Part 4

2ZR-FE ENGINE CONTROL: SFI SYSTEM: P1604: Startability Malfunction
P1604 - Startability Malfunction - Continued

75. CHECK FUEL INJECTOR ASSEMBLY (POWER SOURCE VOLTAGE)

(a) Disconnect the fuel injector assembly connector.

(b) Turn the ignition switch to ON.

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

Standard Voltage:

HINT
* Jiggle the wire harness and connector to increase the likelihood of detecting malfunctions that do not always occur.
* Make sure there is not an excessive amount of force applied to the wire harness.

(d) Reconnect the fuel injector assembly connector.

NG -- CHECK FUEL INJECTOR CIRCUIT Component Tests and General Diagnostics
OK -- Continue to next step.

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

(a) Disconnect the fuel injector assembly connector.

(b) Disconnect the ECM connector.

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

Standard Resistance (Check for Open):

Standard Resistance (Check for Short):

HINT
* Jiggle the wire harness and connector to increase the likelihood of detecting malfunctions that do not always occur.
* Make sure there is not an excessive amount of force applied to the wire harness.

(d) Reconnect the ECM connector.

(e) Reconnect the fuel injector assembly connector.

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

77. CHECK CRANKSHAFT POSITION SENSOR

(a) Replace the crankshaft position sensor Removal.

(b) Check the engine start operation.

OK:

Malfunction has been repaired successfully.

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

OK -- END (CRANKSHAFT POSITION SENSOR WAS DEFECTIVE)

78. CHECK CAMSHAFT POSITION SENSOR (FOR INTAKE CAMSHAFT)

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

(b) Check the engine start operation.

OK:

Malfunction has been repaired successfully.

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

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

79. CHECK CAMSHAFT POSITION SENSOR (FOR EXHAUST CAMSHAFT)

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

(b) Check the engine start operation.

OK:

Malfunction has been repaired successfully.

NG -- REPLACE ECM Removal

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

80. CHECK SENSOR INSTALLATION (CRANKSHAFT POSITION SENSOR)

(a) Check the tightening and installation condition of the crankshaft position sensor bolt.

(b) Check the connection of the crankshaft position sensor connector.

OK:

Sensor is installed correctly.

NG -- SECURELY REINSTALL CRANKSHAFT POSITION SENSOR Installation
OK -- Continue to next step.

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

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

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

OK:

Sensor is installed correctly.

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

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

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

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

OK:

Sensor is installed correctly.

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

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

(a) Disconnect the crankshaft position sensor connector.

(b) Disconnect the ECM connector.

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

Standard Resistance (Check for Open):

Standard Resistance (Check for Short):

HINT
* Jiggle the wire harness and connector to increase the likelihood of detecting malfunction that do not always occur.
* Make sure there is not an excessive amount of force applied to the wire harness.

(d) Reconnect the ECM connector.

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

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

86. CHECK CRANKSHAFT POSITION SENSOR

(a) Replace the crankshaft position sensor Removal.

(b) Check the engine start operation.

OK:

Malfunction has been repaired successfully.

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

OK -- END (CRANKSHAFT POSITION SENSOR WAS DEFECTIVE)

87. CHECK CAMSHAFT POSITION SENSOR (FOR INTAKE CAMSHAFT)

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

(b) Check the engine start operation.

OK:

Malfunction has been repaired successfully.

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

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

88. CHECK CAMSHAFT POSITION SENSOR (FOR EXHAUST CAMSHAFT)

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

(b) Check the engine start operation.

OK:

Malfunction has been repaired successfully.

NG -- REPLACE ECM Removal

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

89. READ VALUE USING TECHSTREAM (ISC LEARNING VALUE)

(a) Connect the Techstream to the DLC3.

(b) Turn the ignition switch to ON.

(c) Turn the Techstream on.

(d) Enter the following menus: Powertrain / Engine and ECT / Data List / ISC Learning Value.

(e) Start the engine and warm it up until the engine coolant temperature stabilizes with the A/C switch and all the accessory switches off.

Result:

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

90. CHECK CYLINDER COMPRESSION PRESSURE

(a) Inspect the compression Engine.

NG -- REPAIR OR REPLACE ENGINE ASSEMBLY

OK -- ADJUST VALVE TIMING Reassembly

91. INSPECT ENGINE COOLANT TEMPERATURE SENSOR

(a) Inspect the engine coolant temperature sensor Testing and Inspection.

NG -- REPLACE ENGINE COOLANT TEMPERATURE SENSOR Removal
OK -- Continue to next step.

92. CHECK FUEL PRESSURE

HINT
For the fuel pressure inspection, refer to the following procedures Fuel System.

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

Result:

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

93. READ VALUE USING TECHSTREAM (LONG FT #1)

(a) Connect the Techstream to the DLC3.

(b) Turn the ignition switch to ON.

(c) Turn the Techstream on.

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

Result:

B -- REPLACE FUEL INJECTOR ASSEMBLY Removal
A -- Continue to next step.

94. PERFORM SIMULATION TEST

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

Result:

HINT
Through the customer problem analysis, confirm the fuel being used and the location at which the fuel was added to check if the malfunction is caused by the fuel in the vehicle.

B -- REPLACE FUEL
A -- Continue to next step.

95. CHECK SENSOR INSTALLATION (CRANKSHAFT POSITION SENSOR)

(a) Check the tightening and installation condition of the crankshaft position sensor bolt.

(b) Check the connection of the crankshaft position sensor connector.

OK:

Sensor is installed correctly.

NG -- SECURELY REINSTALL CRANKSHAFT POSITION SENSOR Installation
OK -- Continue to next step.

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

(a) Disconnect the crankshaft position sensor connector.

(b) Disconnect the ECM connector.

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

Standard Resistance (Check for Open):

Standard Resistance (Check for Short):

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

A -- REPAIR OR REPLACE HARNESS OR CONNECTOR

99. INSPECT FUEL PUMP

(a) Inspect fuel pump Fuel Pump.

HINT
* 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.

(b) Reconnect the fuel pump connector.

NG -- REPLACE FUEL PUMP Removal

OK -- REPLACE PRESSURE REGULATOR Removal