NO.4 HARD START/LONG CRANK/ERRATIC START/ERRATIC CRANK [WL-C, WE-C]

id0103b6804600

4

HARD START/LONG CRANK/ERRATIC START/ERRATIC CRANK
DESCRIPTION
•  Starter cranks engine at the normal speed but the engine requires excessive cranking time before starting.
•  Battery is in normal condition.
POSSIBLE CAUSE
•  Poor fuel quality
•  Intake-air system restriction or clogging
•  Starting system malfunction
•  Inadequate fuel pressure
•  Fuel pressure limiter malfunction (built-in common rail)
•  Engine overheating
•  Glow system malfunction
•  Fuel filter clogging or restriction
•  Fuel line clogging or restriction
•  Fuel leakage
•  Exhaust system and/or oxidation catalytic converter restriction or clogging
•  Incorrect fuel injection timing
•  Erratic signal from CKP sensor
•  Erratic signal from CMP sensor
•  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
•  Fuel pressure sensor or related circuit malfunction
•  Supply pump malfunction
•  Fuel injector malfunction
•  Low engine compression
•  EGR system 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.

Diagnostic Procedure

STEP

INSPECTION

RESULTS

ACTION
1
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 1.
2
Is the engine overheating?
Yes
Go to the symptom troubleshooting “NO.17 COOLING SYSTEM CONCERNS-OVERHEATING [WL-C, WE-C]”.
No
Go to the next step.
3
Connect the M-MDS to the DLC-2.
Turn the engine switch to the ON position (Engine off).
Retrieve any DTCs.
Are any DTCs displayed?
Yes
DTC is displayed:
Go to the appropriate DTC test.
(See DTC TABLE [WL-C, WE-C (Thailand, General (L.H.D. R.H.D.) specs.)].)
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 to vehicle body ground
No
No DTC is displayed:
Go to the next step.
4
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.
5
Is there any restriction in the exhaust system or oxidation catalytic converter?
Yes
Repair or replace if necessary.
No
Go to the next step.
6
Inspect for fuel leakage from the fuel pipe.
Is any fuel leakage found on the fuel pipe?
Yes
Repair or replace if necessary.
No
Go to the next step.
7
Inspect the APP sensor.
(See ACCELERATOR PEDAL POSITION (APP) SENSOR INSPECTION [WL-C, WE-C].)
Is the APP sensor normal?
Yes
Go to the next step.
No
Replace the accelerator pedal component.
8
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.
9
Visually inspect the CMP sensor and teeth of pulse wheel.
Are 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 the malfunctioning parts.
If the PID value is normal, go to the next step.
No
Replace malfunctioning parts.
10
Inspect fuel pressure sensor.
(See FUEL PRESSURE SENSOR INSPECTION [WL-C, WE-C].)
Is fuel pressure normal?
Yes
Go to the next step.
No
Replace common rail.
11
Is 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
Service if necessary.
12
Inspect fuel injector.
(See FUEL INJECTOR INSPECTION [WL-C, WE-C].)
Is fuel injector normal?
Yes
Go to the next step.
No
Repair or replace if necessary.
(See FUEL INJECTOR REMOVAL/INSTALLATION [WL-C, WE-C].)
13
Inspect the EGR system operation.
Is the EGR system operation normal?
Yes
Go to the next step.
No
Repair or replace the malfunctioning part according to the EGR system operation results.
14
Inspect starting system.
Is the starting system normal?
Yes
Inspect for loose connectors or poor terminal contact.
If normal, remove and inspect supply pump and common rail.
No
Repair or replace components as required.
15
Verify test results.
•  If normal, return to the diagnostic index to service any additional symptoms.
•  If the malfunction remains, inspect the related Service Information and perform repair or diagnosis.
―  If the vehicle is repaired, troubleshooting completed.
―  If the vehicle is not repaired or additional diagnostic information is not available, reprogram the PCM if later calibration is available. Retest.