Engine Stalls [09/2014 - 11/2017]: Procedure

1. Interview the customer for details about the conditions when the engine stalled.

   HINT: 

   • Use any information from the customer problem analysis about the conditions of the vehicle when the malfunction occurred (how the engine stalled, conditions when the engine was restarted, etc.)
   • Depending on the conditions when the engine stalled, a malfunction in one of the following areas is suspected.

     Symptom	Suspected Area
     Engine vibration occurs and engine stalls	Abnormal mass air flow meter sub-assembly output due to existence of foreign matter Abnormal air fuel ratio due to malfunction of air fuel ratio sensor or heated oxygen sensor, air leaks in intake system or insufficient fuel supply
     Engine stalls without vibration	Ignition stoppage, fuel injection stoppage or high load from another system
     Engine can be started with accelerator pedal depressed	Insufficient air volume
     Engine stalls or is difficult to start immediately after engine stalled, regardless of whether engine is cold or warm	Deposits in intake system or combustion chamber caught temporarily on intake or exhaust valve

   Result

   Proceed to
   NEXT

Result: 

NEXT 

See step  2

1. Connect the Techstream to the DLC3.
2. Turn the engine switch on (IG).
3. Turn the Techstream on.
4. Perform a road test.
5. Enter the following menus: Powertrain / Engine / Trouble Codes.
6. Read the DTCs.

   Powertrain > Engine > Trouble Codes 

   Result

   Result	Proceed to
   DTCs are not output	A
   DTC is output (DTCs other than P1603, P1604 or P1605 are output)	B

Result: 

B 

GO TO DTC CHART. Refer to  DIAGNOSTIC TROUBLE CODE CHART [09/2014 - 10/2015]  , or refer to  DIAGNOSTIC TROUBLE CODE CHART [10/2015 - 08/2016]  , or refer to  DIAGNOSTIC TROUBLE CODE CHART [08/2016 - 11/2017] 

Result: 

A 

See step  3

1. 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

Result: 

B 

CHECK FOR INTERMITTENT PROBLEMS. Refer to  CHECK FOR INTERMITTENT PROBLEMS [09/2014 - ] 

Result: 

A 

See step  4

1. Connect the Techstream to the DLC3.
2. Turn the engine switch on (IG).
3. Turn the Techstream on.
4. Enter the following menus: Powertrain / Engine / Data List / Gas Rough Idle / ISC Learning Value.

   Powertrain > Engine > Data List 

   Tester Display
   ISC Learning Value

5. Read the value displayed on the Techstream.

   Result

   Result	Proceed to
   Less than 6.2 L/s	A
   Other than above	B

Result: 

B 

See step  11

Result: 

A 

See step  5

1. Connect the Techstream to the DLC3.
2. Turn the engine switch on (IG).
3. Turn the Techstream on.
4. Enter the following menus: Powertrain / Engine / Data List / Gas AF O2 Sensor / Short FT #1 (#2) and Long FT #1 (#2).

   Powertrain > Engine > Data List 

   Tester Display
   Short FT #1
   Long FT #1
   Short FT #2
   Long FT #2

5. Read the value displayed on the Techstream.

   Result

   Data List	Result	Proceed to
   Short FT #1 (#2) + Long FT #1 (#2)	-15% or higher, or less than 15%	A
   	Other than above	B

   HINT: 

   • "Total FT #1 (#2)" is used to detect an abnormal air fuel ratio. As the value of "Total FT #1 (#2)" 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 #1 (#2)" and "Long FT #1 (#2)".
   • An abnormally lean or rich tendency can be checked by reading the following Data List items: A/F Learn Value Idle #1 (#2), A/F Learn Value Low #1 (#2), A/F Learn Value Mid1 #1 (#2), A/F Learn Value Mid2 #1 (#2), A/F Learn Value High #1 (#2), A/F Learn Val Low #1 (Dual) (#2 (Dual)), A/F Learn Val Mid1 #1 (Dual) (#2 (Dual)), A/F Learn Val Mid2 #1 (Dual) (#2 (Dual)) and A/F Learn Val High #1 (Dual) (#2 (Dual)). (For vehicles equipped with a V type engine, check that both banks have the same correction tendency.) If the correction of either bank is -15% or less or +15% or more, the air fuel ratio sensor or heated oxygen sensor of that bank may be malfunctioning.
   • The following may cause a lean air fuel ratio (an operating range in which the air fuel ratio learned value correction is +15% or more):
     1. Decrease in fuel injector assembly injection volume
     2. Decrease in mass air flow meter sub-assembly output (due to existence of foreign matter)
     3. Air leaks in intake system after mass air flow meter sub-assembly
     4. Decrease in fuel pressure (at fuel filter, fuel pump or fuel pressure regulator assembly)
   • On vehicles which the learning value for each operating range can be checked, if the value of "A/F Learn Value High #1 (#2) or A/F Learn Val High #1 (Dual) (#2 (Dual))" 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 #1 (#2)" or "A/F Learn Value Low #1 (#2) or A/F Learn Val Low #1 (Dual) (#2 (Dual))" 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 -15% or less):
     1. Increase in the fuel injector assembly injection volume
     2. Purge VSV system

Result: 

B 

See step  15

Result: 

A 

See step  6

1. Connect the Techstream to the DLC3.
2. Turn the engine switch on (IG).
3. Turn the Techstream on.
4. 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).

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

   Powertrain > Engine > Active Test 

   Active Test Display
   D-4S (Fuel Cut)

   Data List Display
   Engine Speed

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

   HINT: 

   • Perform fuel-cut of the port injection and direct injection simultaneously 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 change while performing the Active Test, it can be determined that multiple cylinders are malfunctioning.
   • A cylinder for which the Data List item "Cylinder Misfire Count #1 (to #8)" 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

Result: 

B 

See step  15

Result: 

A 

See step  7

HINT: 

If the vehicle does not support the Active Test "Check the Cylinder Compression", measure the compression pressure. If the compression pressure is normal, go to step 8.

1. Warm up the engine.
2. Turn the engine switch off.
3. Connect the Techstream to the DLC3.
4. Turn the engine switch on (IG).
5. Turn the Techstream on.
6. Enter the following menus: Powertrain / Engine / Active Test / Check the Cylinder Compression.

   Powertrain > Engine > Active Test 

   Tester Display
   Check the Cylinder Compression

   HINT: 

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

7. While the engine is not running, press the RIGHT or LEFT button to change Check the Cylinder Compression to ON.

   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.

8. Crank the engine for about 10 seconds.
9. Monitor the engine speed (Engine Speed of Cyl #1 to #8 and Av Engine Speed of All Cyl) displayed on the Techstream.

   HINT: 

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

   NOTE:

   • 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 ON and the engine has been cranked once, press Exit to return to the Active Test menu screen. Then change Check the Cylinder Compression to ON and crank the engine.
   • Use a fully-charged battery.
10. Stop cranking the engine, and then change "Check the Cylinder Compression" to OFF after the engine stops.
    NOTE:

    • If the Active Test is changed to OFF while the engine is being cranked, the engine will start.
    • When performing the Active Test, DTC P1604 (Startability Malfunction) may be stored.
    • After performing the Active Test, make sure to check and clear DTCs.
11. Read the value.

    HINT: 

    • If the value of Data List item "Engine Speed of Cyl #1 to #8" of a cylinder is higher than other cylinders, the cylinder may be malfunctioning.
    • If the value of Data List item "Engine Speed of Cyl #1 to #8" is high for only one cylinder, compression loss is suspected.

    Result

    Result	Proceed to
    There is no variation in "Engine Speed of Cyl #1 to #8" (All cylinders display approximately the same value for "Engine Speed of Cyl #1 to #8")	A
    There is variation in "Engine Speed of Cyl #1 to #8" (Only one cylinder displays a value for "Engine Speed of Cyl #1 to #8" that differs considerably)	B

Result: 

B 

See step  13

Result: 

A 

See step  8

1. Connect the Techstream to the DLC3.
2. Turn the engine switch on (IG).
3. Turn the Techstream on.
4. Start the engine and warm it up until the engine coolant temperature 75°C (167°F) or higher with all the accessories switched off.
5. Idle the engine.
6. Enter the following menus: Powertrain / Engine / Active Test / D-4S (Injection Volume).

   Powertrain > Engine > Active Test 

   Tester Display
   D-4S (Injection Volume)

7. According to the display on the Techstream, perform the Active Test and check the vehicle conditions when increasing and decreasing the fuel injection volume.

   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 12.5%).

   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

Result: 

B 

See step  14

Result: 

A 

See step  9

1. 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

Result: 

B 

See step  25

Result: 

A 

See step  10

1. Check the ignition coil assembly power source circuit, wire harness and connectors.

   Result

   Proceed to
   NEXT

Result: 

NEXT 

See step  25

1. Clean off any deposits from the inside of the throttle body with motor assembly.
2. Push open the throttle valve and wipe off any carbon from the valve and bore using a piece of cloth soaked in non-residue solvent.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1	Throttle Body with Motor Assembly	*2	Bore
   *3	Valve	-	-
   *a	Reference	*b	Throttle Body with Motor Assembly Cross-section Diagram
   *c	When valve fully opened	*d	Do not directly apply cleaner
   *e	Deposits	-	-

   NOTE:

   • Make sure that the cloth or your fingers do not get caught in the valve.
   • Make sure that foreign matter does not enter the throttle valve.
   • Do not directly apply non-residue solvent to the throttle body with motor assembly or wash the throttle body with motor assembly. Cleaning solvent may leak into the motor from the shaft and cause problems such as rust or valve movement problems.
   • If there is coating material on the edge of the valve, be careful not to remove it.

   HINT: 

   The illustrations are for reference only. Actual parts may differ.

   Result

   Proceed to
   NEXT

Result: 

NEXT 

See step  12

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

   Refer to INITIALIZATION [09/2014 - ]

2. Connect the Techstream to the DLC3.
3. Turn the engine switch on (IG).
4. Turn the Techstream on.
5. Start the engine and warm it up until the engine coolant temperature reaches 75°C (167°F) or higher.
6. 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.

   Result

   Proceed to
   NEXT

Result: 

NEXT 

See step  26

1. 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.

   Refer to PROCEDURE - Step 10

   Result

   Proceed to
   NEXT

Result: 

NEXT 

See step  26

1. Replace the fuel injector assembly of the malfunctioning cylinder.

   HINT: 

   • If the air fuel ratio learned vale 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.

     Refer to INITIALIZATION [09/2014 - ]

   Result

   Proceed to
   NEXT

Result: 

NEXT 

See step  26

1. Connect the Techstream to the DLC3.
2. Turn the engine switch on (IG).
3. Turn the Techstream on.
4. Start the engine and warm it up until the engine coolant temperature 75°C (167°F) or higher with all the accessories switched off.
5. Enter the following menus: Powertrain / Engine / Data List / Primary / MAF.

   Powertrain > Engine > Data List 

   Tester Display
   MAF

6. According to the display on the Techstream.

   Result

   Result	Proceed to
   Idling (without load): 4.0 to 7.0 gm/sec Engine speed 2000 rpm (without load): 12.0 to 16.0 gm/sec Engine speed 3000 rpm (without load): 17.0 to 23.0 gm/sec	A
   Other than above	B

Result: 

B 

See step  19

Result: 

A 

See step  16

1. Connect the Techstream to the DLC3.
2. Turn the engine switch on (IG).
3. Turn the Techstream on.
4. Start the engine and warm it up until the engine coolant temperature 75°C (167°F) or higher with all the accessories switched off.
5. Warm up the air fuel ratio sensor at an engine speed of 2500 rpm for 90 seconds.
6. Idle the engine.
7. Enter the following menus: Powertrain / Engine / Active Test / D-4S (Injection Volume) / Gas AF O2 Sensor / AFS Voltage B1S1, AFS Voltage B2S1, O2S B1S2 and O2S B2S2.

   Powertrain > Engine > Active Test 

   Active Test Display
   D-4S (Injection Volume)

   Data List Display
   AFS Voltage B1S1
   AFS Voltage B2S1
   O2S B1S2
   O2S B2S2

8. According to the display on the Techstream, perform the Active Test and check the vehicle conditions when increasing and decreasing the fuel injection volume.
   NOTE:

   • 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.
   • Read the output voltage immediately after warming up the air fuel ratio sensor and heated oxygen sensor 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 the minimum and maximum range of correction (e.g. -12.5% to 12.5%).

   Standard

   Techstream Display (Sensor)	Injection Volume	Voltage
   AFS Voltage B1S1 AFS Voltage B2S1 (Air fuel ratio)	12.5%	Below 3.1 V
   	-12.5%	Higher than 3.4 V
   O2S B1S2 O2S B2S2 (Heated oxygen)	12.5%	Higher than 0.55 V
   	-12.5%	Below 0.4 V

   Result

   Result	Proceed to
   Output voltage 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 voltage values are normal	C

Result: 

B 

See step  18

Result: 

C 

See step  20

Result: 

A 

See step  17

1. Replace the air fuel ratio sensor.

   Refer to REMOVAL [09/2014 - ]

   HINT: 

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

   Refer to INITIALIZATION [09/2014 - ]

2. Replace the heated oxygen sensor.

   Refer to REMOVAL [09/2014 - ]

   HINT: 

   Perform "Inspection After Repair" after replacing the heated oxygen sensor.

   Refer to INITIALIZATION [09/2014 - ]

   Result

   Proceed to
   NEXT

Result: 

NEXT 

See step  26

1. Replace the fuel injector assemblies of all cylinders.

   HINT: 

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

   Refer to INITIALIZATION [09/2014 - ]

   Result

   Proceed to
   NEXT

Result: 

NEXT 

See step  26

1. 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.
   • Perform "Inspection After Repair" after repairing or replacing the intake system.

     Refer to INITIALIZATION [09/2014 - ]

   Result

   Proceed to
   NEXT

Result: 

NEXT 

See step  26

HINT: 

Inspect the EFI-MAIN fuse before inspecting the circuit relay.

1. Connect the Techstream to the DLC3.
2. Turn the engine switch on (IG).
3. Turn the Techstream on.
4. Enter the following menus: Powertrain / Engine / Active Test / Control the Fuel Pump / Speed.

   Powertrain > Engine > Active Test 

   Tester Display
   Control the Fuel Pump / Speed

5. When performing the Active Test, check for an operating sound from the fuel pump.

   OK

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

   Result

   Proceed to
   OK
   NG

Result: 

NG 

See step  24

Result: 

OK 

See step  21

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

   Refer to PROCEDURE - Step 2

   Standard

   Vehicle State	Specified Condition
   Cranking engine	196 to 588 kPa (2.0 to 6.0 kgf/cm2 , 28 to 85 psi)
   5 minutes after stopping engine	147 kPa (1.5 kgf/cm2 , 21 psi) or higher

   HINT: 

   • If there is foreign matter such as iron particles on the fuel pump (for low pressure side), remove it.
   • Make sure that there are no leaks from the fuel lines, signs of fuel leakage or fuel odors.

   Result

   Proceed to
   OK
   NG

Result: 

NG 

See step  23

Result: 

OK 

See step  22

1. 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.

   • Engine mount deterioration
   • Deposits in the intake manifold or on an intake valve
   • Delay in fuel supply due to adherence of the fuel to the deposits

   Result

   Proceed to
   NEXT

Result: 

NEXT 

See step  25

1. Inspect the following fuel pump related parts:
   • Fuel pump (for low pressure side)
   • Fuel pressure regulator assembly
   • Fuel lines and connecting parts
   • Fuel filter

   Result

   Proceed to
   NEXT

Result: 

NEXT 

See step  25

1. Inspect the fuel pump control system (for low pressure side).

   Result

   Proceed to
   NEXT

Result: 

NEXT 

See step  25

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

   Result

   Proceed to
   NEXT

Result: 

NEXT 

See step  26

1. Check that the engine has returned to normal.

   Result

   Proceed to
   NEXT

Result: 

NEXT 

END