Engine Control System (Diagnostic Codes (P0604-P1603): Diagnosis Scion FR-S I

INSPECTION PROCEDURE

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

1. The following troubleshooting flowchart is based on the premise that the engine can be cranked normally. If the engine does not crank, proceed to Problem Symptoms Table. Refer to «PROBLEM SYMPTOMS TABLE [07/2013 - 12/2013]»(ref-612245-S26851307302014042900000) .
2. 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

1. If DTC P1261 is output, check the No. 1 fuel injector (for direct injection) (No. 1 cylinder) circuit.
2. If DTC P1262 is output, check the No. 2 fuel injector (for direct injection) (No. 2 cylinder) circuit.
3. If DTC P1263 is output, check the No. 3 fuel injector (for direct injection) (No. 3 cylinder) circuit.
4. If DTC P1264 is output, check the No. 4 fuel injector (for direct injection) (No. 4 cylinder) circuit.
5. If the current from the INJ relay is cut because DTC P062D is stored, DTC P1235 will be stored even if the fuel pump assembly (for high pressure) is normal.
6. 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.

Scheme 181

1. CHECK DTC OUTPUT Connect the Techstream to the DLC3. Turn the ignition switch to ON. Turn the Techstream on. Enter the following menus: Powertrain / Engine / Trouble Codes. Read the DTCs. Result Result Proceed to P1261, P1262, P1263 and/or P1264 are output A DTC P062D is output B B --> See step 6 A: Go to next step
2. CHECK HARNESS AND CONNECTOR Disconnect the injector driver (EDU) connectors. Measure the resistance according to the value(s) in the table below. Standard Resistance (Check for open) Tester Connection Condition Specified Condition C3-2 (IJ1-) - C3-5 (IJ1+) 20°C (68°F) 1.74 to 2.04 ohms C4-1 (IJ2-) - C4-4 (IJ2+) 20°C (68°F) 1.74 to 2.04 ohms C3-1 (IJ3-) - C3-4 (IJ3+) 20°C (68°F) 1.74 to 2.04 ohms C4-3 (IJ4-) - C4-6 (IJ4+) 20°C (68°F) 1.74 to 2.04 ohms HINT: The standard values shown are fuel injector assembly resistance values. Standard Resistance (Check for short) Tester Connection Condition Specified Condition C3-2 (IJ1-) or C3-5 (IJ1+) - Body ground 20°C (68°F) 1 Mohms or higher C4-1 (IJ2-) or C4-4 (IJ2+) - Body ground 20°C (68°F) 1 Mohms or higher C3-1 (IJ3-) or C3-4 (IJ3+) - Body ground 20°C (68°F) 1 Mohms or higher C4-3 (IJ4-) or C4-6 (IJ4+) - Body ground 20°C (68°F) 1 Mohms or higher NG --> See step 8 OK: Go to next step
3. CHECK HARNESS AND CONNECTOR (ECM - INJECTOR DRIVER (EDU)) Disconnect the ECM connectors. Disconnect the injector driver (EDU) connector. Measure the resistance according to the value(s) in the table below. Standard Resistance (Check for open) Tester Connection Condition Specified Condition A36-14 (#1) - C1-3 (IJT1) Always Below 1 ohms A36-25 (#2) - C1-12 (IJT2) Always Below 1 ohms A36-24 (#3) - C1-11 (IJT3) Always Below 1 ohms A36-23 (#4) - C1-2 (IJT4) Always Below 1 ohms Standard Resistance (Check for short) Tester Connection Condition Specified Condition A36-14 (#1) or C1-3 (IJT1) - Body ground Always 10 kohms or higher A36-25 (#2) or C1-12 (IJT2) - Body ground Always 10 kohms or higher A36-24 (#3) or C1-11 (IJT3) - Body ground Always 10 kohms or higher A36-23 (#4) or C1-2 (IJT4) - Body ground Always 10 kohms or higher NG --> REPAIR OR REPLACE HARNESS OR CONNECTOR OK: Go to next step
4. CLEAR DTC Connect the Techstream to the DLC3. Turn the ignition switch to ON. Turn the Techstream on. Clear the DTCs. Refer to «DTC CHECK / CLEAR [07/2013 - ]»(ref-612245-S39444024262014042900000) . Turn the ignition switch off and wait for at least 30 seconds. NEXT: Go to next step
5. CHECK ECM (ECM OUTPUT VOLTAGE) Disconnect the injector driver (EDU) connector. Inspect the ECM using an oscilloscope. While cranking the engine, check waveform the terminals of the ECM connector. Standard Signal waveform appears as shown in the illustration. ECM Terminal Name A36-14 (#1) or A36-23 (#4) - Body ground A36-25 (#2) or A36-24 (#3) - Body ground Tester Range 2 V/DIV., 4 ms./DIV. Condition Cranking TEXT IN ILLUSTRATION *a Component with harness connected (ECM) NG --> See step 9 OK --> See step 10
6. CHECK HARNESS OR CONNECTOR (ECM - INJECTOR DRIVER (EDU)) Disconnect the ECM connector. Disconnect the injector driver (EDU) connector. Measure the resistance according to the value(s) in the table below. Standard Resistance (Check for open) Tester Connection Condition Specified Condition A34-11 (IJF1) - C1-6 (IJF1) Always Below 1 ohms A34-31 (IJF2) - C1-5 (IJF2) Always Below 1 ohms Standard Resistance (Check for short) Tester Connection Condition Specified Condition A34-11 (IJF1) or C1-6 (IJF1) - Body ground Always 10 kohms or higher A34-31 (IJF2) or C1-5 (IJF2) - Body ground Always 10 kohms or higher NG --> REPAIR OR REPLACE HARNESS OR CONNECTOR OK: Go to next step
7. CHECK TERMINAL VOLTAGE (ECM OUTPUT VOLTAGE) Disconnect the injector driver (EDU) connector. Inspect the ECM using an oscilloscope. While start the engine, check waveform the terminals of the ECM connector. Standard Signal waveform appears as shown in the illustration. ECM Terminal Name A34-11 (IJF1) - Body ground A34-31 (IJF2) - Body ground Tester Range 2 V/DIV., 4 ms./DIV. Condition Idling TEXT IN ILLUSTRATION *a Component with harness connected (ECM) NG --> See step 9 OK --> See step 10
8. INSPECT FUEL INJECTOR ASSEMBLY (FOR DIRECT INJECTION) Inspect the resistance of the fuel injector (for direct injection). Refer to «INSPECTION [07/2013 - ]»(ref-612355-S12904111072014042900000) . NG --> See step 11 OK --> REPAIR OR REPLACE HARNESS OR CONNECTOR
9. REPLACE ECM. Refer to «REMOVAL [07/2013 - 12/2013]»(ref-612354-S32372465292014042900000)
10. REPLACE INJECTOR DRIVER (EDU). Refer to «REMOVAL [07/2013 - ]»(ref-612355-S33605946552014042900000)
11. REPLACE FUEL INJECTOR ASSEMBLY (FOR DIRECT INJECTION). Refer to «REMOVAL [07/2013 - ]»(ref-612355-S26558519832014042900000)

Note. After turning ignition 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 [07/2013 - ] .

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

1. 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.
2. Stop light switch assembly conditions can be checked using the Techstream. Connect the Techstream to the DLC3. Turn the ignition switch to ON. Turn the Techstream on. Enter the following menus: Powertrain / Engine / Data List / Stop Light Switch and ST1. Check the Data List indication when the brake pedal is depressed and released. Brake Pedal Operation Stop Light Switch ST1 Depressed ON ON Released OFF OFF

Scheme 182

1. CHECK VEHICLE TYPE Confirm the transmission. RESULT Result Proceed to Manual Transmission A Automatic Transmission B B --> See step 5 A: Go to next step
2. INSPECT TERMINAL VOLTAGE (POWER SOURCE OF NEUTRAL POSITION SWITCH) Disconnect the neutral position switch connector. Measure the voltage according to the value(s) in the table below. Standard Voltage Tester Connection Condition Specified Condition A54-1 - A54-2 Ignition switch ON 11 to 14 V TEXT IN ILLUSTRATION *a Front view of wire harness connector (to Neutral Position Switch) NG --> See step 4 OK: Go to next step
3. INSPECT NEUTRAL POSITION SWITCH Inspect the neutral position switch. Refer to «INSPECTION [07/2013 - ]»(ref-612362-S21562670082014042900000) . NG --> See step 11 OK --> See step 10
4. CHECK HARNESS AND CONNECTOR (NEUTRAL POSITION SWITCH - ECM) Disconnect the ECM connector. Disconnect the neutral position switch connector. Measure the resistance according to the value(s) in the table below. Standard Resistance (Check for open) Tester Connection Condition Specified Condition A33-16 (NSW) - A54-2 Always Below 1 ohms A33-4 (EC) - A54-1 Always Below 1 ohms Standard Resistance (Check for short) Tester Connection Condition Specified Condition A33-16 (NSW) or A54-2 - Body ground Always 10 kohms or higher A33-4 (EC) or A54-1 - Body ground Always 10 kohms or higher NG --> REPAIR OR REPLACE HARNESS OR CONNECTOR OK --> See step 9
5. INSPECT TERMINAL VOLTAGE (POWER SOURCE OF PARK/NEUTRAL POSITION SWITCH ASSEMBLY) Disconnect the park/neutral position switch assembly connector. Measure the voltage according to the value(s) in the table below. Standard Voltage Tester Connection Condition Specified Condition L2-4 - L2-5 Ignition switch ON 11 to 14 V TEXT IN ILLUSTRATION *a Front view of wire harness connector (to Park/Neutral Position Switch Assembly) NG --> See step 7 OK: Go to next step
6. INSPECT PARK/NEUTRAL POSITION SWITCH ASSEMBLY Inspect the park/neutral position switch assembly. Refer to «INSPECTION [07/2013 - ]»(ref-612361-S22229953602014042900000) . NG --> See step 8 OK --> See step 10
7. CHECK HARNESS AND CONNECTOR (PARK/NEUTRAL POSITION SWITCH ASSEMBLY - ECM - BODY GROUND) Disconnect the ECM connector. Disconnect the park/neutral position switch assembly connector. Measure the resistance according to the value(s) in the table below. Standard Resistance (Check for open) Tester Connection Condition Specified Condition A33-16 (NSW) - L2-4 Always Below 1 ohms L2-5 - Body ground Always Below 1 ohms Standard Resistance (Check for short) Tester Connection Condition Specified Condition A33-16 (NSW) or L2-4 - Body ground Always 10 kohms or higher NG --> REPAIR OR REPLACE HARNESS OR CONNECTOR OK --> See step 9
8. REPLACE PARK/NEUTRAL POSITION SWITCH ASSEMBLY. Refer to «REMOVAL [07/2013 - ]»(ref-612361-S21658826542014042900000)
9. REPLACE ECM. Refer to «REMOVAL [07/2013 - 12/2013]»(ref-612354-S32372465292014042900000)
10. CHECK FOR INTERMITTENT PROBLEMS. Refer to «CHECK FOR INTERMITTENT PROBLEMS [07/2013 - ]»(ref-612245-S25693203212014042900000)
11. REPLACE NEUTRAL POSITION SWITCH. Refer to «REMOVAL [07/2013 - ]»(ref-612362-S35218262332014042900000)

Note. Never clean the throttle with motor body assembly.

HINT

1. Read freeze frame data using the Techstream. Freeze frame data records engine conditions when a malfunction occurs. This information can be useful when troubleshooting.
2. 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.

Note. Never clean the throttle with motor body assembly.

HINT

1. Read freeze frame data using the Techstream. Freeze frame data records engine conditions when a malfunction occurs. This information can be useful when troubleshooting.
2. 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.

Note. Never clean the throttle with motor body assembly. Inspect the fuses for circuits related to this system before performing the following inspection procedure.

HINT

1. Refer to "Data List / Active Test" [Throttle Position No. 1, Throttle Motor Position No. 2, Throttle Position Command, Throttle Motor Duty (Open) and Throttle Motor Duty (Close)]. Refer to «DATA LIST / ACTIVE TEST [07/2013 - ]»(ref-612245-S03756204762014042900000) .
2. 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

1. Read freeze frame data using the Techstream. Freeze frame data records the engine condition when malfunctions are detected. 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.
2. Bank 1 refers to the bank that includes the No. 1 cylinder*. *: The No. 1 cylinder is the cylinder which is farthest from the transmission.
3. Bank 2 refers to the bank that does not include the No. 1 cylinder.
4. Sensor 1 refers to the sensor closest to the engine assembly.
5. Sensor 2 refers to the sensor farthest away from the engine assembly.

HINT

1. If the current from the INJ relay is cut because DTC P062D is stored, DTC P1235 will be stored even if the fuel pump assembly (for high pressure) is normal.
2. 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.

DTC SUMMARY

HINT

1. In contrast to normal malfunction diagnosis for components, circuits and systems, DTCs P1603 is used to determine the malfunctioning area from the problem symptoms and freeze frame data when the user mentions problems such as engine stall. As these DTCs can be stored as a result of certain user actions, even if these DTCs are output, if the customer makes no mention of problems, clear these DTCs without performing any troubleshooting and return the vehicle to the customer.
2. If any other DTCs are output, perform troubleshooting for those DTCs first.
3. Use any information from the customer problem analysis about the condition of the vehicle at the time when the problem occurred (how the engine stopped, conditions when the engine was restarted, etc.) as a reference. Symptom Suspected Area Engine vibration occurs and engine stops Air-fuel ratio abnormal Engine stops with no engine vibration Ignition system, injection stoppage, high load from external parts Rough idling after engine started Air-fuel ratio abnormal, abnormal combustion
4. Read freeze frame data using the Techstream. Freeze frame data records engine conditions when a malfunction occurs. This information can be useful when troubleshooting.
5. When confirming the freeze frame data, be sure to check all 5 sets of freeze frame data. Refer to «FREEZE FRAME DATA [07/2013 - ]»(ref-612245-S16816801152014042900000) .
6. When confirming freeze frame data, if there are multiple items related to the cause of the malfunction, perform troubleshooting for all related items.
7. Try to operate 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 the data when the engine is idling (engine warmed up, no load, and shift lever in D, N or neutral) and compare these data with the freeze frame data.
8. Inspections take into account the fact that the malfunction may not have reoccurred and place emphasis on checking the vehicle conditions present at the time when the malfunction occurred.
9. When performing inspections, jiggle the relevant wire harnesses and connectors in an attempt to reproduce malfunctions that do not always occur.

Inspection flow

Using freeze frame data, narrow down the parts to be inspected according to the vehicle conditions at the time when the malfunction occurred.

Scheme 183

1

1. If the engine stalled when the intake air volume was low (during idling or deceleration), there may be a decrease in torque due to an incorrect air-fuel ratio, etc.
2. If the engine stalled when the intake air volume was high (during driving or acceleration), there may be a major malfunction such as continuous misfire due to ignition stoppage, fuel injection stoppage, etc. and the torque drops to zero.

2

1. If the engine speed decreased slowly, there may have been a decrease in torque due to an air-fuel ratio that was incorrect (by approximately 20 to 30%), etc.
2. If the engine speed decreased rapidly, there may have been a malfunction such as when the engine misfires almost continuously due to ignition stoppage, fuel injection stoppage, etc., or when the external load increases due to an external part malfunctioning.

3

1. If the air-fuel ratio is abnormal, there may have been an intake air leak, sensor malfunction, or fuel supply problem.
2. If the vehicle was normal, the air volume may have been insufficient or the ignition timing may have been incorrect.

P1603 inspection flow: Narrow down the parts to be inspected according to the vehicle conditions at the time when the malfunction occurred (freeze frame data).

*: If the engine stalls immediately after the injection method is switched from port injection to direct injection, the injector driver (EDU) may be malfunctioning.

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

HINT

1. In contrast to normal malfunction diagnosis for components, circuits and systems, DTCs P1603 is used to determine the malfunctioning area from the problem symptoms and freeze frame data when the user mentions problems such as engine stall. As these DTCs can be stored as a result of certain user actions, even if these DTCs are output, if the customer makes no mention of problems, clear these DTCs without performing any troubleshooting and return the vehicle to the customer.
2. If any other DTCs are output, perform troubleshooting for those DTCs first.
3. Use any information from the customer problem analysis about the condition of the vehicle at the time when the problem occurred (how the engine stopped, conditions when the engine was restarted, etc.) as a reference. Symptom Suspected Area Engine vibration occurs and engine stops Air-fuel ratio abnormal Engine stops with no engine vibration Ignition system, injection stoppage, high load from external parts Rough idling after engine started Air-fuel ratio abnormal, abnormal combustion
4. Read freeze frame data using the Techstream. Freeze frame data records engine conditions when a malfunction occurs. This information can be useful when troubleshooting.
5. When confirming the freeze frame data, be sure to check all 5 sets of freeze frame data. Refer to «FREEZE FRAME DATA [07/2013 - ]»(ref-612245-S16816801152014042900000) .
6. When confirming freeze frame data, if there are multiple items related to the cause of the malfunction, perform troubleshooting for all related items.
7. Try to operate 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 the data when the engine is idling (engine warmed up, no load, and shift lever in D, N or neutral) and compare these data with the freeze frame data.
8. Inspections take into account the fact that the malfunction may not have reoccurred and place emphasis on checking the vehicle conditions present at the time when the malfunction occurred.
9. When performing inspections, jiggle the relevant wire harnesses and connectors in an attempt to reproduce malfunctions that do not always occur.

Inspection flow

Using freeze frame data, narrow down the parts to be inspected according to the vehicle conditions at the time when the malfunction occurred.

1

1. If the engine stalled when the intake air volume was low (during idling or deceleration), there may be a decrease in torque due to an incorrect air-fuel ratio, etc.
2. If the engine stalled when the intake air volume was high (during driving or acceleration), there may be a major malfunction such as continuous misfire due to ignition stoppage, fuel injection stoppage, etc. and the torque drops to zero.

2

1. If the engine speed decreased slowly, there may have been a decrease in torque due to an air-fuel ratio that was incorrect (by approximately 20 to 30%), etc.
2. If the engine speed decreased rapidly, there may have been a malfunction such as when the engine misfires almost continuously due to ignition stoppage, fuel injection stoppage, etc., or when the external load increases due to an external part malfunctioning.

3

1. If the air-fuel ratio is abnormal, there may have been an intake air leak, sensor malfunction, or fuel supply problem.
2. If the vehicle was normal, the air volume may have been insufficient or the ignition timing may have been incorrect.

P1603 inspection flow: Narrow down the parts to be inspected according to the vehicle conditions at the time when the malfunction occurred (freeze frame data).

*: If the engine stalls immediately after the injection method is switched from port injection to direct injection, the injector driver (EDU) may be malfunctioning.

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