Part 2

1NZ-FE ENGINE CONTROL SYSTEM: SFI SYSTEM: P1604: Startability Malfunction
P1604 - Startability Malfunction - (Continued)

20. INSPECT FUEL INJECTOR

(a) Clean the inside of the surge tank with compressed air.

(b) After stopping the engine, measure the HC concentration inside the surge tank for 15 minutes.

Result:

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

B -- INSPECT THROTTLE BODY
A -- Continue to next step.

21. INSPECT FUEL INJECTOR

(a) Inspect the fuel injectors Testing and Inspection.

Result:

B -- INSPECT THROTTLE BODY

A -- REPLACE FUEL INJECTOR

22. INSPECT THROTTLE BODY

(a) Check if carbon is in the air flow passage.

Result:

B -- CHECK AIR INDUCTION SYSTEM

A -- CLEAN OR REPLACE THROTTLE BODY

23. CHECK AIR INDUCTION SYSTEM

(a) Check the air induction system for vacuum leak Testing and Inspection.

OK:

No leak in air induction system.

NG -- REPAIR OR REPLACE AIR INDUCTION SYSTEM
OK -- Continue to next step.

24. PERFORM SIMULATION TEST

(a) Check if the engine can be started.

Result:

B -- CONFIRM PROBLEM SYMPTOM

A -- END

25. CONFIRM PROBLEM SYMPTOM

(a) Confirm the problem symptoms.

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

Result:

HINT
- If there is hesitation (cranking speed is slow and combustion occurs before passing TDC) during the initial cranking period, the battery charge may be insufficient or the starter may be malfunctioning.
- *1: If there is no initial combustion, a wire harness may be malfunctioning, or the ignition or fuel system may be malfunctioning.
- *2: If the engine stalls after starter turnoff, the air-fuel ratio may be incorrect or the camshaft timing oil control valve may have a problem returning.
- *3: If the initial combustion and starter turnoff occur late, the fuel injection volume may be incorrect (too low or too high).
E -- INSPECT ENGINE COOLANT TEMPERATURE SENSOR

D -- INSPECT MASS AIR FLOW METER

C -- INSPECT FUEL INJECTOR

B -- PERFORM SIMULATION TEST
A -- Continue to next step.

26. PERFORM SIMULATION TEST

(a) When cranking the engine, check for a noise indicating that the starter pinion gear is extending, and check that the starter pinion gear is not spinning freely.

Result:

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

C -- INSPECT BATTERY

B -- INSPECT STARTER (STARTER PINION GEAR)
A -- Continue to next step.

27. INSPECT BATTERY

(a) Check the electrolyte quantity.

OK:

Electrolyte quantity is within the specified range.

(b) Inspect the specific gravity.

(1) Inspect the specific gravity of each cell.

Standard specific gravity:

1.25 to 1.29 (electrolyte is at 20°C [68°F])

HINT
- If the result is not as specified, recharge or replace the battery.
- It is not necessary to inspect a maintenance-free battery.
(c) Inspect the battery voltage.

(1) Turn the ignition switch off and turn on the headlights for 20 to 30 seconds. This will remove the surface charge from the battery.

(2) Measure the battery voltage.

Standard voltage:

12.5 to 12.9 V (electrolyte is at 20°C [68°F])

HINT
If the result is not as specified, recharge or replace the battery.

(3) Measure the battery voltage when cranking the engine.

Standard voltage:

Approximately 6 V or higher (0°C [32°F] or higher)

HINT
When the battery is depleted, the horn becomes quieter.

NG -- CHARGE OR REPLACE BATTERY
OK -- Continue to next step.

28. CHECK ENGINE ASSEMBLY

(a) Check that the crankshaft rotates smoothly when rotating it by hand.

OK:

Crankshaft rotates smoothly.

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

NG -- REPAIR OR REPLACE ENGINE ASSEMBLY

OK -- INSPECT STARTER

29. INSPECT STARTER (STARTER PINION GEAR)

(a) Remove the starter (for 0.8 kW type) Removal.

(b) Remove the starter (for 1.6 kW type) Removal.

(c) Check for starter pinion gear wear and damage.

OK:

There is no wear or damage.

NG -- REPLACE STARTER

OK -- REPLACE FLYWHEEL SUB-ASSEMBLY OR DRIVE PLATE AND RING GEAR

30. INSPECT BATTERY

(a) Check the electrolyte quantity.

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

B -- CHECK AND REPAIR ENGINE ASSEMBLY
A -- Continue to next step.

33. INSPECT BATTERY

(a) Check the electrolyte quantity.

OK:

Electrolyte quantity is within the specified range.

(b) Inspect the specific gravity.

(1) Inspect the specific gravity of each cell.

Standard specific gravity:

1.25 to 1.29 (electrolyte is at 20°C [68°F])

HINT
- If the result is not as specified, recharge or replace the battery.
- It is not necessary to inspect a maintenance-free battery.
(c) Inspect the battery voltage.

(1) Turn the ignition switch off and turn on the headlights for 20 to 30 seconds. This will remove the surface charge from the battery.

(2) Measure the battery voltage.

Standard voltage:

12.5 to 12.9 V (electrolyte is at 20°C [68°F])

HINT
If the result is not as specified, recharge or replace the battery.

(3) Measure the battery voltage when cranking the engine.

Standard voltage:

Approximately 6 V or higher (0°C [32°F] or higher)

HINT
When the battery is depleted, the horn becomes quieter.

NG -- CHARGE OR REPLACE BATTERY
OK -- Continue to next step.

34. CHECK ENGINE ASSEMBLY

(a) Check that the crankshaft rotates smoothly when rotating it by hand.

OK:

Crankshaft rotates smoothly.

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

NG -- CHECK AND REPAIR ENGINE ASSEMBLY

OK -- INSPECT STARTER

35. INSPECT FUEL INJECTOR

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

OK:

Fuel injector operating sound is heard.

NG -- READ VALUE USING TECHSTREAM (ENGINE SPEED)
OK -- Continue to next step.

36. CHECK FUEL PRESSURE

(a) Inspect the fuel pressure Testing and Inspection.

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

37. CHECK SPARK PLUG AND SPARK

(a) Check for sparks Testing and Inspection.

NG -- INSPECT SPARK PLUG
OK -- Continue to next step.

38. CONFIRM VEHICLE CONDITION

(a) Confirm the conditions present when the malfunction occurred based on the customer problem analysis.

Result:

HINT
*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 a 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 69, perform fuel system troubleshooting C (steps 70 to 73).

C -- CHECK MALFUNCTION CONDITION

B -- INSPECT FUEL INJECTOR
A -- Continue to next step.

39. CHECK FUEL PRESSURE

HINT
For the fuel pressure inspection, refer to the following procedures Testing and Inspection.

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

Result:

HINT
- If the engine cannot be started, check the fuel pressure after cranking the engine.
- *1: From step 69, perform fuel system troubleshooting C (steps 70 to 73).
B -- REPLACE FUEL PRESSURE REGULATOR

A -- CHECK MALFUNCTION CONDITION

40. INSPECT FUEL INJECTOR

(a) After stopping the engine, measure the HC concentration inside the surge tank for 15 minutes.

Result:

HINT
- If the concentration is 400 ppm or higher, a fuel injector may have a sealing problem.
- *1: From step 69, perform fuel system troubleshooting C (steps 70 to 73).
B -- CHECK MALFUNCTION CONDITION

A -- REPLACE FUEL INJECTOR

41. INSPECT SPARK PLUG

(a) Inspect the spark plugs Testing and Inspection.

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

NG -- REPLACE SPARK PLUG
OK -- Continue to next step.

42. READ VALUE USING TECHSTREAM (ENGINE SPEED)

(a) Connect the Techstream to the DLC3.

(b) Turn the ignition switch to ON.

(c) Using the Techstream, select [Engine Speed] of the Data List.

(d) Start the engine.

(e) While running the engine, read the [Engine Speed] value.

OK:

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

HINT
- 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
OK -- Continue to next step.

43. CHECK HARNESS AND CONNECTOR (IGNITION COIL POWER SOURCE)

(a) Check the harnesses and connectors, referring to DTC P0351 inspection procedure P0351.

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.
NG -- CHECK IGNITION COIL POWER SOURCE CIRCUIT
OK -- Continue to next step.

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

(a) Check the harnesses and connectors, referring to DTC P0351 inspection procedure P0351.

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.
- If the wire harness is normal, after replacing the ignition coil assembly, check if engine starting trouble occurs again. If engine starting trouble occurs again, proceed to step 69 and perform troubleshooting for the ignition system (steps 74 to 79).
NG -- REPAIR OR REPLACE HARNESS OR CONNECTOR

OK -- REPLACE IGNITION COIL

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

(a) Connect the Techstream to the DLC3.

(b) Turn the ignition switch to ON.

(c) Using the Techstream, select the [Control the Fuel Pump / Speed] Active Test.

(d) When performing the Active Test, check for an operating sound from the fuel pump.

OK:

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

NG -- CHECK FUEL PUMP CONTROL CIRCUIT
OK -- Continue to next step.