NO.5 ENGINE STALLS-AFTER START/AT IDLE [WL-C, WE-C]

5	ENGINE STALLS‐AFTER START/AT IDLE
DESCRIPTION	• Engine stops unexpectedly.
POSSIBLE CAUSE	• Poor fuel quality • Intake-air system restriction or clogging • Engine overheating • A/C system improper operation • Immobilizer system and/or circuit malfunction (if equipped) • Main relay malfunction • Glow system malfunction • Inadequate fuel pressure • Fuel pressure sensor related circuit malfunction • Fuel pressure limiter malfunction (built-in common rail) • Fuel leakage • Fuel line clogging or restriction • Fuel filter clogging or restriction • Incorrect fuel injection timing • Erratic signal from CKP sensor • Erratic signal from CMP sensor • Supply pump malfunction • Fuel injector malfunction • Low engine compression • Improper valve timing • Exhaust system and/or catalyst converter restriction or clogging • EGR system malfunction • ECT sensor or related circuit malfunction • Accelerator pedal position (APP) sensor or related circuit malfunction • MAF sensor/IAT sensor No.2 or related circuit malfunction • V-reference voltage supply circuit 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 injury or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete “BEFORE REPAIR PROCEDURE” and “AFTER REPAIR PROCEDURE” described in this manual.

ENGINE STALLS‐AFTER START/AT IDLE

DESCRIPTION

• Engine stops unexpectedly.

POSSIBLE CAUSE

• Poor fuel quality

• Intake-air system restriction or clogging

• Engine overheating

• A/C system improper operation

• Immobilizer system and/or circuit malfunction (if equipped)

• Main relay malfunction

• Glow system malfunction

• Inadequate fuel pressure

• Fuel pressure sensor related circuit malfunction

• Fuel pressure limiter malfunction (built-in common rail)

• Fuel leakage

• Fuel line clogging or restriction

• Fuel filter clogging or restriction

• Incorrect fuel injection timing

• Erratic signal from CKP sensor

• Erratic signal from CMP sensor

• Supply pump malfunction

• Fuel injector malfunction

• Low engine compression

• Improper valve timing

• Exhaust system and/or catalyst converter restriction or clogging

• EGR system malfunction

• ECT sensor or related circuit malfunction

• Accelerator pedal position (APP) sensor or related circuit malfunction

• MAF sensor/IAT sensor No.2 or related circuit malfunction

• V-reference voltage supply circuit 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 injury or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete “BEFORE REPAIR PROCEDURE” and “AFTER REPAIR PROCEDURE” described in this manual.

STEP	INSPECTION	RESULTS	ACTION
1	Note • The following test should be perform for vehicles with immobilizer system. Go to Step 10 for vehicles without immobilizer system. Connect the M-MDS to the DLC-2. Do following conditions appear? • Engine is not completely started. • DTC P1260 is displayed.	Yes	Both conditions appear: Go to Step 4.
No	Either or other condition appears: Go to the next step.
2	Is the coil connector securely connected to coil?	Yes	Go to the next step.
No	Connect the coil connector securely. Return to Step 1.
3	Does the security light illuminate?	Yes	Go to the next step.
No	Inspect the instrument cluster and wiring harness.
4	Connect the M-MDS to the DLC-2 and retrieve the any DTCs. DTC P1259, P1260, P1602, P1603, P1621, P1622, P1623, P1624	Yes	Go to the appropriate DTC test.
No	Go to the next step.
5	Is there continuity between PCM ground terminals 202, 204, 206 and ground?	Yes	Go to the next step.
No	Repair or replace wiring harness.
6	Turn the engine switch to the ON position (Engine off). Access the VPWR PID. Is the VPWR PID normal? Specification Battery voltage	Yes	Go to the next step.
No	Repair or replace wiring harness.
7	Inspect the following wiring harnesses and connectors. • Between immobilizer unit terminal F and coil terminal A • Between immobilizer unit terminal D and coil terminal C Is there any malfunction (open or short circuit, terminal corrosion, etc.)?	Yes	Repair or replace malfunctioning part.
No	Go to the next step.
8	Inspect the following: • Fuel quality (e.g.: include water contamination, winter/summer blend) • Fuel line/fuel filter clogging • Intake-air system restriction Are all items normal?	Yes	Go to the next step.
No	Service if necessary. Repeat Step 8.
9	Is the engine overheating?	Yes	Go to symptom troubleshooting “NO.17 COOLING SYSTEM CONCERNS-OVERHEATING [WL-C, WE-C]”.
No	Go to the next step.
10	Note • Ignore DTC P0122, P0123, P0222 or P0223 while performing this test. Disconnect the APP sensor connector. Measure the voltage at the APP sensor connector the VREF terminal (terminal A) with the engine switch to the ON position. Specification 4.5—5.5 V Is the voltage normal?	Yes	Go to the next step.
No	Inspect the open or short circuit for wiring harness. • Between PCM terminal 213 and APP sensor terminal A
11	Connect the M-MDS to the DLC-2. Turn the engine switch to the ON position (Engine off). Retrieve the any DTCs. Are any DTC displayed?	Yes	DTC is displayed: Go to the appropriate DTC test. Communication error message is displayed: Inspect the following: • Open circuit between main relay and PCM terminal 201, 203, 205 • Open circuit main relay and PCM terminal 219 • Main relay stuck open • Open or poor ground circuit (PCM terminal 202, 204, 206) • Poor connection vehicle body ground
No	No DTC is displayed: Go to the next step.
12	Does the engine start normally after warm-up?	Yes	Inspect the glow system operation. (See GLOW PLUG RELAY INSPECTION [WL-C, WE-C].) Replace any malfunctioning part if necessary. If the glow system is normal, go to the next step.
No	Go to the next step.
13	Is there any restriction in the exhaust system or the catalyst converter?	Yes	Repair or replace if necessary.
No	Go to the next step.
14	Access the RPM PID. Is the RPM PID indicating engine speed during cranking engine?	Yes	Go to the next step.
No	Go to Step 17.
15	Note • The following test should be performed on the vehicles with A/C system. If the following test cannot be performed due to engine stalling, go to the next step. • Go to the next step for the vehicle without A/C system. Connect the pressure gauge to the A/C line. Turn the blower and the A/C switches on. Is the pressure within specifications?	Yes	Go to the next step.
No	A/C is always on: Go to symptom troubleshooting “NO.24 A/C ALWAYS ON OR A/C COMPRESSOR RUNS CONTINUOUSLY [WL-C, WE-C]”. Other symptoms: Inspect following: • Refrigerant charging amount • Cooling fan No.1 and/or cooling fan No.2 operation
16	Inspect the adjustment of the APP sensor. (See ACCELERATOR PEDAL POSITION (APP) SENSOR INSPECTION [WL-C, WE-C].) Are APP sensor adjusted correctly?	Yes	Go to the next step.
No	Adjust APP sensor correctly.
17	Depress the accelerator pedal slightly. Crank engine. Does the engine start now?	Yes	Inspect the idle speed. (See ENGINE TUNE-UP [WL-C, WE-C].)
No	Go to the next step.
18	Inspect for fuel leakage from fuel pipe. Is any fuel leakage found on fuel pipe?	Yes	Repair or replace if necessary.
No	Go to the next step.
19	Inspect the CKP sensor. (See CRANKSHAFT POSITION (CKP) SENSOR INSPECTION [WL-C, WE-C].) (See CRANKSHAFT POSITION (CKP) SENSOR REMOVAL/INSTALLATION [WL-C, WE-C].) Is the CKP sensor normal?	Yes	Go to the next step.
No	Replace the CKP sensor. Then go to the next step.
20	Visually inspect the CMP sensor and teeth of the pulse wheel. Are the CMP sensor and teeth of pulse wheel normal?	Yes	Inspect following PIDs: (See PCM INSPECTION (Thailand, General (L.H.D. R.H.D.) specs.) [WL-C, WE-C].) • ECT • IAT • MAF • RPM If the PID value is not as specified, repair or replace malfunctioning parts. If the PID value is normal, go to the next step.
No	Replace malfunctioning parts.
21	Inspect the fuel pressure sensor. (See FUEL PRESSURE SENSOR INSPECTION [WL-C, WE-C].) Is the fuel pressure normal?	Yes	Go to the next step.
No	Replace common rail.
22	Is the engine compression correct? (See COMPRESSION INSPECTION [WL-C, WE-C].)	Yes	Go to the next step.
No	Inspect the following: • Damaged valve seat • Worn valve stem and valve guide • Worn or stuck piston ring • Worn piston, piston ring or cylinder • Improper valve timing Service if necessary.
23	Inspect the fuel injector. (See FUEL INJECTOR INSPECTION [WL-C, WE-C].) Is the fuel injector normal?	Yes	Go to the next step.
No	Repair or replace if necessary.
24	Inspect the EGR system operation. Is the EGR system operation normal?	Yes	Go to the next step.
No	Repair or replace malfunctioning part according to EGR system operation results.
25	Verify test results. • If normal, return to the diagnostic index to service any additional symptoms. (See SYMPTOM DIAGNOSTIC INDEX [WL-C, WE-C].) • If the malfunction remains, inspect the related Service Information and perform repair or diagnosis. ― If the vehicle is repaired, the troubleshooting completed. ― If the vehicle is not repaired or additional diagnostic information is not available, reprogram the PCM if later calibration is available. Retest.

STEP

INSPECTION

RESULTS

ACTION

Note

• The following test should be perform for vehicles with immobilizer system. Go to Step 10 for vehicles without immobilizer system.

Connect the M-MDS to the DLC-2.

Do following conditions appear?

• Engine is not completely started.

• DTC P1260 is displayed.

Yes

Both conditions appear:

Go to Step 4.

Either or other condition appears:

Go to the next step.

Is the coil connector securely connected to coil?

Yes

Go to the next step.

Connect the coil connector securely.

Return to Step 1.

Does the security light illuminate?

Yes

Go to the next step.

Inspect the instrument cluster and wiring harness.

Connect the M-MDS to the DLC-2 and retrieve the any DTCs.

DTC

P1259, P1260, P1602, P1603, P1621, P1622, P1623, P1624

Yes

Go to the appropriate DTC test.

Go to the next step.

Is there continuity between PCM ground terminals 202, 204, 206 and ground?

Yes

Go to the next step.

Repair or replace wiring harness.

Turn the engine switch to the ON position (Engine off).

Access the VPWR PID.

Is the VPWR PID normal?

Specification

Battery voltage

Yes

Go to the next step.

Repair or replace wiring harness.

Inspect the following wiring harnesses and connectors.

• Between immobilizer unit terminal F and coil terminal A

• Between immobilizer unit terminal D and coil terminal C

Is there any malfunction (open or short circuit, terminal corrosion, etc.)?

Yes

Repair or replace malfunctioning part.

Go to the next step.

Inspect the following:

• Fuel quality (e.g.: include water contamination, winter/summer blend)

• Fuel line/fuel filter clogging

• Intake-air system restriction

Are all items normal?

Yes

Go to the next step.

Service if necessary.

Repeat Step 8.

Is the engine overheating?

Yes

Go to symptom troubleshooting “NO.17 COOLING SYSTEM CONCERNS-OVERHEATING [WL-C, WE-C]”.

Go to the next step.

Note

• Ignore DTC P0122, P0123, P0222 or P0223 while performing this test.

Disconnect the APP sensor connector.

Measure the voltage at the APP sensor connector the VREF terminal (terminal A) with the engine switch to the ON position.

Specification

4.5—5.5 V

Is the voltage normal?

Yes

Go to the next step.

Inspect the open or short circuit for wiring harness.

• Between PCM terminal 213 and APP sensor terminal A

Connect the M-MDS to the DLC-2.

Turn the engine switch to the ON position (Engine off).

Retrieve the any DTCs.

Are any DTC displayed?

Yes

DTC is displayed:

Go to the appropriate DTC test.

Communication error message is displayed:

Inspect the following:

• Open circuit between main relay and PCM terminal 201, 203, 205

• Open circuit main relay and PCM terminal 219

• Main relay stuck open

• Open or poor ground circuit (PCM terminal 202, 204, 206)

• Poor connection vehicle body ground

No DTC is displayed:

Go to the next step.

Does the engine start normally after warm-up?

Yes

Inspect the glow system operation.

(See GLOW PLUG RELAY INSPECTION [WL-C, WE-C].)

Replace any malfunctioning part if necessary.

If the glow system is normal, go to the next step.

Go to the next step.

Is there any restriction in the exhaust system or the catalyst converter?

Yes

Repair or replace if necessary.

Go to the next step.

Access the RPM PID.

Is the RPM PID indicating engine speed during cranking engine?

Yes

Go to the next step.

Go to Step 17.

Note

• The following test should be performed on the vehicles with A/C system. If the following test cannot be performed due to engine stalling, go to the next step.

• Go to the next step for the vehicle without A/C system.

Connect the pressure gauge to the A/C line.

Turn the blower and the A/C switches on.

Is the pressure within specifications?

Yes

Go to the next step.

A/C is always on:

Go to symptom troubleshooting “NO.24 A/C ALWAYS ON OR A/C COMPRESSOR RUNS CONTINUOUSLY [WL-C, WE-C]”.

Other symptoms:

Inspect following:

• Refrigerant charging amount

• Cooling fan No.1 and/or cooling fan No.2 operation

Inspect the adjustment of the APP sensor.

(See ACCELERATOR PEDAL POSITION (APP) SENSOR INSPECTION [WL-C, WE-C].)

Are APP sensor adjusted correctly?

Yes

Go to the next step.

Adjust APP sensor correctly.

Depress the accelerator pedal slightly.

Crank engine.

Does the engine start now?

Yes

Inspect the idle speed.

(See ENGINE TUNE-UP [WL-C, WE-C].)

Go to the next step.

Inspect for fuel leakage from fuel pipe.

Is any fuel leakage found on fuel pipe?

Yes

Repair or replace if necessary.

Go to the next step.

Inspect the CKP sensor.

(See CRANKSHAFT POSITION (CKP) SENSOR INSPECTION [WL-C, WE-C].)

(See CRANKSHAFT POSITION (CKP) SENSOR REMOVAL/INSTALLATION [WL-C, WE-C].)

Is the CKP sensor normal?

Yes

Go to the next step.

Replace the CKP sensor.

Then go to the next step.

Visually inspect the CMP sensor and teeth of the pulse wheel.

Are the CMP sensor and teeth of pulse wheel normal?

Yes

Inspect following PIDs:

(See PCM INSPECTION (Thailand, General (L.H.D. R.H.D.) specs.) [WL-C, WE-C].)

• ECT

• IAT

• MAF

• RPM

If the PID value is not as specified, repair or replace malfunctioning parts.

If the PID value is normal, go to the next step.

Replace malfunctioning parts.

Inspect the fuel pressure sensor.

(See FUEL PRESSURE SENSOR INSPECTION [WL-C, WE-C].)

Is the fuel pressure normal?

Yes

Go to the next step.

Replace common rail.

Is the engine compression correct?

(See COMPRESSION INSPECTION [WL-C, WE-C].)

Yes

Go to the next step.

Inspect the following:

• Damaged valve seat

• Worn valve stem and valve guide

• Worn or stuck piston ring

• Worn piston, piston ring or cylinder

• Improper valve timing

Service if necessary.

Inspect the fuel injector.

(See FUEL INJECTOR INSPECTION [WL-C, WE-C].)

Is the fuel injector normal?

Yes

Go to the next step.

Repair or replace if necessary.

Inspect the EGR system operation.

Is the EGR system operation normal?

Yes

Go to the next step.

Repair or replace malfunctioning part according to EGR system operation results.

Verify test results.

• If normal, return to the diagnostic index to service any additional symptoms.

(See SYMPTOM DIAGNOSTIC INDEX [WL-C, WE-C].)

• If the malfunction remains, inspect the related Service Information and perform repair or diagnosis.

― If the vehicle is repaired, the troubleshooting completed.

― If the vehicle is not repaired or additional diagnostic information is not available, reprogram the PCM if later calibration is available. Retest.