This DTC is stored when the engine does not start even though the STA signal is input, 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.	DTC Detection Condition	Trouble Area
P1604	Either condition is met: The engine speed is less than 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 (the 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 immobiliser system (w/ engine immobiliser system) Engine assembly (excess friction, compression loss) Starter assembly Crankshaft position sensor VVT sensor Engine coolant temperature sensor Fuel pump Fuel pump control circuit Fuel pipes Fuel injector assembly Throttle body with motor assembly Fuel pressure regulator assembly Battery Drive plate and ring gear sub-assembly (for automatic transmission) Flywheel sub-assembly (for manual transmission) Spark plug Ignition coil circuit Intake system Camshaft timing oil control valve assembly Mass air flow meter Air fuel ratio sensor Valve timing Fuel Purge VSV Intake valve Exhaust valve ECM

Dtc P1604 Startability Malfunction. 1GR-FE ENGINE CONTROL. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

INSPECTION PROCEDURE

HINT:

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 this DTC is output, if the customer makes no mention of problems, clear this 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 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 ().

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 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 reoccur, carefully check the vehicle conditions from when the malfunction occurred using freeze frame data.

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 reoccurred 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 ECM may be malfunctioning.

Dtc P1604 Startability Malfunction. 1GR-FE ENGINE CONTROL. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

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

HINT:

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

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

Dtc P1604 Startability Malfunction. 1GR-FE ENGINE CONTROL. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

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

HINT:

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 too high, compression loss may have occurred due to carbon interfering with the valve operation.

Dtc P1604 Startability Malfunction. 1GR-FE ENGINE CONTROL. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

When the malfunction (starting difficulty) can be reproduced, or malfunction conditions are known, confirm the following details of the problem symptom and inspect the systems listed below.

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 turnoff.

HINT:

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

The initial combustion and starter turnoff occur late.

HINT:

If the initial combustion and starter turnoff 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 fuel 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: Fuel 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 reoccurred and the malfunction conditions are unknown.

Freeze Frame Data Item	Result	Suspected Area	Procedure
Engine Speed	0 rpm (no engine cranking at all)	Battery fully depleted Engine assembly (excess friction) Starter assembly Crankshaft position sensor ECM	4 to 9
	100 to 250 rpm (engine cranks but no initial combustion*1)	Engine immobiliser system Fuel pump control circuit 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 immobiliser system Engine assembly (compression loss) Fuel injection system Fuel pump control circuit	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 31
	Starting system	Starter assembly (includes pinion gear wear or tooth damage) Starting system
	Engine assembly	Engine assembly (excess friction) Drive plate wear or tooth damage (for automatic transmission) Ring gear wear or tooth damage (for manual transmission)
Cranking speed too low	Battery malfunction	Battery fully depleted	32 to 34
	Starting system	Starter assembly
	Engine assembly	Engine assembly (excess friction)
Cranking speed too high	Engine assembly	Engine assembly (compression loss)
There is no initial combustion	Fuel supply problem	Cannot maintain pressure due to fuel pressure regulator malfunction Fuel injector leak Fuel leak from fuel line Fuel pump control circuit Fuel pump	35 to 50
	Engine immobiliser system	Engine immobiliser system (w/ immobiliser system)
	Ignition system malfunction	Spark plug Crankshaft position sensor Ignition coil assembly
Engine stalls after starter turnoff	Air suction	Intake system connections	51 to 57
	Deposits in throttle body	Throttle body with motor assembly
	VVT valve does not return properly	Camshaft timing oil control valve assembly
	Mass air flow meter malfunction	Mass air flow meter
Initial combustion and starter turnoff occur late	Engine coolant temperature sensor malfunction	Engine coolant temperature sensor	58 to 71
	Mass air flow meter malfunction	Mass air flow meter
	Abnormal A/F learned value	Air fuel ratio sensor
	Deviation from fuel injection characteristics	Fuel injector assembly
	Wet-fouled or dry-fouled spark plug	Spark plug
	Lack of fuel pressure	Fuel pressure regulator assembly Fuel pump Fuel pump control circuit

Systems to Inspect

Troubleshooting by System	Suspected Area	Suspected Component	Procedure
Fuel system troubleshooting A	Abnormal A/F learned 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 Fuel pressure regulator assembly
Fuel system troubleshooting B	Abnormal concentration of HC in surge tank	Purge VSV system Fuel injector assembly	103 to 105
Fuel system troubleshooting C	Injection signal system malfunction	Fuel injector assembly Crankshaft position sensor VVT sensor ECM	73 to 77
Intake system troubleshooting	Difference between ISC target value and opening angle when idling	Engine assembly (compression loss) Valve timing Engine coolant temperature sensor ECM	84 to 86 106 to 108
Ignition system troubleshooting	Camshaft and/or crankshaft position sensor signal malfunction	Crankshaft position sensor system (including sensor installation) VVT sensor system (including sensor installation) ECM	78 to 83 109 to 114

1.CHECK FOR ANY OTHER DTCS OUTPUT AND RECORD FREEZE FRAME DATA

Connect the GTS to the DLC3.

Turn the ignition switch to ON.

Enter the following menus: Powertrain / Engine and ECT / Trouble Codes.

Dtc P1604 Startability Malfunction. 1GR-FE ENGINE CONTROL. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Read the DTCs and record the freeze frame data.

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 the DTC is stored.

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

GO TO DTC CHART ()

A

2.CHECK ENGINE IMMOBILISER SYSTEM

HINT:

If the vehicle is not equipped with an engine immobiliser system, proceed to the next step (OK).

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.

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.

REPAIR ENGINE IMMOBILISER SYSTEM

OK

3.CHECK MALFUNCTION CONDITION

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

Go to step 25

A

4.CHECK FREEZE FRAME DATA

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 ().

Result
Freeze Frame Data Item		Suspected Area	Proceed to
Engine Speed	Battery Voltage	Suspected Area	Proceed to
All 5 sets of freeze frame data are 0 rpm (no engine cranking at all)	Minimum voltage is below 5 V	Battery fully depleted	A
	Minimum voltage is 5 V or higher	Starter malfunction Crankshaft position sensor system Excess engine friction ECM	B
60 to 250 rpm (engine cranks but no initial combustion)	-	Engine immobiliser system Fuel pump control circuit Ignition system Engine coolant temperature sensor Fuel injection system	C
250 rpm or higher (combustion occurs but initial combustion and starter turnoff occur late)	-	Engine immobiliser system Engine assembly Fuel injection system Fuel pump control circuit	D

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)

CHARGE OR REPLACE BATTERY

5.CHECK FREEZE FRAME DATA

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 ().

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 fluctuates2, 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.

Go to step 6

CHECK AND REPAIR ENGINE OR BATTERY

CHECK STARTER SIGNAL CIRCUIT ()

6.CHECK CRANKSHAFT POSITION SENSOR (SENSOR INSTALLATION)

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

Check the connection of the crankshaft position sensor connector.

Result
Result	Proceed to
Normal	A
Abnormal	B

SECURELY REINSTALL SENSOR ()

A

7.CHECK CRANKSHAFT POSITION SENSOR

Disconnect the crankshaft position sensor connector.

Check for oil on the connector terminals.

OK:
No oil on the terminals.

REPLACE CRANKSHAFT POSITION SENSOR ()

OK

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

Disconnect the crankshaft position sensor connector.

Disconnect the ECM connector.

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

Standard Resistance:

for LHD
Tester Connection	Condition	Specified Condition
C1-1 - C45-110 (NE+)	Always	Below 1 Ω
C1-2 - C45-111 (NE-)	Always	Below 1 Ω
C1-1 or C45-110 (NE+) - Body ground	Always	10 kΩ or higher
C1-2 or C45-111 (NE-) - Body ground	Always	10 kΩ or higher

for RHD
Tester Connection	Condition	Specified Condition
C1-1 - C46-110 (NE+)	Always	Below 1 Ω
C1-2 - C46-111 (NE-)	Always	Below 1 Ω
C1-1 or C46-110 (NE+) - Body ground	Always	10 kΩ or higher
C1-2 or C46-111 (NE-) - 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.

REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

9.CHECK CRANKSHAFT POSITION SENSOR

Replace the crankshaft position sensor ().

Check the engine start operation.

OK:
Malfunction has been repaired successfully.

REPLACE ECM ()

END (CRANKSHAFT POSITION SENSOR IS DEFECTIVE)

10.CHECK FREEZE FRAME DATA

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 ().

Result
Freeze Frame Data Item			Suspected Area	Proceed to
Coolant Temp, Ambient Temp for A/C, Intake Air	Coolant Temp, Ambient Temp for A/C	Fuel Pump Duty	Suspected Area	Proceed to
Difference between Coolant Temp, Ambient Temp for A/C and Intake Air is 10°C or more*1	Coolant Temp is 125°C or higher, or below Ambient Temp for A/C by 15°C or more	-	Engine coolant temperature sensor	A
	Other than above	No sets of freeze frame data are 0%	-	B
	Other than above	At least 1 of the 5 sets of freeze frame data is 0%	Fuel pump control circuit	C
Difference between Coolant Temp, Ambient Temp for A/C and Intake Air is less than 10°C*2	-	At least 1 of the 5 sets of freeze frame data is 0%	Fuel pump control circuit	C
	-	No sets of freeze frame data are 0%	-	B

HINT:

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

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

Go to step 11

CHECK FUEL PUMP CONTROL CIRCUIT ()

REPLACE ENGINE COOLANT TEMPERATURE SENSOR ()

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

Connect the GTS to the DLC3.

Turn the ignition switch to ON.

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

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.

REPAIR FUEL PUMP CONTROL CIRCUIT ()

OK

12.CHECK TERMINAL VOLTAGE (FUEL INJECTOR POWER SOURCE)

Disconnect the fuel injector assembly connectors.

Turn the ignition switch to ON.

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

Standard Voltage:

Cylinder	Tester Connection	Switch Condition	Specified Condition
No. 1	C5-1 - Body ground	Ignition switch ON	11 to 14 V
No. 2	C16-1 - Body ground	Ignition switch ON	11 to 14 V
No. 3	C7-1 - Body ground	Ignition switch ON	11 to 14 V
No. 4	C14-1 - Body ground	Ignition switch ON	11 to 14 V
No. 5	C9-1 - Body ground	Ignition switch ON	11 to 14 V
No. 6	C12-1 - Body ground	Ignition switch ON	11 to 14 V

Text in Illustration
*a	Front view of wire harness connector (to Fuel Injector Assembly)

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.

REPAIR FUEL INJECTOR POWER SOURCE CIRCUIT ()

OK

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

Connect the GTS to the DLC3.

Turn the ignition switch to ON.

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

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.

Go to step 14

REPAIR OR REPLACE FUEL LINE

14.CHECK FUEL SYSTEM

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

Go to step 24

REPAIR OR REPLACE FUEL SYSTEM

15.CHECK FREEZE FRAME DATA

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 ().

Result
Freeze Frame Data Item				Suspected Area	Proceed to
Coolant Temp, Ambient Temp for A/C, Intake Air	Coolant Temp, Ambient Temp for A/C	Long FT	Engine Speed	Suspected Area	Proceed to
Difference between Coolant Temp, Ambient Temp for A/C and Intake Air is 10°C or more	Coolant Temp is 125°C or higher, or below Ambient Temp for A/C by 15°C or more	-	-	Engine coolant temperature sensor	A
	Other than above	-15% or less, or +15% or more	-	Fuel pump control circuit Fuel injector assembly	B
		-15 to +15%	Minimum speed is 300 rpm or more*	Engine assembly	C
		-15 to +15%	Minimum speed is less than 300 rpm	Fuel system Intake air system	D
Difference between Coolant Temp, Ambient Temp for A/C and Intake Air is less than 10°C	-	-15% or less, or +15% or more	-	Fuel pump control circuit Fuel injector assembly	B
		-15 to +15%	Minimum speed is 300 rpm or more*	Engine assembly	C
		-15 to +15%	Minimum speed is less than 300 rpm	Fuel system Intake air system	D

HINT:

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

Go to step 16

CHECK AND REPAIR ENGINE ASSEMBLY

Go to step 18

REPLACE ENGINE COOLANT TEMPERATURE SENSOR ()

16.INSPECT FUEL INJECTOR ASSEMBLY

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

OK:
No carbon present.

REPLACE FUEL INJECTOR ASSEMBLY ()

OK

17.CHECK FUEL SYSTEM

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

Go to step 24

REPAIR OR REPLACE FUEL SYSTEM

18.CHECK FREEZE FRAME DATA

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 ().

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

HINT:

*1: If the engine coolant temperature is 40°C or less (after stopping the engine and the vehicle has not been driven for a long period of time), the fuel pressure regulator may be stuck open. Attach a fuel pressure gauge and check the ability of the system to maintain fuel pressure after stopping the engine.

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

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

Go to step 20

A

19.CHECK FUEL PRESSURE

HINT:

For the fuel pressure inspection, refer to the following procedures ().

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)

HINT:

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

Result
Result	Proceed to
Normal	A
Abnormal	B

Go to step 24

REPLACE FUEL PRESSURE REGULATOR ASSEMBLY ()

20.CHECK FUEL INJECTOR ASSEMBLY

Clean the inside of the surge tank with compressed air.

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

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

HINT:

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

Go to step 22

A

21.CHECK FUEL INJECTOR ASSEMBLY

Inspect the fuel injector assemblies ().

Result
Result	Proceed to
Abnormal	A
Normal	B

Go to step 22

REPLACE FUEL INJECTOR ASSEMBLY ()

22.CHECK THROTTLE BODY WITH MOTOR ASSEMBLY

Check if carbon is in the airflow passage.

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

Go to step 23

CLEAN OR REPLACE THROTTLE BODY WITH MOTOR ASSEMBLY ()

23.CHECK INTAKE SYSTEM

Check the intake system for vacuum leaks ().

OK:
No leaks in intake system.

REPAIR OR REPLACE INTAKE SYSTEM

OK

24.PERFORM SIMULATION TEST

Check if the engine can be started.

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

Go to step 25

END

25.CONFIRM PROBLEM SYMPTOM

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 tooth damage) Starter system Engine assembly (excess friction) Drive plate wear or tooth damage (for automatic transmission) Ring gear wear or tooth damage (for manual transmission)	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	Failure of fuel pressure regulator to maintain pressure Fuel injector leak Fuel leak from fuel line Fuel pump control circuit Fuel pump Spark plug Crankshaft position sensor system Ignition coil system	C
The engine stalls after starter turnoff (engine stalls immediately after the first time the engine speed increases)*2	Intake system connections Throttle body with motor assembly Camshaft timing oil control valve assembly Mass air flow meter system	D
The initial combustion and starter turnoff occur late*3	Engine coolant temperature sensor Mass air flow meter Air fuel ratio sensor Heated oxygen sensor Fuel injector assembly Spark plug Fuel pressure regulator assembly Fuel pump Fuel pump control circuit	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 turnoff, the air-fuel ratio may be incorrect or the camshaft timing oil control valve assembly 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).

A

26.PERFORM SIMULATION TEST

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 (for automatic transmission) Ring gear (for manual transmission) 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.

Go to step 29

Go to step 30

A

27.INSPECT BATTERY

Check the electrolyte quantity.

OK:
Electrolyte quantity is within the specified range.

Inspect the specific gravity.

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.

Inspect the battery voltage.

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

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.

Measure the battery voltage when cranking the engine.

Standard:
Approximately 6 V or higher (0°C (32°F) or higher)

HINT:

When the battery is depleted, the horn becomes quieter.

CHARGE OR REPLACE BATTERY

OK

28.CHECK ENGINE ASSEMBLY

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.

REPAIR OR REPLACE ENGINE ASSEMBLY

INSPECT STARTER ASSEMBLY ()

29.CHECK STARTER ASSEMBLY

Remove the starter assembly ().

Check for starter pinion gear wear and damage.

OK:
There is no wear or damage.

REPLACE STARTER ASSEMBLY ()

REPLACE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY OR FLYWHEEL RING GEAR ()

30.INSPECT BATTERY

Check the electrolyte quantity.

OK:
Electrolyte quantity is within the specified range.

Inspect the specific gravity.

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.

Inspect the battery voltage.

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

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.

Measure the battery voltage when cranking the engine.

Standard:
Approximately 6 V or higher (0°C (32°F) or higher)

HINT:

When the battery is depleted, the horn becomes quieter.

CHARGE OR REPLACE BATTERY

OK

31.INSPECT STARTER ASSEMBLY

Inspect the starter assembly ().

REPLACE STARTER ASSEMBLY ()

CHECK STARTER SIGNAL CIRCUIT ()

32.PERFORM SIMULATION TEST

Check the cranking speed.

Result
Problem Symptom	Suspected Area	Proceed to
Cranking speed is slow (100 rpm or less)	Battery Starter assembly Excess engine friction	A
Cranking speed is fast (300 rpm or more)*	Engine compression loss	B

HINT:

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

CHECK AND REPAIR ENGINE ASSEMBLY

A

33.INSPECT BATTERY

Check the electrolyte quantity.

OK:
Electrolyte quantity is within the specified range.

Inspect the specific gravity.

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.

Inspect the battery voltage.

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

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.

Measure the battery voltage when cranking the engine.

Standard:
Approximately 6 V or higher (0°C (32°F) or higher)

HINT:

When the battery is depleted, the horn becomes quieter.

CHARGE OR REPLACE BATTERY

OK

34.CHECK ENGINE ASSEMBLY

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.

REPAIR OR REPLACE ENGINE ASSEMBLY

INSPECT STARTER ASSEMBLY ()

35.CHECK FUEL INJECTOR ASSEMBLY

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

OK:
Fuel injector operating noise is heard.

Go to step 48

OK

36.CHECK FUEL PRESSURE

Inspect the fuel pressure ().

Go to step 46

OK

37.CHECK SPARK PLUG AND SPARK

Check for sparks ().

Go to step 41

OK

38.CONFIRM VEHICLE CONDITION

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

Result
Problem Symptom	Suspected Area	Proceed to
When the engine is stopped and a long time has passed, engine starting trouble occurs*1	Fuel pressure regulator 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 of fuel pressure regulator to maintain fuel pressure	A
Condition other than above, or there is an inconsistency in the conditions present when engine starting trouble occurs	-	C*4

HINT:

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

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

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

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

Go to step 40

Go to step 72

A

39.CHECK FUEL PRESSURE

HINT:

For the fuel pressure inspection, refer to the following procedures ().

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

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

HINT:

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

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

Go to step 72

REPLACE FUEL PRESSURE REGULATOR ASSEMBLY ()

40.CHECK FUEL INJECTOR ASSEMBLY

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

Result
Result	Proceed to
4000 ppm or more	A
Less than 4000 ppm	B*

HINT:

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

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

Go to step 72

REPLACE FUEL INJECTOR ASSEMBLY ()

41.CHECK SPARK PLUG

Inspect the spark plugs ().

HINT:

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

REPLACE SPARK PLUG ()

OK

42.READ VALUE USING GTS (ENGINE SPEED)

Connect the GTS to the DLC3.

Turn the ignition switch to ON.

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

Start the engine.

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

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.

CHECK CRANKSHAFT POSITION SENSOR CIRCUIT ()

OK

43.CHECK TERMINAL VOLTAGE (IGNITION COIL POWER SOURCE)

Disconnect the ignition coil assembly connectors.

Turn the ignition switch to ON.

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

Standard Voltage:

Tester Connection	Switch Condition	Specified Condition
C4-1 (+B) - C4-4 (GND)	Ignition switch ON	11 to 14 V
C15-1 (+B) - C15-4 (GND)	Ignition switch ON	11 to 14 V
C130-1 (+B) - C130-4 (GND)	Ignition switch ON	11 to 14 V
C140-1 (+B) - C140-4 (GND)	Ignition switch ON	11 to 14 V
C8-1 (+B) - C8-4 (GND)	Ignition switch ON	11 to 14 V
C11-1 (+B) - C11-4 (GND)	Ignition switch ON	11 to 14 V

Text in Illustration
*a	Front view of wire harness connector (to Ignition Coil Assembly)

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.

CHECK IGNITION COIL POWER SOURCE CIRCUIT ()

OK

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

Disconnect the ignition coil assembly connector.

Disconnect the ECM connector.

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

Standard Resistance:

for LHD
Tester Connection	Condition	Specified Condition
C4-2 (IGF) - C45-104 (IGF1)	Always	Below 1 Ω
C15-2 (IGF) - C45-104 (IGF1)	Always	Below 1 Ω
C130-2 (IGF) - C45-104 (IGF1)	Always	Below 1 Ω
C140-2 (IGF) - C45-104 (IGF1)	Always	Below 1 Ω
C8-2 (IGF) - C45-104 (IGF1)	Always	Below 1 Ω
C11-2 (IGF) - C45-104 (IGF1)	Always	Below 1 Ω
C4-2 (IGF) or C45-104 (IGF1) - Body ground	Always	10 kΩ or higher
C15-2 (IGF) or C45-104 (IGF1) - Body ground	Always	10 kΩ or higher
C130-2 (IGF) or C45-104 (IGF1) - Body ground	Always	10 kΩ or higher
C140-2 (IGF) or C45-104 (IGF1) - Body ground	Always	10 kΩ or higher
C8-2 (IGF) or C45-104 (IGF1) - Body ground	Always	10 kΩ or higher
C11-2 (IGF) or C45-104 (IGF1) - Body ground	Always	10 kΩ or higher

for RHD
Tester Connection	Condition	Specified Condition
C4-2 (IGF) - C46-104 (IGF1)	Always	Below 1 Ω
C15-2 (IGF) - C46-104 (IGF1)	Always	Below 1 Ω
C130-2 (IGF) - C46-104 (IGF1)	Always	Below 1 Ω
C140-2 (IGF) - C46-104 (IGF1)	Always	Below 1 Ω
C8-2 (IGF) - C46-104 (IGF1)	Always	Below 1 Ω
C11-2 (IGF) - C46-104 (IGF1)	Always	Below 1 Ω
C4-2 (IGF) or C46-104 (IGF1) - Body ground	Always	10 kΩ or higher
C15-2 (IGF) or C46-104 (IGF1) - Body ground	Always	10 kΩ or higher
C130-2 (IGF) or C46-104 (IGF1) - Body ground	Always	10 kΩ or higher
C140-2 (IGF) or C46-104 (IGF1) - Body ground	Always	10 kΩ or higher
C8-2 (IGF) or C46-104 (IGF1) - Body ground	Always	10 kΩ or higher
C11-2 (IGF) or C46-104 (IGF1) - 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.

REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

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

Disconnect the ignition coil assembly connector.

Disconnect the ECM connector.

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

Standard Resistance:

for LHD
Tester Connection	Condition	Specified Condition
C4-3 (IGT1) - C45-40 (IGT1)	Always	Below 1 Ω
C15-3 (IGT2) - C45-39 (IGT2)	Always	Below 1 Ω
C130-3 (IGT3) - C45-38 (IGT3)	Always	Below 1 Ω
C140-3 (IGT4) - C45-37 (IGT4)	Always	Below 1 Ω
C8-3 (IGT5) - C45-36 (IGT5)	Always	Below 1 Ω
C11-3 (IGT6) - C45-35 (IGT6)	Always	Below 1 Ω
C4-3 (IGT1) or C45-40 (IGT1) - Body ground	Always	10 kΩ or higher
C15-3 (IGT2) or C45-39 (IGT2) - Body ground	Always	10 kΩ or higher
C130-3 (IGT3) or C45-38 (IGT3) - Body ground	Always	10 kΩ or higher
C140-3 (IGT4) or C45-37 (IGT4) - Body ground	Always	10 kΩ or higher
C8-3 (IGT5) or C45-36 (IGT5) - Body ground	Always	10 kΩ or higher
C11-3 (IGT6) or C45-35 (IGT6) - Body ground	Always	10 kΩ or higher

for RHD
Tester Connection	Condition	Specified Condition
C4-3 (IGT1) - C46-40 (IGT1)	Always	Below 1 Ω
C15-3 (IGT2) - C46-39 (IGT2)	Always	Below 1 Ω
C130-3 (IGT3) - C46-38 (IGT3)	Always	Below 1 Ω
C140-3 (IGT4) - C46-37 (IGT4)	Always	Below 1 Ω
C8-3 (IGT5) - C46-36 (IGT5)	Always	Below 1 Ω
C11-3 (IGT6) - C46-35 (IGT6)	Always	Below 1 Ω
C4-3 (IGT1) or C46-40 (IGT1) - Body ground	Always	10 kΩ or higher
C15-3 (IGT2) or C46-39 (IGT2) - Body ground	Always	10 kΩ or higher
C130-3 (IGT3) or C46-38 (IGT3) - Body ground	Always	10 kΩ or higher
C140-3 (IGT4) or C46-37 (IGT4) - Body ground	Always	10 kΩ or higher
C8-3 (IGT5) or C46-36 (IGT5) - Body ground	Always	10 kΩ or higher
C11-3 (IGT6) or C46-35 (IGT6) - 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 is normal, after replacing the ignition coil assembly, check if engine starting trouble occurs again. If engine starting trouble occurs again, proceed to step 71 and perform troubleshooting for the ignition system (steps 77 to 82).

REPAIR OR REPLACE HARNESS OR CONNECTOR

REPLACE IGNITION COIL ASSEMBLY ()

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

Connect the GTS to the DLC3.

Turn the ignition switch to ON.

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

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.

CHECK FUEL PUMP CONTROL CIRCUIT ()

OK

47.PERFORM ACTIVE TEST USING GTS (CONTROL THE FUEL PUMP / SPEED)

Connect the GTS to the DLC3.

Turn the ignition switch to ON.

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

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 circuit, check if engine starting trouble occurs again. If engine starting trouble occurs again, proceed to step 72 and perform fuel system troubleshooting (steps 73 to 77).

CHECK FUEL PUMP CONTROL CIRCUIT ()

REPAIR OR REPLACE FUEL LINE

48.READ VALUE USING GTS (ENGINE SPEED)

Connect the GTS to the DLC3.

Turn the ignition switch to ON.

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

Start the engine.

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

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.

REPLACE CRANKSHAFT POSITION SENSOR ()

OK

49.CHECK TERMINAL VOLTAGE (FUEL INJECTOR POWER SOURCE)

Disconnect the fuel injector assembly connectors.

Turn the ignition switch to ON.

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

Standard Voltage:

Cylinder	Tester Connection	Switch Condition	Specified Condition
No. 1	C5-1 - Body ground	Ignition switch ON	11 to 14 V
No. 2	C16-1 - Body ground	Ignition switch ON	11 to 14 V
No. 3	C7-1 - Body ground	Ignition switch ON	11 to 14 V
No. 4	C14-1 - Body ground	Ignition switch ON	11 to 14 V
No. 5	C9-1 - Body ground	Ignition switch ON	11 to 14 V
No. 6	C12-1 - Body ground	Ignition switch ON	11 to 14 V

Text in Illustration
*a	Front view of wire harness connector (to Fuel Injector Assembly)

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.

REPAIR FUEL INJECTOR POWER SOURCE CIRCUIT ()

OK

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

Disconnect the fuel injector assembly connector.

Disconnect the ECM connector.

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

Standard Resistance:

for LHD
Cylinder	Tester Connection	Condition	Specified Condition
No. 1	C5-2 - Body ground	Always	10 kΩ or higher
No. 1	C5-2 - C45-86 (#10)	Always	Below 1 Ω
No. 2	C16-2- Body ground	Always	10 kΩ or higher
No. 2	C16-2 - C45-109 (#20)	Always	Below 1 Ω
No. 3	C7-2 - Body ground	Always	10 kΩ or higher
No. 3	C7-2 - C45-85 (#30)	Always	Below 1 Ω
No. 4	C14-2 - Body ground	Always	10 kΩ or higher
No. 4	C14-2 - C45-108 (#40)	Always	Below 1 Ω
No. 5	C9-2 - Body ground	Always	10 kΩ or higher
No. 5	C9-2 - C45-84 (#50)	Always	Below 1 Ω
No. 6	C12-2 - Body ground	Always	10 kΩ or higher
No. 6	C12-2 - C45-107 (#60)	Always	Below 1 Ω

for RHD
Cylinder	Tester Connection	Condition	Specified Condition
No. 1	C5-2 - Body ground	Always	10 kΩ or higher
No. 1	C5-2 - C46-86 (#10)	Always	Below 1 Ω
No. 2	C16-2- Body ground	Always	10 kΩ or higher
No. 2	C16-2 - C46-109 (#20)	Always	Below 1 Ω
No. 3	C7-2 - Body ground	Always	10 kΩ or higher
No. 3	C7-2 - C46-85 (#30)	Always	Below 1 Ω
No. 4	C14-2 - Body ground	Always	10 kΩ or higher
No. 4	C14-2 - C46-108 (#40)	Always	Below 1 Ω
No. 5	C9-2 - Body ground	Always	10 kΩ or higher
No. 5	C9-2 - C46-84 (#50)	Always	Below 1 Ω
No. 6	C12-2 - Body ground	Always	10 kΩ or higher
No. 6	C12-2 - C46-107 (#60)	Always	Below 1 Ω

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.

REPAIR OR REPLACE HARNESS OR CONNECTOR

REPLACE ECM ()

51.CHECK MASS AIR FLOW METER

Connect the GTS to the DLC3.

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

HINT:

The A/C switch and all accessory switches should be off, and the shift lever should be in N or P.

Turn the GTS on.

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

Check MAF in the Data List during idling.

Standard:
2.5 to 4.7 gm/s

Go to step 57

OK

52.CHECK INTAKE SYSTEM

Check for air leakage in the intake system [vacuum hose disconnection, cracks, damaged gaskets, etc.] ().

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 and Long FT 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 is no air leakage.

REPAIR OR REPLACE INTAKE SYSTEM

OK

53.CHECK THROTTLE BODY WITH MOTOR ASSEMBLY

Disconnect the throttle body with motor 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

Connect the throttle body with motor assembly connector.

HINT:

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

Go to step 55

A

54.CHECK THROTTLE BODY WITH MOTOR ASSEMBLY

Check if carbon is in the airflow passage.

OK:
No carbon present.

REMOVE FOREIGN OBJECT AND CLEAN THROTTLE BODY WITH MOTOR ASSEMBLY

OK

55.PERFORM ACTIVE TEST USING GTS (CONTROL THE VVT LINEAR)

Connect the GTS to the DLC3.

Turn the GTS on.

Warm up the engine.

Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the VVT Linear (Bank1) or Control the VVT Linear (Bank2).

HINT:

When performing the Active Test, make sure the A/C is on and the shift lever is in P or N.

Check the engine speed while operating the camshaft timing oil control valve using the GTS.

OK*:
GTS Operation Specified Condition
0% Normal engine speed
100% Engine idles roughly or stalls

Result
Result	Proceed to
NG	A
OK	B

HINT:

*: From step 72, perform intake system troubleshooting (steps 84 to 86). If engine starting trouble still occurs, perform fuel system troubleshooting A (steps 87 to 94).

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.

Go to step 56

REPLACE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (FOR INTAKE SIDE) ()

56.PERFORM ACTIVE TEST USING GTS (CONTROL THE VVT EXHAUST LINEAR)

Connect the GTS to the DLC3.

Turn the GTS on.

Warm up the engine.

Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the VVT Exhaust Linear (Bank1) or Control the VVT Exhaust Linear (Bank2).

HINT:

When performing the Active Test, make sure the A/C is on and the shift lever is in P or N.

Check the engine speed while operating the camshaft timing oil control valve using the GTS.

OK*:
GTS Operation Specified Condition
0% Normal engine speed
100% Engine idles roughly or stalls

HINT:

*: From step 72, perform intake system troubleshooting (steps 84 to 86). If engine starting trouble still occurs, perform fuel system troubleshooting A (steps 87 to 94).

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.

Go to step 72

REPLACE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (FOR EXHAUST SIDE) ()

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

Disconnect the mass air flow meter connector.

Disconnect the ECM connector.

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

Standard Resistance:
for LHD
Tester Connection Condition Specified Condition
C50-5 (VG) - C45-74 (VG) Always Below 1 Ω
C50-4 (E2G) - C45-75 (E2G) Always Below 1 Ω
C50-5 (VG) or C45-74 (VG) - Body ground Always 10 kΩ or higher
for RHD
Tester Connection Condition Specified Condition
C50-5 (VG) - C46-74 (VG) Always Below 1 Ω
C50-4 (E2G) - C46-75 (E2G) Always Below 1 Ω
C50-5 (VG) or C46-74 (VG) - 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 is normal, after replacing the mass air flow meter, check if engine starting trouble occurs again. If engine starting trouble occurs again, proceed to step 72 and perform intake system troubleshooting (steps 84 to 86). If engine starting trouble still occurs, perform fuel system troubleshooting A (steps 87 to 94).

REPAIR OR REPLACE HARNESS OR CONNECTOR

REPLACE MASS AIR FLOW METER ()

58.INSPECT ENGINE COOLANT TEMPERATURE SENSOR

Inspect the engine coolant temperature sensor ().

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 72 and perform fuel system troubleshooting A (steps 95 to 102), fuel system troubleshooting B (steps 103 to 105), intake system troubleshooting (steps 106 to 108), and ignition system troubleshooting (steps 109 to 114), in that order.

REPLACE ENGINE COOLANT TEMPERATURE SENSOR ()

OK

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

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:

for LHD
Tester Connection	Condition	Specified Condition
C18-2 - C45-76 (THW)	Always	Below 1 Ω
C18-1 - C45-97 (ETHW)	Always	Below 1 Ω
C18-2 or C45-76 (THW) - Body ground	Always	10 kΩ or higher
C18-1 or C45-97 (ETHW) - Body ground	Always	10 kΩ or higher

for RHD
Tester Connection	Condition	Specified Condition
C18-2 - C46-76 (THW)	Always	Below 1 Ω
C18-1 - C46-97 (ETHW)	Always	Below 1 Ω
C18-2 or C46-76 (THW) - Body ground	Always	10 kΩ or higher
C18-1 or C46-97 (ETHW) - 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 72 and perform fuel system troubleshooting A (steps 95 to 102), fuel system troubleshooting B (steps 103 to 105), intake system troubleshooting (steps 106 to 108), and ignition system troubleshooting (steps 109 to 114), in that order.

REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

60.CHECK MASS AIR FLOW METER

Connect the GTS to the DLC3.

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

HINT:

The A/C switch and all accessory switches should be off, and the shift lever should be in N or P.

Turn the GTS on.

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

Check MAF in the Data List during idling.

Standard:
2.5 to 4.7 gm/s

HINT:

If the mass air flow meter is malfunctioning, after replacing it, check if engine starting trouble occurs again. If engine starting trouble occurs, replace the ECM. If engine starting trouble still occurs, proceed to step 72 and perform fuel system troubleshooting A (steps 95 to 102), fuel system troubleshooting B (steps 103 to 105), intake system troubleshooting (steps 106 to 108), and ignition system troubleshooting (steps 109 to 114), in that order.

REPLACE MASS AIR FLOW METER ()

OK

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

Disconnect the mass air flow meter connector.

Disconnect the ECM connector.

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

Standard Resistance:
for LHD
Tester Connection Condition Specified Condition
C50-5 (VG) - C45-74 (VG) Always Below 1 Ω
C50-4 (E2G) - C45-75 (E2G) Always Below 1 Ω
C50-5 (VG) or C45-74 (VG) - Body ground Always 10 kΩ or higher
for RHD
Tester Connection Condition Specified Condition
C50-5 (VG) - C46-74 (VG) Always Below 1 Ω
C50-4 (E2G) - C46-75 (E2G) Always Below 1 Ω
C50-5 (VG) or C46-74 (VG) - 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.

REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

62.READ VALUE USING GTS

Connect the GTS to the DLC3.

Turn the ignition switch to ON.

Enter the following menus: Powertrain / Engine and ECT / Data List / Atmospheric Pressure and Long FT.

Result
Data List Item	Result	Suspected Area	Proceed to
Long FT	+25% or more or less than -25%	Air fuel ratio sensor Heated oxygen sensor Mass air flow meter Fuel injector assembly ECM	A
Atmosphere Pressure	80 kPa or less (when elevation is 0 m)		A
Both Data List items listed above	Values are other than above	-	B

Go to step 66

A

63.PERFORM SIMULATION TEST

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

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

Check if the engine can be started.

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

Go to step 66

A

64.INSPECT AIR FUEL RATIO SENSOR

Connect the GTS to the DLC3.

Start the engine.

Turn the GTS on.

Enter the following menus: Powertrain / Engine and ECT / Data List / Fuel System Status #1 and Fuel System Status #2.

Confirm that Fuel System Status #1 and Fuel System Status #2 are both CL.

Enter the following menus: Powertrain / Engine and ECT / Data List / AF Lambda B1S1 and AF Lambda B2S1.

Confirm that AF Lambda B1S1 and AF Lambda B2S1 are both 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.

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
AFS Voltage B2S1 +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

Result
Result	Proceed to
Normal	A
Abnormal	B

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 72 and perform fuel system troubleshooting A (steps 95 to 102), fuel system troubleshooting B (steps 103 to 105), intake system troubleshooting (steps 106 to 108), and ignition system troubleshooting (steps 109 to 114), in that order.

REPLACE AIR FUEL RATIO SENSOR ()

A

65.PERFORM SIMULATION TEST

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

OK:
Speed is stable.

HINT:

After replacing the fuel injector assembly or mass air flow meter, check if engine starting trouble occurs again. If engine starting trouble occurs, replace the ECM. If engine starting trouble still occurs, proceed to step 72 and perform fuel system troubleshooting A (steps 95 to 102), fuel system troubleshooting B (steps 103 to 105), intake system troubleshooting (steps 106 to 108), and ignition system troubleshooting (steps 109 to 114), in that order.

REPLACE FUEL INJECTOR ASSEMBLY ()

REPLACE MASS AIR FLOW METER ()

66.CHECK FUEL PRESSURE

Inspect the fuel pressure ().

Go to step 71

OK

67.CHECK SPARK PLUG

Inspect the spark plugs ().

Result
Result	Proceed to
All cylinders are normal	A
One cylinder is abnormal*1	B
All cylinders are abnormal2, 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 72 and perform fuel system troubleshooting A (steps 95 to 102), fuel system troubleshooting B (steps 103 to 105), intake system troubleshooting (steps 106 to 108), and ignition system troubleshooting (steps 109 to 114), in that order.

*2: If all cylinders are abnormal, replace the spark plugs of all cylinders and check if engine starting trouble occurs again. If engine starting trouble still occurs, proceed to step 72 and perform fuel system troubleshooting A (steps 95 to 102), fuel system troubleshooting B (steps 103 to 105), intake system troubleshooting (steps 106 to 108), and ignition system troubleshooting (steps 109 to 114), in that order.

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

REPLACE SPARK PLUG (ABNORMAL CYLINDER) ()

REPLACE SPARK PLUG (ALL) ()

A

68.CONFIRM VEHICLE CONDITION

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

Result
Problem Symptom	Suspected Area	Proceed to
When the engine is stopped and a long time has passed, engine starting trouble occurs*1	Fuel pressure regulator 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 of fuel pressure regulator to maintain fuel pressure	A
Condition other than above, or there is an inconsistency in the conditions present when engine starting trouble occurs	-	C*4

HINT:

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

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

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

*4: From step 72, perform fuel system troubleshooting A (steps 95 to 102), fuel system troubleshooting B (steps 103 to 105), intake system troubleshooting (steps 106 to 108), and ignition system troubleshooting (steps 109 to 114), in that order.

Go to step 70

Go to step 72

A

69.CHECK FUEL PRESSURE

HINT:

For the fuel pressure inspection, refer to the following procedures ().

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

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

HINT:

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

*: From step 72, perform fuel system troubleshooting A (steps 95 to 102), fuel system troubleshooting B (steps 103 to 105), intake system troubleshooting (steps 106 to 108), and ignition system troubleshooting (steps 109 to 114), in that order.

Go to step 72

REPLACE FUEL PRESSURE REGULATOR ASSEMBLY ()

70.CHECK FUEL INJECTOR ASSEMBLY

Clean the inside of the surge tank with compressed air.

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

Result
Result	Proceed to
4000 ppm or more	A
Less than 4000 ppm	B*

HINT:

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

Go to step 72

REPLACE FUEL INJECTOR ASSEMBLY ()

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

Connect the GTS to the DLC3.

Turn the ignition switch to ON.

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

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 circuit, check if engine starting trouble occurs again. If engine starting trouble still occurs, proceed to step 72 and perform fuel system troubleshooting A (steps 95 to 102), fuel system troubleshooting B (steps 103 to 105), intake system troubleshooting (steps 106 to 108), and ignition system troubleshooting (steps 109 to 114), in that order.

CHECK FUEL PUMP CONTROL CIRCUIT ()

REPAIR OR REPLACE FUEL LINE

72.CHECK MALFUNCTION CONDITION

If the malfunction could not be identified during the inspections in steps 38, 39, 40 and 47, perform fuel system troubleshooting C (steps 73 to 77).

Result
Step Performed	Troubleshooting by System	Procedure	Proceed to
Steps 38, 39, 40 and 47	Fuel system troubleshooting C	73 to 77	A

If the malfunction could not be identified during the inspection in step 45, perform ignition system troubleshooting (steps 78 to 83).

Result
Step Performed	Troubleshooting by System	Procedure	Proceed to
Step 45	Ignition system troubleshooting	78 to 83	B

If the malfunction could not be identified during the inspections in steps 55, 56 and 57, 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
Step Performed	Troubleshooting by System	Procedure	Proceed to
Step 55, 56 and 57	Intake air system troubleshooting	84 to 86	C
Step 55, 56 and 57	Fuel system troubleshooting A	87 to 94	C

If the malfunction could not be identified during the inspections in steps 58, 59, 60, 61, 64, 65, 67, 68, 69, 70 and 71, perform fuel system troubleshooting A (steps 95 to 102), fuel system troubleshooting B (steps 103 to 105), intake air system troubleshooting (steps 106 to 108), and ignition system troubleshooting (steps 109 to 114), in that order.

Result
Step Performed	Troubleshooting by System	Procedure	Proceed to
Steps 58, 59, 60, 61, 64, 65, 67, 68, 69, 70 and 71	Fuel system troubleshooting A	95 to 102	D
	Fuel system troubleshooting B	103 to 105
	Intake air system troubleshooting	106 to 108
	Ignition system troubleshooting	109 to 114

Go to step 78

Go to step 84

Go to step 95

A

73.INSPECT FUEL INJECTOR ASSEMBLY

Inspect the fuel injector assemblies ().

REPLACE FUEL INJECTOR ASSEMBLY ()

OK

74.CHECK TERMINAL VOLTAGE (FUEL INJECTOR POWER SOURCE)

Disconnect the fuel injector assembly connectors.

Turn the ignition switch to ON.

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

Standard Voltage:

Cylinder	Tester Connection	Switch Condition	Specified Condition
No. 1	C5-1 - Body ground	Ignition switch ON	11 to 14 V
No. 2	C16-1 - Body ground	Ignition switch ON	11 to 14 V
No. 3	C7-1 - Body ground	Ignition switch ON	11 to 14 V
No. 4	C14-1 - Body ground	Ignition switch ON	11 to 14 V
No. 5	C9-1 - Body ground	Ignition switch ON	11 to 14 V
No. 6	C12-1 - Body ground	Ignition switch ON	11 to 14 V

Text in Illustration
*a	Front view of wire harness connector (to Fuel Injector Assembly)

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.

REPAIR FUEL INJECTOR POWER SOURCE CIRCUIT ()

OK

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

Disconnect the fuel injector assembly connector.

Disconnect the ECM connector.

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

Standard Resistance:

for LHD
Cylinder	Tester Connection	Condition	Specified Condition
No. 1	C5-2 - Body ground	Always	10 kΩ or higher
No. 1	C5-2 - C45-86 (#10)	Always	Below 1 Ω
No. 2	C16-2- Body ground	Always	10 kΩ or higher
No. 2	C16-2 - C45-109 (#20)	Always	Below 1 Ω
No. 3	C7-2 - Body ground	Always	10 kΩ or higher
No. 3	C7-2 - C45-85 (#30)	Always	Below 1 Ω
No. 4	C14-2 - Body ground	Always	10 kΩ or higher
No. 4	C14-2 - C45-108 (#40)	Always	Below 1 Ω
No. 5	C9-2 - Body ground	Always	10 kΩ or higher
No. 5	C9-2 - C45-84 (#50)	Always	Below 1 Ω
No. 6	C12-2 - Body ground	Always	10 kΩ or higher
No. 6	C12-2 - C45-107 (#60)	Always	Below 1 Ω

for RHD
Cylinder	Tester Connection	Condition	Specified Condition
No. 1	C5-2 - Body ground	Always	10 kΩ or higher
No. 1	C5-2 - C46-86 (#10)	Always	Below 1 Ω
No. 2	C16-2- Body ground	Always	10 kΩ or higher
No. 2	C16-2 - C46-109 (#20)	Always	Below 1 Ω
No. 3	C7-2 - Body ground	Always	10 kΩ or higher
No. 3	C7-2 - C46-85 (#30)	Always	Below 1 Ω
No. 4	C14-2 - Body ground	Always	10 kΩ or higher
No. 4	C14-2 - C46-108 (#40)	Always	Below 1 Ω
No. 5	C9-2 - Body ground	Always	10 kΩ or higher
No. 5	C9-2 - C46-84 (#50)	Always	Below 1 Ω
No. 6	C12-2 - Body ground	Always	10 kΩ or higher
No. 6	C12-2 - C46-107 (#60)	Always	Below 1 Ω

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.

REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

76.CHECK CRANKSHAFT POSITION SENSOR

Replace the crankshaft position sensor ().

Check the engine start operation.

OK:
Malfunction has been repaired successfully.

Go to step 77

END (CRANKSHAFT POSITION SENSOR IS DEFECTIVE)

77.CHECK VVT SENSOR

Replace the VVT sensor ().

Check the engine start operation.

OK:
Malfunction has been repaired successfully.

REPLACE ECM ()

END (VVT SENSOR IS DEFECTIVE)

78.CHECK CRANKSHAFT POSITION SENSOR

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

Check the connection of the crankshaft position sensor connector.

OK:
Sensor is installed correctly.

SECURELY REINSTALL SENSOR ()

OK

79.CHECK VVT SENSOR

Check the tightening torque and installation condition of the VVT sensor bolt.

Check the connection of the VVT sensor connector.

OK:
Sensor is installed correctly.

SECURELY REINSTALL SENSOR ()

OK

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

Disconnect the crankshaft position sensor connector.

Disconnect the ECM connector.

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

Standard Resistance:

for LHD
Tester Connection	Condition	Specified Condition
C1-1 - C45-110 (NE+)	Always	Below 1 Ω
C1-2 - C45-111 (NE-)	Always	Below 1 Ω
C1-1 or C45-110 (NE+) - Body ground	Always	10 kΩ or higher
C1-2 or C45-111 (NE-) - Body ground	Always	10 kΩ or higher

for RHD
Tester Connection	Condition	Specified Condition
C1-1 - C46-110 (NE+)	Always	Below 1 Ω
C1-2 - C46-111 (NE-)	Always	Below 1 Ω
C1-1 or C46-110 (NE+) - Body ground	Always	10 kΩ or higher
C1-2 or C46-111 (NE-) - 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.

REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

81.CHECK HARNESS AND CONNECTOR (VVT SENSOR - ECM)

Disconnect the VVT sensor connector.

Disconnect the ECM connector.

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

Standard Resistance:

for LHD
Tester Connection	Condition	Specified Condition
C26-1 (VVR+) - C45-90 (VV1+)	Always	Below 1 Ω
C26-2 (VVR-) - C45-89 (VV1-)	Always	Below 1 Ω
C26-3 (VC) - C45-67 (VCV1)	Always	Below 1 Ω
C26-1 (VVR+) or C45-90 (VV1+) - Body ground	Always	10 kΩ or higher
C26-2 (VVR-) or C45-89 (VV1-) - Body ground	Always	10 kΩ or higher
C26-3 (VC) or C45-67 (VCV1) - Body ground	Always	10 kΩ or higher

for RHD
Tester Connection	Condition	Specified Condition
C26-1 (VVR+) - C46-90 (VV1+)	Always	Below 1 Ω
C26-2 (VVR-) - C46-89 (VV1-)	Always	Below 1 Ω
C26-3 (VC) - C46-67 (VCV1)	Always	Below 1 Ω
C26-1 (VVR+) or C46-90 (VV1+) - Body ground	Always	10 kΩ or higher
C26-2 (VVR-) or C46-89 (VV1-) - Body ground	Always	10 kΩ or higher
C26-3 (VC) or C46-67 (VCV1) - 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.

REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

82.CHECK AND REPLACE CRANKSHAFT POSITION SENSOR

Replace the crankshaft position sensor ().

Check the engine start operation.

OK:
Malfunction has been repaired successfully.

Go to step 83

END (CRANKSHAFT POSITION SENSOR IS DEFECTIVE)

83.CHECK VVT SENSOR

Replace the VVT sensor ().

Check the engine start operation.

OK:
Malfunction has been repaired successfully.

REPLACE ECM ()

END (VVT SENSOR IS DEFECTIVE)

84.READ VALUE USING GTS (ISC LEARNING VALUE)

Connect the GTS to the DLC3.

Turn the ignition switch to ON.

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

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

Result
Data List Item	Result	Suspected Area	Proceed to
ISC Learning Value	(Engine displacement (liters) x 0.9) or more	Valve timing Compression	A
ISC Learning Value	Less than (engine displacement (liters) x 0.9)	-	B

Go to step 86

A

85.CHECK CYLINDER COMPRESSION PRESSURE

Inspect the compression ().

REPAIR OR REPLACE ENGINE ASSEMBLY

CHECK ENGINE MECHANICAL SYSTEM

86.INSPECT ENGINE COOLANT TEMPERATURE SENSOR

Inspect the engine coolant temperature sensor ().

REPLACE ENGINE COOLANT TEMPERATURE SENSOR ()

OK

87.CHECK FUEL PRESSURE

HINT:

For the fuel pressure inspection, refer to the following procedures ().

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

Result
Vehicle State	Specified Condition
Cranking engine	281 to 287 kPa (2.87 to 2.93 kgf/cm²)
5 minutes after stopping engine	147 kPa (1.5 kgf/cm²) or higher

Go to step 93

OK

88.READ VALUE USING GTS (LONG FT)

Connect the GTS to the DLC3.

Turn the ignition switch to ON.

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

Result
Data List Item	Result	Suspected Area	Proceed to
Long FT	-15 to +15%	Wire harness or connector Fuel	A
Long FT	+15% or more, or less than -15%	Fuel injector assembly	B

REPLACE FUEL INJECTOR ASSEMBLY ()

A

89.PERFORM SIMULATION TEST

Check if the idling speed is stable after starting the engine and if an unstable idling speed has ever occurred in the past.

Result
Problem Symptom	Suspected Area	Proceed to
Current idling speed unstable 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.

REPLACE FUEL

A

90.CHECK CRANKSHAFT POSITION SENSOR

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

Check the connection of the crankshaft position sensor connector.

OK:
Sensor is installed correctly.

SECURELY REINSTALL SENSOR ()

OK

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

Disconnect the crankshaft position sensor connector.

Disconnect the ECM connector.

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

Standard Resistance:

for LHD
Tester Connection	Condition	Specified Condition
C1-1 - C45-110 (NE+)	Always	Below 1 Ω
C1-2 - C45-111 (NE-)	Always	Below 1 Ω
C1-1 or C45-110 (NE+) - Body ground	Always	10 kΩ or higher
C1-2 or C45-111 (NE-) - Body ground	Always	10 kΩ or higher

for RHD
Tester Connection	Condition	Specified Condition
C1-1 - C46-110 (NE+)	Always	Below 1 Ω
C1-2 - C46-111 (NE-)	Always	Below 1 Ω
C1-1 or C46-110 (NE+) - Body ground	Always	10 kΩ or higher
C1-2 or C46-111 (NE-) - 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.

REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

92.CHECK CRANKSHAFT POSITION SENSOR

Replace the crankshaft position sensor ().

Check the engine start operation.

OK:
Malfunction has been repaired successfully.

REPLACE ECM ()

END (CRANKSHAFT POSITION SENSOR IS DEFECTIVE)

93.PERFORM ACTIVE TEST USING GTS (CONTROL THE FUEL PUMP / SPEED)

Connect the GTS to the DLC3.

Turn the ignition switch to ON.

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

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.

Go to step 94

REPAIR OR REPLACE FUEL LINE

94.INSPECT FUEL PUMP

Inspect the 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.

REPLACE FUEL PUMP ()

REPLACE FUEL PRESSURE REGULATOR ASSEMBLY ()

95.CHECK FUEL PRESSURE

HINT:

For the fuel pressure inspection, refer to the following procedures ().

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

Result
Result	Proceed to
147 kPa (1.5 kgf/cm²) or higher (5 minutes after stopping the engine)	A
Below 147 kPa (1.5 kgf/cm²) (5 minutes after stopping the engine)	B

Go to step 101

A

96.READ VALUE USING GTS (LONG FT)

Connect the GTS to the DLC3.

Turn the ignition switch to ON.

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

Result
Data List Item	Result	Suspected Area	Proceed to
Long FT	-15 to +15%	Wire harness or connector Fuel	A
Long FT	+15% or more, or less than -15%	Fuel injector assembly	B

REPLACE FUEL INJECTOR ASSEMBLY ()

A

97.PERFORM SIMULATION TEST

Check if the idling speed is stable after starting the engine and if an unstable idling speed has ever occurred in the past.

Result
Problem Symptom	Suspected Area	Proceed to
Current idling speed unstable 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.

REPLACE FUEL

A

98.CHECK CRANKSHAFT POSITION SENSOR

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

Check the connection of the crankshaft position sensor connector.

OK:
Sensor is installed correctly.

SECURELY REINSTALL SENSOR ()

OK

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

Disconnect the crankshaft position sensor connector.

Disconnect the ECM connector.

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

Standard Resistance:

for LHD
Tester Connection	Condition	Specified Condition
C1-1 - C45-110 (NE+)	Always	Below 1 Ω
C1-2 - C45-111 (NE-)	Always	Below 1 Ω
C1-1 or C45-110 (NE+) - Body ground	Always	10 kΩ or higher
C1-2 or C45-111 (NE-) - Body ground	Always	10 kΩ or higher

for RHD
Tester Connection	Condition	Specified Condition
C1-1 - C46-110 (NE+)	Always	Below 1 Ω
C1-2 - C46-111 (NE-)	Always	Below 1 Ω
C1-1 or C46-110 (NE+) - Body ground	Always	10 kΩ or higher
C1-2 or C46-111 (NE-) - 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.

REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

100.CHECK CRANKSHAFT POSITION SENSOR

Replace the crankshaft position sensor ().

Check the engine start operation.

OK:
Malfunction has been repaired successfully.

REPLACE ECM ()

END (CRANKSHAFT POSITION SENSOR IS DEFECTIVE)

101.PERFORM ACTIVE TEST USING GTS (CONTROL THE FUEL PUMP / SPEED)

Connect the GTS to the DLC3.

Turn the ignition switch to ON.

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

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.

Go to step 102

REPAIR OR REPLACE FUEL LINE

102.INSPECT FUEL PUMP

Inspect the 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.

REPLACE FUEL PUMP ()

OK

103.CHECK PURGE VSV

Disconnect the vacuum 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

Connect the connector of the purge VSV.

Connect the vacuum hose of the purge VSV.

HINT:

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

INSPECT PURGE VSV ()

OK

104.CHECK FUEL INJECTOR ASSEMBLY

Clean the inside of the surge tank with compressed air.

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

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

HINT:

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

Go to step 105

REPLACE FUEL INJECTOR ASSEMBLY ()

105.CHECK INTAKE VALVE

Check if carbon is on the intake valves.

Result
Result	Proceed to
Carbon present	A
No carbon present	B

Go to step 106

CLEAN INTAKE VALVE

106.READ VALUE USING GTS (ISC LEARNING VALUE)

Connect the GTS to the DLC3.

Turn the ignition switch to ON.

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

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

Result
Data List Item	Result	Suspected Area	Proceed to
ISC Learning Value	(Engine displacement (liters) x 0.9) or more	Valve timing Compression	A
ISC Learning Value	Less than (engine displacement (liters) x 0.9)	-	B

Go to step 108

A

107.CHECK CYLINDER COMPRESSION PRESSURE

Inspect the compression ().

REPAIR OR REPLACE ENGINE ASSEMBLY

CHECK ENGINE MECHANICAL SYSTEM ()

108.INSPECT ENGINE COOLANT TEMPERATURE SENSOR

Inspect the engine coolant temperature sensor ().

REPLACE ENGINE COOLANT TEMPERATURE SENSOR ()

OK

109.CHECK CRANKSHAFT POSITION SENSOR

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

Check the connection of the crankshaft position sensor connector.

OK:
Sensor is installed correctly.

SECURELY REINSTALL SENSOR ()

OK

110.CHECK VVT SENSOR

Check the tightening torque and installation condition of the VVT sensor bolt.

Check the connection of the VVT sensor connector.

OK:
Sensor is installed correctly.

SECURELY REINSTALL SENSOR ()

OK

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

Disconnect the crankshaft position sensor connector.

Disconnect the ECM connector.

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

Standard Resistance:

for LHD
Tester Connection	Condition	Specified Condition
C1-1 - C45-110 (NE+)	Always	Below 1 Ω
C1-2 - C45-111 (NE-)	Always	Below 1 Ω
C1-1 or C45-110 (NE+) - Body ground	Always	10 kΩ or higher
C1-2 or C45-111 (NE-) - Body ground	Always	10 kΩ or higher

for RHD
Tester Connection	Condition	Specified Condition
C1-1 - C46-110 (NE+)	Always	Below 1 Ω
C1-2 - C46-111 (NE-)	Always	Below 1 Ω
C1-1 or C46-110 (NE+) - Body ground	Always	10 kΩ or higher
C1-2 or C46-111 (NE-) - 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.

REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

112.CHECK HARNESS AND CONNECTOR (VVT SENSOR - ECM)

Disconnect the VVT sensor connector.

Disconnect the ECM connector.

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

Standard Resistance:

for LHD
Tester Connection	Condition	Specified Condition
C26-1 (VVR+) - C45-90 (VV1+)	Always	Below 1 Ω
C26-2 (VVR-) - C45-89 (VV1-)	Always	Below 1 Ω
C26-3 (VC) - C45-67 (VCV1)	Always	Below 1 Ω
C26-1 (VVR+) or C45-90 (VV1+) - Body ground	Always	10 kΩ or higher
C26-2 (VVR-) or C45-89 (VV1-) - Body ground	Always	10 kΩ or higher
C26-3 (VC) or C45-67 (VCV1) - Body ground	Always	10 kΩ or higher

for RHD
Tester Connection	Condition	Specified Condition
C26-1 (VVR+) - C46-90 (VV1+)	Always	Below 1 Ω
C26-2 (VVR-) - C46-89 (VV1-)	Always	Below 1 Ω
C26-3 (VC) - C46-67 (VCV1)	Always	Below 1 Ω
C26-1 (VVR+) or C46-90 (VV1+) - Body ground	Always	10 kΩ or higher
C26-2 (VVR-) or C46-89 (VV1-) - Body ground	Always	10 kΩ or higher
C26-3 (VC) or C46-67 (VCV1) - 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.

REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

113.CHECK CRANKSHAFT POSITION SENSOR

Replace the crankshaft position sensor ().

Check the engine start operation.

OK:
Malfunction has been repaired successfully.

Go to step 114

END (CRANKSHAFT POSITION SENSOR IS DEFECTIVE)

114.CHECK VVT SENSOR

Replace the VVT sensor ().

Check the engine start operation.

OK:
Malfunction has been repaired successfully.

REPLACE ECM ()

END (VVT SENSOR IS DEFECTIVE)

1GR-FE ENGINE CONTROL

Land Cruiser URJ200 URJ202 GRJ200 VDJ200

SFI SYSTEM

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

GTS Operation	Specified Condition
0%	Normal engine speed
100%	Engine idles roughly or stalls

GTS Display	Injection Volume	Specified Condition
AFS Voltage B1S1 AFS Voltage B2S1	+12.5%	Air fuel ratio sensor output voltage is below 3.1 V
AFS Voltage B1S1 AFS Voltage B2S1	-12.5%	Air fuel ratio sensor output voltage is higher than 3.4 V