1ZR-FE ENGINE CONTROL SFI SYSTEM 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 GTS, 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. | Detection Item | DTC Detection Condition | Trouble Area | MIL | Memory |
---|---|---|---|---|---|
P1604 | Startability Malfunction | Either of the following conditions is met:
·
The engine speed is below 500 rpm with the STA signal on for a certain amount of time (refer to the illustration below) (1 trip detection logic). ·
After the engine starts (engine speed is 500 rpm or more), the engine speed drops to 200 rpm or less within approximately 2 seconds (1 trip detection logic). |
·
Engine assembly (excess friction, compression loss) ·
Starter assembly ·
Crankshaft position sensor ·
Camshaft position sensor ·
Engine coolant temperature sensor ·
Fuel pump ·
Fuel pump control system ·
Fuel line (fuel filter, pipes and hoses) ·
Fuel injector assembly ·
Throttle body assembly ·
Fuel pressure regulator ·
Battery ·
Drive plate and ring gear sub-assembly ·
Spark plug ·
Ignition coil assembly circuit ·
Intake system ·
Camshaft timing oil control valve assembly ·
Mass air flow meter sub-assembly ·
Air fuel ratio sensor ·
Valve timing ·
Fuel ·
Purge VSV ·
Intake valve ·
Engine immobiliser system ·
ECM |
Does not come on | DTC stored |
CAUTION / NOTICE / HINT
- HINT:
- ·
DTC P1604
·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 this 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.
·As DTCs may be stored when an Active Test or learning is performed, make sure to clear the DTCs before returning the vehicle to the customer.
·If any other DTCs are output, perform troubleshooting for those DTCs first.
·DATA LIST / FREEZE FRAME DATA
·When this Data List item "Immobiliser Communication" is OFF or "Immobiliser Fuel Cut" is ON, the engine cannot be started.
·Read freeze frame data using the GTS. 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 hereEngine / Hybrid System>1ZR-FE ENGINE CONTROL>SFI SYSTEM>FREEZE FRAME DATA
·When confirming the 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 vehicle 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 recur, carefully check the vehicle conditions from when the malfunction occurred using freeze frame data.
·PRECAUTIONS
·When performing inspections, jiggle the relevant wire harnesses 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.
Malfunction Recurrence and Inspection Areas
Freeze frame data exists, but the malfunction (starting difficulty) has not recurred and the malfunction conditions are unknown.
The engine speed recorded in the freeze frame data is 0 rpm (the engine does not crank).
- HINT:
-
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.
All engine speeds recorded in the freeze frame data are between 60 and 250 rpm (the engine cranks but there is no combustion).
- HINT:
-
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 an engine coolant temperature sensor malfunction, the fuel injection volume is extremely high or low and the engine may not be able to be started.
The engine speed recorded in the freeze frame data is 250 rpm or higher (the initial combustion and starter turn off timing is too late).
- HINT:
-
If the engine speed is 250 rpm or higher (combustion occurs but the initial combustion and starter turn off 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 #1 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 too high, compression loss may have occurred due to carbon interfering with the valve operation.
When the malfunction (starting difficulty) can be reproduced, or malfunction conditions are known, perform the following inspections ("Problem symptoms" and "Systems to inspect")
Problem symptoms
The engine does not crank.
- HINT:
-
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.
The engine cranking speed is abnormal.
- HINT:
-
If the engine cranking speed is too high (for example, 300 rpm or higher with no combustion), compression loss may have occurred because carbon interfered with valve operation, etc.
There is no initial combustion.
- HINT:
-
If there is no initial combustion, there is probably a wiring problem or an ignition or fuel system part malfunction.
The engine stalls after starter turn off.
- HINT:
-
If the engine stalls after starter turn off, the air fuel ratio may be incorrect or the VVT may have a problem returning.
Initial combustion and starter turn off occur late.
- HINT:
-
If initial combustion and starter turn off occur late, the fuel injection volume is probably incorrect (too low or too high).
- HINT:
-
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.
Systems to inspect.
Intake system
Ignition system
Fuel system
INSPECTION FLOW
Freeze frame data exists, but the malfunction (starting difficulty) has not recurred and the malfunction conditions are unknown.
Freeze Frame Data Item | Result | Suspected Area | Procedure |
---|---|---|---|
Engine Speed | 0 rpm (no engine cranking at all) | ·
Battery fully depleted ·
Engine assembly (excess friction) ·
Starter assembly ·
Crankshaft position sensor ·
ECM |
5 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 turn off*2 occur late) | ·
Engine assembly (compression loss) ·
Fuel injection system ·
Fuel pump control system |
15 to 23 |
- HINT:
- ·
*1: First combustion after cranking begins.
·*2: Condition when engine speed increases and starter can be turned off.
When the malfunction (starting difficulty) can be reproduced, or when malfunction conditions are known.
Problem symptoms
Problem Symptom | Suspected Area | Suspected Component | Procedure |
---|---|---|---|
The engine does not crank | Battery malfunction | ·
Battery fully depleted |
26 to 29, and 35 to 36 |
Starting system | ·
Starter assembly (includes pinion gear wear or tooth damage) ·
Starting system |
||
Engine assembly | ·
Engine assembly (excess friction) ·
Drive plate and ring gear sub-assembly wear or tooth damage |
||
Cranking speed too low | Battery malfunction | ·
Battery fully depleted |
37 to 39 |
Starting system | ·
Starter assembly |
||
Engine assembly | ·
Engine assembly (excess friction) |
||
Cranking speed too high | Engine assembly | ·
Engine assembly (compression loss) |
|
There is no initial combustion | Fuel supply problem | ·
Cannot maintain pressure due to pressure regulator malfunction ·
Fuel injector assembly leak ·
Fuel leak from fuel line ·
Fuel pump control system ·
Fuel pump |
41 to 54 |
Ignition system malfunction | ·
Spark plug ·
Crankshaft position sensor ·
Ignition coil assembly |
||
Engine stalls after starter turn off | Air suction | ·
Intake system connections |
30 to 34 and 40 |
Deposits in throttle body assembly | ·
Throttle body assembly |
||
VVT valve does not return properly | ·
Camshaft timing oil control valve assembly |
||
Mass air flow meter malfunction | ·
Mass air flow meter sub-assembly |
||
Initial combustion and starter turn off occur late | Engine coolant temperature sensor malfunction | ·
Engine coolant temperature sensor |
55 to 67 and 74 |
Mass air flow meter sub-assembly malfunction | ·
Mass air flow meter sub-assembly |
||
Abnormal air fuel learning value | ·
Air fuel ratio sensor |
||
Deviation from fuel injection characteristics | ·
Fuel injector assembly |
||
Wet-fouled or dry-fouled spark plug | ·
Spark plug |
||
Lack of fuel pressure | ·
Pressure regulator ·
Fuel pump ·
Fuel pump control system |
Systems to inspect.
Troubleshooting by System | Suspected Area | Suspected Component | Procedure |
---|---|---|---|
Fuel system troubleshooting A | Abnormal air fuel ratio learning value | ·
Fuel injector assembly |
87 to 94
95 to 102 |
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 intake manifold | ·
Purge VSV system ·
Fuel injector assembly |
103 to 104 |
Fuel system troubleshooting C | Injection signal system malfunction | ·
Fuel injector assembly ·
Crankshaft position sensor ·
Camshaft position sensor ·
ECM |
69 to 73 |
Intake system troubleshooting | Difference between ISC target value and opening angle when idling | ·
Engine assembly (compression loss) ·
Valve timing ·
Engine coolant temperature sensor ·
ECM |
84 to 86
105 to 108 |
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 |
75 to 83
109 to 117 |
- NOTICE:
-
Inspect the fuses for circuits related to this system before performing the following procedure.
PROCEDURE
Connect the GTS to the DLC3.
Turn the ignition switch to ON.
Turn the GTS on.
Enter the following menus: Powertrain / Engine and ECT / Trouble Codes.
Read the DTCs and record the Freeze Frame Data.
- Powertrain > Engine and ECT > Trouble Codes
- 50001 234
- HINT:
- ·
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 DTC P1604 is output A DTC P1604 and other DTCs are output B
A
B
Connect the GTS to the DLC3.
Turn the ignition switch to ON.
Turn the GTS on.
Enter the following menus: Powertrain / Engine and ECT / Data List / All Data / Immobiliser Fuel Cut.
- Powertrain > Engine and ECT > Data List
-
Tester Display Immobiliser Fuel Cut - 50003 234 505
Read the value displayed on the GTS.
- OK:
Immobiliser Fuel Cut is OFF
- HINT:
- ·
If the engine is started immediately after reconnecting the battery terminal, the engine may stall immediately after it starts due to the intercommunication process between each ECU. For this reason, when starting the engine after reconnecting the battery terminal, first turn the ignition switch to ON and then wait several seconds for the communication process to complete before starting the engine.
·When this operation causes DTC P1604 to be stored, this is due to normal operation of the immobiliser system and does not indicate a malfunction, so clear the DTC and return the vehicle to the customer.
- Result:
Proceed to OK NG
OK
NG
Confirm the problem symptoms.
- Result:
Result Proceed to Freeze frame data exists, but the starting difficulty cannot be reproduced and it is unknown what kind of starting difficulty occurred A The problem symptoms can be reproduced, or the malfunction conditions are known B
A
B
Connect the GTS to the DLC3.
Turn the ignition switch to ON.
Using the GTS, confirm the vehicle conditions recorded in the freeze frame data which were present when the DTC was stored.
Click hereEngine / Hybrid System>1ZR-FE ENGINE CONTROL>SFI SYSTEM>FREEZE FRAME DATA
- Result:
Freeze Frame Data Item Suspected Area Proceed to Engine Speed Battery Voltage All 5 sets of freeze frame data are 0 rpm (no engine cranking at all) Minimum voltage is less than 5 V Battery fully depleted A Minimum voltage is 5 V or higher ·Starter assembly malfunction
·Crankshaft position sensor system
·Excess engine friction
·ECM
B 60 to 250 rpm (engine cranks but no initial combustion) - ·Fuel pump control system
·Ignition system
·Engine coolant temperature sensor
·Fuel injection system
C 250 rpm or higher (combustion occurs but initial combustion and starter turn off occur late) - ·Engine assembly
·Engine coolant temperature sensor
·Fuel injection system
·Fuel pump control system
D
- Result:
Freeze Frame Data Item Suspected Area Proceed to Low Rev for Eng Start ON ·Intake system connections
·Throttle body assembly
·Camshaft timing oil control valve assembly
·Mass air flow meter sub-assembly
E
- HINT:
- ·
When DTC P1604 is stored, either "Engine Start Hesitation"*1 or "Low Rev for Eng Start"*2 in the Freeze Frame Data will be ON. If "Low Rev for Eng Start" is ON, proceed to E.
·*1: This value turns ON when the engine speed does not reach a certain value for a certain period of time when starting the engine.
·*2: This value turns ON when the engine stalls immediately after starting the engine. If "Low Rev for Eng Start" is ON, as there is a possibility that the low engine speed or engine stall was caused by the user, confirm the following freeze frame data items.
·Immobiliser Fuel Cut
·Engine Speed (Starter Off)
·Shift SW Status (R, D Range)
A
B
C
D
E
Connect the GTS to the DLC3.
Turn the ignition switch to ON.
Using the GTS, confirm the vehicle conditions recorded in the freeze frame data which were present when the DTC was stored.
Click hereEngine / Hybrid System>1ZR-FE ENGINE CONTROL>SFI SYSTEM>FREEZE FRAME DATA
- 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 Minimum voltage is 6 V or higher and voltage fluctuates*2, *3 ·Crankshaft position sensor system
·ECM
B Minimum voltage is 5 to 6 V*4 ·Excess engine friction
·Battery fully depleted
C
- HINT:
-
- ·
*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. 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.
A
B
C
Check the tightening and installation condition of the crankshaft position sensor bolt.
Check the connection of the crankshaft position sensor connector.
- OK:
Sensor is installed correctly.
- Result:
Proceed to OK NG
OK
NG
Disconnect the crankshaft position sensor connector.
Check for oil on the connector terminals.
- OK:
No oil on the terminals.
- Result:
Proceed to OK NG
OK
NG
Check the harnesses and connectors, referring to DTC P0335 inspection procedure.
Click hereEngine / Hybrid System>1ZR-FE ENGINE CONTROL>SFI SYSTEM>P0335
- 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.
- Result:
Proceed to OK NG
OK
NG
Replace the crankshaft position sensor.
Click hereEngine / Hybrid System>1ZR-FE ENGINE CONTROL>CRANKSHAFT POSITION SENSOR>REMOVAL
Check the engine start operation.
- OK:
Malfunction has been repaired successfully.
- Result:
Proceed to OK NG
OK
NG
Connect the GTS to the DLC3.
Turn the ignition switch to ON.
Using the GTS, confirm the vehicle conditions recorded in the freeze frame data which were present when the DTC was stored.
Click hereEngine / Hybrid System>1ZR-FE ENGINE CONTROL>SFI SYSTEM>FREEZE FRAME DATA
- Result:
Freeze Frame Data Item Suspected Area Proceed to Coolant Temp, Intake Air Coolant Temp Fuel Pump / Speed Status Difference between Coolant Temp and Intake Air is 10°C (18°F) or higher*1 Coolant Temp is 125°C (257°F) or higher, or less than ambient temperature*3 by 15°C (27°F) or higher - 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 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 All 5 sets of freeze frame data are ON - B
- HINT:
- ·
*1: A long time had not elapsed after stopping the engine.
·*2: A long time had elapsed after stopping the engine.
·*3: Use an actual ambient temperature estimated from the Initial Intake Air, Ambient Temp for A/C, and (if possible) the weather when the DTC was detected.
A
B
C
*a | Front view of wire harness connector
(to Fuel Pump) |
Connect the GTS to the DLC3.
Disconnect the fuel pump connector.
Turn the ignition switch to ON.
Turn the GTS on.
Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump / Speed.
- Powertrain > Engine and ECT > Active Test
-
Tester Display Control the Fuel Pump / Speed - 50004 234 5
Measure the voltage according to the value(s) in the table below.
- Standard Voltage:
Tester Connection Condition Specified Condition L20-4 (B) - Body ground Active Test is being performed 11 to 14 V
- 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.
- Result:
Proceed to OK NG
OK
NG
Disconnect the ECM connector.
Turn the ignition switch to ON.
Measure the voltage according to the value(s) in the table below.
- Standard Voltage:
Tester Connection Condition Specified Condition B56-86 (#10) - B56-46 (E01) Ignition switch ON 11 to 14 V B56-85 (#20) - B56-46 (E01) Ignition switch ON 11 to 14 V B56-84 (#30) - B56-46 (E01) Ignition switch ON 11 to 14 V B56-83 (#40) - B56-46 (E01) Ignition switch ON 11 to 14 V
- 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.
- Result:
Proceed to OK NG
OK
NG
Connect the GTS to the DLC3.
Turn the ignition switch to ON.
Turn the GTS on.
Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump / Speed.
- Powertrain > Engine and ECT > Active Test
-
Tester Display Control the Fuel Pump / Speed - 50004 234 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
- 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.
A
B
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
- HINT:
-
If there is foreign matter such as iron particles around the fuel pump, fuel pump filter or inside the fuel tank, remove the foreign matter.
A
B
Connect the GTS to the DLC3.
Turn the ignition switch to ON.
Using the GTS, confirm the vehicle conditions recorded in the freeze frame data which were present when the DTC was stored.
Click hereEngine / Hybrid System>1ZR-FE ENGINE CONTROL>SFI SYSTEM>FREEZE FRAME DATA
- Result:
Freeze Frame Data Item Suspected Area Proceed to Coolant Temp, Intake Air Coolant Temp Long FT #1 Engine Speed Difference between Coolant Temp and Intake Air is 10°C (18°F) or higher*1 Coolant Temp is 125°C (257°F) or higher, or less than ambient temperature*4 by 15°C (27°F) or higher - - Engine coolant temperature sensor A Other than above -15% or less, or 15% or higher - ·Fuel pump control system
·Fuel injector assembly
B -15 to 15% Minimum speed is 300 rpm or higher*3 Engine assembly C Minimum speed is less than 300 rpm ·Fuel system
·Intake air system
D Difference between Coolant Temp and Intake Air is less than 10°C (18°F)*2 - -15% or less, or 15% or higher - ·Fuel pump control system
·Fuel injector assembly
B -15 to 15% Minimum speed is 300 rpm or higher*3 Engine assembly C Minimum speed is less than 300 rpm ·Fuel system
·Intake air system
D
- HINT:
- ·
*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.
·*4: Use an actual ambient temperature estimated from the Initial Intake Air, Ambient Temp for A/C, and (if possible) the weather when the DTC was detected.
A
B
C
D
Check that no carbon is stuck to the fuel injector assembly.
- OK:
No carbon present.
- Result:
Proceed to OK NG
OK
NG
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
- HINT:
-
If there is foreign matter such as iron particles around the fuel pump, fuel pump filter or inside the fuel tank, remove the foreign matter.
A
B
Connect the GTS to the DLC3.
Turn the ignition switch to ON.
Using the GTS, confirm the vehicle conditions recorded in the freeze frame data which were present when the DTC was stored.
Click hereEngine / Hybrid System>1ZR-FE ENGINE CONTROL>SFI SYSTEM>FREEZE FRAME DATA
- 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 assembly A Engine coolant temperature is 90°C (194°F) or higher*2 Engine coolant temperature is 40 to 90°C (104 to 194°F)*3 Fuel injector assembly B
- HINT:
- ·
*1: If the engine coolant temperature is 40°C [104°F] or less (after the engine is stopped and the vehicle is 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 90°C [194°F] or higher (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.
·*3: 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 a fuel injector.
A
B
- HINT:
-
For the fuel pressure inspection, refer to the following procedures.
-
Click hereEngine / Hybrid System>1ZR-FE FUEL>FUEL SYSTEM>ON-VEHICLE INSPECTION
Attach a fuel pressure gauge and check the fuel pressure after stopping the engine.
- Standard:
147 kPa (1.5 kgf/cm2, 21 psi) or higher (5 minutes after stopping the engine)
- HINT:
-
If the engine cannot be started, read the values after cranking the engine.
- Result:
Result Proceed to Abnormal A Normal B
A
B
Clean the inside of the intake manifold with compressed air.
After stopping the engine, measure the HC concentration inside the intake manifold for 15 minutes.
- Result:
Result Proceed to 4000 ppm or higher A Less than 4000 ppm B
- HINT:
-
If the concentration is 4000 ppm or higher, a fuel injector assembly may have a sealing problem.
A
B
Inspect the fuel injector assemblies.
Click hereEngine / Hybrid System>1ZR-FE FUEL>FUEL INJECTOR>INSPECTION
- Result:
Proceed to OK NG
OK
NG
Check if carbon is in the air flow passage.
- Result:
Result Proceed to No carbon present A Carbon in passage B
A
B
Check the intake system for vacuum leak.
Click hereEngine / Hybrid System>1ZR-FE INTAKE / EXHAUST>INTAKE SYSTEM>ON-VEHICLE INSPECTION
- OK:
No leak in intake system.
- Result:
Proceed to OK NG
OK
NG
Check if the engine can be started.
- Result:
Result Proceed to Engine can be started A Engine cannot be started B
A
B
Confirm the problem symptoms.
- HINT:
-
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 assembly (includes pinion gear wear or teeth damage)
·Starter system
·Engine assembly (excess friction)
·Drive plate and ring gear sub-assembly wear or teeth damage
A Abnormal cranking speed ·Battery fully depleted
·Starter assembly
·Engine assembly (excess friction, compression loss)
B There is no initial combustion (combustion does not occur even once)*1 ·Pressure regulator assembly fuel pressure maintenance
·Fuel injector assembly leak
·Fuel leak from fuel line
·Fuel pump control system
·Fuel pump
·Spark plug
·Crankshaft position sensor system
·Ignition coil assembly system
C The engine stalls after starter turn off (engine stalls immediately after the first time the engine speed increases)*2 ·Intake system connections
·Throttle body assembly
·Camshaft timing oil control valve assembly
·Mass air flow meter sub-assembly
D The initial combustion and starter turn off occur late*3 ·Engine coolant temperature sensor
·Mass air flow meter sub-assembly
·Air fuel ratio sensor
·Heated oxygen sensor
·Fuel injector assembly
·Spark plug
·Pressure regulator assembly
·Fuel pump
·Fuel pump control system
E
- 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 turn off, 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 turn off occur late, the fuel injection volume may be incorrect (too low or too high).
A
B
C
D
E
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.* ·Battery
·Excess engine friction
·Starter assembly
A A noise indicating that the starter pinion gear is extending is heard but the starter pinion gear is spinning freely. ·Drive plate and ring gear sub-assembly
·Starter assembly
B A noise indicating that the starter pinion gear is extending is not heard ·Battery
·Starter assembly
·Starter system
C
- HINT:
*: The battery may be fully depleted or there may be excess engine friction.
A
B
C
Inspect the battery.
Click herePower Source / Network>1ZR-FE BATTERY / CHARGING>CHARGING SYSTEM>ON-VEHICLE INSPECTION
- Result:
Proceed to OK NG
OK
NG
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.
- Result:
Proceed to OK NG
OK
NG
Remove the starter assembly.
Click hereEngine / Hybrid System>1ZR-FE STARTING>STARTER>REMOVAL
Check for starter pinion gear wear and damage.
- OK:
There is no wear or damage.
- Result:
Proceed to OK NG
OK
NG
Inspect the mass air flow meter sub-assembly.
Click hereEngine / Hybrid System>1ZR-FE ENGINE CONTROL>MASS AIR FLOW METER>ON-VEHICLE INSPECTION
- Result:
Proceed to OK NG
OK
NG
Check for air leaks in the intake system (vacuum hose disconnection, cracks, damaged gaskets, etc.).
Click hereEngine / Hybrid System>1ZR-FE INTAKE / EXHAUST>INTAKE SYSTEM>ON-VEHICLE INSPECTION
- HINT:
- ·
If the accelerator pedal is released after racing the engine, the inspection is easier to perform because the vacuum inside the intake manifold increases and the air suction noise becomes louder.
·If Short FT #1 and Long FT #1 are largely different from the normal values (differ by more than 15%) when idling (intake air volume is small) and almost the same as the normal values when racing the engine (for example, when maintaining a speed of 3000 rpm) (intake air volume is high), air leakage may be present.
- OK:
There are no air leaks.
- Result:
Proceed to OK NG
OK
NG
Disconnect the throttle body assembly connector.
- HINT:
-
When the connector is disconnected, the vehicle enters fail-safe mode and the throttle valve opening angle is 4 to 7°.
Crank the engine and check that it starts.
- Result:
Result Proceed to Engine starts A Engine does not start B
- HINT:
-
When this inspection is performed, the MIL may illuminate. After finishing the inspection, check and clear the DTCs.
A
B
Check if carbon is in the air flow passage.
- OK:
No carbon present.
- Result:
Proceed to OK NG
OK
NG
Operate the VVT system through the Active Test, and check if the VVT system is operating normally.
Perform the Active Test, referring to DTC P0011 inspection procedure (VVT system for intake camshaft).
Click hereEngine / Hybrid System>1ZR-FE ENGINE CONTROL>SFI SYSTEM>P0011
Perform the Active Test, referring to DTC P0014 inspection procedure (VVT system for exhaust camshaft).
Click hereEngine / Hybrid System>1ZR-FE ENGINE CONTROL>SFI SYSTEM>P0014
- Result:
Result Proceed to NG A OK B
*
- HINT:
- ·
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.
·*: From step 68, perform intake system troubleshooting (steps 84 to 86). If engine starting trouble still occurs, perform fuel system troubleshooting A (steps 87 to 94).
A
B
Inspect the battery.
Click herePower Source / Network>1ZR-FE BATTERY / CHARGING>CHARGING SYSTEM>ON-VEHICLE INSPECTION
- Result:
Proceed to OK NG
OK
NG
Inspect the starter assembly.
Click hereEngine / Hybrid System>1ZR-FE STARTING>STARTER>INSPECTION
- Result:
Proceed to OK NG
OK
NG
Check the cranking speed.
- Result:
Problem Symptom Suspected Area Proceed to Cranking speed is slow (100 rpm or less) ·Battery
·Starter assembly
·Excess engine friction
A Cranking speed is fast (300 rpm or higher)* Engine compression loss B
- HINT:
-
*: If the cranking speed is fast, there may be compression loss.
A
B
Inspect the battery.
Click herePower Source / Network>1ZR-FE BATTERY / CHARGING>CHARGING SYSTEM>ON-VEHICLE INSPECTION
- Result:
Proceed to OK NG
OK
NG
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.
- Result:
Proceed to OK NG
OK
NG
Check the harnesses and connectors, referring to DTC P0102 inspection procedure.
Click hereEngine / Hybrid System>1ZR-FE ENGINE CONTROL>SFI SYSTEM>P0102
- 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 mass air flow meter, check if engine starting trouble occurs again. If engine starting trouble occurs again, proceed to step 68 and perform intake system troubleshooting (steps 84 to 86). If engine starting trouble still occurs, perform fuel system troubleshooting A (steps 87 to 94).
- Result:
Proceed to OK NG
OK
NG
Using a sound scope or screwdriver, check for an injector operating sound while cranking the engine.
- OK:
Fuel injector assembly operating sound is heard.
- Result:
Proceed to OK NG
OK
NG
Inspect the fuel pressure.
Click hereEngine / Hybrid System>1ZR-FE FUEL>FUEL SYSTEM>ON-VEHICLE INSPECTION
- Result:
Proceed to OK NG
OK
NG
Check for sparks.
Click hereEngine / Hybrid System>1ZR-FE ENGINE CONTROL>IGNITION SYSTEM>ON-VEHICLE INSPECTION
- Result:
Proceed to OK NG
OK
NG
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 assembly is stuck open A When the engine is stopped and approximately 2 to 3 minutes have passed, engine starting trouble occurs*2 Failure to maintain fuel pressure by pressure regulator assembly When the engine is stopped and approximately 15 to 120 minutes have passed, engine starting trouble occurs*3 Fuel injector assembly leak B Condition other than above, or there is an inconsistency in the conditions present when engine starting trouble occurs - C
*4
- 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: 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.
·*3: Fuel may be leaking from a fuel injector assembly.
·*4: From step 68, perform fuel system troubleshooting C (steps 69 to 73).
A
B
C
- HINT:
-
For the fuel pressure inspection, refer to the following procedures.
-
Click hereEngine / Hybrid System>1ZR-FE FUEL>FUEL SYSTEM>ON-VEHICLE INSPECTION
Attach a fuel pressure gauge and check the fuel pressure after stopping the engine.
- Standard:
147 kPa (1.5 kgf/cm2, 21 psi) or higher (5 minutes after stopping the engine)
- Result:
Result Proceed to Abnormal A Normal B
*
- HINT:
- ·
If the engine cannot be started, read the values after cranking the engine.
·*: from step 68, perform fuel system troubleshooting C (steps 69 to 73).
A
B
Clean the inside of the intake manifold with compressed air.
After stopping the engine, measure the HC concentration inside the intake manifold for 15 minutes.
- Result:
Result Proceed to 4000 ppm or higher A Less than 4000 ppm B
*
- HINT:
- ·
If the concentration is 4000 ppm or higher, a fuel injector assembly may have a sealing problem.
·*: From step 68, perform fuel system troubleshooting C (steps 69 to 73).
A
B
Inspect the spark plugs.
Click hereEngine / Hybrid System>1ZR-FE ENGINE CONTROL>IGNITION SYSTEM>ON-VEHICLE INSPECTION
- HINT:
-
Even if the spark plug of only one cylinder is malfunctioning, replace the spark plugs of all cylinders.
- Result:
Proceed to OK NG
OK
NG
Connect the GTS to the DLC3.
Turn the ignition switch to ON.
Turn the GTS on.
Enter the following menus: Powertrain / Engine and ECT / Data List / All Data / Engine Speed.
- Powertrain > Engine and ECT > Data List
-
Tester Display Engine Speed - 50003 234 9
Start the engine.
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.
- Result:
Proceed to OK NG
OK
NG
Check the harnesses and connectors, referring to DTC P0351 inspection procedure.
Click hereEngine / Hybrid System>1ZR-FE ENGINE CONTROL>SFI SYSTEM>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.
- Result:
Proceed to OK NG
OK
NG
Check the harnesses and connectors, referring to DTC P0351 inspection procedure.
Click hereEngine / Hybrid System>1ZR-FE ENGINE CONTROL>SFI SYSTEM>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 68 and perform troubleshooting for the ignition system (steps 75 to 83).
- Result:
Proceed to OK NG
OK
NG
Connect the GTS to the DLC3.
Turn the ignition switch to ON.
Turn the GTS on.
Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump / Speed.
- Powertrain > Engine and ECT > Active Test
-
Tester Display Control the Fuel Pump / Speed - 50004 234 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
- HINT:
-
Jiggle the wire harness and connector to increase the likelihood of detecting malfunctions that do not always occur.
- Result:
Proceed to OK NG
OK
NG
Connect the GTS to the DLC3.
Turn the ignition switch to ON.
Turn the GTS on.
Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump / Speed.
- Powertrain > Engine and ECT > Active Test
-
Tester Display Control the Fuel Pump / Speed - 50004 234 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
- HINT:
- ·
Jiggle the wire harness and connector to increase the likelihood of detecting malfunctions that do not always occur.
·Check if the vehicle ran out of fuel, as engine starting trouble due to running out of fuel is also detected.
·If there are no fuel leaks, after inspecting the fuel pump control system, check if engine starting trouble occurs again. If engine starting trouble occurs again, proceed to step 68 and perform fuel system troubleshooting C (steps 69 to 73).
A
B
Connect the GTS to the DLC3.
Turn the ignition switch to ON.
Turn the GTS on.
Enter the following menus: Powertrain / Engine and ECT / Data List / All Data / Engine Speed.
- Powertrain > Engine and ECT > Data List
-
Tester Display Engine Speed - 50003 234 9
Start the engine.
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.
- Result:
Proceed to OK NG
OK
NG
Disconnect the ECM connector.
Turn the ignition switch to ON.
Measure the voltage according to the value(s) in the table below.
- Standard Voltage:
Tester Connection Condition Specified Condition B56-86 (#10) - B56-46 (E01) Ignition switch ON 11 to 14 V B56-85 (#20) - B56-46 (E01) Ignition switch ON 11 to 14 V B56-84 (#30) - B56-46 (E01) Ignition switch ON 11 to 14 V B56-83 (#40) - B56-46 (E01) Ignition switch ON 11 to 14 V
- 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.
- Result:
Proceed to OK NG
OK
NG
Inspect the engine coolant temperature sensor.
Click hereEngine / Hybrid System>1ZR-FE ENGINE CONTROL>ENGINE COOLANT TEMPERATURE SENSOR>INSPECTION
- HINT:
-
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 68 and perform fuel system troubleshooting A (steps 95 to 102), fuel system troubleshooting B (steps 103 to 104), intake system troubleshooting (steps 105 to 108), and ignition system troubleshooting (steps 109 to 117), in that order.
- Result:
Proceed to OK NG
OK
NG
Disconnect the engine coolant temperature sensor connector.
Disconnect the ECM connector.
Measure the resistance according to the value(s) in the table below.
- Standard Resistance:
Tester Connection Condition Specified Condition B4-2 - B56-64 (THW) Always Below 1 Ω B4-1 - B56-65 (ETHW) Always Below 1 Ω B4-2 or B56-64 (THW) - Body ground Always 10 kΩ or higher
- 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 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 68 and perform fuel system troubleshooting A (steps 95 to 102), fuel system troubleshooting B (steps 103 to 104), intake system troubleshooting (steps 105 to 108), and ignition system troubleshooting (steps 109 to 117), in that order.
- Result:
Proceed to OK NG
OK
NG
Inspect the mass air flow meter sub-assembly.
Click hereEngine / Hybrid System>1ZR-FE ENGINE CONTROL>MASS AIR FLOW METER>ON-VEHICLE INSPECTION
- HINT:
-
If the mass air flow meter sub-assembly 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 68 and perform fuel system troubleshooting A (steps 95 to 102), fuel system troubleshooting B (steps 103 to 104), intake system troubleshooting (steps 105 to 108), and ignition system troubleshooting (steps 109 to 117), in that order.
- Result:
Proceed to OK NG
OK
NG
Check the harnesses and connectors, referring to DTC P0102 inspection procedure.
Click hereEngine / Hybrid System>1ZR-FE ENGINE CONTROL>SFI SYSTEM>P0102
- 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 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 68 and perform fuel system troubleshooting A (steps 95 to 102), fuel system troubleshooting B (steps 103 to 104), intake system troubleshooting (steps 105 to 108), and ignition system troubleshooting (steps 109 to 117), in that order.
- Result:
Proceed to OK NG
OK
NG
Connect the GTS to the DLC3.
Turn the ignition switch to ON.
Turn the GTS on.
Enter the following menus: Powertrain / Engine and ECT / Data List / All Data / Long FT #1 and Atmosphere Pressure.
- Powertrain > Engine and ECT > Data List
-
Tester Display Long FT #1 Atmosphere Pressure - 50003 234 26,7
- Result:
Data List Item Result Suspected Area Proceed to Long FT #1 25% or higher, or less than -25% ·Air fuel ratio sensor
·Heated oxygen sensor
·Mass air flow meter sub-assembly
·Fuel injector assembly
·ECM
A Atmosphere Pressure 80 kPa(abs) [600 mmHg(abs)] or less (when altitude is 0 m [0 ft]) Both Data List items listed above Values are other than above - B
A
B
Remove the ECU-B NO. 3 and ETCS fuses from the engine room relay block assembly.
After 60 seconds or more elapse, install the fuses.
Check if the engine can be started.
- Result:
Result Proceed to Engine can be started A Engine cannot be started B
A
B
Connect the GTS to the DLC3.
Start the engine.
Turn the GTS on.
Enter the following menus: Powertrain / Engine and ECT / Data List / All Data / Fuel System Status #1.
- Powertrain > Engine and ECT > Data List
-
Tester Display Fuel System Status #1 - 50003 234 23
Confirm that Fuel System Status #1 is CL.
Enter the following menus: Powertrain / Engine and ECT / Data List / All Data / AF Lambda B1S1.
- Powertrain > Engine and ECT > Data List
-
Tester Display AF Lambda B1S1 - 50003 234 34
Confirm that AF Lambda B1S1 is within the range of 0.95 to 1.05 when idling.
Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Injection Volume for A/F Sensor / All Data / AFS Voltage B1S1 and O2S B1S2.
- Powertrain > Engine and ECT > Active Test
-
Active Test Display Control the Injection Volume for A/F Sensor -
Data List Display AFS Voltage B1S1 O2S B1S2 - 50004 234 2 35,44
Read the output voltage from the air fuel ratio sensor when increasing and decreasing the fuel injection volume.
- Standard:
GTS Display Injection Volume Specified Condition AFS Voltage B1S1 12.5% Air fuel ratio sensor output voltage is below 3.1 V -12.5% Air fuel ratio sensor output voltage is higher than 3.4 V
- HINT:
- ·
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 68 and perform fuel system troubleshooting A (steps 95 to 102), fuel system troubleshooting B (steps 103 to 104), intake system troubleshooting (steps 105 to 108), and ignition system troubleshooting (steps 109 to 117), in that order.
- Result:
Proceed to OK NG
OK
NG
Check if the idling speed is stable after starting the engine.
- OK:
Engine speed is stable.
- HINT:
-
After replacing the fuel injector assembly or mass air flow meter sub-assembly, check if engine starting trouble occurs again. If engine starting trouble occurs, replace the ECM. If engine starting trouble still occurs, proceed to step 68 and perform fuel system troubleshooting A (steps 95 to 102), fuel system troubleshooting B (steps 103 to 104), intake system troubleshooting (steps 105 to 108), and ignition system troubleshooting (steps 109 to 117), in that order.
- Result:
Proceed to OK NG
OK
NG
Check the fuel pressure.
Click hereEngine / Hybrid System>1ZR-FE FUEL>FUEL SYSTEM>ON-VEHICLE INSPECTION
- Result:
Proceed to OK NG
OK
NG
Inspect the spark plugs.
Click hereEngine / Hybrid System>1ZR-FE ENGINE CONTROL>IGNITION SYSTEM>ON-VEHICLE INSPECTION
- Result:
Result Proceed to All cylinders are normal A One cylinder is abnormal*1 B All cylinders are abnormal*2, *3 C
- HINT:
- ·
*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 68 and perform fuel system troubleshooting A (steps 95 to 102), fuel system troubleshooting B (steps 103 to 104), intake system troubleshooting (steps 105 to 108), and ignition system troubleshooting (steps 109 to 117), 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 68 and perform fuel system troubleshooting A (steps 95 to 102), fuel system troubleshooting B (steps 103 to 104), intake system troubleshooting (steps 105 to 108), and ignition system troubleshooting (steps 109 to 117), in that order.
·*3: Engine starting trouble may occur if the vehicle is driven extremely short distances repeatedly.
A
B
C
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 assembly is stuck open A When the engine is stopped and approximately 2 to 3 minutes have passed, engine starting trouble occurs*2 Failure to maintain fuel pressure by pressure regulator assembly When the engine is stopped and approximately 15 to 120 minutes have passed, engine starting trouble occurs*3 Fuel injector assembly leak B Condition other than above, or there is an inconsistency in the conditions present when engine starting trouble occurs - C
*4
- 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: 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.
·*3: Fuel may be leaking from a fuel injector assembly.
·*4: From step 68, perform fuel system troubleshooting A (steps 95 to 102), fuel system troubleshooting B (steps 103 to 104), intake system troubleshooting (steps 105 to 108), and ignition system troubleshooting (steps 109 to 117), in that order.
A
B
C
- HINT:
-
For the fuel pressure inspection, refer to the following procedures.
-
Click hereEngine / Hybrid System>1ZR-FE FUEL>FUEL SYSTEM>ON-VEHICLE INSPECTION
Attach a fuel pressure gauge and check the fuel pressure after stopping the engine.
- Standard:
147 kPa (1.5 kgf/cm2, 21 psi) or higher (5 minutes after stopping the engine)
- Result:
Result Proceed to Abnormal A Normal B
*
- HINT:
- ·
If the engine cannot be started, read the values after cranking the engine.
·*: From step 68, perform fuel system troubleshooting A (steps 95 to 102), fuel system troubleshooting B (steps 103 to 104), intake system troubleshooting (steps 105 to 108), and ignition system troubleshooting (steps 109 to 117), in that order.
A
B
Clean the inside of the intake manifold with compressed air.
After stopping the engine, measure the HC concentration inside the intake manifold for 15 minutes.
- Result:
Result Proceed to 4000 ppm or higher A Less than 4000 ppm B
*
- HINT:
- ·
If the concentration is 4000 ppm or higher, a fuel injector may have a sealing problem.
·*: From step 68, perform fuel system troubleshooting A (steps 95 to 102), fuel system troubleshooting B (steps 103 to 104), intake system troubleshooting (steps 105 to 108), and ignition system troubleshooting (steps 109 to 117), in that order.
A
B
If the malfunction could not be identified during the inspection in steps 44, 45, 46 and 52, perform fuel system troubleshooting C (steps 69 to 73).
- Result:
Performed Step Troubleshooting by System Procedure Proceed to Steps 44, 45, 46 and 52 Fuel system troubleshooting C 69 to 73 A
If the malfunction could not be identified during the inspection in step 50, perform ignition system troubleshooting (steps 75 to 83).
- Result:
Performed Step Troubleshooting by System Procedure Proceed to Step 50 Ignition system troubleshooting 75 to 83 B
If the malfunction could not be identified during the inspection in steps 34 and 40, perform intake air system troubleshooting (steps 84 to 86). If engine starting trouble still occurs, perform fuel system troubleshooting A (steps 87 to 94).
- Result:
Performed Step Troubleshooting by System Procedure Proceed to Step 34 and 40 Intake air system troubleshooting 84 to 86 C Fuel system troubleshooting A 87 to 94
If the malfunction could not be identified during the inspection in steps 55, 56, 57, 58, 61, 62, 64, 65, 66, 67 and 74, perform fuel system troubleshooting A (steps 95 to 102), fuel system troubleshooting B (steps 103 to 104), intake air system troubleshooting (steps 105 to 108), and ignition system troubleshooting (steps 109 to 117), in that order.
- Result:
Performed Step Troubleshooting by System Procedure Proceed to Steps 55, 56, 57, 58, 61, 62, 64, 65, 66, 67 and 74 Fuel system troubleshooting A 95 to 102 D Fuel system troubleshooting B 103 to 104 Intake air system troubleshooting 105 to 108 Ignition system troubleshooting 109 to 117
A
B
C
D
Inspect the fuel injector assemblies.
Click hereEngine / Hybrid System>1ZR-FE FUEL>FUEL INJECTOR>INSPECTION
- Result:
Proceed to OK NG
OK
NG
Disconnect the ECM connector.
Turn the ignition switch to ON.
Measure the voltage according to the value(s) in the table below.
- Standard Voltage:
Tester Connection Condition Specified Condition B56-86 (#10) - B56-46 (E01) Ignition switch ON 11 to 14 V B56-85 (#20) - B56-46 (E01) Ignition switch ON 11 to 14 V B56-84 (#30) - B56-46 (E01) Ignition switch ON 11 to 14 V B56-83 (#40) - B56-46 (E01) Ignition switch ON 11 to 14 V
- 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.
- Result:
Proceed to OK NG
OK
NG
Replace the crankshaft position sensor.
Click hereEngine / Hybrid System>1ZR-FE ENGINE CONTROL>CRANKSHAFT POSITION SENSOR>REMOVAL
Check the engine start operation.
- OK:
Malfunction has been repaired successfully.
- Result:
Proceed to OK NG
OK
NG
Replace the camshaft position sensor (for intake camshaft).
Click hereEngine / Hybrid System>1ZR-FE ENGINE CONTROL>CAMSHAFT POSITION SENSOR>REMOVAL
Check the engine start operation.
- OK:
Malfunction has been repaired successfully.
- Result:
Proceed to OK NG
OK
NG
Replace the camshaft position sensor (for exhaust camshaft).
Click hereEngine / Hybrid System>1ZR-FE ENGINE CONTROL>CAMSHAFT POSITION SENSOR>REMOVAL
Check the engine start operation.
- OK:
Malfunction has been repaired successfully.
- Result:
Proceed to OK NG
OK
NG
Connect the GTS to the DLC3.
Turn the ignition switch to ON.
Turn the GTS on.
Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump / Speed.
- Powertrain > Engine and ECT > Active Test
-
Tester Display Control the Fuel Pump / Speed - 50004 234 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
- HINT:
- ·
Jiggle the wire harness and connector to increase the likelihood of detecting malfunctions that do not always occur.
·Check if the vehicle ran out of fuel, as engine starting trouble due to running out of fuel is also detected.
·If there are no fuel leaks, after inspecting the fuel pump control system, check if engine starting trouble occurs again. If engine starting trouble still occurs, proceed to step 68 and perform fuel system troubleshooting A (steps 95 to 102), fuel system troubleshooting B (steps 103 to 104), intake system troubleshooting (steps 105 to 108), and ignition system troubleshooting (steps 109 to 117), in that order.
A
B
Check the tightening and installation condition of the crankshaft position sensor bolt.
Check the connection of the crankshaft position sensor connector.
- OK:
Sensor is installed correctly.
- Result:
Proceed to OK NG
OK
NG
Check the tightening and installation condition of the camshaft position sensor (for intake camshaft) bolt.
Check the connection of the camshaft position sensor (for intake camshaft) connector.
- OK:
Sensor is installed correctly.
- Result:
Proceed to OK NG
OK
NG
Check the tightening and installation condition of the camshaft position sensor (for exhaust camshaft) bolt.
Check the connection of the camshaft position sensor (for exhaust camshaft) connector.
- OK:
Sensor is installed correctly.
- Result:
Proceed to OK NG
OK
NG
Check the harnesses and connectors, referring to DTC P0335 inspection procedure.
Click hereEngine / Hybrid System>1ZR-FE ENGINE CONTROL>SFI SYSTEM>P0335
- 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.
- Result:
Proceed to OK NG
OK
NG
Check the harnesses and connectors, referring to DTC P0340 inspection procedure.
Click hereEngine / Hybrid System>1ZR-FE ENGINE CONTROL>SFI SYSTEM>P0340
- 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.
- Result:
Proceed to OK NG
OK
NG
Check the harnesses and connectors, referring to DTC P0365 inspection procedure.
Click hereEngine / Hybrid System>1ZR-FE ENGINE CONTROL>SFI SYSTEM>P0365
- 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.
- Result:
Proceed to OK NG
OK
NG
Replace the crankshaft position sensor.
Click hereEngine / Hybrid System>1ZR-FE ENGINE CONTROL>CRANKSHAFT POSITION SENSOR>REMOVAL
Check the engine start operation.
- OK:
Malfunction has been repaired successfully.
- Result:
Proceed to OK NG
OK
NG
Replace the camshaft position sensor (for intake camshaft).
Click hereEngine / Hybrid System>1ZR-FE ENGINE CONTROL>CAMSHAFT POSITION SENSOR>REMOVAL
Check the engine start operation.
- OK:
Malfunction has been repaired successfully.
- Result:
Proceed to OK NG
OK
NG
Replace the camshaft position sensor (for exhaust camshaft).
Click hereEngine / Hybrid System>1ZR-FE ENGINE CONTROL>CAMSHAFT POSITION SENSOR>REMOVAL
Check the engine start operation.
- OK:
Malfunction has been repaired successfully.
- Result:
Proceed to OK NG
OK
NG
Connect the GTS to the DLC3.
Turn the ignition switch to ON.
Turn the GTS on.
Enter the following menus: Powertrain / Engine and ECT / Data List / All Data / ISC Learning Value.
- Powertrain > Engine and ECT > Data List
-
Tester Display ISC Learning Value - 50003 234 495
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:
Data List Item Result Suspected Area Proceed to ISC Learning Value (Engine displacement (liters) x 0.9) or higher ·Valve timing
·Compression
A Less than (engine displacement (liters) x 0.9) - B
A
B
Check the compression.
Click hereEngine / Hybrid System>1ZR-FE ENGINE MECHANICAL>ENGINE>ON-VEHICLE INSPECTION
- Result:
Proceed to OK NG
OK
NG
Inspect the engine coolant temperature sensor.
Click hereEngine / Hybrid System>1ZR-FE ENGINE CONTROL>ENGINE COOLANT TEMPERATURE SENSOR>INSPECTION
- Result:
Proceed to OK NG
OK
NG
- HINT:
-
For the fuel pressure inspection, refer to the following procedures.
-
Click hereEngine / Hybrid System>1ZR-FE FUEL>FUEL SYSTEM>ON-VEHICLE INSPECTION
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, 44 to 50 psi) 5 minutes after stopping engine 147 kPa (1.5 kgf/cm2, 21 psi) or higher
- Result:
Proceed to OK NG
OK
NG
Connect the GTS to the DLC3.
Turn the ignition switch to ON.
Turn the GTS on.
Enter the following menus: Powertrain / Engine and ECT / Data List / All Data / Long FT #1.
- Powertrain > Engine and ECT > Data List
-
Tester Display Long FT #1 - 50003 234 26
- Result:
Data List Item Result Suspected Area Proceed to Long FT #1 -15 to 15% ·Wire harness or connector
·Fuel
A 15% or higher, or less than -15% Fuel injector assembly B
A
B
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 idle speed or history of unstable idle speed Crankshaft position sensor system A All current and past idle speeds are stable Fuel B
- 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.
A
B
Check the tightening and installation condition of the crankshaft position sensor bolt.
Check the connection of the crankshaft position sensor connector.
- OK:
Sensor is installed correctly.
- Result:
Proceed to OK NG
OK
NG
Check the harnesses and connectors, referring to DTC P0335 inspection procedure.
Click hereEngine / Hybrid System>1ZR-FE ENGINE CONTROL>SFI SYSTEM>P0335
- 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.
- Result:
Proceed to OK NG
OK
NG
Replace the crankshaft position sensor.
Click hereEngine / Hybrid System>1ZR-FE ENGINE CONTROL>CRANKSHAFT POSITION SENSOR>REMOVAL
Check the engine start operation.
- OK:
Malfunction has been repaired successfully.
- Result:
Proceed to OK NG
OK
NG
Connect the GTS to the DLC3.
Turn the ignition switch to ON.
Turn the GTS on.
Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump / Speed.
- Powertrain > Engine and ECT > Active Test
-
Tester Display Control the Fuel Pump / Speed - 50004 234 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
- 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.
A
B
Inspect the fuel pump.
Click hereEngine / Hybrid System>1ZR-FE FUEL>FUEL PUMP>INSPECTION
- 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.
- Result:
Proceed to OK NG
OK
NG
- HINT:
-
For the fuel pressure inspection, refer to the following procedures.
-
Click hereEngine / Hybrid System>1ZR-FE FUEL>FUEL SYSTEM>ON-VEHICLE INSPECTION
Attach a fuel pressure gauge and check the fuel pressure after stopping the engine.
- Standard:
147 kPa (1.5 kgf/cm2, 21 psi) or higher (5 minutes after stopping the engine)
- HINT:
-
If the engine cannot be started, read the values after cranking the engine.
- Result:
Proceed to OK NG
OK
NG
Connect the GTS to the DLC3.
Turn the ignition switch to ON.
Turn the GTS on.
Enter the following menus: Powertrain / Engine and ECT / Data List / All Data / Long FT #1.
- Powertrain > Engine and ECT > Data List
-
Tester Display Long FT #1 - 50003 234 26
- Result:
Data List Item Result Suspected Area Proceed to Long FT #1 -15 to 15% ·Wire harness or connector
·Fuel
A 15% or higher, or less than -15% Fuel injector assembly B
A
B
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
- 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.
A
B
Check the tightening and installation condition of the crankshaft position sensor bolt.
Check the connection of the crankshaft position sensor connector.
- OK:
Sensor is installed correctly.
- Result:
Proceed to OK NG
OK
NG
Check the harnesses and connectors, referring to DTC P0335 inspection procedure.
Click hereEngine / Hybrid System>1ZR-FE ENGINE CONTROL>SFI SYSTEM>P0335
- 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.
- Result:
Proceed to OK NG
OK
NG
Replace the crankshaft position sensor.
Click hereEngine / Hybrid System>1ZR-FE ENGINE CONTROL>CRANKSHAFT POSITION SENSOR>REMOVAL
Check the engine start operation.
- OK:
Malfunction has been repaired successfully.
- Result:
Proceed to OK NG
OK
NG
Connect the GTS to the DLC3.
Turn the ignition switch to ON.
Turn the GTS on.
Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump / Speed.
- Powertrain > Engine and ECT > Active Test
-
Tester Display Control the Fuel Pump / Speed - 50004 234 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
- 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.
A
B
Inspect the fuel pump.
Click hereEngine / Hybrid System>1ZR-FE FUEL>FUEL PUMP>INSPECTION
- 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.
- Result:
Proceed to OK NG
OK
NG
*1 | Purge VSV |
*2 | Fuel Vapor Feed Hose
(to Canister) |
*3 | Connector |
Disconnect the fuel vapor feed hose (on the canister side) of the purge VSV.
Start the engine.
Idle the engine.
Disconnect the connector of the purge VSV.
Check if air flows through the purge VSV.
- OK:
Air does not flow
- HINT:
-
When this inspection is performed, the MIL may illuminate. After finishing the inspection, check and clear the DTCs.
- Result:
Proceed to OK NG
OK
NG
Clean the inside of the intake manifold with compressed air.
After stopping the engine, measure the HC concentration inside the intake manifold for 15 minutes.
- Result:
Result Proceed to 4000 ppm or higher A Less than 4000 ppm B
- HINT:
-
If the concentration is 4000 ppm or higher, a fuel injector assembly may have a sealing problem.
A
B
Check if carbon is on the intake valves.
- Result:
Result Proceed to Carbon present A No carbon present B
A
B
Connect the GTS to the DLC3.
Turn the ignition switch to ON.
Turn the GTS on.
Enter the following menus: Powertrain / Engine and ECT / Data List / All Data / ISC Learning Value.
- Powertrain > Engine and ECT > Data List
-
Tester Display ISC Learning Value - 50003 234 495
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:
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
A
B
Check the compression.
Click hereEngine / Hybrid System>1ZR-FE ENGINE MECHANICAL>ENGINE>ON-VEHICLE INSPECTION
- Result:
Proceed to OK NG
OK
NG
Inspect the engine coolant temperature sensor.
Click hereEngine / Hybrid System>1ZR-FE ENGINE CONTROL>ENGINE COOLANT TEMPERATURE SENSOR>INSPECTION
- Result:
Proceed to OK NG
OK
NG
Check the tightening and installation condition of the crankshaft position sensor bolt.
Check the connection of the crankshaft position sensor connector.
- OK:
Sensor is installed correctly.
- Result:
Proceed to OK NG
OK
NG
Check the tightening and installation condition of the camshaft position sensor (for intake camshaft) bolt.
Check the connection of the camshaft position sensor (for intake camshaft) connector.
- OK:
Sensor is installed correctly.
- Result:
Proceed to OK NG
OK
NG
Check the tightening and installation condition of the camshaft position sensor (for exhaust camshaft) bolt.
Check the connection of the camshaft position sensor (for exhaust camshaft) connector.
- OK:
Sensor is installed correctly.
- Result:
Proceed to OK NG
OK
NG
Check the harnesses and connectors, referring to DTC P0335 inspection procedure.
Click hereEngine / Hybrid System>1ZR-FE ENGINE CONTROL>SFI SYSTEM>P0335
- 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.
- Result:
Proceed to OK NG
OK
NG
Check the harnesses and connectors, referring to DTC P0340 inspection procedure.
Click hereEngine / Hybrid System>1ZR-FE ENGINE CONTROL>SFI SYSTEM>P0340
- 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.
- Result:
Proceed to OK NG
OK
NG
Check the harnesses and connectors, referring to DTC P0365 inspection procedure.
Click hereEngine / Hybrid System>1ZR-FE ENGINE CONTROL>SFI SYSTEM>P0365
- 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.
- Result:
Proceed to OK NG
OK
NG
Replace the crankshaft position sensor.
Click hereEngine / Hybrid System>1ZR-FE ENGINE CONTROL>CRANKSHAFT POSITION SENSOR>REMOVAL
Check the engine start operation.
- OK:
Malfunction has been repaired successfully.
- Result:
Proceed to OK NG
OK
NG
Replace the camshaft position sensor (for intake camshaft).
Click hereEngine / Hybrid System>1ZR-FE ENGINE CONTROL>CAMSHAFT POSITION SENSOR>REMOVAL
Check the engine start operation.
- OK:
Malfunction has been repaired successfully.
- Result:
Proceed to OK NG
OK
NG
Replace the camshaft position sensor (for exhaust camshaft).
Click hereEngine / Hybrid System>1ZR-FE ENGINE CONTROL>CAMSHAFT POSITION SENSOR>REMOVAL
Check the engine start operation.
- OK:
Malfunction has been repaired successfully.
- Result:
Proceed to OK NG
OK
NG