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DTC P1603-00: Engine Stall History [11/2016 - ]: Procedure

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  1. CHECK DTC OUTPUT (SFI SYSTEM) 
    1. Connect the Techstream to the DLC3.
    2. Turn the ignition switch to ON.
    3. Turn the Techstream on.
    4. Enter the following menus: Powertrain / Engine / Trouble Codes.

      Powertrain > Engine > Trouble Codes 

    5. Read the DTCs.
      Result Proceed to
      SFI system DTCs are not output A
      SFI system starting malfunction circuit DTC is output and starter assembly does not operate
      SFI system starting malfunction circuit DTC is output and starter assembly operates B
      DTCs other than SFI system starting malfunction circuit DTC are output

      HINT: 

      • According to the display on the Techstream, check the freeze frame data item [Cranking Time] in the sets of freeze frame data.
      • If the value of [Cranking Time] is approximately 3 seconds, the stop and start control system or starter system may be malfunctioning.
      • If the value of [Cranking Time] is small (approximately 0.5 seconds or less: the minimum value varies depending on the model), the SFI system may be malfunctioning.
      • The Data List item [Cranking Time] indicates the length of time starter operation is requested by the engine stop and start ECU. If the engine speed exceeds the specified value, the engine stop and start ECU cancels its start request.

    Result: 

    B 

    GO TO SFI SYSTEM: 

    Refer to DIAGNOSTIC TROUBLE CODE CHART [11/2016 - 10/2017]

    Refer to DIAGNOSTIC TROUBLE CODE CHART [10/2017 - ]

    Result: 

    A 

    Go to next step 

  2. CHECK FREEZE FRAME DATA 
    NOTE:

    The freeze frame data is cleared when DTCs are cleared. Be sure to make a note of necessary data in advance.

    HINT: 

    Using the time-series freeze frame data, confirm the freeze frame data recorded the moment the DTC was stored and after the DTC was stored. This information can be useful when troubleshooting.

    1. According to the prompts on the Techstream screen, read the time-series freeze frame data to confirm the vehicle conditions when an engine stall occurred while stop and start control was operating.

      Refer to FREEZE FRAME DATA [11/2016 - ]

    2. Check the freeze frame data for engine stall history and engine start failure.
      Techstream Display Result Proceed to
      Engine Stall History during Stop&Start (Hood Open) Yes A
      Engine Stall History during Stop&Start (Collision or Battery Voltage Low) Yes B
      Engine Stall History during Engine Starting (Collision) Yes
      Engine Start Fail Yes C

    Result: 

    B 

    See step  7

    Result: 

    C 

    See step  8

    Result: 

    A 

    Go to next step 

  3. READ VALUE USING TECHSTREAM (HOOD COURTESY SWITCH) 
    NOTE:

    Before performing this step, check that the engine hood can be opened by pulling the hood lock control cable.

    1. Connect the Techstream to the DLC3.
    2. Turn the ignition switch to ON.
    3. Turn the Techstream on.
    4. Enter the following menus: Powertrain / Stop and Start / Data List / Hood Courtesy Switch.

      Powertrain > Stop and Start > Data List 

      Tester Display
      Hood Courtesy Switch
    5. According to the display on the Techstream, read the Data List.

      OK

      Techstream Display Condition Normal Condition
      Hood Courtesy Switch Engine hood closed ON
      Engine hood open OFF
      Proceed to
      OK
      NG

    Result: 

    OK 

    USE SIMULATION METHOD TO CHECK.  Refer to HOW TO PROCEED WITH TROUBLESHOOTING [11/2016 - ] .

    Result: 

    NG 

    Go to next step 

  4. INSPECT HOOD LOCK ASSEMBLY (ENGINE HOOD COURTESY SWITCH) 
    1. Inspect the engine hood courtesy switch (hood lock assembly).

      Refer to INSPECTION [12/2013 - ]

      Proceed to
      OK
      NG

    Result: 

    NG 

    REPLACE HOOD LOCK ASSEMBLY (ENGINE HOOD COURTESY SWITCH).  Refer to REMOVAL [11/2016 - ] .

    Result: 

    OK 

    Go to next step 

  5. CHECK HARNESS AND CONNECTOR (ENGINE HOOD COURTESY SWITCH (HOOD LOCK ASSEMBLY) - BODY GROUND) 
    1. Disconnect the engine hood courtesy switch (hood lock assembly) connector.
    2. Measure the resistance according to the value(s) in the table below.

      Standard Resistance

      Tester Connection Condition Specified Condition
      A10-2 - Body ground Always Below 1 Ω
      Proceed to
      OK
      NG

    Result: 

    NG 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result: 

    OK 

    Go to next step 

  6. CHECK HARNESS AND CONNECTOR (ENGINE STOP AND START ECU - ENGINE HOOD COURTESY SWITCH (HOOD LOCK ASSEMBLY)) 
    1. Disconnect the engine stop and start ECU connector.
    2. Disconnect the engine hood courtesy switch (hood lock assembly) connector.
    3. Measure the resistance according to the value(s) in the table below.

      Standard Resistance

      Tester Connection Condition Specified Condition
      A92-7 (BNT1) - A10-1 Always Below 1 Ω
      A92-7 (BNT1) or A10-1 - Body ground and other terminals Always 10 kΩ or higher
      Proceed to
      OK
      NG

    Result: 

    OK 

    REPLACE ENGINE STOP AND START ECU.  Refer to REMOVAL [11/2016 - ] .

    Result: 

    NG 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

  7. CHECK VEHICLE CONDITION (COLLISION HISTORY) 
    1. Check if the vehicle was in a collision when the engine stalled.
      Result Proceed to
      Vehicle was in collision when engine stalled A
      Vehicle was not in collision when engine stalled B

      HINT: 

      When "Engine Stall History during Stop&Start (Collision or Battery Voltage Low)" or "Engine Stall History during Engine Starting (Collision)" is stored:

      This may have been stored because the vehicle was in a collision or a collision detection signal was input while stop and start control was operating.

    Result: 

    A 

    END (ENGINE STALLED BECAUSE COLLISION DETECTION SIGNAL WAS RECEIVED) 

    Result: 

    B 

    GO TO AIRBAG SYSTEM.  Refer to HOW TO PROCEED WITH TROUBLESHOOTING [12/2013 - ] .

  8. CHECK HARNESS AND CONNECTOR (ENGINE STOP AND START ECU - ST RELAY AND ST NO. 2 RELAY) 
    1. Disconnect the engine stop and start ECU connector.
    2. Remove the ST relay and ST NO. 2 relay from the No. 1 engine room relay block and No. 1 junction block assembly.
    3. Disconnect the certification ECU (smart key ECU assembly) connector. (w/ Smart Key System)
    4. Disconnect the park/neutral position switch assembly connector.
    5. Disconnect the ECM connector.
    6. Measure the resistance according to the value(s) in the table below.

      Standard Resistance

      Tester Connection Condition Specified Condition
      A92-21 (STA) - ST relay terminal 2 Always Below 1 Ω
      A92-23 (STA2) - ST NO. 2 relay terminal 2 Always Below 1 Ω
      A92-21 (STA) or ST relay terminal 2 - Body ground and other terminals Always 10 kΩ or higher
      A92-23 (STA2) or ST NO. 2 relay terminal 2 - Body ground and other terminals Always 10 kΩ or higher
      Proceed to
      OK
      NG

    Result: 

    NG 

    REPAIR OR REPLACE HARNESS OR CONNECTOR (ENGINE STOP AND START ECU - ST RELAY OR ST NO. 2 RELAY) 

    Result: 

    OK 

    Go to next step 

  9. CHECK HARNESS AND CONNECTOR (ST RELAY AND ST NO. 2 RELAY - BODY GROUND) 
    1. Remove the ST relay and ST NO. 2 relay from the No. 1 engine room relay block and No. 1 junction block assembly.
    2. Measure the resistance according to the value(s) in the table below.

      Standard Resistance

      Tester Connection Condition Specified Condition
      ST relay terminal 1 - Body ground Always Below 1 Ω
      ST NO. 2 relay terminal 1 - Body ground Always Below 1 Ω
      Proceed to
      OK
      NG

    Result: 

    NG 

    REPAIR OR REPLACE HARNESS OR CONNECTOR (ST RELAY OR ST NO. 2 RELAY - BODY GROUND) 

    Result: 

    OK 

    Go to next step 

  10. CHECK HARNESS AND CONNECTOR (ST RELAY AND ST NO. 2 RELAY - BATTERY) 
    GTY725820Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *1 No. 1 Engine Room Relay Block and No. 1 Junction Block Assembly
    *2 ST NO. 2 Relay
    *3 ST Relay
    1. Remove the ST relay and ST NO. 2 relay from the No. 1 engine room relay block and No. 1 junction block assembly.
    2. Measure the voltage according to the value(s) in the table below.

      Standard Voltage

      Tester Connection Condition Specified Condition
      ST relay terminal 5 - Body ground Always 9.5 to 14 V
      ST NO. 2 relay terminal 5 - Body ground Always 9.5 to 14 V
      Proceed to
      OK
      NG

    Result: 

    NG 

    REPAIR OR REPLACE HARNESS OR CONNECTOR (ST RELAY OR ST NO. 2 RELAY - BATTERY) 

    Result: 

    OK 

    Go to next step 

  11. CHECK HARNESS AND CONNECTOR (STARTER ASSEMBLY - BATTERY) 
    GTY687886Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *1 Starter Assembly
    *a D4-1
    1. Measure the voltage according to the value(s) in the table below.

      Standard Voltage

      Tester Connection Condition Specified Condition
      D4-1 - Body ground Always 9.5 to 14 V
      NOTE:

      Before performing this step, check that the starter assembly connector D4 is not disconnected or loose.

      Proceed to
      OK
      NG

    Result: 

    NG 

    REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Result: 

    OK 

    Go to next step 

  12. CHECK HARNESS AND CONNECTOR (ST RELAY AND ST NO. 2 RELAY - STARTER ASSEMBLY) 
    1. Remove the ST relay and ST NO. 2 relay from the engine room relay block and junction block assembly.
    2. Disconnect the starter assembly connector.
    3. Measure the resistance according to the value(s) in the table below.

      Standard Resistance

      Tester Connection Condition Specified Condition
      ST relay terminal 3 - C65-2 Always Below 1 Ω
      ST NO. 2 relay terminal 3 - C65-1 (SL2) Always Below 1 Ω
      Proceed to
      OK
      NG

    Result: 

    NG 

    REPAIR OR REPLACE HARNESS OR CONNECTOR (ST RELAY OR ST NO. 2 RELAY - STARTER ASSEMBLY) 

    Result: 

    OK 

    Go to next step 

  13. INSPECT RELAY (ST RELAY AND ST NO. 2 RELAY) 
    1. Inspect the ST relay.

      Refer to PROCEDURE - Step 1

    2. Inspect the ST NO. 2 relay.

      Refer to PROCEDURE - Step 2

      Proceed to
      OK
      NG

    Result: 

    NG 

    REPLACE RELAY (ST RELAY OR ST NO. 2 RELAY) 

    Result: 

    OK 

    Go to next step 

  14. INSPECT STARTER ASSEMBLY 
    1. Inspect the starter assembly.

      Refer to INSPECTION [11/2016 - ]

      Proceed to
      OK
      NG

    Result: 

    OK 

    REPLACE ENGINE STOP AND START ECU.  Refer to REMOVAL [11/2016 - ] .

    Result: 

    NG 

    REPLACE STARTER ASSEMBLY.  Refer to REMOVAL [11/2016 - ] .

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