuel system troubleshooting B (steps 104 to 106), intake system troubleshooting (steps 107 to 109), and ignition system troubleshooting (steps 110 to 115), in that order.


    B

    CHECK MALFUNCTION CONDITION Click here

    A

    REPLACE FUEL PRESSURE REGULATOR ASSEMBLY Click here

  71. 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
      400 ppm or higher A
      Less than 400 ppm B*1

      Tech Tips


      • If the concentration is 400 ppm or higher, the fuel injector may have a sealing problem.

      • *1: From step 73, perform fuel system troubleshooting A (steps 96 to 103), fuel system troubleshooting B (steps 104 to 106), intake system troubleshooting (steps 107 to 109), and ignition system troubleshooting (steps 110 to 115), in that order.


    B

    CHECK MALFUNCTION CONDITION Click here

    A

    REPLACE FUEL INJECTOR ASSEMBLY Click here

  72. 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 73 and perform fuel system troubleshooting A (steps 96 to 103), fuel system troubleshooting B (steps 104 to 106), intake system troubleshooting (steps 107 to 109), and ignition system troubleshooting (steps 110 to 115), in that order.


    B

    CHECK FUEL PUMP CONTROL CIRCUIT Click here

    A

    REPAIR OR REPLACE FUEL LINE

  73. CHECK MALFUNCTION CONDITION


    1. If the malfunction could not be identified during the inspection in steps 38, 39, 40 and 47, perform fuel system troubleshooting C (steps 74 to 78).

      Result
      Performed Step Troubleshooting by System Procedure Proceed to
      Steps 38, 39, 40 and 47 Fuel system troubleshooting C 74 to 78 A

    2. If the malfunction could not be identified during the inspection in step 45, perform ignition system troubleshooting (steps 79 to 84).

      Result
      Performed Step Troubleshooting by System Procedure Proceed to
      Step 45 Ignition system troubleshooting 79 to 84 B

    3. If the malfunction could not be identified during the inspection in steps 55 and 58, perform intake air system troubleshooting (steps 85 to 87). If engine starting trouble still occurs, perform fuel intake system troubleshooting A (steps 88 to 95).

      Result
      Performed Step Troubleshooting by System Procedure Proceed to
      Step 55 and 58 Intake air system troubleshooting 85 to 87 C
      Fuel system troubleshooting A 88 to 95

    4. If the malfunction could not be identified during the inspection in steps 59, 60, 61, 62, 65, 66, 68, 69, 70, 71 and 72, perform fuel system troubleshooting A (steps 96 to 103), fuel system troubleshooting B (steps 104 to 106), intake air system troubleshooting (steps 107 to 109), and ignition system troubleshooting (steps 110 to 115), in that order.

      Result
      Performed Step Troubleshooting by System Procedure Proceed to
      Steps 59, 60, 61, 62, 65, 66, 68, 69, 70, 71 and 72 Fuel system troubleshooting A 96 to 103 D
      Fuel system troubleshooting B 104 to 106
      Intake air system troubleshooting 107 to 109
      Ignition system troubleshooting 110 to 115

    B

    CHECK CRANKSHAFT POSITION SENSOR (SENSOR INSTALLATION) Click here

    C

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

    D

    CHECK FUEL PRESSURE Click here

    A

  74. INSPECT FUEL INJECTOR ASSEMBLY


    1. Inspect the fuel injector Click here.


    NG

    REPLACE FUEL INJECTOR ASSEMBLY Click here

    OK

  75. CHECK HARNESS AND CONNECTOR (FUEL INJECTOR POWER SOURCE)


    1. Check the harnesses and connectors, referring to Fuel Injector Circuit inspection procedure Click here.

      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

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


    1. Check the harnesses and connectors, referring to Fuel Injector Circuit inspection procedure Click here.

      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

  77. CHECK CRANKSHAFT POSITION SENSOR


    1. Replace the crankshaft position sensor Click here.

    2. Check the engine start operation.

      OK
      Malfunction has been repaired successfully.

    NG

    CHECK CAMSHAFT POSITION SENSOR Click here

    OK

    END (CRANKSHAFT POSITION SENSOR IS DEFECTIVE)

  78. CHECK CAMSHAFT POSITION SENSOR


    1. Replace the camshaft position sensor Click here.

    2. Check the engine start operation.

      OK
      Malfunction has been repaired successfully.

    NG

    REPLACE ECM Click here

    OK

    END (CAMSHAFT POSITION SENSOR IS DEFECTIVE)

  79. CHECK CRANKSHAFT POSITION SENSOR (SENSOR INSTALLATION)


    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 CRANKSHAFT POSITION SENSOR Click here

    OK

  80. CHECK CAMSHAFT POSITION SENSOR (SENSOR INSTALLATION)


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

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

      OK
      Sensor is installed correctly.

    NG

    SECURELY REINSTALL CAMSHAFT POSITION SENSOR Click here

    OK

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


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

      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 - ECM)


    1. Check the harnesses and connectors, referring to DTC P0340 inspection procedure Click here.

      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 CRANKSHAFT POSITION SENSOR


    1. Replace the crankshaft position sensor Click here.

    2. Check the engine start operation.

      OK
      Malfunction has been repaired successfully.

    NG

    CHECK CAMSHAFT POSITION SENSOR Click here

    OK

    END (CRANKSHAFT POSITION SENSOR IS DEFECTIVE)

  84. CHECK CAMSHAFT POSITION SENSOR


    1. Replace the camshaft position sensor Click here.

    2. Check the engine start operation.

      OK
      Malfunction has been repaired successfully.

    NG

    REPLACE ECM Click here

    OK

    END (CAMSHAFT POSITION SENSOR IS DEFECTIVE)

  85. READ VALUE USING INTELLIGENT TESTER (ISC LEARNING VALUE)


    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 Learning Value.

    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 Learning Value (Engine displacement (liters) x 0.9) or more

      • Valve timing

      • Compression

      		 A
      Less than (engine displacement (liters) x 0.9) - B

    B

    INSPECT ENGINE COOLANT TEMPERATURE SENSOR Click here

    A

  86. CHECK CYLINDER COMPRESSION PRESSURE


    1. Check the compression Click here.


    NG

    CHECK AND REPAIR ENGINE ASSEMBLY

    OK

    CHECK VALVE TIMING

  87. INSPECT ENGINE COOLANT TEMPERATURE SENSOR


    1. Inspect the engine coolant temperature sensor Click here.


    NG

    REPLACE ENGINE COOLANT TEMPERATURE SENSOR Click here

    OK

  88. 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

  89. 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 B

    B

    REPLACE FUEL INJECTOR ASSEMBLY Click here

    A

  90. 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

  91. CHECK CRANKSHAFT POSITION SENSOR (SENSOR INSTALLATION)


    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 CRANKSHAFT POSITION SENSOR Click here

    OK

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


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

      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

  93. CHECK CRANKSHAFT POSITION SENSOR


    1. Replace the crankshaft position sensor Click here.

    2. Check the engine start operation.

      OK
      Malfunction has been repaired successfully.

    NG

    REPLACE ECM Click here

    OK

    END (CRANKSHAFT POSITION SENSOR IS DEFECTIVE)

  94. 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.


    B

    INSPECT FUEL PUMP (RESISTANCE) Click here

    A

    REPAIR OR REPLACE FUEL LINE

  95. INSPECT FUEL PUMP (RESISTANCE)


    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.


    NG

    REPLACE FUEL PUMP Click here

    OK

    REPLACE FUEL PRESSURE REGULATOR ASSEMBLY Click here

  96. 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

  97. 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 B

    B

    REPLACE FUEL INJECTOR ASSEMBLY Click here

    A

  98. 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

  99. CHECK CRANKSHAFT POSITION SENSOR (SENSOR INSTALLATION)


    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 CRANKSHAFT POSITION SENSOR Click here

    OK

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


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

      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

  101. CHECK CRANKSHAFT POSITION SENSOR


    1. Replace the crankshaft position sensor Click here.

    2. Check the engine start operation.

      OK
      Malfunction has been repaired successfully.

    NG

    REPLACE ECM Click here

    OK

    END (CRANKSHAFT POSITION SENSOR IS DEFECTIVE)

  102. 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.


    B

    INSPECT FUEL PUMP (RESISTANCE) Click here

    A

    REPAIR OR REPLACE FUEL LINE

  103. INSPECT FUEL PUMP (RESISTANCE)


    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.


    NG

    REPLACE FUEL PUMP Click here

    OK

  104. INSPECT PURGE VSV


    1. A01182K

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

    2. Start the engine.

    3. Idle the engine.

    4. Disconnect the connector of the purge VSV.

    5. Check if air flows through the purge VSV.

      OK
      Air does not flow

    6. Connect the connector of the purge VSV.

    7. Connect the vacuum hose of the purge VSV.

      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

  105. 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
      400 ppm or higher A
      Less than 400 ppm B

      Tech Tips

      If the concentration is 400 ppm or higher, the fuel injector may have a sealing problem.


    B

    INSPECT INTAKE VALVE Click here

    A

    REPLACE FUEL INJECTOR ASSEMBLY Click here

  106. INSPECT INTAKE VALVE


    1. Inspect if carbon is on the intake valve.

      Result
      Result Proceed to
      Carbon present A
      No carbon present B

    B

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

    A

    CLEAN INTAKE VALVE

  107. READ VALUE USING INTELLIGENT TESTER (ISC LEARNING VALUE)


    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 Learning Value.

    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 Learning Value (Engine displacement (liters) x 0.9) or more

      • Valve timing

      • Compression

      		 A
      Less than (engine displacement (liters) x 0.9) - B

    B

    INSPECT ENGINE COOLANT TEMPERATURE SENSOR Click here

    A

  108. CHECK CYLINDER COMPRESSION PRESSURE


    1. Check the compression Click here.


    NG

    CHECK AND REPAIR ENGINE ASSEMBLY

    OK

    CHECK VALVE TIMING

  109. INSPECT ENGINE COOLANT TEMPERATURE SENSOR


    1. Inspect the engine coolant temperature sensor Click here.


    NG

    REPLACE ENGINE COOLANT TEMPERATURE SENSOR Click here

    OK

  110. CHECK CRANKSHAFT POSITION SENSOR (SENSOR INSTALLATION)


    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 CRANKSHAFT POSITION SENSOR Click here

    OK

  111. CHECK CAMSHAFT POSITION SENSOR (SENSOR INSTALLATION)


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

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

      OK
      Sensor is installed correctly.

    NG

    SECURELY REINSTALL CAMSHAFT POSITION SENSOR Click here

    OK

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


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

      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

  113. CHECK HARNESS AND CONNECTOR (CAMSHAFT POSITION SENSOR - ECM)


    1. Check the harnesses and connectors, referring to DTC P0340 inspection procedure Click here.

      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

  114. CHECK CRANKSHAFT POSITION SENSOR


    1. Replace the crankshaft position sensor Click here.

    2. Check the engine start operation.

      OK
      Malfunction has been repaired successfully.

    NG

    CHECK CAMSHAFT POSITION SENSOR Click here

    OK

    END (CRANKSHAFT POSITION SENSOR IS DEFECTIVE)

  115. CHECK CAMSHAFT POSITION SENSOR


    1. Replace the camshaft position sensor Click here.

    2. Check the engine start operation.

      OK
      Malfunction has been repaired successfully.

    NG

    REPLACE ECM Click here

    OK

    END (CAMSHAFT POSITION SENSOR IS DEFECTIVE)