M20C-FKS ENGINE CONTROL  SFI SYSTEM  Engine Difficult to Start  

Interview the customer for details about the conditions when the engine was difficult to start.

HINT:

In addition to the usual questions, be sure to ask the customer about the specific details when the problem symptoms occurred.

Condition When Problem Symptom Occurred	Suspected Area
After refueling at an unfamiliar gas station, the engine became difficult to start.	Fuel quality
After the addition of fuel additives, the engine became difficult to start.	Addition of fuel additive
Only after leaving the vehicle for a long time, the engine becomes difficult to start.	Leaking fuel injector assembly
The vehicle mostly driven for short distances only.	Formation of carbon deposits on spark plug

Connect the GTS to the DLC3.

Turn the ignition switch to ON.

Turn the GTS on.

Perform a road test.

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

Read the DTCs.

Powertrain > Engine > Trouble Codes

50001 372

Result:

Result	Proceed to
DTCs are not output	A
DTC is output	B

Connect the GTS to the DLC3.

Turn the ignition switch to ON.

Turn the GTS on.

Enter the following menus: Powertrain / Engine / Utility / Vehicle Control History (RoB).

Powertrain > Engine > Utility

Tester Display
Vehicle Control History (RoB)

50005 372 55

HINT:

It is also possible to display vehicle control history during the Health Check, if "Store All Data" is selected.

Confirm if any data relating to the problem symptoms exist in the Vehicle Control History.

HINT:

·

The vehicle condition when the problem symptoms occurred can be determined by confirming the Vehicle Control History Freeze Frame Data.

·

As the Vehicle Control History data may be overwritten whenever the trigger conditions are met, make sure to save the Vehicle Control History data before performing any inspections.

·

Using information from the customer about when the problem symptom occurred, find the Freeze Frame Data with the appropriate Key Cycle, Total Distance Traveled, etc., to find vehicle history that may be related to the problem symptoms.

Check if the problem symptoms stated by the customer are currently occurring.

HINT:

·

By using snapshot to store the Data List, the Data List items can be compared to the Vehicle Control History.

·

If the problem symptoms cannot be reproduced, refer to Check for Intermittent Problems, and try to reproduce the conditions when the problem symptoms occurred as stated by the customer. If the problem symptoms still cannot be reproduced, perform the following procedure.

Click hereEngine / Hybrid System>M20C-FKS (ENGINE CONTROL)>SFI SYSTEM>CHECK FOR INTERMITTENT PROBLEMS202004,999999,_51,_087036,_0418131,RM100000001MIHX,

Read the Data List or the Vehicle Control History Freeze Frame Data.

HINT:

·

If the malfunction is currently occurring, compare the values of the Data List items with the vehicle control history freeze frame data.

·

If the malfunction is not currently occurring, read the Vehicle Control History Freeze Frame Data.

Result:

Vehicle Control History	Vehicle Control History Freeze Frame Data / Data List While Problem Symptoms Are Occurring	Suspected Area	Proceed to
Engine Difficult to Start (Engine Starting Time Long) is stored (Vehicle Control History Code: X0810)	Engine speed is 0 rpm (engine does not crank)	Battery depletion, excessive engine friction, starter malfunction or crankshaft position sensor malfunction	A
	Engine speed is between 100 and 500 rpm (engine cranks but combustion does not occur, initial combustion delays or combustion occurs late)	Ignition system, fuel system malfunction or wire harness	B
Engine Difficult to Start (Engine Stall Immediately After Starting) is stored (Vehicle Control History Code: X0811)	-	· Improper fuel injection volume (too low or too high) · If Long FT is out of specified range: insufficient fuel supply due to clogging of injectors or fuel pump · If engine cranking speed is high: compression loss due to deposits caught on valves	B
	ISC F/B Learn Torque is 15 Nm or higher	The offset correction value is insufficient due to deposits in the throttle body causing a low idle air flow rate.	C
Engine Difficult to Start (Immobiliser) is stored (Vehicle Control History Code: X0812)	-	The engine stalled due to operation of immobiliser system. Check the immobiliser system for malfunctions.	D
The malfunction is not currently occurring and there is no Vehicle Control History related to the problem symptoms stated by the customer.			B

Check the interview result.

Result:

Result	Proceed to
Engine is difficult to start only when the vehicle has been left as is for a long time (1 hour or more)	A
Other than above	B

Check for leaks from the port fuel injector assembly.

Click hereEngine / Hybrid System>M20C-FKS (FUEL)>FUEL INJECTOR (for Port Injection)>INSPECTION202004,999999,_51,_087038,_0417286,RM100000001MDRN,

Check the engine cranking operation.

Result:

Result	Proceed to
The engine does not crank or cranks slowly	A
The engine cranks normally	B

Inspect the battery.

Click herePower Source / Network>M20C-FKS (BATTERY / CHARGING)>CHARGING SYSTEM>ON-VEHICLE INSPECTION202304,202405,_57,_087045,_0418150,RM100000002A3HH,202405,202409,_57,_087045,_0418150,RM100000002LW0D,202409,999999,_57,_087045,_0418150,RM100000002NHRA,

Check if the problem symptoms reported in the customer problem analysis recur.

HINT:

If the problem symptoms do not recur, attempt to reproduce the conditions when the malfunction occurred based on the result of the customer problem analysis.

Result:

Result	Proceed to
The problem symptom recurs	A
The problem symptom does not recur (occurred in the past)	B

Check that the engine starts or there is initial combustion.

HINT:

If there is no initial combustion, perform a simple spark test by removing the bolt of the ignition coil assembly, partially lifting the ignition coil assembly, and checking for spark.

Click hereEngine / Hybrid System>M20C-FKS (ENGINE CONTROL)>IGNITION SYSTEM>ON-VEHICLE INSPECTION202004,999999,_51,_087036,_0418132,RM100000001MIM4,

Result:

Result	Proceed to
The engine starts or there is initial combustion	A
There is no initial combustion and no spark occurs	B

Connect the GTS to the DLC3.

Turn the ignition switch to ON.

Turn the GTS on.

Enter the following menus: Powertrain / Engine / Data List / ISC F/B Learn Torque.

Powertrain > Engine > Data List

Tester Display
ISC F/B Learn Torque

50003 372 114

Read the value displayed on the GTS.

Result:

Result	Proceed to
Less than 15 Nm	A
Other than above	B

Connect the GTS to the DLC3.

Turn the ignition switch to ON.

Turn the GTS on.

Enter the following menus: Powertrain / Engine / Data List / Short FT B1S1 and Long FT B1S1.

Powertrain > Engine > Data List

Tester Display
Short FT B1S1
Long FT B1S1

50003 372 207,209

Read the value displayed on the GTS.

Result:

Data List	Result	Proceed to
Short FT B1S1 + Long FT B1S1	-20% or higher, or less than 20%	A
	Other than above	B

HINT:

·

"Total FT Bank 1" is used to detect an abnormal air fuel ratio. As the value of "Total FT Bank 1" is corrected by the ECM before it is displayed in the Data List, the displayed value may not be equal to the sum of the measured "Short FT B1S1" and "Long FT B1S1".

·

An abnormally lean or rich tendency can be checked by reading the following Data List items: A/F Learn Value Idle (Port) Bank 1, A/F Learn Value Low (Port) Bank 1, A/F Learn Value Mid No.1 (Port) Bank 1, A/F Learn Value Mid No.2 (Port) Bank 1, A/F Learn Value High (Port) Bank 1, A/F Learn Value Idle Bank 1, A/F Learn Value Low Bank 1, A/F Learn Value Mid No.1 Bank 1, A/F Learn Value Mid No.2 Bank 1 and A/F Learn Value High Bank 1.

·

The following may cause a lean air fuel ratio (an operating range in which the air fuel ratio learned value correction is +20% or more):

(a)

Decrease in fuel injector assembly injection volume

(b)

Decrease in mass air flow meter sub-assembly output (due to existence of foreign matter)

(c)

Air leaks in intake system after mass air flow meter sub-assembly

(d)

Decrease in fuel pressure (at fuel filter, fuel pump, fuel main valve assembly or fuel suction plate sub-assembly)

·

On vehicles which the learning value for each operating range can be checked, if the value of "A/F Learn Value High (Port) Bank 1" or "A/F Learn Value High Bank 1" only is corrected to the positive side, a malfunction in the fuel system (clogging of the fuel pump or fuel filter) is suspected.

·

On vehicles which the learning value for each operating range can be checked, if the value of "A/F Learn Value Idle (Port) Bank 1", "A/F Learn Value Low (Port) Bank 1", "A/F Learn Value Idle Bank 1" or "A/F Learn Value Low Bank 1" only is corrected to the positive side, an air leak after the mass air flow meter sub-assembly is suspected.

·

The following may cause a rich air fuel ratio (an operating range in which the air fuel ratio learned value correction is -20% or less):

(a)

Increase in the fuel injector assembly injection volume

(b)

Purge VSV system

Connect the GTS to the DLC3.

Start the engine.

HINT:

Reproduce the vehicle conditions when the malfunction occurred. (such as after the engine is warmed up or after a cold start).

Turn the GTS on.

Enter the following menus: Powertrain / Engine / Active Test / D-4S (Fuel Cut) / Data List / Engine Speed.

Powertrain > Engine > Active Test

Active Test Display
D-4S (Fuel Cut)

Data List Display
Engine Speed

50004 372 42011 211

According to the display on the GTS, perform the Active Test and check for a malfunctioning cylinder.

HINT:

·

Perform fuel-cut of port injection and direct injection for each cylinder and check the change in the engine speed.

·

If the engine speed of a cylinder does not change while performing the Active Test, it can be determined that the cylinder is malfunctioning.

·

If the engine speed of all cylinders changes while performing the Active Test, it can be determined that multiple cylinders are malfunctioning.

·

A cylinder for which the Data List item "Misfire Count Cylinder #1 to #4" increases may be malfunctioning.

Result:

Result	Proceed to
One cylinder is malfunctioning	A
Multiple or all cylinders are malfunctioning, or the malfunctioning cylinder cannot be determined	B

Warm up the engine.

Turn the ignition switch off.

Connect the GTS to the DLC3.

Turn the ignition switch to ON.

Turn the GTS on.

Enter the following menus: Powertrain / Engine / Active Test / Check the Cylinder Compression / Data List / Compression / Engine Speed Cylinder #1 to #4 and Average Engine Speed of All Cylinder.

Powertrain > Engine > Active Test

Active Test Display
Check the Cylinder Compression

Data List Display
Engine Speed Cylinder #1
Engine Speed Cylinder #2
Engine Speed Cylinder #3
Engine Speed Cylinder #4
Average Engine Speed of All Cylinder

50004 372 42007 134,135,136,137,133

HINT:

To display the entire Data List, press the pull down menu button next to Primary. Then select Compression.

Push the snapshot button to turn the snapshot function on.

HINT:

Using the snapshot function, data can be recorded during the Active Test.

While the engine is not running, press the Active button to change Check the Cylinder Compression to "Start".

HINT:

After performing the above procedure, Check the Cylinder Compression will start. Fuel injection for all cylinders is prohibited and each cylinder engine speed measurement enters standby mode.

Crank the engine for about 10 seconds.

Monitor the engine speed (Engine Speed Cylinder #1 to #4 and Average Engine Speed of All Cylinder) displayed on the GTS.

NOTICE:

·

Do not crank the engine continuously for 20 seconds or more.

·

If it is necessary to crank the engine again after Check the Cylinder Compression has been changed to "Start" and the engine has been cranked once, press Exit to return to the Active Test menu screen. Then change Check the Cylinder Compression to "Start" and crank the engine.

·

Make sure the battery is fully charged before performing this Active Test.

HINT:

·

At first, the GTS will display extremely high cylinder engine speed values. After approximately 10 seconds of engine cranking, the engine speed measurement of each cylinder will change to the actual engine speed.

·

If the cylinder engine speed values (Engine Speed Cylinder #1 to #4) displayed in the Data List do not change from an extremely high value, return to the Active Test menu screen, change "Check the Cylinder Compression" to "Start" and crank the engine again within 1 second.

Stop cranking the engine, and then change "Check the Cylinder Compression" to "Stop" after the engine stops.

NOTICE:

·

If the Active Test is changed to "Stop" while the engine is being cranked, the engine will start.

·

When performing the Active Test, Vehicle Control History code X0810 (Engine Difficult to Start (Engine Starting Time Long)) may be stored.

·

After performing the Active Test, make sure to check and clear DTCs.

Push the snapshot button to turn the snapshot function off.

Select "Stored Data" on the GTS screen, select the recorded data and display the data as a graph.

HINT:

If the data is not displayed as a graph, the change of the values cannot be observed.

Read the value.

HINT:

·

If the value of Data List item "Engine Speed Cylinder" of a cylinder is higher than other cylinders, the cylinder may be malfunctioning.

·

If the value of Data List item "Engine Speed Cylinder" is high for only one cylinder, compression loss is suspected.

Result:

Result	Proceed to
There is no variation in "Engine Speed Cylinder" (All cylinders display approximately the same value for "Engine Speed Cylinder")	A
There is variation in "Engine Speed Cylinder" (Only one cylinder displays a value for "Engine Speed Cylinder" that differs considerably)	B

Connect the GTS to the DLC3.

Turn the ignition switch to ON.

Turn the GTS on.

Start the engine and warm it up until the engine coolant temperature 75°C (167°F) or higher with all the accessories switched off.

Idle the engine.

Enter the following menus: Powertrain / Engine / Active Test / D-4S (Injection Volume) / Data List / Coolant Temperature.

Powertrain > Engine > Active Test

Active Test Display
D-4S (Injection Volume)

Data List Display
Coolant Temperature

50004 372 42012 205

According to the display on the GTS, perform the Active Test and check the vehicle conditions when increasing and decreasing the fuel injection volume of port injection and direct injection.

HINT:

·

Increase and decrease the fuel injection volume of the port injection and direct injection simultaneously and check the vehicle condition.

·

Change the fuel injection volume between the minimum and maximum range of correction (e.g. -12.5% to 24.8%).

Result:

Result	Proceed to
Malfunction is still present even if the fuel injection volume is changed	A
Malfunction disappears when the fuel injection volume is changed	B

Check the ignition system.

HINT:

·

Interchange the ignition coil assembly and spark plug of the malfunctioning cylinder with those of a known good cylinder and check if the malfunctioning cylinder returns to normal.

·

If the spark plug of the malfunctioning cylinder is abnormally wet with fuel even after the ignition coil assembly and spark plug are replaced, a leaking fuel injector assembly is suspected.

Result:

Result	Proceed to
The malfunctioning cylinder does not return to normal	A
The malfunctioning cylinder returned to normal	B

Check the power source circuit, wire harness and connectors.

Replace the abnormal fuel injector assembly.

HINT:

·

If the air fuel ratio learned value is corrected to the positive side for all operating ranges due to low fuel injector assembly injection volume, replace the fuel injector assemblies of all cylinders.

·

Perform "Inspection After Repair" after replacing the fuel injector assembly.

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Measure the cylinder compression pressure. If the compression pressure of a cylinder is low, inspect the engine assembly and repair or replace parts as necessary.

Click hereEngine / Hybrid System>M20C-FKS (ENGINE MECHANICAL)>ENGINE>ON-VEHICLE INSPECTION202004,999999,_51,_087037,_0417206,RM100000001MD0D_01_0010,

Connect the GTS to the DLC3.

Turn the ignition switch to ON.

Turn the GTS on.

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.

Enter the following menus: Powertrain / Engine / Active Test / Control the EGR Step Position / Data List / Engine Speed and Coolant Temperature.

Powertrain > Engine > Active Test

Active Test Display
Control the EGR Step Position

Data List Display
Engine Speed
Coolant Temperature

50004 372 25 211,205

Perform the Active Test and check the vehicle condition when operating the EGR valve assembly.

NOTICE:

·

Do not leave the EGR valve open for 10 seconds or more during the Active Test.

·

Be sure to return the EGR valve to step 0 when the Active Test is completed.

·

Do not open the EGR valve 30 steps or more during the Active Test.

HINT:

Operate the EGR valve between step 0 and 30 when performing this step.

Result:

Result	Proceed to
Vehicle condition changes during the Active Test (Malfunction occurs when the EGR valve is open and disappears when the EGR valve is closed)	A
Vehicle condition does not change during the Active Test (Malfunction occurs whether the EGR valve is open or closed)	B

HINT:

During Active Test, if the idling condition does not change in response to EGR step position, then there is probably a malfunction in the EGR valve.

Connect the GTS to the DLC3.

Turn the ignition switch to ON.

Turn the GTS on.

Start the engine and warm it up until the engine coolant temperature 75°C (167°F) or higher with all the accessories switched off.

Enter the following menus: Powertrain / Engine / Data List / Engine Speed, Mass Air Flow Sensor and Coolant Temperature.

Powertrain > Engine > Data List

Tester Display
Engine Speed
Mass Air Flow Sensor
Coolant Temperature

50003 372 211,215,205

According to the display on the GTS, read the Data List when the engine is running.

Result:

Result	Proceed to
Idling (engine warmed up): 1.5 to 3.3 gm/sec Engine speed 3000 rpm (without load): 8.0 to 13.0 gm/sec	A
Other than below	B

Connect the GTS to the DLC3.

Turn the ignition switch to ON.

Turn the GTS on.

Start the engine and warm it up until the engine coolant temperature 75°C (167°F) or higher with all the accessories switched off.

Warm up the air fuel ratio sensors at an engine speed of 2500 rpm for 90 seconds.

Idle the engine.

Enter the following menus: Powertrain / Engine / Active Test / D-4S (Injection Volume) / Data List / Coolant Temperature, A/F (O2) Sensor Current B1S1 and A/F (O2) Sensor Current B1S2.

Powertrain > Engine > Active Test

Active Test Display
D-4S (Injection Volume)

Data List Display
Coolant Temperature
A/F (O2) Sensor Current B1S1
A/F (O2) Sensor Current B1S2

50004 372 42012 205,230,564

According to the display on the GTS, perform the Active Test and check the vehicle conditions when increasing and decreasing the fuel injection volume of port injection and direct injection.

NOTICE:

·

The air fuel ratio sensor (sensor 1) has an output delay of a few seconds and the air fuel ratio sensor (sensor 2) has a maximum output delay of approximately 20 seconds.

·

Read the output current immediately after warming up the air fuel ratio sensors to avoid an inaccurate reading due to a sensor cooling.

HINT:

·

Increase and decrease the fuel injection volume of the port injection and direct injection simultaneously and check the vehicle condition.

·

Change the fuel injection volume between -12 to 12%.

Standard:

GTS Display (Sensor)	Injection Volume	Current
A/F (O2) Sensor Current B1S1 (Air fuel ratio (sensor 1))	12%	Below -0.075 mA
	-12%	More than 0.037 mA
A/F (O2) Sensor Current B1S2 (Air fuel ratio (sensor 2))	12%	Below -0.86 mA
	-12%	More than 0.33 mA

Result:

Result	Proceed to
Output current values are abnormal	A
Malfunction disappears when fuel injection volume is increased	B
Malfunction is still present when fuel injection volume is increased, even if output current values are normal	C

Replace the air fuel ratio sensor (sensor 1).

Click hereEngine / Hybrid System>M20C-FKS (ENGINE CONTROL)>AIR FUEL RATIO SENSOR>REMOVAL202304,999999,_51,_087036,_0418148,RM100000002B2LZ,

HINT:

Perform "Inspection After Repair" after replacing the air fuel ratio sensor (sensor 1).

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Replace the air fuel ratio sensor (sensor 2).

Click hereEngine / Hybrid System>M20C-FKS (ENGINE CONTROL)>AIR FUEL RATIO SENSOR>REMOVAL202304,999999,_51,_087036,_0418148,RM100000002B2LZ,

HINT:

Perform "Inspection After Repair" after replacing the air fuel ratio sensor (sensor 2).

Click hereEngine / Hybrid System>M20C-FKS (ENGINE CONTROL)>SFI SYSTEM>INITIALIZATION202304,202405,_51,_087036,_0418131,RM1000000029CMT,202405,999999,_51,_087036,_0418131,RM100000002IF8T,

Replace the fuel injector assemblies of all cylinders.

HINT:

Perform "Inspection After Repair" after replacing the fuel injector assembly.

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Connect the GTS to the DLC3.

Turn the ignition switch to ON.

Turn the GTS on.

Enter the following menus: Powertrain / Engine / Active Test / Activate the Circuit Relay (Brushless).

Powertrain > Engine > Active Test

Tester Display
Activate the Circuit Relay (Brushless)

50004 372 40

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

OK:

Activate the Circuit Relay	Specified Condition
ON	Operating sound heard
OFF	Operating sound not heard

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

Click hereEngine / Hybrid System>M20C-FKS (FUEL)>FUEL SYSTEM>ON-VEHICLE INSPECTION202004,999999,_51,_087038,_0417285,RM100000001MDRM_01_0002,

Standard:

Vehicle State	Specified Condition
Cranking engine	196 to 833 kPa (2.0 to 8.5 kgf/cm2, 28 to 121 psi)
5 minutes after stopping engine	98 kPa (1.0 kgf/cm2, 14 psi) or higher

HINT:

·

If there is foreign matter such as iron particles on the fuel pump, remove it.

·

Make sure that there are no leaks from the fuel lines, signs of fuel leakage or fuel odors.

Connect the GTS to the DLC3.

Start the engine and warm it up until the engine coolant temperature is 75°C (167°F) or higher with all the accessories switched off.

Turn the GTS on.

Enter the following menus: Powertrain / Engine / Data List / Engine Speed, Coolant Temperature, Fuel Pressure (High) and Injection Mode.

Powertrain > Engine > Data List

Tester Display
Engine Speed
Coolant Temperature
Fuel Pressure (High)
Injection Mode

50003 372 211,205,265,294

According to the display on the GTS, read the Data List.

Standard:

GTS Display	Condition	Specified Condition
Fuel Pressure (High)	· Shift position: P · A/C: Off · Engine warmed up · Engine Speed: 3000 rpm · Injection Mode: Direct	2400 to 20000 kPag

Inspect other related components.

HINT:

If the malfunctioning part could not be determined by performing the preceding inspections, one of the following malfunctions is suspected.

·

Deposits in the intake manifold or on an intake valve

·

Delay in fuel supply due to adherence of the fuel to the deposits

Inspect the following fuel pump related parts:

Inspect the fuel pump control system.

Check for air leaks or blockage in the intake system components. If a connection problem or foreign matter is found, repair the connection or remove the foreign matter.

HINT:

·

If there is foreign matter in the intake system components, remove it before proceeding to the next step.

·

If there is no foreign matter in the intake system components, check for foreign matter in the mass air flow meter sub-assembly. If there is foreign matter in the mass air flow meter sub-assembly, remove it.

Replace the EGR valve assembly.

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HINT:

Perform "Inspection After Repair" after replacing the EGR valve assembly.

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Clean off any deposits from the inside of the throttle body with motor assembly.

Perform "Inspection After Repair" after cleaning the throttle body with motor assembly.

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Connect the GTS to the DLC3.

Turn the ignition switch to ON.

Turn the GTS on.

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

Allow the engine to idle for 3 minutes or more and confirm that the engine speed is within the specified range.

HINT:

If the engine is operated without performing learning value reset and idle learning after cleaning the deposits from the throttle body with motor assembly, the idle speed may increase.

Perform a spark test.

Click hereEngine / Hybrid System>M20C-FKS (ENGINE CONTROL)>IGNITION SYSTEM>ON-VEHICLE INSPECTION202004,999999,_51,_087036,_0418132,RM100000001MIM4,

HINT:

·

If there is a malfunction for a specific cylinder, exchange the ignition coil assembly and spark plug of the malfunctioning cylinder with that of another cylinder and check if the malfunction disappears.

·

If the malfunction does not disappear after the ignition coil assembly and spark plug is exchanged or spark does not occur for any cylinder, inspect the ignition circuit.

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Repair or replace the malfunctioning part.

HINT:

Perform "Inspection After Repair" after repairing or replacing the malfunctioning part.

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Check that the engine has returned to normal.