Engine Control System (Diagnostic Codes (P1604-U0101) & Circuit Tests): Diagnosis

INSPECTION PROCEDURE

HINT

In contrast to normal malfunction diagnosis for components, circuits and systems, DTC P1604 is used to determine the malfunctioning area from the problem symptoms and freeze frame data when the user mentions problems such as starting difficulty. As the DTC can be stored as a result of certain user actions, even if the DTC is output, if the customer makes no mention of problems, clear the DTC without performing any troubleshooting and return the vehicle to the customer.
If any other DTCs are output, perform troubleshooting for those DTCs first.
When the Data List item "Immobiliser Fuel Cut" is ON, the engine cannot be started.
Read freeze frame data using the Techstream. Freeze frame data records engine conditions when a malfunction occurs. This information can be useful when troubleshooting.
When confirming the freeze frame data, be sure to check all 5 sets of freeze frame data. Refer to «FREEZE FRAME DATA [06/2012 - ]»(ref-598472-S37095654262014021400000) .
When confirming the freeze frame data, if there are multiple items related to the cause of the malfunction, perform troubleshooting for all related items.
Try to start the vehicle under the conditions recorded in the freeze frame data which were present when the malfunction occurred. Confirm the data at this time and compare it with the freeze frame data.
If the malfunction does not reoccur, carefully check the vehicle conditions from when the malfunction occurred using freeze frame data.
When performing inspections, jiggle the relevant wire harnesses and connectors in an attempt to reproduce malfunctions that do not always occur.
If the same inspection or replacement procedure appears 2 times when performing an inspection procedure, it is not necessary to repeat the procedure the second time.

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Malfunction Recurrence and Inspection Areas Freeze frame data exists, but the malfunction (starting difficulty) has not reoccurred and the malfunction conditions are unknown. The engine speed recorded in the freeze frame data is 0 rpm (the engine does not crank). HINT: One of the following problems may be present: battery depletion, excess engine friction, a starter malfunction or a crankshaft position sensor malfunction. If the battery voltage is less than 6 V during cranking, there is a high probability that engine friction is abnormal. If the battery voltage drops to 5 V or less when starting the engine, the battery may be malfunctioning. If the battery voltage fluctuates while cranking the engine, it can be concluded that cranking is being performed. When the engine speed is 0 rpm, the crankshaft position sensor and/or an ECM may be malfunctioning. All engine speeds recorded in the freeze frame data are between 60 and 250 rpm (the engine cranks but there is no combustion). HINT: If the engine speed is between 60 and 250 rpm (no initial combustion), there may be a wiring problem or a complete failure of an ignition or fuel system part. Due to an engine coolant temperature sensor malfunction, the fuel injection volume is extremely high or low and the engine may not be able to be started. The engine speed recorded in the freeze frame data is 250 rpm or higher (the initial combustion and starter turn off timing is too late). HINT: If the engine speed is 250 rpm or higher (combustion occurs but the initial combustion and starter turn off timing is too late), the fuel injection volume is often incorrect (too low or too high) and determining the cause of the malfunction is often difficult. Due to an engine coolant temperature sensor malfunction, the fuel injection volume is extremely high or low and engine starting trouble may occur. If Long FT is incorrect, there may be a fuel supply problem due to the injectors or fuel pump being clogged, etc. If the engine cranking speed is too high, compression loss may have occurred due to carbon interfering with the valve operation. When the malfunction (starting difficulty) can be reproduced, or malfunction conditions are known, perform the following inspections ("Problem symptoms" and "Systems to inspect") Problem symptoms The engine does not crank. HINT: The starter is normal if a noise that indicates the starter pinion gear is extending is heard. The battery may be fully depleted or there may be excess engine friction. The engine cranking speed is abnormal. HINT: If the engine cranking speed is too high (for example, 300 rpm or higher with no combustion), compression loss may have occurred because carbon interfered with valve operation, etc. There is no initial combustion. HINT: If there is no initial combustion, there is probably a wiring problem or an ignition or fuel system part malfunction. The engine stalls after starter turn off. HINT: If the engine stalls after starter turn off, the air fuel ratio may be incorrect or the VVT may have a problem returning. The initial combustion and starter turn off occur late. HINT: If the initial combustion and starter turn off occur late, the fuel injection volume is probably incorrect (too low or too high). HINT: Causes of fuel system malfunctions according to conditions present at the time of the malfunction. When 2 to 3 minutes have elapsed after stopping the engine: Fuel pressure loss due to the pressure regulator failing to maintain the fuel pressure. When 15 to 120 minutes have elapsed after stopping the engine: Problem with injector fuel seal. When a long time has elapsed after stopping the engine: Pressure regulator is stuck open. Systems to inspect. Intake system Ignition system Fuel system
INSPECTION FLOW Freeze frame data exists, but the malfunction (starting difficulty) has not reoccurred and the malfunction conditions are unknown. Freeze Frame Data Item Result Suspected Area Procedure Engine Speed 0 rpm (no engine cranking at all) Battery fully depleted Engine assembly (excess friction) Starter assembly Engine immobiliser system Crankshaft position sensor ECM 4 to 9 60 to 250 rpm (engine cranks but no initial combustion*1) Fuel pump control system Ignition system Engine coolant temperature sensor Fuel injection system 10 to 14 250 rpm or higher (combustion occurs but initial combustion and starter turn off*2 occur late) Engine assembly (compression loss) Fuel injection system Fuel pump control system 15 to 23 HINT: *1: First combustion after cranking begins. *2: Condition when engine speed increases and starter can be turned off. When the malfunction (starting difficulty) can be reproduced, or when malfunction conditions are known. Problem symptoms Problem Symptom Suspected Area Suspected Component Procedure The engine does not crank Battery malfunction Battery fully depleted 26 to 31 Starting system Starter assembly (includes pinion gear wear or tooth damage) Starting system Engine assembly Engine assembly (excess friction) Drive plate and ring gear sub-assembly wear or tooth damage Cranking speed too low Battery malfunction Battery fully depleted 32 to 34 Starting system Starter assembly Engine assembly Engine assembly (excess friction) Cranking speed too high Engine assembly Engine assembly (compression loss) There is no initial combustion Fuel supply problem Cannot maintain pressure due to pressure regulator malfunction Fuel injector assembly leak Fuel leak from fuel line Fuel pump control system Fuel pump 35 to 48 Ignition system malfunction Spark plug Crankshaft position sensor Ignition coil assembly Engine stalls after starter turn off Air suction Intake system connections 49 to 54 Deposits in throttle body with motor assembly Throttle body with motor assembly VVT valve does not return properly Camshaft timing oil control valve assembly Mass air flow meter sub-assembly malfunction Mass air flow meter sub-assembly The initial combustion and starter turn off occur late Engine coolant temperature sensor malfunction Engine coolant temperature sensor 55 to 68 Mass air flow meter sub-assembly malfunction Mass air flow meter sub-assembly Abnormal air fuel ratio learning value Air fuel ratio sensor Deviation from fuel injection characteristics Fuel injector assembly Wet-fouled or dry-fouled spark plug Spark plug Lack of fuel pressure Pressure regulator Fuel pump Fuel pump control system Systems to inspect. Troubleshooting by System Suspected Area Suspected Component Procedure Fuel system troubleshooting A Abnormal air fuel ratio learning value Fuel injector assembly 87 to 94 95 to 102 Rough idling Crankshaft position sensor Abnormal fuel pressure Fuel Fuel leak from fuel line Fuel pump Pressure regulator Fuel system troubleshooting B Abnormal concentration of HC in surge tank Purge VSV system Fuel injector assembly 103 to 105 Fuel system troubleshooting C Injection signal system malfunction Fuel injector assembly Crankshaft position sensor VVT sensor ECM 70 to 74 Intake system troubleshooting Difference between ISC target value and opening angle when idling Engine assembly (compression loss) Valve timing Engine coolant temperature sensor ECM 84 to 86 106 to 108 Ignition system troubleshooting Crankshaft position sensor and/or VVT sensor signal malfunction Crankshaft position sensor system (including sensor installation) VVT sensor system (including sensor installation) ECM 75 to 83 109 to 117 NOTE: Inspect the fuses for circuits related to this system before performing the following inspection procedure. After turning engine switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to «PRECAUTION [06/2012 - ]»(ref-598449-S42461431542014021400000) .

Note. After turning engine switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to PRECAUTION [06/2012 - ] .

HINT

Read freeze frame data using the Techstream. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the air fuel ratio was lean or rich, and other data from the time the malfunction occurred.

Note. Inspect the fuses for circuits related to this system before performing the following inspection procedure.

HINT

Read freeze frame data using the Techstream. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the air fuel ratio was lean or rich, and other data from the time the malfunction occurred.
The throttle actuator current (Throttle Motor Current) and the throttle actuator duty ratio (Throttle Motor Duty (Open) / Throttle Motor Duty (Close)) can be read using the Techstream. However, the ECM shuts off the throttle actuator current when the electronic throttle control system malfunctions.

HINT

Read freeze frame data using the Techstream. Freeze frame data records engine conditions when a malfunction occurs. This information can be useful when troubleshooting.
Since a pending DTC is not stored for this DTC, it takes time to confirm whether the malfunction has been successfully repaired by checking for this DTC. When confirming whether the malfunction has been successfully repaired, compare "ISC Learning Value" recorded in the freeze frame data with "ISC Learning Value" in the Data List after repairs have been made to save time.

HINT

Read freeze frame data using the Techstream. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the air fuel ratio was lean or rich, and other data from the time the malfunction occurred.
Refer to "Data List / Active Test" [Throttle Position Command, Throttle Position No. 1, Throttle Motor Current, Throttle Motor Duty (Open), Throttle Motor Duty (Close)]. Refer to «DATA LIST / ACTIVE TEST [06/2012 - ]»(ref-598472-S10277657772014021400000) .

Note. Inspect the fuses for circuits related to this system before performing the following inspection procedure.

HINT

Refer to "Data List / Active Test" [Throttle Position Commanded, Throttle Position No. 1, Throttle Motor Current, Throttle Motor Duty (Open) and Throttle Motor Duty (Close)]. Refer to «DATA LIST / ACTIVE TEST [06/2012 - ]»(ref-598472-S10277657772014021400000) .
Read freeze frame data using the Techstream. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the air fuel ratio was lean or rich, and other data from the time the malfunction occurred.

HINT

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Scheme 72: PROCEDURE

READ VALUE USING TECHSTREAM (ACCEL SENSOR OUT NO. 1 AND NO. 2) Connect the Techstream to the DLC3. Turn the engine switch on (IG). Turn the Techstream on. Enter the following menus: Powertrain / Engine / Data List / Gas Throttle / Accel Sensor Out No. 1 and Accel Sensor Out No. 2. Read the value displayed on the Techstream. Standard Voltage Accelerator Pedal Operation Accel Sensor Out No. 1 Accel Sensor Out No. 2 Difference between Accel Sensor Out No. 1 and Accel Sensor Out No. 2 Fully Released 0.5 to 1.1 V 1.2 to 2.0 V More than 0.02 V Fully Depressed 2.6 to 4.5 V 3.4 to 4.75 V TEXT IN ILLUSTRATION *a Fully Depressed *b Fully Released NG --> See step 2 OK --> See step 8
CHECK HARNESS AND CONNECTOR (ACCELERATOR PEDAL SENSOR ASSEMBLY - ECM) Disconnect the accelerator pedal sensor assembly connector. Disconnect the ECM connector. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition A30-6 (VPA) - A22-54 (VPA) Always Below 1 ohms A30-5 (EPA) - A22-55 (EPA) Always Below 1 ohms A30-4 (VCPA) - A22-56 (VCPA) Always Below 1 ohms A30-3 (VPA2) - A22-57 (VPA2) Always Below 1 ohms A30-2 (EPA2) - A22-58 (EPA2) Always Below 1 ohms A30-1 (VCP2) - A22-59 (VCP2) Always Below 1 ohms A30-6 (VPA) or A22-54 (VPA) - Body ground Always 10 kohms or higher A30-4 (VCPA) or A22-56 (VCPA) - Body ground Always 10 kohms or higher A30-3 (VPA2) or A22-57 (VPA2) - Body ground Always 10 kohms or higher A30-1 (VCP2) or A22-59 (VCP2) - Body ground Always 10 kohms or higher NG --> REPAIR OR REPLACE HARNESS OR CONNECTOR OK: Go to next step
CHECK TERMINAL VOLTAGE (POWER SOURCE OF ACCELERATOR PEDAL SENSOR ASSEMBLY) Disconnect the accelerator pedal sensor assembly connector. Turn the engine switch on (IG). Measure the voltage according to the value(s) in the table below. Standard Voltage Tester Connection Condition Specified Condition A30-4 (VCPA) - A30-5 (EPA) Engine switch on (IG) 4.5 to 5.5 V A30-1 (VCP2) - A30-2 (EPA2) Engine switch on (IG) 4.5 to 5.5 V TEXT IN ILLUSTRATION *a Front view of wire harness connector (to Accelerator Pedal Sensor Assembly) NG --> See step 6 OK: Go to next step
REPLACE ACCELERATOR PEDAL SENSOR ASSEMBLY Replace the accelerator pedal sensor assembly. Refer to «REMOVAL [06/2012 - ]»(ref-598604-S28391930042014021400000) . NEXT: Go to next step
CHECK WHETHER DTC OUTPUT RECURS (ACCELERATOR PEDAL SENSOR DTCS) Connect the Techstream to the DLC3. Turn the engine switch on (IG). Turn the Techstream on. Clear the DTCs. Refer to «DTC CHECK / CLEAR [06/2012 - ]»(ref-598472-S02009234142014021400000) . Turn the engine switch off and wait for at least 30 seconds. Turn the engine switch on (IG) and turn the Techstream on. Drive the vehicle in accordance with the driving pattern described in Confirmation Driving Pattern. Enter the following menus: Powertrain / Engine / Trouble Codes. Read the DTCs. RESULT Result Proceed to DTC P2120, P2122, P2123, P2125, P2127, P2128, and/or P2138 are output A DTC is not output B B --> END A --> See step 7
REPLACE ECM. Refer to «REMOVAL [06/2012 - ]»(ref-598604-S28038138762014021400000)
REPLACE ECM. Refer to «REMOVAL [06/2012 - ]»(ref-598604-S28038138762014021400000)
CHECK FOR INTERMITTENT PROBLEMS. Refer to «CHECK FOR INTERMITTENT PROBLEMS [06/2012 - ]»(ref-598472-S09889535102014021400000)

HINT

Note. Inspect the fuses for circuits related to this system before performing the following inspection procedure.

HINT

Read freeze frame data using the Techstream. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the air fuel ratio was lean or rich, and other data from the time the malfunction occurred.
A low air fuel ratio sensor voltage could be caused by a rich air fuel mixture. Check for conditions that would cause the engine to run rich.
A high air fuel ratio sensor voltage could be caused by a lean air fuel mixture. Check for conditions that would cause the engine to run lean.
Bank 1 refers to the bank that includes the No. 1 cylinder*. *: The No. 1 cylinder is the cylinder which is farthest from the transaxle.
Bank 2 refers to the bank that does not include the No. 1 cylinder.
Sensor 1 refers to the sensor closest to the engine assembly.
Sensor 2 refers to the sensor farthest away from the engine assembly.

HINT

Read freeze frame data using the Techstream. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the air fuel ratio was lean or rich, and other data from the time the malfunction occurred.
Refer to A/F Sensor Determination (worst value) #1, A/F Sensor Determination (worst value) #2, Engine Speed Fluctuation Avg (worst value) #1 to #6, Cylinder #1 to #6 Misfire Count, Short FT #1, Short FT #2, Long FT #1 and long FT #2 in the Data List / Active Test. Refer to «DATA LIST / ACTIVE TEST [06/2012 - ]»(ref-598472-S10277657772014021400000) .
Bank 1 refers to the bank that includes the No. 1 cylinder*. *: The No. 1 cylinder is the cylinder which is farthest from the transaxle.
Bank 2 refers to the bank that does not include the No. 1 cylinder.
Sensor 1 refers to the sensor closest to the engine assembly.
Sensor 2 refers to the sensor farthest away from the engine assembly.

Note. Inspect the fuses for circuits related to this system before performing the following inspection procedure.

HINT

Refer to "Data List / Active Test" [AFS Voltage B1S1 and AFS Voltage B2S1]. Refer to «DATA LIST / ACTIVE TEST [06/2012 - ]»(ref-598472-S10277657772014021400000) .
Read freeze frame data using the Techstream. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the air fuel ratio was lean or rich, and other data from the time the malfunction occurred.
Bank 1 refers to the bank that includes the No. 1 cylinder*. *: The No. 1 cylinder is the cylinder which is farthest from the transaxle.
Bank 2 refers to the bank that does not include the No. 1 cylinder.
Sensor 1 refers to the sensor closest to the engine assembly.
Sensor 2 refers to the sensor farthest away from the engine assembly.

DTC SUMMARY

DTC No.	Monitoring Item	Malfunction Detection Condition	Trouble Area	Detection Timing	Detection Logic
P2420	Vent valve stuck open (vent)	Following condition met during key-off EVAP monitor: EVAP pressure change when vent valve closed (on) less than 0.3 kPa(gauge) [2.25 mmHg(gauge)]	Canister pump module (reference orifice, leak detection pump, vent valve) Connector/wire harness (Canister pump module - ECM) Canister (filter inside canister clogged) ECM	While engine switch off	2 trip

HINT

The vent valve is built into the canister pump module.

Refer to EVAP System. Refer to INSPECTION PROCEDURE .

DTC No.	Monitoring Item	Malfunction Detection Condition	Trouble Area	Detection Timing	Detection Logic
P2610	Soak timer (built into ECM)	ECM internal malfunction.	ECM	Engine running	2 trip

HINT

DTC P2610 is set if an internal ECM problem is detected. Diagnostic procedures are not required. ECM replacement is required.
Read freeze frame data using the Techstream. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the air fuel ratio was lean or rich, and other data from the time the malfunction occurred.

Note. Inspect the fuses for circuits related to this system before performing the following inspection procedure.

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Scheme 73: PROCEDURE

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CHECK VACUUM HOSES Check the air and vacuum hoses for looseness, disconnection and blockage. OK No looseness, disconnection or blockage. TEXT IN ILLUSTRATION *1 Engine *2 Duty Vacuum Switching Valve (for Active Control Engine Mount) *3 Front Engine Mounting Insulator Assembly *4 ECM *5 Air Cleaner *6 Vacuum Tank *a to Vacuum Switching Valve (for Air Intake Control Valve) NG --> REPAIR OR REPLACE VACUUM HOSES OK: Go to next step
CHECK VACUUM Disconnect the vacuum hose from the air cleaner cap. Start the engine. Check that the disconnected port located on the vacuum tank applies suction to your finger. OK Vacuum exists. NG --> CHECK AND REPLACE VACUUM SOURCE AND HOSES OK: Go to next step
INSPECT DUTY VACUUM SWITCHING VALVE (FOR ACTIVE CONTROL ENGINE MOUNT) (OPERATION) Inspect the duty vacuum switching valve (for active control engine mount) operation. Refer to «INSPECTION [06/2012 - ] - Step 1»(ref-598604-S04644854852014021400000) . NG --> See step 9 OK: Go to next step
INSPECT DUTY VACUUM SWITCHING VALVE (FOR ACTIVE CONTROL ENGINE MOUNT) (RESISTANCE) Inspect the duty vacuum switching valve (for active control engine mount) resistance. Refer to «INSPECTION [06/2012 - ] - Step 2»(ref-598604-S04644854852014021400000) . NG --> See step 9 OK: Go to next step
INSPECT FRONT ENGINE MOUNTING INSULATOR ASSEMBLY Inspect the front engine mounting insulator assembly. Refer to «ON-VEHICLE INSPECTION [06/2012 - ]»(ref-598604-S14217813152014021400000) . NG --> See step 10 OK: Go to next step
CHECK TERMINAL VOLTAGE (POWER SOURCE OF DUTY VACUUM SWITCHING VALVE (FOR ACTIVE CONTROL ENGINE MOUNT) Disconnect the duty vacuum switching valve (for active control engine mount) connector. Turn the engine switch on (IG). Measure the voltage according to the value(s) in the table below. Standard Voltage Tester Connection Condition Specified Condition D9-1 - Body ground Engine switch on (IG) 11 to 14 V TEXT IN ILLUSTRATION *a Front view of wire harness connector (to Duty Vacuum Switching Valve (for Active Control Engine Mount)) NG --> See step 8 OK: Go to next step
CHECK HARNESS AND CONNECTOR (DUTY VACUUM SWITCHING VALVE (FOR ACTIVE CONTROL ENGINE MOUNT) - ECM) Disconnect the duty vacuum switching valve (for active control engine mount) connector. Disconnect the ECM connector. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition D9-2 - A22-8 (ACM) Always Below 1 ohms D9-2 or A22-8 (ACM) - Body ground Always 10 kohms or higher NG --> REPAIR OR REPLACE HARNESS OR CONNECTOR OK --> See step 11
CHECK HARNESS AND CONNECTOR (DUTY VACUUM SWITCHING VALVE (FOR ACTIVE CONTROL ENGINE MOUNT) - NO. 1 INTEGRATION RELAY) Disconnect the duty vacuum switching valve (for active control engine mount) connector. Remove the No. 1 integration relay from the engine room relay block and junction block assembly. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition D9-1 - 1A-8 Always Below 1 ohms D9-1 or 1A-8 - Body ground Always 10 kohms or higher NG --> REPAIR OR REPLACE HARNESS OR CONNECTOR OK --> See step 12
REPLACE DUTY VACUUM SWITCHING VALVE (FOR ACTIVE CONTROL ENGINE MOUNT). Refer to «REMOVAL [06/2012 - ]»(ref-598604-S14482661502014021400000)
REPLACE FRONT ENGINE MOUNTING INSULATOR ASSEMBLY. Refer to «REMOVAL [06/2012 - ]»(ref-598604-S29374903382014021400000)
REPLACE ECM. Refer to «REMOVAL [06/2012 - ]»(ref-598604-S28038138762014021400000)
GO TO ECM POWER SOURCE CIRCUIT. Refer to «ECM Power Source Circuit»(ref-598599-S31649039382014021400000)

Note. Inspect the fuses for circuits related to this system before performing the following inspection procedure. The Techstream is required to conduct the following diagnostic troubleshooting procedure.

HINT

Using the Techstream monitor results enables the EVAP (Evaporative Emission) system to be confirmed.
Read freeze frame data using the Techstream. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the air fuel ratio was lean or rich, and other data from the time the malfunction occurred.

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CONFIRM DTC Turn the engine switch off and wait for 10 seconds. Turn the engine switch on (IG). Turn the engine switch off and wait for 10 seconds. Connect the Techstream to the DLC3. Turn the engine switch on (IG). Turn the Techstream on. Enter the following menus: Powertrain / Engine / Trouble Codes. Confirm the DTCs and freeze frame data. If any EVAP system DTCs are stored, the malfunctioning area can be determined using the table below. NOTE: If the reference pressure difference between the first and second checks is greater than the specification, all the DTCs relating to the reference pressure (P043E, P043F, P2401, P2402 and P2419) are stored. NEXT: Go to next step
PERFORM EVAP SYSTEM CHECK (AUTOMATIC MODE) NOTE: The Evaporative System Check (Automatic Mode) consists of 6 steps performed automatically by the Techstream. It takes a maximum of approximately 24 minutes. Do not perform the Evaporative System Check when the fuel tank is more than 90% full because the cut-off valve may be closed, making the fuel tank leak check unavailable. Do not run the engine during this operation. When the temperature of the fuel is 35°C (95°F) or higher, a large amount of vapor forms and any check results become inaccurate. When performing the Evaporative System Check, keep the temperature less than 35°C (95°F). Connect the Techstream to the DLC3. Turn the engine switch on (IG). Turn the Techstream on. Clear the DTCs. Refer to «DTC CHECK / CLEAR [06/2012 - ]»(ref-598472-S02009234142014021400000) . Enter the following menus: Powertrain / Engine / Utility / Evaporative System Check / Automatic Mode. After the Evaporative System Check is completed, check for pending DTCs by entering the following menus: Powertrain / Engine / Trouble Codes. HINT: If no pending DTCs are displayed, perform the Confirmation Driving Pattern. After this confirmation, check for pending DTCs. If no DTCs are displayed, the EVAP system is normal. NEXT: Go to next step
PERFORM EVAP SYSTEM CHECK (MANUAL MODE) NOTE: In the Evaporative System Check (Manual Mode), the series of 6 Evaporative System Check steps are performed manually using the Techstream. Do not perform the Evaporative System Check when the fuel tank is more than 90% full because the cut-off valve may be closed, making the fuel tank leak check unavailable. Do not run the engine during this operation. When the temperature of the fuel is 35°C (95°F) or higher, a large amount of vapor forms and any check results become inaccurate. When performing the Evaporative System Check, keep the temperature less than 35°C (95°F). Connect the Techstream to the DLC3. Turn the engine switch on (IG). Turn the Techstream on. Clear the DTCs. Refer to «DTC CHECK / CLEAR [06/2012 - ]»(ref-598472-S02009234142014021400000) . Enter the following menus: Powertrain / Engine / Utility / Evaporative System Check / Manual Mode. NEXT: Go to next step
PERFORM EVAP SYSTEM CHECK (STEP 1/6) Check the EVAP pressure in step 1/6. RESULT DTC *1 Result Suspected Trouble Area Proceed to - Virtually no variation in EVAP pressure Not yet determined A P0451 EVAP pressure fluctuates by +/-0.3 kPa(gauge) [2.25 mmHg(gauge)] or higher Canister pressure sensor signal noise B (P0452 or P0453) *2 EVAP pressure is below 42.11 kPa(abs) [315.867 mmHg(abs)] or 123.761 kPa(abs) [928.331 mmHg(abs)] or higher EVAP pressure deviates +/-10 kPa(gauge) [75 mmHg(gauge)] from actual atmosphere pressure *3 Canister pressure sensor or its circuit has malfunction C *1: These DTCs are already present in the ECM when the vehicle arrives and are confirmed in the "Confirm DTC" procedure above. *2: If the canister pressure sensor circuit has an open or short, DTC P0452 or P0453 is stored 0.5 seconds after the engine switch is turned on (IG). HINT: *3: Canister pressure sensor standard output range is 70 to 110 kPa(abs) [525 to 825 mmHg(abs)]. This varies by weather. B --> See step 38 C --> See step 12 A: Go to next step
PERFORM EVAP SYSTEM CHECK (STEP 1/6 TO 2/6) Check the EVAP pressure in steps 1/6 and 2/6. RESULT DTC* Result Suspected Trouble Area Proceed to - Virtually no variation in EVAP pressure during step 1/6. Then decreases to reference pressure Not yet determined A P2402 Small difference between EVAP pressures during steps 1/6 and 2/6 Leak detection pump stuck ON B *: These DTCs are already present in the ECM when the vehicle arrives and are confirmed in the "Confirm DTC" procedure above. HINT: The first reference pressure is the value determined in step 2/6. B --> See step 31 A: Go to next step
PERFORM EVAP SYSTEM CHECK (STEP 2/6) HINT: Make a note of the pressures checked in inspection items (A) and (B) below. Check the EVAP pressure 4 seconds after the leak detection pump is activated*1 (A). *1: The leak detection pump begins to operate as step 1/6 finishes and step 2/6 starts. Check the EVAP pressure again when it has stabilized. This pressure is the reference pressure (B). RESULT DTC*2 Result Suspected Trouble Area Proceed to - EVAP pressure in inspection item (B) is between -4.85 kPa(gauge) and -1.057 kPa(gauge) [-36.38 mmHg(gauge) and -7.929 mmHg(gauge)] Not yet determined A P043F and P2401 EVAP pressure in inspection item (B) is -1.057 kPa(gauge) [-7.929 mmHg(gauge)] or higher Reference orifice high-flow Leak detection pump stuck off B P043E EVAP pressure in inspection item (B) is less than -4.85 kPa(gauge) [-36.38 mmHg(gauge)] Reference orifice clogged C P2419 EVAP pressure in inspection item (A) is higher than -0.25 kPa(gauge) [-1.875 mmHg(gauge)] Vent valve stuck closed Leak detection pump performance deteriorates Leak detection pump circuit malfunctioning (large resistance exists in the circuit) D *2: These DTCs are already present in the ECM when the vehicle arrives and are confirmed in the "Confirm DTC" procedure above. B --> See step 11 C --> See step 38 D --> See step 13 A: Go to next step
PERFORM EVAP SYSTEM CHECK (STEP 2/6 TO 3/6) Check the EVAP pressure in step 3/6. RESULT DTC* Result Suspected Trouble Area Proceed to - EVAP pressure increases by 0.3 kPa(gauge) [2.25 mmHg(gauge)] or higher within 10 seconds of proceeding from step 2/6 to step 3/6 Not yet determined A P2420 No variation in EVAP pressure even after proceeding from step 2/6 to step 3/6 Vent valve stuck open (vent) Canister (charcoal filter inside canister) clogged B P0451 No variation in EVAP pressure during steps 1/6 through 3/6 Canister pressure sensor output value stuck Vent valve broken (valve split in two) Leak detection pump performance deteriorates Leak detection pump circuit malfunctioning (large resistance exists in the circuit) C *: These DTCs are already present in the ECM when the vehicle arrives and are confirmed in the "Confirm DTC" procedure above. B --> See step 27 C --> See step 15 A: Go to next step
PERFORM EVAP SYSTEM CHECK (STEP 3/6) Wait until the EVAP pressure change is less than 0.1 kPa(gauge) [0.75 mmHg(gauge)] for 40 seconds. Measure the EVAP pressure and record it. HINT: A few minutes are required for the EVAP pressure to become saturated. When there is little fuel in the fuel tank, it takes up to 15 minutes. NEXT: Go to next step
PERFORM EVAP SYSTEM CHECK (STEP 4/6) Check the EVAP pressure in step 4/6. RESULT DTC*1 Result Suspected Trouble Area Proceed to - EVAP pressure increases by 0.3 kPa(gauge) [2.25 mmHg(gauge)] or higher within 10 seconds of proceeding from step 3/6 to step 4/6 Not yet determined A P0441 *2 EVAP pressure increases by 0.3 kPa(gauge) [2.25 mmHg(gauge)] or higher within 10 seconds of proceeding from step 3/6 to step 4/6 Purge VSV Purge VSV circuit Problems in EVAP hose between purge VSV and intake air surge tank assembly Problems in EVAP hose between canister and purge VSV ECM B P0441 Variation in EVAP pressure is less than 0.3 kPa(gauge) [2.25 mmHg(gauge)] for 10 seconds, after proceeding from step 3/6 to step 4/6 Purge VSV stuck closed Purge VSV circuit Canister (charcoal filter inside canister) clogged Problems in EVAP hose between purge VSV and intake air surge tank assembly Problems in EVAP hose between canister and purge VSV ECM C *1: These DTCs are already present in the ECM when the vehicle arrives and are confirmed in the "Confirm DTC" procedure above. *2: This result suggests that due to purge line blockage or purge VSV malfunction, the DTC was stored by the purge flow monitor while the engine was running, or that key-off monitor test result were nearly borderline values. B --> See step 22 C --> See step 17 A: Go to next step
PERFORM EVAP SYSTEM CHECK (STEP 5/6) Check the EVAP pressure in step 5/6. Compare the EVAP pressure in step 3/6 and the second reference pressure (step 5/6). RESULT DTC* Result Suspected Trouble Area Proceed to - EVAP pressure from step 3/6 lower than second reference pressure (step 5/6) Not yet determined (no leakage from EVAP system) A P0441 and P0455 EVAP pressure from step 3/6 higher than [second reference pressure (step 5/6) x 0.2] Purge VSV stuck open EVAP gross leak B P0456 EVAP pressure from step 3/6 higher than second reference pressure (step 5/6) EVAP small leak B *: These DTCs are already present in the ECM when the vehicle arrives and are confirmed in the "Confirm DTC" procedure above. A --> See step 43 B --> See step 17
PERFORM EVAP SYSTEM CHECK (STEP 3/6) Check the EVAP pressure in step 3/6. RESULT DTC* Result Suspected Trouble Area Proceed to P043F EVAP pressure less than [reference pressure] measured in step 2/6 Reference orifice high-flow A P2401 EVAP pressure almost same as [reference pressure] measured in step 2/6 Leak detection pump stuck off B *: These DTCs are already present in the ECM when the vehicle arrives and are confirmed in the "Confirm DTC" procedure above. HINT: The first reference pressure is the value determined in step 2/6. A --> See step 38 B --> See step 31
INSPECT CANISTER PUMP MODULE (CANISTER PRESSURE SENSOR CIRCUIT) Check the canister pressure sensor circuit, referring to DTC P0451 canister pressure sensor circuit inspection procedure. Refer to «INSPECTION PROCEDURE»(ref-598602-S09348399072014021400000) . NEXT --> See step 49
INSPECT CANISTER PUMP MODULE (VENT VALVE OPERATION) Turn the engine switch off. Disconnect the canister pump module connector. TEXT IN ILLUSTRATION *a Component without harness connected (Canister Pump Module) Apply the battery voltage to terminals VLVB and VGND of the canister pump module. Touch the canister pump module to confirm the vent valve operation. RESULT Condition Tester Result Suspected Trouble Area Proceed to Apply battery voltage to terminals VLVB and VGND Operating Wire harness or connector between vent valve and ECM Leak detection pump performance deteriorates Leak detection pump circuit malfunctioning (large resistance exists in the circuit) ECM A Not operating Vent valve B B --> See step 38 A: Go to next step
CHECK HARNESS AND CONNECTOR (CANISTER PUMP MODULE - ECM) Turn the engine switch off. Disconnect the ECM connector. Disconnect the canister pump module connector. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition A22-7 (VPMP) - P28-1 (VGND) Always Below 1 ohms A22-7 (VPMP) or P28-1 (VGND) - Body ground Always 10 kohms or higher RESULT Result Suspected Trouble Area Proceed to OK Leak detection pump performance deteriorates Leak detection pump circuit malfunctioning (large resistance exists in the circuit) ECM A NG Wire harness or connector between ECM and canister pump module B B --> See step 40 A: Go to next step
CHECK HARNESS AND CONNECTOR (CANISTER PUMP MODULE - BODY GROUND) Disconnect the canister pump module connector. Measure the resistance according to the value(s) in the table below. RESULT Tester Connection Condition Specified Condition Suspected Trouble Area Proceed to P28-4 (MGND) - Body ground Always Below 1 ohms Canister pump module Wire harness or connector between canister pump module and ECM ECM A 10 kohms or higher Wire harness or connector between canister pump module and body ground B B --> See step 40 A: Go to next step
CHECK HARNESS AND CONNECTOR (ECM - CANISTER PUMP MODULE) Disconnect the canister pump module connector. Disconnect the ECM connector. Measure the resistance according to the value(s) in the table below. RESULT Tester Connection Condition Specified Condition Suspected Trouble Area Proceed to A22-6 (MPMP) - P28-3 (MTRB) Always Below 1 ohms Canister pump module ECM A 10 kohms or higher Wire harness or connector between ECM and canister pump module B A --> See step 45 B --> See step 40
PERFORM ACTIVE TEST USING TECHSTREAM (PURGE VSV) Enter the following menus: Powertrain / Engine / Active Test / Activate the VSV for EVAP Control. Disconnect the fuel vapor feed hose assembly (connected to the canister) from the purge VSV. TEXT IN ILLUSTRATION *1 Purge VSV *2 Fuel Vapor Feed Hose Assembly (to Canister) Start the engine. Using the Techstream, turn off the purge VSV (Activate the VSV for Evap Control: OFF). Use your finger to confirm that the purge VSV has no suction. Using the Techstream, turn on the purge VSV (Activate the VSV for Evap Control: ON). Use your finger to confirm that the purge VSV has suction. RESULT Test Result Suspected Trouble Area Proceed to No suction when purge VSV turned off, and suction applied when turned on Blockage in the purge line is considered (based on result of step 9): Problems with EVAP hose between canister and purge VSV Canister (charcoal filter inside canister) clogged ECM A Leakage is considered (based on result of step 10): Fuel cap Leakage from EVAP line, fuel tank, or canister B Suction applied when purge VSV turned off Purge VSV stuck open C No suction when purge VSV turned on Purge VSV stuck closed Problems with EVAP hose between purge VSV and intake air surge tank assembly D B --> See step 20 C --> See step 21 D --> See step 23 A: Go to next step
INSPECT EVAP HOSE (PURGE VSV - CANISTER) Check for blockages in the EVAP purge line between the purge VSV and canister. OK No blockages in the EVAP purge line between the purge VSV and canister. NG --> See step 44 OK: Go to next step
INSPECT CANISTER (CHARCOAL FILTER INSIDE CANISTER) Check for filter blockage in the canister. Refer to «INSPECTION [06/2012 - ]»(ref-598593-S30509092962014021400000) . OK No blockages in the canister. OK --> See step 47 NG --> See step 48
CHECK FUEL CAP Check that the fuel cap is correctly installed and confirm that the fuel cap meets OEM specifications. Tighten the fuel cap firmly (only one click sound could be heard). HINT: If an EVAP tester is available, check the fuel cap using the tester. Remove the fuel cap and install it onto a fuel cap adapter. Connect an EVAP tester pump hose to the adapter, and pressurize the cap to 3.2 to 3.7 kPa(gauge) [24 to 27.75 mmHg(gauge)] using an EVAP tester pump. Seal the adapter and wait for 2 minutes. Check the pressure. If the pressure is 2 kPa(gauge) [15 mmHg(gauge)] or higher, the fuel cap is normal. RESULT Test Result Suspected Trouble Area Proceed to Fuel cap correctly installed - A Fuel cap loose Fuel cap improperly installed Defective fuel cap Fuel cap does not meet OEM specifications B Defective fuel cap - B No fuel cap - C A --> See step 37 B --> See step 35 C --> See step 36
INSPECT PURGE VSV Turn the engine switch off. Disconnect the purge VSV connector. TEXT IN ILLUSTRATION *1 Fuel Vapor Feed Hose Assembly (to Canister) *2 Purge VSV Connector *3 Purge VSV Disconnect the fuel vapor feed hose assembly (connected to the canister) from the purge VSV. Start the engine. Use your finger to confirm that the purge VSV has no suction. RESULT Test Result Suspected Trouble Area Proceed to No suction Wire harness or connector between purge VSV and ECM ECM A Suction applied Purge VSV B A --> See step 26 B --> See step 39
INSPECT EVAP HOSE (PURGE VSV - CANISTER) Check for blockages in the EVAP purge line between the purge VSV and canister. OK No blockages in the EVAP purge line between the purge VSV and canister. NG --> See step 44 OK: Go to next step
CHECK EVAP HOSE (PURGE VSV - INTAKE AIR SURGE TANK ASSEMBLY) Disconnect the fuel vapor feed hose assembly (connected to the intake air surge tank assembly) from the purge VSV. TEXT IN ILLUSTRATION *1 Purge VSV *2 Fuel Vapor Feed Hose Assembly (to Intake Air Surge Tank Assembly) Start the engine. Use your finger to confirm that the hose has suction. RESULT Test Result Suspected Trouble Area Proceed to Suction applied EVAP hose between purge VSV and intake air surge tank assembly normal Purge VSV Purge VSV power source Wire harness or connector between purge VSV and ECM A No suction Intake air surge tank assembly port EVAP hose between purge VSV and intake air surge tank assembly B B --> See step 34 A: Go to next step
INSPECT PURGE VSV Remove the purge VSV. Apply battery voltage to the terminals of the purge VSV. TEXT IN ILLUSTRATION *1 Purge VSV Confirm that air flows from port E to port F. RESULT Test Result Condition Suspected Trouble Area Proceed to Air flows Battery voltage is applied to purge VSV terminals Purge VSV normal Purge VSV power source Wire harness or connector between purge VSV and ECM A No air flow Battery voltage is applied to purge VSV terminals Purge VSV B B --> See step 39 A: Go to next step
CHECK TERMINAL VOLTAGE (POWER SOURCE OF PURGE VSV) Disconnect the purge VSV connector. TEXT IN ILLUSTRATION *a Front view of wire harness connector (to Purge VSV) Turn the engine switch on (IG). Measure the voltage according to the value(s) in the table below. RESULT Tester Connection Condition Specified Condition Suspected Trouble Area Proceed to D46-1 - Body ground Engine switch on (IG) 11 to 14 V Purge VSV power source normal Wire harness or connector between purge VSV and ECM A Other than result above Wire harness or connectors between purge VSV and battery B B --> See step 40 A: Go to next step
CHECK HARNESS AND CONNECTOR (PURGE VSV - ECM) Disconnect the ECM connector. Disconnect the purge VSV connector. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition D46-2 - D23-48 (PRG) Always Below 1 ohms D46-2 or D23-48 (PRG) - Body ground Always 10 kohms or higher OK --> See step 47 NG --> See step 40
INSPECT CANISTER PUMP MODULE (POWER SOURCE FOR VENT VALVE) Turn the engine switch off. TEXT IN ILLUSTRATION *a Front view of wire harness connector (to Canister Pump Module) - - Disconnect the canister pump module connector. Turn the engine switch on (IG). Measure the voltage according to the value(s) in the table below. RESULT Tester Connection Condition Specified Condition Suspected Trouble Area Proceed to P28-5 (VLVB) - Body ground Engine switch on (IG) 11 to 14 V Wire harness or connector between vent valve and ECM Vent valve Canister (charcoal filter inside canister) clogged ECM A Below 3 V Power source wire harness of vent valve B B --> See step 40 A: Go to next step
INSPECT CANISTER PUMP MODULE (VENT VALVE OPERATION) Turn the engine switch off. Disconnect the canister pump module connector. TEXT IN ILLUSTRATION *a Component without harness connected (Canister Pump Module) Apply the battery voltage to terminals VLVB and VGND of the canister pump module. Touch the canister pump module to confirm the vent valve operation. RESULT Condition Tester Result Suspected Trouble Area Proceed to Apply battery voltage to terminals VLVB and VGND Operating Wire harness or connector between vent valve and ECM Canister (charcoal filter inside canister) clogged ECM A Not operating Vent valve B B --> See step 38 A: Go to next step
CHECK HARNESS AND CONNECTOR (CANISTER PUMP MODULE - ECM) Turn the engine switch off. Disconnect the canister pump module connector. Disconnect the ECM connector. Measure the resistance according to the value(s) in the table below. RESULT Tester Connection Condition Test Result Suspected Trouble Area Proceed to P28-1 (VGND) - A22-7 (VPMP) Always Below 1 ohms Canister (charcoal filter inside canister) clogged ECM A 10 kohms or higher Wire harness or connector between ECM and canister pump module B B --> See step 40 A: Go to next step
INSPECT CANISTER (CHARCOAL FILTER INSIDE CANISTER) Check for filter blockage in the canister. Refer to «INSPECTION [06/2012 - ]»(ref-598593-S30509092962014021400000) . OK No blockages in the canister. OK --> See step 47 NG --> See step 48
CHECK TERMINAL VOLTAGE (CANISTER PUMP MODULE) Turn the engine switch off. Disconnect the canister pump module connector. TEXT IN ILLUSTRATION *a Front view of wire harness connector (to Canister Pump Module) - - Turn the engine switch on (IG). Measure the voltage according to the value(s) in the table below. RESULT Tester Connection Condition Test Result Suspected Trouble Area Proceed to P28-3 (MTRB) - Body ground Engine switch on (IG) 9 to 14 V Wire harness or connector between leak detection pump and body ground Leak detection pump A Below 3 V Wire harness or connector between leak detection pump and ECM ECM B B --> See step 33 A: Go to next step
CHECK HARNESS AND CONNECTOR (CANISTER PUMP MODULE - BODY GROUND) Turn the engine switch off. Disconnect the canister pump module connector. Measure the resistance according to the value(s) in the table below. RESULT Tester Connection Condition Specified Condition Suspected Trouble Area Proceed to P28-4 (MGND) - Body ground Always Below 1 ohms Leak detection pump A 10 kohms or higher Wire harness or connector between canister pump module and body ground B A --> See step 38 B --> See step 40
CHECK HARNESS AND CONNECTOR (ECM - CANISTER PUMP MODULE) Turn the engine switch off. Disconnect the ECM connector. Disconnect the canister pump module connector. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition A22-6 (MPMP) - P28-3 (MTRB) Always Below 1 ohms A22-6 (MPMP) or P28-3 (MTRB) - Body ground Always 10 kohms or higher RESULT Result Suspected Trouble Area Proceed to OK ECM A NG Wire harness or connector between ECM and canister pump module B A --> See step 47 B --> See step 40
INSPECT INTAKE AIR SURGE TANK ASSEMBLY (EVAP PURGE PORT) Stop the engine. Disconnect the EVAP hose from the intake air surge tank assembly. Start the engine. Use your finger to confirm that the port of the intake air surge tank assembly has suction. RESULT Tester Connection Suspected Trouble Area Proceed to Suction applied EVAP hose between intake air surge tank assembly and purge VSV A No suction Intake air surge tank assembly B A --> See step 41 B --> See step 42
CORRECTLY REINSTALL OR REPLACE FUEL CAP HINT: When reinstalling the fuel cap, tighten it firmly (only one click sound could be head). When replacing the fuel cap, use a fuel cap that meets OEM specifications, and install it firmly. NEXT --> See step 49
REPLACE FUEL CAP HINT: When installing the fuel cap, tighten it firmly (only one click sound could be head). NEXT --> See step 49
LOCATE EVAP LEAK PART Disconnect the vent hose. TEXT IN ILLUSTRATION *1 Fuel Tank *2 Canister *3 Canister Filter *4 Fuel Cap *5 Canister Pump Module - - *a Disconnect the vent hose here - - Connect the EVAP pressure tester tool to the canister pump module with the adapter. TEXT IN ILLUSTRATION *1 Canister Pump Module *2 Adapter *3 EVAP Pressure Tester Tool - - Pressurize the EVAP system to 3.2 to 3.7 kPa(gauge) [24 to 28 mmHg(gauge)]. Apply soapy water to the piping and connecting parts of the EVAP system. Look for areas where bubbles appear. This indicates the leak point. Repair or replace the leak point. HINT: Disconnect the hose between the canister and fuel tank from the canister. Block the canister side and conduct an inspection. In this way, the fuel tank can be excluded as an area suspected of causing fuel leaks. NEXT --> See step 49
REPLACE CANISTER PUMP MODULE Replace the canister pump module. Refer to «REMOVAL [06/2012 - ]»(ref-598593-S28167230832014021400000) . NOTE: When replacing canister pump module, check the canister pump module interior, canister interior and related pipes for water, fuel and other liquids. If liquids are present, check for disconnections and/or cracks in the following: 1) the pipe from the air inlet port to the canister pump module; 2) the canister filter; and 3) the fuel tank vent hose. If liquids are present in canister interior, replace canister and canister pump module together. Check for filter blockage in the canister. If the charcoal filter inside the canister is clogged, replace canister and canister pump module together. Check for filter blockage in the canister filter. if the canister filter has blockages, replace the canister filter. TEXT IN ILLUSTRATION *1 Fuel Tank Vent Hose *2 Air Inlet Port *3 Vent Hose *4 Fuel Tank *5 Canister Pump Module *6 Canister *7 Canister Filter - - *a Inspection Area (check for disconnection and/or cracks) - - NEXT --> See step 49
REPLACE PURGE VSV Replace the purge VSV. Refer to «REMOVAL [06/2012 - ]»(ref-598593-S36187198452014021400000) . NEXT --> See step 49
REPAIR OR REPLACE HARNESS OR CONNECTOR NEXT --> See step 49
REPAIR OR REPLACE EVAP PURGE LINE (INTAKE AIR SURGE TANK ASSEMBLY - PURGE VSV) NEXT --> See step 49
INSPECT INTAKE AIR SURGE TANK ASSEMBLY (EVAP PURGE PORT) Check that the EVAP purge port of the intake air surge tank assembly is not clogged. If necessary, replace the intake air surge tank assembly. Refer to «REMOVAL [06/2012 - ]»(ref-598608-S29092353242014021400000) . NEXT --> See step 49
REPAIR OR REPLACE PARTS AND COMPONENTS INDICATED BY OUTPUT DTCS Repair the malfunctioning areas indicated by the DTCs that had been confirmed when the vehicle was brought in. NEXT --> See step 49
REPAIR OR REPLACE EVAP PURGE LINE (PURGE VSV - CANISTER) NEXT --> See step 49
REPLACE CANISTER PUMP MODULE Replace the canister pump module. Refer to «REMOVAL [06/2012 - ]»(ref-598593-S28167230832014021400000) . NOTE: When replacing canister pump module, check the canister pump module interior, canister interior and related pipes for water, fuel and other liquids. If liquids are present, check for disconnections and/or cracks in the following: 1) the pipe from the air inlet port to the canister pump module; 2) the canister filter; and 3) the fuel tank vent hose. If liquids are present in canister interior, replace canister and canister pump module together. Check for filter blockage in the canister. If the charcoal filter inside the canister is clogged, replace canister and canister pump module together. Check for filter blockage in the canister filter. If the canister filter has blockages, replace the canister filter. TEXT IN ILLUSTRATION *1 Fuel Tank Vent Hose *2 Air Inlet Port *3 Vent Hose *4 Fuel Tank *5 Canister Pump Module *6 Canister *7 Canister Filter - - *a Inspection Area (check for disconnection and/or cracks) - - NEXT: Go to next step
PERFORM EVAP SYSTEM CHECK (AUTOMATIC MODE) NOTE: The Evaporative System Check (Automatic Mode) consists of 6 steps performed automatically by the Techstream. It takes a maximum of approximately 24 minutes. Do not perform the Evaporative System Check when the fuel tank is more than 90% full because the cut-off valve may be closed, making the fuel tank leak check unavailable. Do not run the engine in this step. When the temperature of the fuel is 35°C (95°F) or more, a large amount of vapor forms and any check results become inaccurate. When performing an Evaporative System Check, keep the fuel temperature below 35°C (95°F). Connect the Techstream to the DLC3. Turn the engine switch on (IG). Turn the Techstream on. Clear the DTCs. Refer to «DTC CHECK / CLEAR [06/2012 - ]»(ref-598472-S02009234142014021400000) . Enter the following menus: Powertrain / Engine / Utility / Evaporative System Check / Automatic Mode. After the Evaporative System Check is completed, check for pending DTCs by entering the following menus: Powertrain / Engine / Trouble Codes. Result Proceed to EVAP system DTCs are output A DTC is not output (Pending DTC is not output) B B --> END A: Go to next step
REPLACE ECM Replace the ECM. Refer to «REMOVAL [06/2012 - ]»(ref-598604-S28038138762014021400000) . NEXT --> See step 49
REPLACE CANISTER Replace the canister. Refer to «REMOVAL [06/2012 - ]»(ref-598593-S28167230832014021400000) . NOTE: When replacing the canister, check the canister pump module interior and related pipes for water, fuel and other liquids. If liquids are present, check for disconnections and/or cracks in the following: 1) the pipe from the air inlet port to the canister pump module; 2) the canister filter; and 3) the fuel tank vent hose. Check for filter blockage in the canister filter. If the canister filter has blockages, replace the canister filter. TEXT IN ILLUSTRATION *1 Fuel Tank Vent Hose *2 Air Inlet Port *3 Vent Hose *4 Fuel Tank *5 Canister Pump Module *6 Canister *7 Canister Filter - - *a Inspection Area (check for disconnection and/or cracks) - - NEXT: Go to next step
PERFORM EVAP SYSTEM CHECK (AUTOMATIC MODE) NOTE: The Evaporative System Check (Automatic Mode) consists of 6 steps performed automatically by the Techstream. It takes a maximum of approximately 24 minutes. Do not perform the Evaporative System Check when the fuel tank is more than 90% full because the cut-off valve may be closed, making the fuel tank leak check unavailable. Do not run the engine in this step. When the temperature of the fuel is 35°C (95°F) or more, a large amount of vapor forms and any check results become inaccurate. When performing an Evaporative System Check, keep the fuel temperature below 35°C (95°F). Connect the Techstream to the DLC3. Turn the engine switch on (IG). Turn the Techstream on. Clear the DTCs. Refer to «DTC CHECK / CLEAR [06/2012 - ]»(ref-598472-S02009234142014021400000) . Enter the following menus: Powertrain / Engine / Utility / Evaporative System Check / Automatic Mode. After the Evaporative System Check is completed, check for pending DTCs by entering the following menus: Powertrain / Engine / Trouble Codes. HINT: If no pending DTCs are found, the repair has been successfully completed. NEXT --> END

Note. Inspect the fuses for circuits related to this system before performing the following inspection procedure.

Scheme 96

Scheme 96: PROCEDURE

Scheme 97

Scheme 98

CHECK HARNESS AND CONNECTOR (ECM - BODY GROUND) Disconnect the ECM connector. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition D23-49 (E1) - Body ground Always Below 1 ohms NG --> REPAIR OR REPLACE HARNESS OR CONNECTOR OK: Go to next step
CHECK TERMINAL VOLTAGE (IGSW VOLTAGE) Disconnect the ECM connector. Turn the engine switch on (IG). Measure the voltage according to the value(s) in the table below. Standard Voltage Tester Connection Condition Specified Condition A22-32 (IGSW) - Body ground Engine switch on (IG) 11 to 14 V TEXT IN ILLUSTRATION *a Front view of wire harness connector (to ECM) NG --> See step 6 OK: Go to next step
INSPECT NO. 1 INTEGRATION RELAY (EFI MAIN RELAY) Inspect the No. 1 integration relay (EFI MAIN relay). Refer to «INSPECTION [06/2012 - ]»(ref-598604-S11563729852014021400000) . NG --> See step 11 OK: Go to next step
CHECK HARNESS AND CONNECTOR (NO. 1 INTEGRATION RELAY - ECM) Remove the No. 1 integration relay from the engine room relay block and junction block assembly. Disconnect the ECM connector. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition 1C-9 - A22-2 (+B) Always Below 1 ohms 1C-10 - A22-3 (+B2) Always Below 1 ohms 1C-7 - A22-46 (MREL) Always Below 1 ohms 1C-9 or A22-2 (+B) - Body ground Always 10 kohms or higher 1C-10 or A22-3 (+B2) - Body ground Always 10 kohms or higher 1C-7 or A22-46 (MREL) - Body ground Always 10 kohms or higher NG --> REPAIR OR REPLACE HARNESS OR CONNECTOR OK: Go to next step
CHECK TERMINAL VOLTAGE (POWER SOURCE OF NO. 1 INTEGRATION RELAY) Remove the No. 1 integration relay from the engine room relay block and junction block assembly. Measure the voltage according to the value(s) in the table below. Standard Voltage Tester Connection Condition Specified Condition 1B-1 - Body ground Always 11 to 14 V TEXT IN ILLUSTRATION *a Front view of wire harness connector (to No. 1 Integration Relay) NG --> REPAIR OR REPLACE HARNESS OR CONNECTOR (BATTERY - NO. 1 INTEGRATION RELAY) OK --> See step 13
INSPECT NO. 1 INTEGRATION RELAY (IG2 RELAY) Inspect the No. 1 integration relay (IG2 relay). Refer to «INSPECTION [06/2012 - ]»(ref-598604-S11563729852014021400000) . NG --> See step 12 OK: Go to next step
CHECK HARNESS AND CONNECTOR (NO. 1 INTEGRATION RELAY - ECM) Remove the No. 1 integration relay from the engine room relay block and junction block assembly. Disconnect the ECM connector. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition 1C-1 - A22-32 (IGSW) Always Below 1 ohms 1C-1 or A22-32 (IGSW) - Body ground Always 10 kohms or higher NG --> REPAIR OR REPLACE HARNESS OR CONNECTOR OK: Go to next step
CHECK TERMINAL VOLTAGE (POWER SOURCE OF NO. 1 INTEGRATION RELAY) Remove the No. 1 integration relay from the engine room relay block and junction block assembly. Measure the voltage according to the value(s) in the table below. Standard Voltage Tester Connection Condition Specified Condition 1D-3 - Body ground Always 11 to 14 V TEXT IN ILLUSTRATION *a Front view of wire harness connector (to No. 1 Integration Relay) NG --> REPAIR OR REPLACE HARNESS OR CONNECTOR (BATTERY - NO. 1 INTEGRATION RELAY) OK: Go to next step
CHECK HARNESS AND CONNECTOR (NO. 1 INTEGRATION RELAY - BODY GROUND) Remove the No. 1 integration relay from the engine room relay block and junction block assembly. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition 1E-2 - Body ground Always Below 1 ohms NG --> REPAIR OR REPLACE HARNESS OR CONNECTOR OK: Go to next step
CHECK HARNESS AND CONNECTOR (CERTIFICATION ECU (SMART KEY ECU ASSEMBLY) - NO. 1 INTEGRATION RELAY Disconnect the certification ECU (smart key ECU assembly) connector. Remove the No. 1 integration relay from the engine room relay block and junction block assembly. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition A36-9 (IG2D) - 1C-8 Always Below 1 ohms A36-9 (IG2D) or 1C-8 - Body ground Always 10 kohms or higher NG --> REPAIR OR REPLACE HARNESS OR CONNECTOR OK --> See step 14
REPLACE NO. 1 INTEGRATION RELAY (EFI MAIN RELAY). Refer to «REMOVAL [06/2012 - ]»(ref-598604-S05116938722014021400000)
REPLACE NO. 1 INTEGRATION RELAY (IG2 RELAY). Refer to «REMOVAL [06/2012 - ]»(ref-598604-S05116938722014021400000)
PROCEED TO NEXT SUSPECTED AREA SHOWN IN PROBLEM SYMPTOMS TABLE. Refer to «PROBLEM SYMPTOMS TABLE [06/2012 - ]»(ref-598472-S12013296402014021400000)
GO TO SMART ACCESS SYSTEM WITH PUSH-BUTTON START. Refer to «HOW TO PROCEED WITH TROUBLESHOOTING [06/2012 - ]»(ref-598458-S23777749782014021400000)

Note. Inspect the fuses for circuits related to this system before performing the following inspection procedure.

Scheme 99

Scheme 99: PROCEDURE

PERFORM ACTIVE TEST USING TECHSTREAM (CONTROL THE FUEL PUMP / SPEED) Connect the Techstream to the DLC3. Turn the engine switch on (IG). Turn the Techstream on. Enter the following menus: Powertrain / Engine / Active Test / Control the Fuel Pump / Speed. Check whether fuel pump operating sounds can be heard while operating the fuel pump using the Techstream. OK Operating sounds can be heard from fuel pump. RESULT Result Proceed to NG A OK B B --> See step 11 A: Go to next step
CHECK TERMINAL VOLTAGE (POWER SOURCE OF FUEL PUMP CONTROL ECU ASSEMBLY) Disconnect the fuel pump control ECU assembly connector. Turn the engine switch on (IG). Measure the voltage according to the value(s) in the table below. Standard Voltage Tester Connection Condition Specified Condition P19-1 (+B) - Body ground Engine switch on (IG) 11 to 14 V TEXT IN ILLUSTRATION *a Front view of wire harness connector (to Fuel Pump Control ECU Assembly) NG --> See step 9 OK: Go to next step
CHECK HARNESS AND CONNECTOR (FUEL PUMP CONTROL ECU ASSEMBLY - BODY GROUND) Disconnect the fuel pump control ECU assembly connector. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition P19-4 (E) - Body ground Always Below 1 ohms NG --> REPAIR OR REPLACE HARNESS OR CONNECTOR OK: Go to next step
CHECK HARNESS AND CONNECTOR (FUEL PUMP CONTROL ECU ASSEMBLY - FUEL PUMP) Disconnect the fuel pump control ECU assembly connector. Disconnect the fuel pump connector. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition P19-6 (FP) - P7-4 (B) Always Below 1 ohms P19-5 (FP-) - P7-5 (E) Always Below 1 ohms P19-6 (FP) or P7-4 (B) - Body ground Always 10 kohms or higher P19-5 (FP-) or P7-5 (E) - Body ground Always 10 kohms or higher NG --> REPAIR OR REPLACE HARNESS OR CONNECTOR OK: Go to next step
INSPECT FUEL PUMP Inspect the fuel pump. Refer to «INSPECTION [06/2012 - ]»(ref-598605-S03788977342014021400000) . HINT: Perform "Inspection After Repair" after replacing the fuel pump. Refer to «INITIALIZATION [06/2012 - ]»(ref-598472-S27174589072014021400000) . NG --> See step 16 OK: Go to next step
CHECK HARNESS AND CONNECTOR (FUEL PUMP CONTROL ECU ASSEMBLY - ECM) Disconnect the fuel pump control ECU assembly connector. Disconnect the ECM connector. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition P19-2 (FPC) - A22-18 (FPC) Always Below 1 ohms P19-2 (FPC) or A22-18 (FPC) - Body ground Always 10 kohms or higher NG --> REPAIR OR REPLACE HARNESS OR CONNECTOR OK: Go to next step
REPLACE FUEL PUMP CONTROL ECU ASSEMBLY Replace the fuel pump control ECU assembly. Refer to «REMOVAL [06/2012 - ]»(ref-598605-S04420355222014021400000) . NEXT: Go to next step
CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED Check the fuel pump operation. OK Malfunction has been repaired successfully. NG --> See step 17 OK --> END
CHECK HARNESS AND CONNECTOR (FUEL PUMP CONTROL ECU ASSEMBLY - NO. 1 INTEGRATION RELAY) Disconnect the fuel pump control ECU assembly connector. Remove the No. 1 integration relay from the engine room relay block and junction block assembly. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition P19-1 (+B) - 1C-6 Always Below 1 ohms P19-1 (+B) or 1C-6 - Body ground Always 10 kohms or higher NG --> REPAIR OR REPLACE HARNESS OR CONNECTOR OK: Go to next step
INSPECT NO. 1 INTEGRATION RELAY (EFI MAIN RELAY) Inspect the No. 1 integration relay (EFI MAIN relay). Refer to «INSPECTION [06/2012 - ]»(ref-598604-S11563729852014021400000) . NG --> See step 19 OK --> See step 18
PERFORM ACTIVE TEST USING TECHSTREAM (CONTROL THE FUEL PUMP DUTY) Remove the fuel pump. Refer to «REMOVAL [06/2012 - ]»(ref-598605-S18754521142014021400000) . Clean the fuel pump to completely remove any remaining fuel. Connect the fuel pump connector. WARNING: Confirm that no fuel remains inside or on the outside of the fuel pump. Connect the Techstream to the DLC3. Turn the engine switch on (IG). Turn the Techstream on. Enter the following menus: Powertrain / Engine / Active Test / Control the Fuel Pump Duty. Operate the fuel pump using the active test function and measure the voltage according to the value(s) in the table below. Standard Voltage Tester Connection Techstream Operation Specified Condition 4 (B) - 5 (E) Fuel pump control duty: 25% 3.4 to 4.1 V Fuel pump control duty: 80% 10.0 to 12.5 V Enter the following menus: Powertrain / Engine / Active Test / Control the Fuel Pump / Speed. Operate the fuel pump using the active test function and measure the voltage according to the value(s) in the table below. Standard Voltage Tester Connection Techstream Operation Specified Condition 4 (B) - 5 (E) ON (Fuel pump control duty: 90%) 10.2 to 14.0 V HINT: Be sure to measure the voltage with the all connectors connected. Before performing this inspection, check that the battery voltage is between 11 and 14 V (not depleted). NG --> See step 14 OK: Go to next step
CHECK HARNESS AND CONNECTOR (FUEL PUMP CONTROL ECU ASSEMBLY - ECM) Disconnect the fuel pump control ECU assembly connector. Disconnect the ECM connector. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition P19-2 (FPC) - A22-18 (FPC) Always Below 1 ohms P19-2 (FPC) or A22-18 (FPC) - Body ground Always 10 kohms or higher NG --> REPAIR OR REPLACE HARNESS OR CONNECTOR OK: Go to next step
REPLACE FUEL PUMP Replace the fuel pump. Refer to «REMOVAL [06/2012 - ]»(ref-598605-S18754521142014021400000) . NEXT --> See step 15
REPLACE FUEL PUMP CONTROL ECU ASSEMBLY Replace the fuel pump control ECU assembly. Refer to «REMOVAL [06/2012 - ]»(ref-598605-S04420355222014021400000) . NEXT: Go to next step
CONFIRM WHETHER MALFUNCTION HAS BEEN SUCCESSFULLY REPAIRED Check the fuel pump operation. OK Malfunction has been repaired successfully. NG --> See step 17 OK --> END
REPLACE FUEL PUMP. Refer to «REMOVAL [06/2012 - ]»(ref-598605-S18754521142014021400000)
REPLACE ECM. Refer to «REMOVAL [06/2012 - ]»(ref-598604-S28038138762014021400000)
GO TO ECM POWER SOURCE CIRCUIT. Refer to «ECM Power Source Circuit»(ref-598599-S31649039382014021400000)
REPLACE NO. 1 INTEGRATION RELAY (EFI MAIN RELAY). Refer to «REMOVAL [06/2012 - ]»(ref-598604-S05116938722014021400000)

Note. Inspect the fuses for circuits related to this system before performing the following inspection procedure.

Scheme 100

Scheme 100: PROCEDURE

CHECK TERMINAL VOLTAGE (POWER SOURCE OF FUEL INJECTOR ASSEMBLY) Disconnect the fuel injector assembly connectors. Turn the engine switch on (IG). Measure the voltage according to the value(s) in the table below. Standard Voltage Tester Connection Condition Specified Condition D26-2 - Body ground Engine switch on (IG) 11 to 14 V D30-2 - Body ground Engine switch on (IG) 11 to 14 V D27-2 - Body ground Engine switch on (IG) 11 to 14 V D31-2 - Body ground Engine switch on (IG) 11 to 14 V D29-2 - Body ground Engine switch on (IG) 11 to 14 V D32-2 - Body ground Engine switch on (IG) 11 to 14 V TEXT IN ILLUSTRATION *a Front view of wire harness connector (to Fuel Injector Assembly) NG --> See step 4 OK: Go to next step
INSPECT FUEL INJECTOR ASSEMBLY Inspect the fuel injector assembly. Refer to «INSPECTION [06/2012 - ]»(ref-598605-S17851075582014021400000) . HINT: Perform "Inspection After Repair" after replacing the fuel injector assembly. Refer to «INITIALIZATION [06/2012 - ]»(ref-598472-S27174589072014021400000) . NG --> See step 6 OK: Go to next step
CHECK HARNESS AND CONNECTOR (FUEL INJECTOR ASSEMBLY - ECM) Disconnect the fuel injector assembly connectors. Disconnect the ECM connector. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition D26-1 - D23-58 (#10) Always Below 1 ohms D30-1 - D23-54 (#20) Always Below 1 ohms D27-1 - D23-57 (#30) Always Below 1 ohms D31-1 - D23-53 (#40) Always Below 1 ohms D29-1 - D23-56 (#50) Always Below 1 ohms D32-1 - D23-55 (#60) Always Below 1 ohms D26-1 or D23-58 (#10) - Body ground Always 10 kohms or higher D30-1 or D23-54 (#20) - Body ground Always 10 kohms or higher D27-1 or D23-57 (#30) - Body ground Always 10 kohms or higher D31-1 or D23-53 (#40) - Body ground Always 10 kohms or higher D29-1 or D23-56 (#50) - Body ground Always 10 kohms or higher D32-1 or D23-55 (#60) - Body ground Always 10 kohms or higher NG --> REPAIR OR REPLACE HARNESS OR CONNECTOR OK --> See step 8
CHECK HARNESS AND CONNECTOR (NO. 1 INTEGRATION RELAY - FUEL INJECTOR ASSEMBLY) Disconnect the fuel injector assembly connectors. Remove the No. 1 integration relay from the engine room relay block and junction block assembly. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition 1A-3 - D26-2 Always Below 1 ohms 1A-3 - D30-2 Always Below 1 ohms 1A-3 - D27-2 Always Below 1 ohms 1A-3 - D31-2 Always Below 1 ohms 1A-3 - D29-2 Always Below 1 ohms 1A-3 - D32-2 Always Below 1 ohms 1A-3 or D26-2 - Body ground Always 10 kohms or higher 1A-3 or D30-2 - Body ground Always 10 kohms or higher 1A-3 or D27-2 - Body ground Always 10 kohms or higher 1A-3 or D31-2 - Body ground Always 10 kohms or higher 1A-3 or D29-2 - Body ground Always 10 kohms or higher 1A-3 or D32-2 - Body ground Always 10 kohms or higher NG --> REPAIR OR REPLACE HARNESS OR CONNECTOR OK: Go to next step
INSPECT NO. 1 INTEGRATION RELAY (IG2 RELAY) Inspect the No. 1 integration relay (IG2 relay). Refer to «INSPECTION [06/2012 - ]»(ref-598604-S11563729852014021400000) . NG --> See step 9 OK --> See step 7
REPLACE FUEL INJECTOR ASSEMBLY. Refer to «REMOVAL [06/2012 - ]»(ref-598605-S36754007882014021400000)
GO TO ECM POWER SOURCE CIRCUIT. Refer to «ECM Power Source Circuit»(ref-598599-S31649039382014021400000)
PROCEED TO NEXT SUSPECTED AREA SHOWN IN PROBLEM SYMPTOMS TABLE. Refer to «PROBLEM SYMPTOMS TABLE [06/2012 - ]»(ref-598472-S12013296402014021400000)
REPLACE NO. 1 INTEGRATION RELAY (IG2 RELAY). Refer to «REMOVAL [06/2012 - ]»(ref-598604-S05116938722014021400000)

Note. Inspect the fuses for circuits related to this system before performing the following inspection procedure.

Scheme 101

Scheme 101: PROCEDURE

PERFORM ACTIVE TEST USING TECHSTREAM (ACTIVATE THE VSV FOR INTAKE CONTROL) Connect the Techstream to the DLC3. Turn the engine switch on (IG). Turn the Techstream on. Enter the following menus: Powertrain / Engine / Active Test / Activate the VSV for Intake Control. Check if operating noise can be heard when operating the intake air control valve assembly using the Techstream. OK Operating noise can be heard. NG --> See step 2 OK --> See step 6
INSPECT INTAKE AIR SURGE TANK ASSEMBLY (INTAKE AIR CONTROL VALVE ASSEMBLY OPERATION) Inspect the intake air surge tank assembly (intake air control valve assembly). Refer to «ON-VEHICLE INSPECTION [06/2012 - ]»(ref-598608-S04315673662014021400000) . NG --> See step 7 OK: Go to next step
CHECK TERMINAL VOLTAGE (POWER SOURCE OF INTAKE AIR CONTROL VALVE ASSEMBLY) Disconnect the intake air control valve assembly connector. Turn the engine switch on (IG). Measure the voltage according to the value(s) in the table below. Standard Voltage Tester Connection Condition Specified Condition D42-2 - Body ground Engine switch on (IG) 11 to 14 V TEXT IN ILLUSTRATION *a Front view of wire harness connector (to Intake Air Control Valve Assembly) NG --> See step 5 OK: Go to next step
CHECK HARNESS AND CONNECTOR (INTAKE AIR CONTROL VALVE ASSEMBLY - ECM) Disconnect the intake air control valve assembly connector. Disconnect the ECM connector. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition D42-1 - D23-47 (ACIS) Always Below 1 ohms D42-1 or D23-47 (ACIS) - Body ground Always 10 kohms or higher NG --> REPAIR OR REPLACE HARNESS OR CONNECTOR OK --> See step 8
CHECK HARNESS AND CONNECTOR (NO. 1 INTEGRATION RELAY - INTAKE AIR CONTROL VALVE ASSEMBLY) Remove the No. 1 integration relay from the engine room relay block and junction block assembly. Disconnect the intake air control valve assembly connector. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition 1A-8 - D42-2 Always Below 1 ohms 1A-8 or D42-2 - Body ground Always 10 kohms or higher NG --> REPAIR OR REPLACE HARNESS OR CONNECTOR OK --> See step 9
PROCEED TO NEXT SUSPECTED AREA SHOWN IN PROBLEM SYMPTOMS TABLE. Refer to «PROBLEM SYMPTOMS TABLE [06/2012 - ]»(ref-598472-S12013296402014021400000)
REPLACE INTAKE AIR SURGE TANK ASSEMBLY. Refer to «REMOVAL [06/2012 - ]»(ref-598608-S29092353242014021400000)
REPLACE ECM. Refer to «REMOVAL [06/2012 - ]»(ref-598604-S28038138762014021400000)
GO TO ECM POWER SOURCE CIRCUIT. Refer to «ECM Power Source Circuit»(ref-598599-S31649039382014021400000)

Note. Inspect the fuses for circuits related to this system before performing the following inspection procedure.

Scheme 102

Scheme 102: PROCEDURE

Scheme 103

PERFORM ACTIVE TEST USING TECHSTREAM (ACTIVATE THE VSV FOR AICS) Disconnect the vacuum hose (Port F) from the vacuum switching valve (for air intake control valve). Connect the Techstream to the DLC3. Start the engine. Turn the Techstream on. Enter the following menus: Powertrain / Engine / Active Test / Activate the VSV for AICS. Check the operation of the vacuum switching valve (for air intake control valve) when the vacuum switching valve (for air intake control valve) is operated using the Techstream. Standard Techstream Operation Specified Condition ON Air from port E flows out through port F OFF Air from port E flows out through the air filter TEXT IN ILLUSTRATION *1 Air *2 Port E *3 Port F *4 Air Filter *a Vacuum Switching Valve is On *b Vacuum Switching Valve is Off NG --> See step 2 OK --> See step 10
INSPECT VACUUM SWITCHING VALVE (FOR AIR INTAKE CONTROL VALVE) Inspect the vacuum switching valve for air intake control valve. Refer to «INSPECTION [06/2012 - ]»(ref-598613-S16617925042014021400000) . NG --> See step 9 OK: Go to next step
CHECK TERMINAL VOLTAGE (POWER SOURCE OF VACUUM SWITCHING VALVE (FOR AIR INTAKE CONTROL VALVE)) Disconnect the vacuum switching valve (for air intake control valve) connector. Turn the engine switch on (IG). Measure the voltage according to the value(s) in the table below. Standard Voltage Tester Connection Condition Specified Condition A9-1 - Body ground Engine switch on (IG) 11 to 14 V TEXT IN ILLUSTRATION *a Front view of wire harness connector (to Vacuum Switching Valve (for Air Intake Control Valve)) NG --> See step 7 OK: Go to next step
CHECK HARNESS AND CONNECTOR (VACUUM SWITCHING VALVE (FOR AIR INTAKE CONTROL VALVE) - ECM) Disconnect the vacuum switching valve (for air intake control valve) connector. Disconnect the ECM connector. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition A9-2 - D23-46 (AICV) Always Below 1 ohms A9-2 or D23-46 (AICV) - Body ground Always 10 kohms or higher NG --> REPAIR OR REPLACE HARNESS OR CONNECTOR OK: Go to next step
INSPECT AIR CLEANER CAP SUB-ASSEMBLY (VACUUM SURGE TANK) Inspect the vacuum surge tank. Refer to «ON-VEHICLE INSPECTION [06/2012 - ]»(ref-598614-S42794851592014021400000) . NG --> REPAIR OR REPLACE AIR CLEANER CAP SUB-ASSEMBLY OK: Go to next step
CHECK VACUUM HOSES (VACUUM SWITCHING VALVE (FOR AIR INTAKE CONTROL VALVE) - AIR CLEANER CAP - AIR INTAKE CONTROL VALVE) Check the vacuum hoses between vacuum switching valve (for air intake control valve), air cleaner cap sub-assembly and air intake control valve. Refer to «ON-VEHICLE INSPECTION [06/2012 - ] - Step 1»(ref-598608-S40895216022014021400000) . NG --> REPAIR OR REPLACE VACUUM HOSE OK --> See step 8
CHECK HARNESS AND CONNECTOR (NO. 1 INTEGRATION RELAY - VACUUM SWITCHING VALVE (FOR AIR INTAKE CONTROL VALVE)) Remove the No. 1 integration relay from the engine room relay block and junction block assembly. Disconnect the vacuum switching valve (for air intake control valve) connector. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition 1C-3 - A9-1 Always Below 1 ohms 1C-3 or A9-1 - Body ground Always 10 kohms or higher NG --> REPAIR OR REPLACE HARNESS OR CONNECTOR OK --> See step 11
REPLACE ECM. Refer to «REMOVAL [06/2012 - ]»(ref-598604-S28038138762014021400000)
REPLACE VACUUM SWITCHING VALVE (FOR AIR INTAKE CONTROL VALVE). Refer to «REMOVAL [06/2012 - ]»(ref-598613-S31483442162014021400000)
PROCEED TO NEXT SUSPECTED AREA SHOWN IN PROBLEM SYMPTOMS TABLE. Refer to «PROBLEM SYMPTOMS TABLE [06/2012 - ]»(ref-598472-S12013296402014021400000)
GO TO ECM POWER SOURCE CIRCUIT. Refer to «ECM Power Source Circuit»(ref-598599-S31649039382014021400000)

Inspection Method

Example

Drive at 10 km/h (6.25 mph), depress the accelerator pedal by 1/2 to 3/4 and keep it in that position. Under these conditions, if the engine speed decreases to 1000 rpm when the brake pedal is depressed, then the brake override system has been activated.

WARNING

When carrying out the inspection, use a place where you are able to carry it out safely and also pay close attention to your surroundings. Also, when driving make absolutely sure that all road traffic laws, such as speed limits, are observed.

HINT

Under normal conditions, the Accelerator Position value changes in response to the Accel Sens. No. 1 Volt % value. For more information on the numerical values, refer to the Data List. Refer to «DATA LIST / ACTIVE TEST [06/2012 - ]»(ref-598472-S10277657772014021400000) .
If the Data List values of Accelerator Position and Accel Sens. No. 1 Volt % do not match, and the value of Accelerator Position changes but the value of Accel Sens. No. 1 Volt % is constant, this confirms that brake override system has activated. (Data can be captured relatively easily by using the snapshot function in the Data List. Confirm the data after performing the drive test.)

Note. The brake override system restricts driving torque if the brake pedal is depressed when driving with the accelerator pedal depressed. If a customer reports experiencing loss of torque after the accelerator and brake pedals have both been intentionally depressed, explain to the customer that this is not a malfunction, and that the customer should avoid depressing both the accelerator and brake pedals at the same time. Example: While operating the accelerator pedal, the customer uses their left foot to operate the brake pedal.

Note. Inspect the fuses for circuits related to this system before performing the following inspection procedure.

Scheme 104

Scheme 104: PROCEDURE

CHECK THAT MIL IS ILLUMINATED Perform troubleshooting in accordance with the table below. RESULT Result Proceed to MIL remains ON A MIL does not illuminate B B --> See step 5 A: Go to next step
CHECK WHETHER DTC OUTPUT RECURS Connect the Techstream to the DLC3. Turn the engine switch on (IG). Turn the Techstream on. Enter the following menus: Powertrain / Engine / Trouble Codes. Check if any DTCs have been detected. Note down any DTCs. RESULT Result Proceed to DTC is not output A Any DTCs is output B HINT: Check for detected DTCs output from other ECUs which relate to the MIL. B --> REPAIR CIRCUIT INDICATED BY OUTPUT DTC A: Go to next step
CHECK HARNESS AND CONNECTOR (CHECK FOR SHORT IN WIRE HARNESS) Disconnect the ECM connector. Turn the engine switch on (IG). Check that the MIL is not illuminated. OK MIL is not illuminated. TEXT IN ILLUSTRATION *a Front view of wire harness connector (to ECM) NG --> See step 4 OK --> See step 8
CHECK HARNESS AND CONNECTOR (COMBINATION METER ASSEMBLY - ECM) Disconnect the combination meter assembly connector. Disconnect the ECM connector. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition H14-5 (CHK) or A22-27 (W) - Body ground Always 10 kohms or higher NG --> REPAIR OR REPLACE HARNESS OR CONNECTOR OK --> See step 9
CHECK THAT MIL IS ILLUMINATED Check if the MIL is illuminated when the engine switch is turned on (IG). OK MIL should be illuminated. NG --> See step 6 OK --> See step 12
CHECK THAT ENGINE STARTS Start the engine. RESULT Result Proceed to Engine starts A Engine does not start* B HINT: *: The Techstream cannot communicate with the ECM. B --> See step 10 A: Go to next step
CHECK HARNESS AND CONNECTOR (COMBINATION METER ASSEMBLY - ECM) Disconnect the combination meter assembly connector. Disconnect the ECM connector. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition H14-5 (CHK) - A22-27 (W) Always Below 1 ohms NG --> REPAIR OR REPLACE HARNESS OR CONNECTOR OK --> See step 11
REPLACE ECM. Refer to «REMOVAL [06/2012 - ]»(ref-598604-S28038138762014021400000)
REPLACE COMBINATION METER ASSEMBLY. Refer to «REMOVAL [06/2012 - ]»(ref-598615-S36710752442014021400000)
GO TO VC OUTPUT CIRCUIT. Refer to «VC Output Circuit»(ref-598599-S27234469082014021400000)
REPLACE COMBINATION METER ASSEMBLY. Refer to «REMOVAL [06/2012 - ]»(ref-598615-S36710752442014021400000)
CHECK FOR INTERMITTENT PROBLEMS. Refer to «CHECK FOR INTERMITTENT PROBLEMS [06/2012 - ]»(ref-598472-S09889535102014021400000)

Engine Control System (Diagnostic Codes (P1604-U0101) & Circuit Tests): Diagnosis Lexus ES XV60

INSPECTION PROCEDURE

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DTC SUMMARY

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