Dtc P1604 Startability Malfunction

DESCRIPTION

INSPECTION PROCEDURE

CHECK FOR ANY OTHER DTCS OUTPUT AND RECORD FREEZE FRAME DATA

CHECK ENGINE IMMOBILISER SYSTEM

CHECK MALFUNCTION CONDITION

READ FREEZE FRAME DATA

READ FREEZE FRAME DATA

CHECK SENSOR INSTALLATION (CRANKSHAFT POSITION SENSOR)

CHECK CRANKSHAFT POSITION SENSOR

CHECK HARNESS AND CONNECTOR (CRANKSHAFT POSITION SENSOR - ECM)

CHECK CRANKSHAFT POSITION SENSOR

READ FREEZE FRAME DATA

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

CHECK TERMINAL VOLTAGE (POWER SOURCE OF FUEL INJECTOR)

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

CHECK FUEL SYSTEM

READ FREEZE FRAME DATA

INSPECT FUEL INJECTOR

CHECK FUEL SYSTEM

READ FREEZE FRAME DATA

CHECK FUEL PRESSURE

INSPECT FUEL INJECTOR

INSPECT FUEL INJECTOR

INSPECT THROTTLE BODY

CHECK INTAKE SYSTEM

PERFORM SIMULATION TEST

CONFIRM PROBLEM SYMPTOM

PERFORM SIMULATION TEST

INSPECT BATTERY

CHECK ENGINE ASSEMBLY

INSPECT STARTER (STARTER PINION GEAR)

INSPECT BATTERY

INSPECT STARTER

PERFORM SIMULATION TEST

INSPECT BATTERY

CHECK ENGINE

INSPECT FUEL INJECTOR

CHECK FUEL PRESSURE

CHECK SPARK PLUG AND SPARK

CONFIRM VEHICLE CONDITION

CHECK FUEL PRESSURE

INSPECT FUEL INJECTOR

INSPECT SPARK PLUG

READ VALUE USING INTELLIGENT TESTER (ENGINE SPEED)

CHECK TERMINAL VOLTAGE (POWER SOURCE OF IGNITION COIL)

CHECK HARNESS AND CONNECTOR (IGNITION COIL - ECM)

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

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

READ VALUE USING INTELLIGENT TESTER (ENGINE SPEED)

CHECK TERMINAL VOLTAGE (POWER SOURCE OF FUEL INJECTOR)

CHECK HARNESS AND CONNECTOR (FUEL INJECTOR - ECM)

INSPECT MASS AIR FLOW METER

CHECK INTAKE SYSTEM

INSPECT THROTTLE BODY

INSPECT THROTTLE BODY

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

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

INSPECT ENGINE COOLANT TEMPERATURE SENSOR

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

INSPECT MASS AIR FLOW METER

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

READ VALUE USING INTELLIGENT TESTER

PERFORM SIMULATION TEST

INSPECT AIR FUEL RATIO SENSOR

PERFORM SIMULATION TEST

CHECK FUEL PRESSURE

INSPECT SPARK PLUG

CONFIRM VEHICLE CONDITION

CHECK FUEL PRESSURE

INSPECT FUEL INJECTOR

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

CHECK MALFUNCTION CONDITION

INSPECT FUEL INJECTOR

CHECK TERMINAL VOLTAGE (POWER SOURCE OF FUEL INJECTOR)

CHECK HARNESS AND CONNECTOR (FUEL INJECTOR - ECM)

CHECK CRANKSHAFT POSITION SENSOR

CHECK CAMSHAFT POSITION SENSOR

CHECK SENSOR INSTALLATION (CRANKSHAFT POSITION SENSOR)

CHECK SENSOR INSTALLATION (CAMSHAFT POSITION SENSOR)

CHECK HARNESS AND CONNECTOR (CRANKSHAFT POSITION SENSOR - ECM)

CHECK HARNESS AND CONNECTOR (CAMSHAFT POSITION SENSOR - ECM)

CHECK CRANKSHAFT POSITION SENSOR

CHECK CAMSHAFT POSITION SENSOR

READ VALUE USING INTELLIGENT TESTER (ISC LEARNING VALUE)

CHECK CYLINDER COMPRESSION PRESSURE

INSPECT ENGINE COOLANT TEMPERATURE SENSOR

CHECK FUEL PRESSURE

READ VALUE USING INTELLIGENT TESTER (LONG FT)

PERFORM SIMULATION TEST

CHECK SENSOR INSTALLATION (CRANKSHAFT POSITION SENSOR)

CHECK HARNESS AND CONNECTOR (CRANKSHAFT POSITION SENSOR - ECM)

CHECK CRANKSHAFT POSITION SENSOR

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

INSPECT FUEL PUMP

CHECK FUEL PRESSURE

READ VALUE USING INTELLIGENT TESTER (LONG FT#1)

PERFORM SIMULATION TEST

CHECK SENSOR INSTALLATION (CRANKSHAFT POSITION SENSOR)

CHECK HARNESS AND CONNECTOR (CRANKSHAFT POSITION SENSOR - ECM)

CHECK CRANKSHAFT POSITION SENSOR

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

INSPECT FUEL PUMP

CHECK PURGE VSV

CHECK FUEL INJECTOR

CHECK INTAKE VALVE

READ VALUE USING INTELLIGENT TESTER (ISC LEARNING VALUE)

CHECK CYLINDER COMPRESSION PRESSURE

INSPECT ENGINE COOLANT TEMPERATURE SENSOR

CHECK SENSOR INSTALLATION (CRANKSHAFT POSITION SENSOR)

CHECK SENSOR INSTALLATION (CAMSHAFT POSITION SENSOR)

CHECK HARNESS AND CONNECTOR (CRANKSHAFT POSITION SENSOR - ECM)

CHECK HARNESS AND CONNECTOR (CAMSHAFT POSITION SENSOR - ECM)

CHECK CRANKSHAFT POSITION SENSOR

CHECK CAMSHAFT POSITION SENSOR

DTC P1604 Startability Malfunction

DESCRIPTION

This DTC is stored when the engine does not start even though the STA signal is input or when the engine takes a long time to start, and when the engine speed is low or the engine stalls just after the engine starts.
Using the intelligent tester, the conditions present when the DTC was stored can be confirmed by referring to the freeze frame data. Freeze frame data records engine conditions when a malfunction occurs. This information can be useful when troubleshooting.
It is necessary to check if the vehicle ran out of fuel before performing troubleshooting, as this DTC is also stored when there is engine starting trouble due to running out of fuel.

DTC No.	DTC Detection Condition	Trouble Area
P1604	Either 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 (engine speed is 500 rpm or more), the engine speed drops to 200 rpm or less within approximately 2 seconds (1 trip detection logic).	Immobiliser system (w/ immobiliser system) Engine assembly (excess friction, compression loss) Starter Crankshaft position sensor Camshaft position sensor Engine coolant temperature sensor Fuel pump Fuel pump control circuit Fuel pipes Fuel line Fuel injector Throttle body Pressure regulator Battery Flywheel 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 ECM

INSPECTION PROCEDURE

HINT:

1. 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 these DTCs can be stored as a result of certain user actions, even if these DTCs are output, if the customer makes no mention of problems, clear these DTCs without performing any troubleshooting and return the vehicle to the customer.
   
2. If any other DTCs are output, perform troubleshooting for those DTCs first.
   
3. When the Data List item "Immobiliser Fuel Cut" is ON, the engine cannot be started.
   
4. Read freeze frame data using the intelligent tester. Freeze frame data records engine conditions when a malfunction occurs. This information can be useful when troubleshooting.
   
5. When confirming the freeze frame data, be sure to check all 5 sets of freeze frame data (HILUX_TGN26 RM000000PDS0WSX.html).
   
6. When confirming freeze frame data, if there are multiple items related to the cause of the malfunction, perform troubleshooting for all related items.
   
7. 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.
   
8. If the malfunction does not reoccur, carefully check the vehicle conditions from when the malfunction occurred using freeze frame data.
   
9. When performing inspections, jiggle the relevant wire harnesses and connectors in an attempt to reproduce malfunctions that do not always occur.
   
10. 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

1. Freeze frame data exists, but the malfunction (starting difficulty) has not reoccurred and the malfunction conditions are unknown.

   1. The engine speed recorded in the freeze frame data is 0 rpm (the engine does not crank).
      

      HINT:

      One of the following problems may be present: battery depletion, excess engine friction, a starter malfunction or a crankshaft position sensor malfunction.

      1. If the battery voltage is less than 6 V during cranking, there is a high probability that engine friction is abnormal.
         
      2. If the battery voltage drops to 5 V or less when starting the engine, the battery may be malfunctioning.
         
      
      
      3. 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.
         
         
         
         
         
         

   2. 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.

      
      
      1. 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.
         
         
         
         
         
         

   3. 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.

      1. Due to an engine coolant temperature sensor malfunction, the fuel injection volume is extremely high or low and engine starting trouble may occur.
         
      2. If Long FT is incorrect, there may be a fuel supply problem due to the injectors or fuel pump being clogged, etc.
         
      
      
      3. If the engine cranking speed is too high, compression loss may have occurred due to carbon interfering with the valve operation.
         
         
         
         
         
         

2. When the malfunction (starting difficulty) can be reproduced, or malfunction conditions are known, perform the following inspections ("Problem Symptoms" and "Systems to Inspect").

   1. Problem Symptoms
      

      1. The engine does not crank.
         

         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.

      2. 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.

      3. 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.

      4. 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.

      5. 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.

         1. 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.
            
         2. When 15 to 120 minutes have elapsed after stopping the engine: Problem with injector fuel seal.
            
         3. When a long time has elapsed after stopping the engine: Pressure regulator is stuck open.
            

   2. Systems to Inspect
      

      1. Intake system
         
      2. Ignition system
         
      3. Fuel system
         

INSPECTION FLOW

1. 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 Crankshaft position sensor ECM	4 to 9
   	100 to 250 rpm (engine cranks but no initial combustion*1)	Fuel pump control circuit Ignition system Immobiliser system (w/ immobiliser system) Engine coolant temperature sensor Fuel injection system	10 to 14
   	250 rpm or higher (combustion occurs but initial combustion and starter turnoff*2 occur late)	Engine assembly (compression loss) Fuel injection system Fuel pump control circuit	15 to 23

   HINT:

   1. *1: First combustion after cranking begins.
      
   2. *2: Condition when engine speed increases and starter can be turned off.
      

2. When the malfunction (starting difficulty) can be reproduced, or when malfunction conditions are known.

   1. Problem Symptoms
      
      

      Problem Symptom	Suspected Area	Suspected Component	Procedure
      The engine does not crank	Battery malfunction	Battery fully depleted	26 to 31
      	Starting system	Starter (includes pinion gear wear or tooth damage) Starting system
      	Engine assembly	Engine assembly (excess friction) Flywheel wear or tooth damage
      Cranking speed too low	Battery malfunction	Battery fully depleted	32 to 34
      	Starting system	Starter
      	Engine assembly	Engine assembly (excess friction)
      Cranking speed too high	Engine assembly	Engine assembly (compression loss)
      There is no initial combustion	Fuel supply problem	Cannot maintain pressure due to pressure regulator malfunction Fuel injector leak Fuel leak from fuel line Fuel pump control circuit Fuel pump	35 to 49
      	Immobiliser system	Immobiliser system (w/ immobiliser system)
      	Ignition system malfunction	Spark plug Crankshaft position sensor Ignition coil
      Engine stalls after starter turnoff	Air suction	Intake system connections	50 to 55
      	Deposits in throttle body	Throttle body
      	VVT valve does not return properly	Camshaft timing oil control valve assembly
      	Mass air flow meter malfunction	Mass air flow meter
      The initial combustion and starter turnoff occur late	Engine coolant temperature sensor malfunction	Engine coolant temperature sensor	56 to 69
      	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
      	Wet-fouled or dry-fouled spark plug	Spark plug
      	Lack of fuel pressure	Pressure regulator Fuel pump Fuel pump control circuit

   2. Systems to Inspect
      
      

      Troubleshooting by System	Suspected Area	Suspected Component	Procedure
      Fuel system troubleshooting A	Abnormal air fuel ratio learned value	Fuel injector	85 to 92 93 to 100
      	Rough idling	Crankshaft position sensor
      	Abnormal fuel pressure	Fuel Fuel leak from fuel line Fuel pump Pressure regulator
      Fuel system troubleshooting B	Abnormal concentration of HC in surge tank	Purge VSV system Fuel injector	101 to 103
      Fuel system troubleshooting C	Injection signal system malfunction	Fuel injector assembly Crankshaft position sensor Camshaft position sensor ECM	71 to 75
      Intake system troubleshooting	Difference between ISC target value and opening angle when idling	Engine assembly (compression loss) Valve timing Engine coolant temperature sensor ECM	82 to 84 104 to 106
      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	76 to 81 107 to 112

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

1. Connect the intelligent tester to the DLC3.
   

2. Turn the ignition switch to ON.
   

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

4. Read the DTCs and record the freeze frame data.
   

   HINT:

   1. This freeze frame data shows the actual engine conditions when engine starting trouble occurred.
      
   2. When confirming the freeze frame data, be sure to check all 5 data sets of freeze frame data.
      
   3. The fourth set of freeze frame data is the data recorded when the DTC is stored.
      

   Result

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

B	GO TO DTC CHART (HILUX_TGN26 RM0000032SF041X.html)

A

2.CHECK ENGINE IMMOBILISER SYSTEM

HINT:

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

1. Connect the intelligent tester to the DLC3.
   

2. Turn the ignition switch to ON.
   

3. Turn the intelligent tester on.
   

4. Enter the following menus: Powertrain / Engine and ECT / Data List / All Data / Immobiliser Fuel Cut.
   

5. Read the value displayed on the intelligent tester.
   

   OK:

   Immobiliser Fuel Cut is OFF.
   

   HINT:

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

NG	REPAIR ENGINE IMMOBILISER SYSTEM (HILUX_TGN26 RM000000Z3201BX.html)

OK

3.CHECK MALFUNCTION CONDITION

1. 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

B	Go to step 25

A

4.READ FREEZE FRAME DATA

1. Connect the intelligent tester to the DLC3.
   

2. Turn the ignition switch to ON.
   

3. Using the intelligent tester, confirm the vehicle conditions recorded in the freeze frame data which were present when the DTC was stored (HILUX_TGN26 RM000000PDS0WSX.html).
   
   

   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 below 5 V	Battery fully depleted	A
   	Minimum voltage is 5 V or higher	Starter malfunction Crankshaft position sensor system (w/ immobiliser system) Excess engine friction ECM	B
   100 to 250 rpm (engine cranks but no initial combustion)	-	Fuel pump control circuit Ignition system Engine coolant temperature sensor Immobiliser system Fuel injection system	C
   250 rpm or higher (combustion occurs but initial combustion and starter turnoff occur late)	-	Engine assembly Fuel injection system Fuel pump control 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.

   1. Immobiliser Fuel Cut
      
   2. Engine Speed (starter off)
      
   3. Shift SW Status
      

B	Go to step 5
C	Go to step 10
D	Go to step 15
E	Go to step 50

A
CHARGE OR REPLACE BATTERY

5.READ FREEZE FRAME DATA

1. Connect the intelligent tester to the DLC3.
   

2. Turn the ignition switch to ON.
   

3. Using the intelligent tester, confirm the vehicle conditions recorded in the freeze frame data which were present when the DTC was stored (HILUX_TGN26 RM000000PDS0WSX.html).
   
   

   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. *1: The 5 sets of freeze frame data show approximately the same battery voltage.
      
   2. *2: The 5 sets of freeze frame data show different battery voltages.
      
   3. *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. *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.
      

B	Go to step 6
C	CHECK AND REPAIR ENGINE OR BATTERY

A
CHECK STARTER SIGNAL CIRCUIT (HILUX_TGN26 RM000002XN20FAX.html)

6.CHECK SENSOR INSTALLATION (CRANKSHAFT POSITION SENSOR)

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

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

   OK:

   Sensor is installed correctly.
   

NG	SECURELY REINSTALL SENSOR (HILUX_TGN26 RM000000VX001PX.html)

OK

7.CHECK CRANKSHAFT POSITION SENSOR

1. Disconnect the crankshaft position sensor connector.
   

2. Check for oil on the connector terminals.
   

   OK:

   No oil on the terminals.
   

NG	REPLACE CRANKSHAFT POSITION SENSOR (HILUX_TGN26 RM000000VX301IX.html)

OK

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

1. Check the harnesses and connectors, referring to DTC P0335 inspection procedure (HILUX_TGN26 RM000000TCW0UFX_09_0002.html).
   

   HINT:

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

NG	REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

9.CHECK CRANKSHAFT POSITION SENSOR

1. Replace the crankshaft position sensor (HILUX_TGN26 RM000000VX301IX.html).
   

2. Check the engine start operation.
   

   OK:

   Malfunction has been repaired successfully.
   

NG	REPLACE ECM (HILUX_TGN26 RM000000VW202TX.html)

OK
END (CRANKSHAFT POSITION SENSOR IS DEFECTIVE)

10.READ FREEZE FRAME DATA

1. Connect the intelligent tester to the DLC3.
   

2. Turn the ignition switch to ON.
   

3. Using the intelligent tester, confirm the vehicle conditions recorded in the freeze frame data which were present when the DTC was stored (HILUX_TGN26 RM000000PDS0WSX.html).
   
   

   Result

   Freeze Frame Data Item			Suspected Area	Proceed to
   Coolant Temp, Intake Air, Ambient Temp for A/C	Coolant Temp, Ambient Temp for A/C	Fuel Pump/Speed Status
   Difference between Coolant Temp, Ambient Temp for A/C and Intake Air is 10°C (18°F) or more*1	Coolant Temp is 125°C (257°F) or higher, or below Ambient Temp for A/C by 15°C (27°F) or more	-	Engine coolant temperature sensor	A
   	Other than above	All 5 sets of freeze frame data are ON	-	B
   		At least 1 of the 5 sets of freeze frame data is OFF	Fuel pump control circuit	C
   Difference between Coolant Temp, Ambient Temp for A/C 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 circuit	C
   		All 5 sets of freeze frame data are ON	-	B

   HINT:

   1. *1: A long time had not elapsed after stopping the engine.
      
   2. *2: A long time had elapsed after stopping the engine.
      

B	Go to step 11
C	CHECK FUEL PUMP CONTROL CIRCUIT (HILUX_TGN26 RM000001DN704OX.html)

A
REPLACE ENGINE COOLANT TEMPERATURE SENSOR (HILUX_TGN26 RM000000VWA01WX.html)

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

1. Connect the intelligent tester to the DLC3.
   

2. Disconnect the connector from the fuel suction tube.
   

3. Turn the ignition switch to ON.
   

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

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

   Standard Voltage:

   Tester Connection	Condition	Specified Condition
   L4-4 - Body ground	Active Test is being performed	11 to 14 V

   Text in Illustration

   *a	Front view of wire harness connector (to Fuel Pump)

   HINT:

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

NG	CHECK FUEL PUMP CONTROL CIRCUIT (HILUX_TGN26 RM000001DN704OX.html)

OK

12.CHECK TERMINAL VOLTAGE (POWER SOURCE OF FUEL INJECTOR)

1. Check the harnesses and connectors, referring to Fuel Injector Circuit inspection procedure (HILUX_TGN26 RM00000330203TX_04_0001.html).
   

   HINT:

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

NG	REPAIR FUEL INJECTOR POWER SOURCE CIRCUIT (HILUX_TGN26 RM00000330203TX.html)

OK

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

1. Connect the intelligent tester to the DLC3.
   

2. Turn the ignition switch to ON.
   

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

4. 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:

   1. Jiggle the wire harness and connector to increase the likelihood of detecting malfunctions that do not always occur.
      
   2. When performing the Active Test, if there is no operating noise from the fuel pump, the fuel pump system may be malfunctioning.
      
   3. Check if the vehicle ran out of fuel, as engine starting trouble due to running out of fuel is also detected.
      

B	Go to step 14

A
REPAIR OR REPLACE FUEL LINE

14.CHECK FUEL SYSTEM

1. Check for foreign matter such as iron particles around the fuel pump (fuel pump, fuel pump filter, and inside the fuel tank), and for signs that the fuel pump was stuck.
   
   

   Result

   Result	Proceed to
   There is foreign matter or signs that fuel pump was stuck	A
   There is no foreign matter and no signs that fuel pump was stuck	B

B	Go to step 24

A
REPAIR OR REPLACE FUEL SYSTEM

15.READ FREEZE FRAME DATA

1. Connect the intelligent tester to the DLC3.
   

2. Turn the ignition switch to ON.
   

3. Using the intelligent tester, confirm the vehicle conditions recorded in the freeze frame data which were present when the DTC was stored (HILUX_TGN26 RM000000PDS0WSX.html).
   
   

   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
   Difference between Coolant Temp, Ambient Temp for A/C and Intake Air is 10°C (18°F) or more	Coolant Temp is 125°C (257°F) or higher, or below Ambient Temp for A/C by 15°C (27°F) or more	-	-	Engine coolant temperature sensor	A
   	Other than above	-15% or less, or +15% or more	-	Fuel pump control circuit Fuel injector	B
   		-15 to +15%	Minimum speed is 300 rpm or more*1	Engine assembly	C
   			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 (18°F)	-	-15% or less, or +15% or more	-	Fuel pump control circuit Fuel injector	B
   		-15 to +15%	Minimum speed is 300 rpm or more*1	Engine assembly	C
   			Minimum speed is less than 300 rpm	Fuel system Intake air system	D

   HINT:

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

B	Go to step 16
C	CHECK AND REPAIR ENGINE
D	Go to step 18

A
REPLACE ENGINE COOLANT TEMPERATURE SENSOR (HILUX_TGN26 RM000000VWA01WX.html)

16.INSPECT FUEL INJECTOR

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

   OK:

   No carbon present.
   

NG	REPLACE FUEL INJECTOR (HILUX_TGN26 RM000000YLB01MX.html)

OK

17.CHECK FUEL SYSTEM

1. Check for foreign matter such as iron particles around the fuel pump (fuel pump, fuel pump filter, and inside the fuel tank), and for signs that the fuel pump was stuck.
   
   

   Result

   Result	Proceed to
   There is foreign matter or signs that fuel pump was stuck	A
   There is no foreign matter and no signs that fuel pump was stuck	B

B	Go to step 24

A
REPAIR OR REPLACE FUEL SYSTEM

18.READ FREEZE FRAME DATA

1. Connect the intelligent tester to the DLC3.
   

2. Turn the ignition switch to ON.
   

3. Using the intelligent tester, confirm the vehicle conditions recorded in the freeze frame data which were present when the DTC was stored (HILUX_TGN26 RM000000PDS0WSX.html).
   
   

   Result

   Freeze Frame Data Item	Result	Suspected Area	Proceed to
   Coolant Temp	Engine coolant temperature is 40°C (104°F) or less*1	Pressure regulator	A
   	Engine coolant temperature is 40 to 90°C (104 to 194°F)*2	Fuel injector	B
   	Engine coolant temperature is 90°C (194°F) or higher*3	Pressure regulator	A

   HINT:

   *1: If the engine coolant temperature is 40°C (104°F) or less (after stopping the engine and the vehicle has not been driven for a long period of time), the 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 (104 to 194°F) (15 to 120 minutes have passed after stopping the engine), there may be fuel leaking from a fuel injector assembly.

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

B	Go to step 20

A

19.CHECK FUEL PRESSURE

1. Check the fuel pressure (HILUX_TGN26 RM000000YL704TX.html).
   

HINT:

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

Result

Result	Proceed to
Abnormal	A
Normal	B

B	Go to step 24

A
REPLACE FUEL PRESSURE REGULATOR ASSEMBLY (HILUX_TGN26 RM000000YLE01MX.html)

20.INSPECT FUEL INJECTOR

1. Clean the inside of the surge tank with compressed air.
   

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

   Result

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

   HINT:

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

B	Go to step 22

A

21.INSPECT FUEL INJECTOR

1. Inspect the fuel injector (HILUX_TGN26 RM000000WQQ076X.html).
   
   

   Result

   Result	Proceed to
   Abnormal	A
   Normal	B

B	Go to step 22

A
REPLACE FUEL INJECTOR (HILUX_TGN26 RM000000YLB01MX.html)

22.INSPECT THROTTLE BODY

1. Check if carbon is in the airflow passage.
   
   

   Result

   Result	Proceed to
   Carbon in passage	A
   No carbon present	B

B	Go to step 23

A
CLEAN OR REPLACE THROTTLE BODY (HILUX_TGN26 RM000000VWO01XX.html)

23.CHECK INTAKE SYSTEM

1. Check the intake system for vacuum leaks.
   

   OK:

   No leaks in intake system.
   

NG	REPAIR OR REPLACE INTAKE SYSTEM

OK

24.PERFORM SIMULATION TEST

1. Check if the engine can be started.
   
   

   Result

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

B	Go to step 25

A
END

25.CONFIRM PROBLEM SYMPTOM

1. 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 (includes pinion gear wear or tooth damage) Starter system Engine assembly (excess friction) Flywheel wear or tooth damage	A
   Abnormal cranking speed	Battery fully depleted Starter Engine assembly (excess friction, compression loss)	B
   There is no initial combustion (combustion does not occur even once)*1	Pressure regulator fuel pressure maintenance 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 Camshaft timing oil control valve 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 Spark plug Pressure regulator Fuel pump Fuel pump control circuit	E

   HINT:

   1. 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.
      
   2. *1: If there is no initial combustion, a wire harness may be malfunctioning, or the ignition or fuel system may be malfunctioning.
      
   3. *2: If the engine stalls after starter turnoff, the air-fuel ratio may be incorrect or the camshaft timing oil control valve may have a problem returning.
      
   4. *3: If the initial combustion and starter turnoff occur late, the fuel injection volume may be incorrect (too low or too high).
      

B	Go to step 32
C	Go to step 35
D	Go to step 50
E	Go to step 56

A

26.PERFORM SIMULATION TEST

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

   Result

   Problem Symptom	Suspected Area	Proceed to
   A noise indicating that the starter pinion gear is extending is heard and the starter pinion gear is not spinning freely*	Battery Excess engine friction Starter	A
   A noise indicating that the starter pinion gear is extending is heard but the starter pinion gear is spinning freely	Flywheel Starter	B
   A noise indicating that the starter pinion gear is extending is not heard	Battery Starter Starter system	C

   HINT:

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

B	Go to step 29
C	Go to step 30

A

27.INSPECT BATTERY

1. Inspect the battery (HILUX_TGN26 RM000000V4301SX.html).
   

NG	CHARGE OR REPLACE BATTERY

OK

28.CHECK ENGINE ASSEMBLY

1. Check that the crankshaft rotates smoothly when rotating it by hand.
   

   OK:

   Crankshaft rotates smoothly.
   

   HINT:

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

NG	REPAIR OR REPLACE ENGINE ASSEMBLY

OK
INSPECT STARTER (HILUX_TGN26 RM000000SH0021X.html)

29.INSPECT STARTER (STARTER PINION GEAR)

1. Remove the starter (HILUX_TGN26 RM000000SH201AX.html).
   

2. Check for starter pinion gear wear and damage.
   

   OK:

   There is no wear or damage.
   

NG	REPLACE STARTER (HILUX_TGN26 RM000000SH201AX.html)

OK
REPLACE FLYWHEEL (HILUX_TGN26 RM000000YMS024X.html)

30.INSPECT BATTERY

1. Inspect the battery (HILUX_TGN26 RM000000V4301SX.html).
   

NG	CHARGE OR REPLACE BATTERY

OK

31.INSPECT STARTER

1. Inspect the starter (HILUX_TGN26 RM000000SH0021X.html).
   

NG	REPLACE STARTER (HILUX_TGN26 RM000000SH201AX.html)

OK
CHECK STARTER SIGNAL CIRCUIT (HILUX_TGN26 RM000002XN20FAX.html)

32.PERFORM SIMULATION TEST

1. Check the cranking speed.
   
   

   Result

   Problem Symptom	Suspected Area	Proceed to
   Cranking speed is slow (100 rpm or less)	Battery Starter Excess engine friction	A
   Cranking speed is fast (300 rpm or more)*1	Engine compression loss	B

   HINT:

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

B	CHECK AND REPAIR ENGINE

A

33.INSPECT BATTERY

1. Inspect the battery (HILUX_TGN26 RM000000V4301SX.html).
   

NG	CHARGE OR REPLACE BATTERY

OK

34.CHECK ENGINE

1. Check that the crankshaft rotates smoothly when rotating it by hand.
   

   OK:

   Crankshaft rotates smoothly.
   

   HINT:

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

NG	REPAIR OR REPLACE ENGINE

OK
INSPECT STARTER (HILUX_TGN26 RM000000SH0021X.html)

35.INSPECT FUEL INJECTOR

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

   OK:

   Fuel injector operating noise is heard.
   

NG	Go to step 47

OK

36.CHECK FUEL PRESSURE

1. Inspect the fuel pressure (HILUX_TGN26 RM000000YL704TX.html).
   

NG	Go to step 45

OK

37.CHECK SPARK PLUG AND SPARK

1. Check for sparks (HILUX_TGN26 RM000000SM604YX_02_0001.html).
   

NG	Go to step 41

OK

38.CONFIRM VEHICLE CONDITION

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

   Result

   Problem Symptom	Suspected Area	Proceed to
   When the engine is stopped and a long time has passed, engine starting trouble occurs*1	Pressure regulator is stuck open	A
   When the engine is stopped and approximately 15 to 120 minutes have passed, engine starting trouble occurs*2	Fuel injector leak	B
   When the engine is stopped and approximately 2 to 3 minutes have passed, engine starting trouble occurs*3	Failure to maintain fuel pressure by pressure regulator	A
   Condition other than above, or there is an inconsistency in the conditions present when engine starting trouble occurs	-	C*4

   HINT:

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

   *4: From step 70, perform fuel system troubleshooting C (steps 71 to 75).

B	Go to step 40
C	Go to step 70

A

39.CHECK FUEL PRESSURE

HINT:

For the fuel pressure inspection, refer to the following procedures (HILUX_TGN26 RM000000YL704TX.html).

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

   Result

   Result	Proceed to
   Below 147 kPa (1.5 kgf/cm2) (5 minutes after stopping the engine)	A
   147 kPa (1.5 kgf/cm2) or higher (5 minutes after stopping the engine)	B*1

   HINT:

   1. If the engine cannot be started, check the fuel pressure after cranking the engine.
      
   2. *1: From step 70, perform fuel system troubleshooting C (steps 71 to 75).
      

B	Go to step 70

A
REPLACE FUEL PRESSURE REGULATOR ASSEMBLY (HILUX_TGN26 RM000000YLE01MX.html)

40.INSPECT FUEL INJECTOR

1. 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*1

   HINT:

   1. If the concentration is 4000 ppm or more, a fuel injector may have a sealing problem.
      
   2. *1: From step 70, perform fuel system troubleshooting C (steps 71 to 75).
      

B	Go to step 70

A
REPLACE FUEL INJECTOR (HILUX_TGN26 RM000000YLB01MX.html)

41.INSPECT SPARK PLUG

1. Inspect the spark plugs (HILUX_TGN26 RM000000SM604YX_02_0002.html).
   

HINT:

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

NG	REPLACE SPARK PLUG (HILUX_TGN26 RM000000SK7015X.html)

OK

42.READ VALUE USING INTELLIGENT TESTER (ENGINE SPEED)

1. Connect the intelligent tester to the DLC3.
   

2. Turn the ignition switch to ON.
   

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

4. Start the engine.
   

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

   OK:

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

   HINT:

   1. Check the engine speed using a line graph.
      
   2. If the engine cannot be started, check the engine speed while cranking the engine.
      
   3. If the engine speed is 0 rpm, the crankshaft position sensor may have an open or short circuit.
      

NG	CHECK CRANKSHAFT POSITION SENSOR CIRCUIT (HILUX_TGN26 RM000000TCW0UFX.html)

OK

43.CHECK TERMINAL VOLTAGE (POWER SOURCE OF IGNITION COIL)

1. Check the harnesses and connectors, referring to DTC P0351 inspection procedure (HILUX_TGN26 RM000000XH40SUX_09_0001.html).
   

   HINT:

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

NG	CHECK IGNITION COIL POWER SOURCE CIRCUIT (HILUX_TGN26 RM000000XH40SUX.html)

OK

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

1. Check harnesses and connectors, referring to DTC P0351 inspection procedure (HILUX_TGN26 RM000000XH40SUX_09_0002.html).
   

   HINT:

   1. Jiggle the wire harness and connector to increase the likelihood of detecting malfunctions that do not always occur.
      
   2. Make sure there is not an excessive amount of force applied to the wire harness.
      
   3. 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 70 and perform troubleshooting for the ignition system (steps 76 to 81).
      

NG	REPAIR OR REPLACE HARNESS OR CONNECTOR

OK
REPLACE IGNITION COIL (HILUX_TGN26 RM000000SK7015X.html)

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

1. Connect the intelligent tester to the DLC3.
   

2. Turn the ignition switch to ON.
   

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

4. 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.

NG	CHECK FUEL PUMP CONTROL CIRCUIT (HILUX_TGN26 RM000001DN704OX.html)

OK

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

1. Connect the intelligent tester to the DLC3.
   

2. Turn the ignition switch to ON.
   

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

4. 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:

   1. Jiggle the wire harness and connector to increase the likelihood of detecting malfunctions that do not always occur.
      
   2. Check if the vehicle ran out of fuel, as engine starting trouble due to running out of fuel is also detected.
      
   3. 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 70 and perform fuel system troubleshooting (steps 71 to 75).
      

B	CHECK FUEL PUMP CONTROL CIRCUIT (HILUX_TGN26 RM000001DN704OX.html)

A
REPAIR OR REPLACE FUEL LINE

47.READ VALUE USING INTELLIGENT TESTER (ENGINE SPEED)

1. Connect the intelligent tester to the DLC3.
   

2. Turn the ignition switch to ON.
   

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

4. Start the engine.
   

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

   OK:

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

   HINT:

   1. Check the engine speed using a line graph.
      
   2. If the engine cannot be started, check the engine speed while cranking the engine.
      
   3. If the engine speed is 0 rpm, the crankshaft position sensor may have an open or short circuit.
      

NG	REPLACE CRANKSHAFT POSITION SENSOR (HILUX_TGN26 RM000000VX301IX.html)

OK

48.CHECK TERMINAL VOLTAGE (POWER SOURCE OF FUEL INJECTOR)

1. Check the harnesses and connectors, referring to Fuel Injector Circuit inspection procedure (HILUX_TGN26 RM00000330203TX_04_0001.html).
   

   HINT:

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

NG	REPAIR FUEL INJECTOR POWER SOURCE CIRCUIT (HILUX_TGN26 RM00000330203TX.html)

OK

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

1. Check the harnesses and connectors, referring to Fuel Injector Circuit inspection procedure (HILUX_TGN26 RM00000330203TX_04_0003.html).
   

   HINT:

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

NG	REPAIR OR REPLACE HARNESS OR CONNECTOR

OK
REPLACE ECM (HILUX_TGN26 RM000000VW202TX.html)

50.INSPECT MASS AIR FLOW METER

1. Inspect the mass air flow meter (HILUX_TGN26 RM000000VW401EX.html).
   

NG	Go to step 55

OK

51.CHECK INTAKE SYSTEM

1. Check for air leaks in the intake system [vacuum hose disconnection, cracks, damaged gaskets, etc.].
   

   HINT:

   1. 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.
      
   2. 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 are no air leaks.
   

NG	REPAIR OR REPLACE INTAKE SYSTEM

OK

52.INSPECT THROTTLE BODY

1. Disconnect the throttle body connector.
   

   HINT:

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

2. Crank the engine and check that it starts.
   
   

   Result

   Result	Proceed to
   Engine starts	A
   Engine does not start	B

3. Reconnect the throttle body connector.
   

   HINT:

   When this inspection is performed, the MIL may illuminate. After finishing the inspection, check and clear DTCs (HILUX_TGN26 RM000000PDK130X.html).

B	Go to step 54

A

53.INSPECT THROTTLE BODY

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

   OK:

   No carbon present.
   

NG	REMOVE FOREIGN OBJECT AND CLEAN THROTTLE BODY

OK

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

1. Performing the Active Test, referring to DTC P0011 inspection procedure (HILUX_TGN26 RM000000PDU0RPX_09_0002.html).
   

   HINT:

   1. Jiggle the wire harness and connector to increase the likelihood of detecting malfunctions that do not always occur.
      
   2. 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.
      
   3. If the camshaft timing oil control valve is stuck ON, the valve overlap increases and combustion worsens due to the internal EGR which may cause rough idle or cause the engine to stall.
      
   4. *: From step 70, perform intake system troubleshooting (steps 82 to 84). If engine starting trouble still occurs, perform fuel system troubleshooting A (steps 85 to 92).
      
   
   

   Result

   Result	Proceed to
   NG	A
   OK*	B

B	Go to step 70

A
REPLACE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (HILUX_TGN26 RM000000VVZ01FX.html)

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

1. Check the harnesses and connectors, referring to DTC P0102 inspection procedure (HILUX_TGN26 RM000000U5B0OZX_09_0004.html).
   

   HINT:

   1. Jiggle the wire harness and connector to increase the likelihood of detecting malfunctions that do not always occur.
      
   2. Make sure there is not an excessive amount of force applied to the wire harness.
      
   3. 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 70 and perform intake system troubleshooting (steps 82 to 84). If engine starting trouble still occurs, perform fuel system troubleshooting A (steps 85 to 92).
      

NG	REPAIR OR REPLACE HARNESS OR CONNECTOR

OK
REPLACE MASS AIR FLOW METER (HILUX_TGN26 RM000000VW602CX.html)

56.INSPECT ENGINE COOLANT TEMPERATURE SENSOR

1. Inspect the engine coolant temperature sensor (HILUX_TGN26 RM000000VW801AX.html).
   

   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 70 and perform fuel system troubleshooting A (steps 93 to 100), fuel system troubleshooting B (steps 101 to 103), intake system troubleshooting (steps 104 to 106), and ignition system troubleshooting (steps 107 to 112), in that order.

NG	REPLACE ENGINE COOLANT TEMPERATURE SENSOR (HILUX_TGN26 RM000000VWA01WX.html)

OK

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

1. Check the harnesses and connectors, referring to DTC P0115 inspection procedure (HILUX_TGN26 RM000000PF50SJX_09_0003.html).
   

   HINT:

   1. Jiggle the wire harness and connector to increase the likelihood of detecting malfunctions that do not always occur.
      
   2. Make sure there is not an excessive amount of force applied to the wire harness.
      
   3. 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 70 and perform fuel system troubleshooting A (steps 93 to 100), fuel system troubleshooting B (steps 101 to 103), intake system troubleshooting (steps 104 to 106), and ignition system troubleshooting (steps 107 to 112), in that order.
      

NG	REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

58.INSPECT MASS AIR FLOW METER

1. Inspect the mass air flow meter (HILUX_TGN26 RM000000VW401EX.html).
   

   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 70 and perform fuel system troubleshooting A (steps 93 to 100), fuel system troubleshooting B (steps 101 to 103), intake system troubleshooting (steps 104 to 106), and ignition system troubleshooting (steps 107 to 112), in that order.

NG	REPLACE MASS AIR FLOW METER (HILUX_TGN26 RM000000VW602CX.html)

OK

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

1. Check the harnesses and connectors, referring to DTC P0102 inspection procedure (HILUX_TGN26 RM000000U5B0OZX_09_0004.html).
   

   HINT:

   1. Jiggle the wire harness and connector to increase the likelihood of detecting malfunctions that do not always occur.
      
   2. Make sure there is not an excessive amount of force applied to the wire harness.
      
   3. 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 70 and perform fuel system troubleshooting A (steps 93 to 100), fuel system troubleshooting B (steps 101 to 103), intake system troubleshooting (steps 104 to 106), and ignition system troubleshooting (steps 107 to 112), in that order.
      

NG	REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

60.READ VALUE USING INTELLIGENT TESTER

1. Connect the intelligent tester to the DLC3.
   

2. Turn the ignition switch to ON.
   

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

   Result

   Data List Item	Result	Suspected Area	Proceed to
   Long FT#1	+25% or more or less than -25%	Air fuel ratio sensor Heated oxygen sensor Mass air flow meter Fuel injector ECM	A
   Atmosphere Pressure	80 kPa or less (when elevation is 0 m)
   Both Data List items listed above	Values are other than above	-	B

B	Go to step 64

A

61.PERFORM SIMULATION TEST

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

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

3. Check if the engine can be started.
   
   

   Result

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

B	Go to step 64

A

62.INSPECT AIR FUEL RATIO SENSOR

1. Connect the intelligent tester to the DLC3.
   

2. Start the engine.
   

3. Turn the intelligent tester on.
   

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

5. Confirm that Fuel System Status #1 is CL.
   

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

7. Confirm that AF Lambda B1S1 is within the range of 0.95 to 1.05 when idling.
   

8. Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Injection Volume for A/F Sensor.
   

9. Read the output voltage from the air fuel ratio sensor when increasing and decreasing the fuel injection volume.
   

   Standard Voltage:

   Intelligent Tester 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:

   1. 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.
      
   2. 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 70 and perform fuel system troubleshooting A (steps 93 to 100), fuel system troubleshooting B (steps 101 to 103), intake system troubleshooting (steps 104 to 106), and ignition system troubleshooting (steps 107 to 112), in that order.
      

NG	REPLACE AIR FUEL RATIO SENSOR (HILUX_TGN26 RM00000142300YX.html)

OK

63.PERFORM SIMULATION TEST

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

   OK:

   Speed is stable.
   

   HINT:

   After replacing the fuel injector 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 70 and perform fuel system troubleshooting A (steps 93 to 100), fuel system troubleshooting B (steps 101 to 103), intake system troubleshooting (steps 104 to 106), and ignition system troubleshooting (steps 107 to 112), in that order.

NG	REPLACE FUEL INJECTOR (HILUX_TGN26 RM000000YLB01MX.html)

OK
REPLACE MASS AIR FLOW METER (HILUX_TGN26 RM000000VW602CX.html)

64.CHECK FUEL PRESSURE

1. Inspect the fuel pressure (HILUX_TGN26 RM000000YL704TX.html).
   

NG	Go to step 69

OK

65.INSPECT SPARK PLUG

1. Inspect the spark plugs (HILUX_TGN26 RM000000SM604YX_02_0002.html).
   
   

   Result

   Result	Proceed to
   All cylinders are normal	A
   One cylinder is abnormal*1	B
   All cylinders are abnormal*2, *3	C

HINT:

1. *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 70 and perform fuel system troubleshooting A (steps 93 to 100), fuel system troubleshooting B (steps 101 to 103), intake system troubleshooting (steps 104 to 106), and ignition system troubleshooting (steps 107 to 112), in that order.
   
2. *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 70 and perform fuel system troubleshooting A (steps 93 to 100), fuel system troubleshooting B (steps 101 to 103), intake system troubleshooting (steps 104 to 106), and ignition system troubleshooting (steps 107 to 112), in that order.
   
3. *3: Engine starting trouble may occur if the vehicle is driven extremely short distances repeatedly.
   

B	REPLACE SPARK PLUG (ABNORMAL CYLINDER) (HILUX_TGN26 RM000000SK7015X.html)
C	REPLACE SPARK PLUG (ALL CYLINDER) (HILUX_TGN26 RM000000SK7015X.html)

A

66.CONFIRM VEHICLE CONDITION

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

   Result

   Problem Symptom	Suspected Area	Proceed to
   When the engine is stopped and a long time has passed, engine starting trouble occurs*1	Pressure regulator is stuck open	A
   When the engine is stopped and approximately 15 to 120 minutes have passed, engine starting trouble occurs*2	Fuel injector leak	B
   When the engine is stopped and approximately 2 to 3 minutes have passed, engine starting trouble occurs*3	Failure to maintain fuel pressure by pressure regulator	A
   Condition other than above, or there is an inconsistency in the conditions present when engine starting trouble occurs	-	C*4

   HINT:

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

   *4: From step 70, perform fuel system troubleshooting A (steps 93 to 100), fuel system troubleshooting B (steps 101 to 103), intake system troubleshooting (steps 104 to 106), and ignition system troubleshooting (steps 107 to 112), in that order.

B	Go to step 68
C	Go to step 70

A

67.CHECK FUEL PRESSURE

HINT:

For the fuel pressure inspection, refer to the following procedures (HILUX_TGN26 RM000000YL704TX.html).

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

   Result

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

   HINT:

   1. If the engine cannot be started, check the fuel pressure after cranking the engine.
      
   2. *: From step 70, perform fuel system troubleshooting A (steps 93 to 100), fuel system troubleshooting B (steps 101 to 103), intake system troubleshooting (steps 104 to 106), and ignition system troubleshooting (steps 107 to 112), in that order.
      

B	Go to step 70

A
REPLACE FUEL PRESSURE REGULATOR ASSEMBLY (HILUX_TGN26 RM000000YLE01MX.html)

68.INSPECT FUEL INJECTOR

1. Clean the inside of the surge tank with compressed air.
   

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

   Result

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

   HINT:

   1. If the concentration is 4000 ppm or more, a fuel injector may have a sealing problem.
      
   2. *: From step 70, perform fuel system troubleshooting A (steps 93 to 100), fuel system troubleshooting B (steps 101 to 103), intake system troubleshooting (steps 104 to 106), and ignition system troubleshooting (steps 107 to 112), in that order.
      

B	Go to step 70

A
REPLACE FUEL INJECTOR (HILUX_TGN26 RM000000YLB01MX.html)

69.PERFORM ACTIVE TEST USING INTELLIGENT TESTER (CONTROL THE FUEL PUMP / SPEED)

1. Connect the intelligent tester to the DLC3.
   

2. Turn the ignition switch to ON.
   

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

4. 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:

   1. Jiggle the wire harness and connector to increase the likelihood of detecting malfunctions that do not always occur.
      
   2. Check if the vehicle ran out of fuel, as engine starting trouble due to running out of fuel is also detected.
      
   3. 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 70 and perform fuel system troubleshooting A (steps 93 to 100), fuel system troubleshooting B (steps 101 to 103), intake system troubleshooting (steps 104 to 106), and ignition system troubleshooting (steps 107 to 112), in that order.
      

B	CHECK FUEL PUMP CONTROL CIRCUIT (HILUX_TGN26 RM000001DN704OX.html)

A
REPAIR OR REPLACE FUEL LINE

70.CHECK MALFUNCTION CONDITION

1. If the malfunction could not be identified during the inspections in steps 38, 39, 40 and 46, perform fuel system troubleshooting C (steps 71 to 75).
   
   

   Result

   Performed Step	Troubleshooting by System	Procedure	Proceed to
   Steps 38, 39, 40 and 46	Fuel system troubleshooting C	71 to 75	A

2. If the malfunction could not be identified during the inspection in step 44, perform ignition system troubleshooting (steps 76 to 81).
   
   

   Result

   Performed Step	Troubleshooting by System	Procedure	Proceed to
   Step 44	Ignition system troubleshooting	76 to 81	B

3. If the malfunction could not be identified during the inspections in steps 54 and 55, perform intake air system troubleshooting (steps 82 to 84). If engine starting trouble still occurs, perform fuel system troubleshooting A (steps 85 to 92).
   
   

   Result

   Performed Step	Troubleshooting by System	Procedure	Proceed to
   Step 54 and 55	Intake air system troubleshooting	82 to 84	C
   	Fuel system troubleshooting A	85 to 92

4. If the malfunction could not be identified during the inspections in steps 56, 57, 58, 59, 62, 63, 65, 66, 67, 68 and 69, perform fuel system troubleshooting A (steps 93 to 100), fuel system troubleshooting B (steps 101 to 103), intake air system troubleshooting (steps 104 to 106), and ignition system troubleshooting (steps 107 to 112), in that order.
   
   

   Result

   Performed Step	Troubleshooting by System	Procedure	Proceed to
   Steps 56, 57, 58, 59, 62, 63, 65, 66, 67, 68 and 69	Fuel system troubleshooting A	93 to 100	D
   	Fuel system troubleshooting B	101 to 103
   	Intake air system troubleshooting	104 to 106
   	Ignition system troubleshooting	107 to 112

B	Go to step 76
C	Go to step 82
D	Go to step 93

A

71.INSPECT FUEL INJECTOR

1. Inspect the fuel injector (HILUX_TGN26 RM000000WQQ076X.html).
   

NG	REPLACE FUEL INJECTOR (HILUX_TGN26 RM000000YLB01MX.html)

OK

72.CHECK TERMINAL VOLTAGE (POWER SOURCE OF FUEL INJECTOR)

1. Check the harnesses and connectors, referring to Fuel Injector Circuit inspection procedure (HILUX_TGN26 RM00000330203TX_04_0001.html).
   

   HINT:

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

NG	CHECK FUEL INJECTOR POWER SOURCE CIRCUIT (HILUX_TGN26 RM00000330203TX.html)

OK

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

1. Check the harnesses and connectors, referring to Fuel Injector Circuit inspection procedure (HILUX_TGN26 RM00000330203TX_04_0003.html).
   

   HINT:

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

NG	REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

74.CHECK CRANKSHAFT POSITION SENSOR

1. Replace the crankshaft position sensor (HILUX_TGN26 RM000000VX301IX.html).
   

2. Check the engine start operation.
   

   OK:

   Malfunction has been repaired successfully.
   

NG	Go to step 75

OK
END (CRANKSHAFT POSITION SENSOR IS DEFECTIVE)

75.CHECK CAMSHAFT POSITION SENSOR

1. Replace the camshaft position sensor (HILUX_TGN26 RM000000VX701JX.html).
   

2. Check the engine start operation.
   

   OK:

   Malfunction has been repaired successfully.
   

NG	REPLACE ECM (HILUX_TGN26 RM000000VW202TX.html)

OK
END (CAMSHAFT POSITION SENSOR IS DEFECTIVE)

76.CHECK SENSOR INSTALLATION (CRANKSHAFT POSITION SENSOR)

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

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

   OK:

   Sensor is installed correctly.
   

NG	SECURELY REINSTALL CRANKSHAFT POSITION SENSOR (HILUX_TGN26 RM000000VX001PX.html)

OK

77.CHECK SENSOR INSTALLATION (CAMSHAFT POSITION SENSOR)

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

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

   OK:

   Sensor is installed correctly.
   

NG	SECURELY REINSTALL CAMSHAFT POSITION SENSOR (HILUX_TGN26 RM000000VX401NX.html)

OK

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

1. Check the harnesses and connectors, referring to DTC P0335 inspection procedure (HILUX_TGN26 RM000000TCW0UFX_09_0002.html).
   

   HINT:

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

NG	REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

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

1. Check the harnesses and connectors, referring to DTC P0340 inspection procedure (HILUX_TGN26 RM000000WBZ0M4X_09_0003.html).
   

   HINT:

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

NG	REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

Go to step 81

80.CHECK CRANKSHAFT POSITION SENSOR

1. Replace the crankshaft position sensor (HILUX_TGN26 RM000000VX301IX.html).
   

2. Check the engine start operation.
   

   OK:

   Malfunction has been repaired successfully.
   

NG	Go to step 81

OK
END (CRANKSHAFT POSITION SENSOR IS DEFECTIVE)

81.CHECK CAMSHAFT POSITION SENSOR

1. Replace the camshaft position sensor (HILUX_TGN26 RM000000VX701JX.html).
   

2. Check the engine start operation.
   

   OK:

   Malfunction has been repaired successfully.
   

NG	REPLACE ECM (HILUX_TGN26 RM000000VW202TX.html)

OK
END (CAMSHAFT POSITION SENSOR IS DEFECTIVE)

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

1. Connect the intelligent tester to the DLC3.
   

2. Turn the ignition switch to ON.
   

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

4. 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
   	Less than (engine displacement (liters) x 0.9)	-	B

B	Go to step 84

A

83.CHECK CYLINDER COMPRESSION PRESSURE

1. Check the compression (HILUX_TGN26 RM000000YN1017X_01_0009.html).
   

NG	CHECK AND REPAIR ENGINE ASSEMBLY

OK
CHECK VALVE TIMING

84.INSPECT ENGINE COOLANT TEMPERATURE SENSOR

1. Inspect the engine coolant temperature sensor (HILUX_TGN26 RM000000VW801AX.html).
   

NG	REPLACE ENGINE COOLANT TEMPERATURE SENSOR (HILUX_TGN26 RM000000VWA01WX.html)

OK

85.CHECK FUEL PRESSURE

HINT:

For the fuel pressure inspection, refer to the following procedures (HILUX_TGN26 RM000000YL704TX.html).

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

   Standard:

   
   

   Vehicle State	Specified Condition
   Cranking engine	304 to 343 kPa (3.1 to 3.5 kgf/cm2)
   5 minutes after stopping engine	147 kPa (1.5 kgf/cm2) or higher

NG	Go to step 91

OK

86.READ VALUE USING INTELLIGENT TESTER (LONG FT)

1. Connect the intelligent tester to the DLC3.
   

2. Turn the ignition switch to ON.
   

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

   Result

   Data List Item	Result	Suspected Area	Proceed to
   Long FT#1	-15 to +15%	Wire harness or connector Fuel	A
   	+15% or more, or less than -15%	Fuel injector	B

B	REPLACE FUEL INJECTOR (HILUX_TGN26 RM000000YLB01MX.html)

A

87.PERFORM SIMULATION TEST

1. 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 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.

B	REPLACE FUEL

A

88.CHECK SENSOR INSTALLATION (CRANKSHAFT POSITION SENSOR)

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

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

   OK:

   Sensor is installed correctly.
   

NG	SECURELY REINSTALL CRANKSHAFT POSITION SENSOR (HILUX_TGN26 RM000000VX001PX.html)

OK

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

1. Check the harnesses and connectors, referring to DTC P0335 inspection procedure (HILUX_TGN26 RM000000TCW0UFX_09_0002.html).
   

   HINT:

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

NG	REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

90.CHECK CRANKSHAFT POSITION SENSOR

1. Replace the crankshaft position sensor (HILUX_TGN26 RM000000VX301IX.html).
   

2. Check the engine start operation.
   

   OK:

   Malfunction has been repaired successfully.
   

NG	REPLACE ECM (HILUX_TGN26 RM000000VW202TX.html)

OK
END (CRANKSHAFT POSITION SENSOR IS DEFECTIVE)

91.PERFORM ACTIVE TEST USING INTELLIGENT TESTER (CONTROL THE FUEL PUMP / SPEED)

1. Connect the intelligent tester to the DLC3.
   

2. Turn the ignition switch to ON.
   

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

4. 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:

   1. Jiggle the wire harness and connector to increase the likelihood of detecting malfunctions that do not always occur.
      
   2. When performing the Active Test, if there is no operating noise from the fuel pump, the fuel pump system may be malfunctioning.
      
   3. Check if the vehicle ran out of fuel, as engine starting trouble due to running out of fuel is also detected.
      

B	Go to step 92

A
REPAIR OR REPLACE FUEL LINE

92.INSPECT FUEL PUMP

1. Inspect the fuel pump (HILUX_TGN26 RM000000YLJ01MX.html).
   

HINT:

1. Make sure there is no foreign matter such as iron particles on the fuel pump and no signs that the fuel pump was stuck.
   
2. Make sure the internal connector is securely connected.
   
3. Make sure the fuel pump filter is not clogged.
   

NG	REPLACE FUEL PUMP (HILUX_TGN26 RM000004PZ300BX.html)

OK
REPLACE FUEL PRESSURE REGULATOR (HILUX_TGN26 RM000000YLE01MX.html)

93.CHECK FUEL PRESSURE

HINT:

For the fuel pressure inspection, refer to the following procedures (HILUX_TGN26 RM000000YL704TX.html).

1. 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

B	Go to step 99

A

94.READ VALUE USING INTELLIGENT TESTER (LONG FT#1)

1. Connect the intelligent tester to the DLC3.
   

2. Turn the ignition switch to ON.
   

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

   Result

   Data List Item	Result	Suspected Area	Proceed to
   Long FT#1	-15 to +15%	Wire harness or connector Fuel	A
   	+15% or more, or less than -15%	Fuel injector	B

B	REPLACE FUEL INJECTOR (HILUX_TGN26 RM000000YLB01MX.html)

A

95.PERFORM SIMULATION TEST

1. 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 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.

B	REPLACE FUEL

A

96.CHECK SENSOR INSTALLATION (CRANKSHAFT POSITION SENSOR)

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

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

   OK:

   Sensor is installed correctly.
   

NG	SECURELY REINSTALL CRANKSHAFT POSITION SENSOR (HILUX_TGN26 RM000000VX001PX.html)

OK

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

1. Check the harnesses and connectors, referring to DTC P0335 inspection procedure (HILUX_TGN26 RM000000TCW0UFX_09_0002.html).
   

   HINT:

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

NG	REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

98.CHECK CRANKSHAFT POSITION SENSOR

1. Replace the crankshaft position sensor (HILUX_TGN26 RM000000VX301IX.html).
   

2. Check the engine start operation.
   

   OK:

   Malfunction has been repaired successfully.
   

NG	REPLACE ECM (HILUX_TGN26 RM000000VW202TX.html)

OK
END (CRANKSHAFT POSITION SENSOR IS DEFECTIVE)

99.PERFORM ACTIVE TEST USING INTELLIGENT TESTER (CONTROL THE FUEL PUMP / SPEED)

1. Connect the intelligent tester to the DLC3.
   

2. Turn the ignition switch to ON.
   

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

4. 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:

   1. Jiggle the wire harness and connector to increase the likelihood of detecting malfunctions that do not always occur.
      
   2. When performing the Active Test, if there is no operating noise from the fuel pump, the fuel pump system may be malfunctioning.
      
   3. Check if the vehicle ran out of fuel, as engine starting trouble due to running out of fuel is also detected.
      

B	Go to step 100

A
REPAIR OR REPLACE FUEL LINE

100.INSPECT FUEL PUMP

1. Inspect the fuel pump (HILUX_TGN26 RM000000YLJ01MX.html).
   

HINT:

1. Make sure there is no foreign matter such as iron particles on the fuel pump and no signs that the fuel pump was stuck.
   
2. Make sure the internal connector is securely connected.
   
3. Make sure the fuel pump filter is not clogged.
   

NG	REPLACE FUEL PUMP (HILUX_TGN26 RM000004PZ300BX.html)

OK

101.CHECK PURGE VSV

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

2. Start the engine.
   

3. Idle the engine.
   

4. Disconnect the connector of the purge VSV.
   

5. Check if air flows through the purge VSV.
   

   OK:

   Air does not flow.
   

6. Connect the connector of the purge VSV.
   

7. Connect the purge hose of the purge VSV.
   

   HINT:

   When this inspection is performed, the MIL may illuminate. After finishing the inspection, check and clear DTCs (HILUX_TGN26 RM000000PDK130X.html).

NG	INSPECT PURGE VSV

OK

102.CHECK FUEL INJECTOR

1. Clean the inside of the surge tank with compressed air.
   

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

   Result

   Result	Proceed to
   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.

B	Go to step 103

A
REPLACE FUEL INJECTOR (HILUX_TGN26 RM000000YLB01MX.html)

103.CHECK INTAKE VALVE

1. Check if carbon is on the intake valves.
   
   

   Result

   Result	Proceed to
   Carbon present	A
   No carbon present	B

B	Go to step 104

A
CLEAN INTAKE VALVE

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

1. Connect the intelligent tester to the DLC3.
   

2. Turn the ignition switch to ON.
   

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

4. 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
   	Less than (engine displacement (liters) x 0.9)	-	B

B	Go to step 106

A

105.CHECK CYLINDER COMPRESSION PRESSURE

1. Inspect the compression (HILUX_TGN26 RM000000YN1017X_01_0009.html).
   

NG	CHECK AND REPAIR ENGINE ASSEMBLY

OK
CHECK VALVE TIMING

106.INSPECT ENGINE COOLANT TEMPERATURE SENSOR

1. Inspect the engine coolant temperature sensor (HILUX_TGN26 RM000000VW801AX.html).
   

NG	REPLACE ENGINE COOLANT TEMPERATURE SENSOR (HILUX_TGN26 RM000000VWA01WX.html)

OK

107.CHECK SENSOR INSTALLATION (CRANKSHAFT POSITION SENSOR)

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

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

   OK:

   Sensor is installed correctly.
   

NG	SECURELY REINSTALL CRANKSHAFT POSITION SENSOR (HILUX_TGN26 RM000000VX001PX.html)

OK

108.CHECK SENSOR INSTALLATION (CAMSHAFT POSITION SENSOR)

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

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

   OK:

   Sensor is installed correctly.
   

NG	SECURELY REINSTALL CAMSHAFT POSITION SENSOR (HILUX_TGN26 RM000000VX401NX.html)

OK

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

1. Check the harnesses and connectors, referring to DTC P0335 inspection procedure (HILUX_TGN26 RM000000TCW0UFX_09_0002.html).
   

   HINT:

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

NG	REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

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

1. Check the harnesses and connectors, referring to DTC P0340 inspection procedure (HILUX_TGN26 RM000000WBZ0M4X_09_0003.html).
   

   HINT:

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

NG	REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

111.CHECK CRANKSHAFT POSITION SENSOR

1. Replace the crankshaft position sensor (HILUX_TGN26 RM000000VX301IX.html).
   

2. Check the engine start operation.
   

   OK:

   Malfunction has been repaired successfully.
   

NG	Go to step 112

OK
END (CRANKSHAFT POSITION SENSOR IS DEFECTIVE)

112.CHECK CAMSHAFT POSITION SENSOR

1. Replace the camshaft position sensor (HILUX_TGN26 RM000000VX701JX.html).
   

2. Check the engine start operation.
   

   OK:

   Malfunction has been repaired successfully.
   

NG	REPLACE ECM (HILUX_TGN26 RM000000VW202TX.html)

OK
END (CAMSHAFT POSITION SENSOR IS DEFECTIVE)