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NO.5 ENGINE STALLS-AFTER START/AT IDLE [L3]

BME010300103243

5 | ENGINE STALLS-AFTER START/AT IDLE
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DESCRIPTION | • Engine stops unexpectedly.
POSSIBLE CAUSE | • A/C system operation is improper • Air leakage from intake-air system parts • Purge solenoid valve malfunction • Improper operation of IAC valve • EGR valve malfunction
• No signal from CKP sensor due to sensor, related wire or wrong installation
• Vacuum leakage
• Engine overheating
• Low engine compression
• Spark leakage from high-tension leads
• Poor fuel quality
• PCV valve malfunction
• Air cleaner restriction
• Restriction in exhaust system
• Electrical connector disconnection
• Open or short circuit in fuel pump body and related harness
• No battery power supply to PCM or poor GND
• Inadequate fuel pressure
• Fuel pump body mechanical malfunction
• Fuel leakage from fuel injector
• Fuel injector clogging
• Ignition coil malfunction
• Improper air/fuel mixture ratio control
• Improper valve timing
• Immobilizer system and/or circuit malfunction (if equipped)
• Pressure regulator malfunction

  Warning
The following troubleshooting flow chart contains the fuel system diagnosis and repair procedures. Read the following warnings before performing the fuel system services:

  • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
  • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE SERVICE PRECAUTION" and "AFTER SERVICE PRECAUTION" described in this manual.
  (See BEFORE SERVICE PRECAUTION [L3].)
  (See AFTER SERVICE PRECAUTION [L3].)

  Caution

• Disconnecting/connecting quick release connector without cleaning it may possibly cause damage to fuel pipe and quick release connector. Always clean quick release connector joint area before disconnecting/connecting, and make sure that it is free of foreign material.

Diagnostic procedure

STEP | INSPECTION | RESULTS | ACTION
--- | --- | --- | ---
1 |

  Note

  • The following test should be performed for vehicles with immobilizer system. Go to Step 12 for the vehicles without immobilizer system.
Connect the WDS or equivalent to the DLC-2.
Do the following conditions appear?

• Engine is not completely started.
• DTC P1624 is displayed.
Yes

Both conditions appear:

Go to Step 4.
No | Either or other condition appears: Go to the next step.
2 | Does the engine stall after approx. 2 s since the engine is started? | Yes | Go to the next step.
No | The immobilizer system is normal. Go to Step 12.
3 | Is the immobilizer control module connector securely connected to the immobilizer control module? | Yes | Go to the next step.
No | Connect the immobilizer control module connector securely. Return to Step 2.
4 | Does the immobilizer indicator light flash and indicate any of the following immobilizer system DTCs? DTC 01, 02, 03, 11, 21 | Yes | Go to "ON-BOARD DIAGNOSTIC FUNCTION" of the immobilizer system.
No | Go to the next step.
5 | Does the security light illuminate? | Yes | Go to Step 8.
No | Go to the next step.
6 | Does the security light flash and indicate any of the following immobilizer system DTCs more than 135 s after the ignition switch is turned to the ON position? DTC 24, 30 | Yes | Go to "ON-BOARD DIAGNOSTIC FUNCTION" of the immobilizer system.
No | Go to the next step.
7 | Turn the ignition switch off. Disconnect the immobilizer control module connector. Connect a jumper wire between immobilizer control module connector terminal M and GND. Turn the ignition switch to the ON position. Does the security light illuminate? | Yes | Reconnect the immobilizer control module connector. Go to the next step.
No | Inspect for open circuit between immobilizer control module connector terminal M and instrument cluster. If normal, inspect the security light bulb. Repair or replace if necessary. Reconnect the immobilizer control module connector, then return to step 4.
8 | Connect the WDS or equivalent to the DLC-2 and retrieve DTC. Are any of the following DTCs displayed? DTC P1602, P1603, P1604, P1621, P1622, P1624 | Yes | Go to the applicable DTC inspection. (See DTC TABLE [L3].)
No | Go to the next step.
9 | Is there continuity between PCM GND terminals 4A, 4B, 4C and GND? | Yes | Go to the next step.
No | Repair or replace the wiring harness.
10 | Turn the ignition switch to the ON position. Access VPWR PID. Is VPWR PID normal? VPWR PID Battery voltage | Yes | Go to the next step.
No | Repair or replace the wiring harness.
11 | Disconnect the coil connector. Turn the ignition switch to the ON position. Is there battery voltage at immobilizer control module connector terminal J? | Yes | Inspect for open circuit between PCM connector terminal 2Q and immobilizer control module connector terminal A.
No | Repair or replace the wiring harness between immobilizer control module connector terminal J and fuse panel.
12 | Verify the following: • Vacuum connection • Air cleaner element • No air leakage from intake-air system • No restriction of intake-air system
• Proper sealing of intake manifold and components attached to intake manifold:
EGR valve, IAC valve
• Ignition wiring
• Fuel quality: proper octane, contamination, winter/summer blend
• Electrical connections
• Smooth operation of throttle valve
Are all items normal?
Yes
Go to the next step.
No | Service if necessary. Repeat Step 12.
13 | Turn the ignition switch to the ON position. Disconnect the TP sensor connector. Measure the voltage at TP sensor connector VREF terminal with the ignition switch at the ON position. Voltage 4.5-5.5 V Is the voltage normal? | Yes | Go to the next step.
No | Go to troubleshooting "No.27 Constant voltage".
14 | Connect the WDS or equivalent to the DLC-2. Retrieve any continuous memory, KOEO and KOER DTCs. If the engine stalls, retrieve continuous memory and KOEO DTCs. Are there any DTC displayed? | Yes | DTC is displayed: Go to the applicable DTC inspection. (See DTC TABLE [L3].) Communication error message is displayed: Inspect for the following:
• Open circuit between main relay and PCM terminal 2Y
• Open main relay GND circuit
• Main relay is stuck open.
• Open or poor GND circuit (PCM terminal 4X, 2AB or 2AC)
• Poor connection of vehicle body GND
No | No DTC is displayed: Go to the next step.
15 | Attempt to start the engine at part throttle. Does the engine run smoothly at part throttle? | Yes | Inspect the IAC valve and the wiring harness.
No | Go to the next step.
16 | Connect the WDS or equivalent to the DLC-2. Access RPM PID. Is RPM PID indicating the engine speed during the engine cranking? | Yes | Go to the next step.
No | Inspect for the following: • Open or short circuit in CKP sensor • Open or short circuit between CKP sensor and PCM terminal 2G or 2D • Open or short circuit in CKP sensor harnesses If the CKP sensor and the wiring harness are normal, go to the next step.
17 | Visually inspect the CKP sensor and teeth of the crankshaft pulley. Are the CKP sensor and teeth of the crankshaft pulley normal? | Yes | Go to the next step.
No | Replace the malfunctioning part.
18 | Measure the gap between the CKP sensor and teeth of the crankshaft pulley. Specification 0.5-1.9 mm {0.020-0.075 in} Is the gap within the specification? | Yes | Go to the next step.
No | Adjust the CKP sensor.
19 | Inspect for cracks on high-tension leads. Are there any cracks on high-tension leads? | Yes | Repair the high-tension leads.
No | Go to the next step.
20 | Is strong blue spark visible at each disconnected high-tension lead while cranking the engine? | Yes | Go to the next step. If symptom occurs with the A/C on, go to Step 24.
No | Inspect for following: • Open or short circuit in ignition coil • Open circuit in high-tension leads • Open circuit between ignition coil connector GND terminal and body GND • Open circuit between ignition switch and ignition coil
• Open circuit between ignition coil and PCM terminal 1A or 1B
21 | Inspect the spark plug condition. Is the spark plug wet, covered with carbon or grayish white? | Yes | Spark plug is wet or covered with carbon: Inspect for fuel leakage from the fuel injector. Spark plug is grayish white: Inspect for the clogged fuel injector.
No | Install the spark plugs on original cylinders. Go to the next step.
22 | Remove and shake the PCV valve. Does the PCV valve rattle? | Yes | Go to the next step.
No | Replace the PCV valve.
23 | Inspect for restriction in the exhaust system. Is there any restriction? | Yes | Inspect the exhaust system.
No | Go to the next step.
24 | Install a fuel pressure gauge between the fuel pipe and the fuel distributor. Connect a jumper wire between F/P terminal at the DLC-2 in the engine compartment and GND. Turn the ignition switch to the ON position. Is fuel line pressure correct with the ignition switch at the ON position?
(See FUEL LINE PRESSURE INSPECTION [L3].)
Yes
Go to the next step.
No | Zero or low: Inspect for clogged fuel line. If normal, replace the fuel pump unit. (See FUEL PUMP UNIT REMOVAL/INSTALLATION [L3].) High:
Replace the fuel pump unit.
(See FUEL PUMP UNIT REMOVAL/INSTALLATION [L3].)
25 | Visually inspect for fuel leakage at the fuel injector O-ring and fuel line. Service if necessary. Is fuel line pressure held after the ignition switch is turned off? (See FUEL LINE PRESSURE INSPECTION [L3].) | Yes | Go to the next step.
No | Inspect the fuel injector. If the fuel injector is normal, replace the fuel pump unit. (See FUEL PUMP UNIT REMOVAL/INSTALLATION [L3].)
26 |

  Note

  • The following test is for stall concerns with the A/C on. If other symptoms exist, go to the next step.
Connect a pressure gauges to the A/C low and high pressure side lines.
Turn the A/C on and measure low side and high side pressures.
Are pressures within the specifications?

Yes
Go to the next step.
No | If A/C is always on, go to symptom troubleshooting "No.24 A/C is always on or A/C compressor runs continuously". (See NO.24 A/C IS ALWAYS ON OR A/C COMPRESSOR RUNS CONTINUOUSLY [L3].) For other symptoms, inspect the following: • Refrigerant charging amount
• Condenser fan operation
27 | Disconnect vacuum hose between the purge solenoid valve and the intake manifold from the purge solenoid side. Plug opening end of vacuum hose. Start the engine. Is the engine stall now eliminated? | Yes | Inspect if the purge solenoid valve sticks open. Inspect the evaporative emission control system.
No | Go to the next step.
28 | Is air leakage felt or heard at the intake-air system components while racing the engine to higher speed? | Yes | Repair or replace the malfunctioning part.
No | Go to the next step.
29 | Inspect the engine condition while tapping the EGR valve housing. Does the engine condition improve? | Yes | Replace the EGR valve. (See EGR VALVE REMOVAL/INSTALLATION [L3].)
No | Go to the next step.
30 | Is the engine compression correct? | Yes | Inspect the valve timing.
No | Inspect for cause.
31 | Verify test results. • If normal, return to diagnostic index to service any additional symptoms. • If malfunction remains, replace PCM.