NO.5 ENGINE STALLS-AFTER START/AT IDLE [AJ (3.0L Duratec)]


5	Engine stalls-after start/at idle
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 or related wire • Vacuum leakage • Low engine compression • Ignition system malfunction • 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 • Inertia fuel pump stop switch malfunction • Fuel pump body mechanical malfunction • Fuel leakage from fuel injector • Fuel injector clogging • Immobilizer system and/or circuit malfunction • Immobilizer system operating properly (Ignition key is not registered) 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 [AJ (3.0L Duratec)].) (See AFTER SERVICE PRECAUTION [AJ (3.0L Duratec)].)


STEP	INSPECTION	RESULTS	ACTION
1	Note • The following test should be perform for the vehicles with immobilizer system. Go to Step 10 for the vehicle without immobilizer system. • Connect the WDS or equivalent to DLC-2. • Do following conditions appear? • Engine is not completely started. • DTC B1681 is displayed.	Yes	Both conditions appear: Go to Step 4.
1		No	Either or conditions appears: Go to the next step.
2	• Is the connector securely connected to coil?	Yes	Go to the next step.
2	• Is the connector securely connected to coil?	No	Connect the coil connector securely. Return to Step 1.
3	• Does security light illuminates?	Yes	Go to the next step.
3	• Does security light illuminates?	No	Inspect for following wiring harness and connectors: • Between PCM terminal 15 and instrument cluster terminal 3C (R.H.D.) • Between PCM terminal 16 and instrument cluster terminal 3E (R.H.D.) If they are okay, inspect instrument cluster. (See INSTRUMENT CLUSTER INSPECTION [EXCEPT L3].)
4	• Connect the WDS or equivalent to DLC-2 and retrieve DTC. • Are there following DTCs displayed? DTC B1213, B1342, B1600, B1601, B1602, B1681, B2103, B2431	Yes	Go to appropriate DTC test.
4		No	Go to the next step.
5	• Is there continuity between PCM GND harness side terminals 3, 24, 51, 76, 103 (R.H.D.)/C-47,C-48,C-49 (L.H.D.) and GND?	Yes	Go to the next step.
5		No	Repair or replace wiring harness.
6	• Measure voltage between PCM GND terminals 3, 3, 24, 51, 76, 103 (R.H.D.)/C-47,C-48,C-49 (L.H.D.) and coil terminal B. • Is the voltage below 1.0 V?	Yes	Go to the next step.
6		No	Repair or replace wiring harness.
7	• Turn the ignition switch to ON position. • Access VPWR PID. • Is VPWR PID okay? Specification Battery voltage	Yes	Go to the next step.
7		No	Repair or replace wiring harness.
8	• Disconnect the coil connector. • Turn the ignition switch to ON position. • Is there battery voltage at coil connector terminal A (harness-side)?	Yes	Go to the next step.
8		No	Repair or replace wiring harness between coil connector terminal A and ignition switch.
9	• Inspect for open or short circuit in following: - Between coil terminal C and PCM terminal 17 (R.H.D.) - Between coil terminal D and PCM terminal 18 (R.H.D.) • Is there any malfunction?	Yes	Repair or replace wiring harness.
9		No	Go to the next step.
10	• Verify 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 okay?	Yes	Go to the next step.
10		No	Service as necessary. Repeat Step 10.
11	Note • Ignore DTC P0122 or P0123 while performing this test. • Turn key to ON (Engine OFF). • Disconnect TP sensor connector. • Measure voltage at TP sensor connector VREF terminal with key at ON. Voltage 4.5-5.5 V • Is voltage okay?	Yes	Go to the next step.
11		No	Go to troubleshooting "No.29 Constant voltage".
12	• Inspect the inertia fuel pump stop switch. (See FUEL PUMP STOP SWITCH INSPECTION [AJ (3.0L Duratec)].) • Is the IFS switch okay?	Yes	Go to the next step.
12		No	Replace the IFS switch.
13	• Connect WDS or equivalent to DLC-2. • Turn key to ON (Engine OFF). • Retrieve any DTCs. • Is "PASSED" displayed?	Yes	No DTC is displayed: • Go to the next step.
13		No	DTC is displayed: • Go to appropriate DTC test. Communication error message is displayed: • Inspect for following: - Open circuit between main relay and PCM terminal 71 or 97 (R.H.D.) - Open circuit between main relay terminal C and PCM terminal C-35 or C-36 (L.H.D.) - Open main relay GND circuit - Main relay is stuck open. - Open or poor GND circuit (PCM terminal 3, 24, 51, 76 or 103 (R.H.D.)/C-47,C-48 or C-49 (L.H.D.)) - Poor connection of vehicle body GND
14	• Attempt to start engine at part throttle. • Does engine run smoothly at part throttle?	Yes	Inspect IAC valve and wiring harness.
14		No	Go to the next step.
15	• Connect WDS or equivalent to DLC-2. • Access RPM PID. • Is RPM PID indicating engine speed during engine cranking?	Yes	Go to the next step.
15		No	Inspect for following: • Open or short circuit in CKP sensor • Open or short circuit between CKP sensor and PCM terminal 21 or 22 (R.H.D.)/E-34 orE-45 (L.H.D.) • Open or short circuit in CKP sensor harnesses - If CKP sensor and harness are okay, go to the next step.
16	• Visually inspect CKP sensor and teeth of crankshaft pulley. • Are CKP sensor and teeth of crankshaft pulley okay?	Yes	Go to the next step.
16		No	Replace malfunctioning part.
17	• Inspect ignition coils. • Are ignition coils okay?	Yes	Repair or replace ignition coil.
17	• Inspect ignition coils. • Are ignition coils okay?	No	Go to the next step.
18	• Perform the spark test. (See Spark Test.) • Is strong blue spark visible at each cylinder?	Yes	Go to the next step. • If symptom occurs with A/C on, go to Step 23.
18		No	Repair or replace malfunction part according to spark test result.
19	• Inspect spark plug conditions. • Is spark plug wet, covered with carbon or grayish white?	Yes	Spark plug is wet or covered with carbon: • Inspect for fuel leakage from injector. Spark plug is grayish white: • Inspect for clogged fuel injector.
19		No	Install spark plugs on original cylinders. Go to the next step.
20	• Remove and shake PCV valve. • Does PCV valve rattle?	Yes	Go to the next step.
20	• Remove and shake PCV valve. • Does PCV valve rattle?	No	Replace PCV valve.
21	• Visually inspect the exhaust system part. • Is there any deformed exhaust system part?	Yes	Replace suspected part.
21		No	Go to the next step.
22	• Install the fuel pressure gauge to fuel line. • Connect the WDS or equivalent to DLC-2. • Turn the fuel pump on using FP PID in output state control of datalogger function. • Is the fuel line pressure correct? (See FUEL LINE PRESSURE INSPECTION [AJ (3.0L Duratec)].)	Yes	Go to the next step.
22		No	Zero or low: Inspect the fuel pump, IFS switch and fuel pump relay related circuit. Inspect clogged fuel line. • If normal, replace the fuel pump unit. (See FUEL PUMP UNIT REMOVAL/INSTALLATION [AJ (3.0L Duratec)].) High: Replace the fuel pump unit. (See FUEL PUMP UNIT REMOVAL/INSTALLATION [AJ (3.0L Duratec)].)
23	• Visually inspect for fuel leakage at fuel injector O-ring and fuel line. • Service as necessary. • Does fuel line pressure hold after FP PID is turned to OFF?	Yes	Go to the next step.
23		No	Inspect the fuel injector. (See FUEL INJECTOR INSPECTION [AJ (3.0L Duratec)].) • If the fuel injector is normal, replace the fuel pump unit. (See FUEL PUMP UNIT REMOVAL/INSTALLATION [AJ (3.0L Duratec)].)
24	Note • Following test is for stall concerns with A/C on. If other symptoms exist, go to the next step. • Connect pressure gauges to A/C low and high pressure side lines. • Turn A/C on and measure low side and high side pressure. • Are pressures within specifications?	Yes	Go to the next step.
24		No	If A/C is always on, go to symptom troubleshooting "No.24 A/C always on/A/C compressor runs continuously". For other symptoms, inspect following: • Refrigerant charging amount • Condenser fan operation
25	• Disconnect vacuum hose between purge solenoid valve and intake manifold from purge solenoid side. • Plug opening end of vacuum hose. • Start engine. • Is engine stall now eliminated?	Yes	Inspect if purge solenoid valve is stuck open. Inspect EVAP control system.
25		No	Go to the next step.
26	• Is air leakage felt or heard at intake-air system components while racing engine to higher speed?	Yes	Repair or replace.
26		No	Go to the next step.
27	• Inspect engine condition while tapping EGR valve housing. • Does engine condition improve?	Yes	Replace EGR valve.
27		No	Go to the next step.
28	• Is engine compression correct?	Yes	Inspect valve timing.
28	• Is engine compression correct?	No	Inspect for cause.
29	• Verify test results. - If okay, return to diagnostic index to service any additional symptoms. - If malfunction remains, inspect related Service Information and perform repair or diagnosis. • If vehicle is repaired, troubleshooting completed. • If vehicle is not repaired or additional diagnostic information is not available, replace PCM.