Toyota Avalon (XX50): High Pressure Fuel Pump Circuit Open (P123513). Engine Stall History (P160300). Startability Malfunction (P160400)

Toyota Avalon (XX50) 2019-2022 Service & Repair Manual / Engine / 2gr-fks Engine Control / Sfi System / High Pressure Fuel Pump Circuit Open (P123513). Engine Stall History (P160300). Startability Malfunction (P160400)

High Pressure Fuel Pump Circuit Open (P123513)

DESCRIPTION

The high-pressure direct injection fuel system consists of a spill control valve, check valve, fuel relief valve, fuel pressure sensor, fuel pump assembly (for high pressure side) and fuel injector assemblies (for direct injection). The spill control valve adjusts the return volume of the high-pressure fuel. The check valve mechanically opens and closes the paths to the fuel delivery pipes. The relief valve releases the fuel back to the fuel tank if the high-pressure fuel system malfunctions. The fuel pump assembly (for high pressure side) is installed to the cylinder head cover and operated by a cam installed to the end of the intake camshaft. Rotation of the camshaft moves the pump plunger inside the fuel pump assembly (for high pressure side) up and down, pressurizing the fuel. The pressurized fuel opens the check valve and is pumped into the fuel delivery pipe.

DTC No.	Detection Item	DTC Detection Condition	Trouble Area	MIL	Memory	Note
P123513	High Pressure Fuel Pump Circuit Open	Open or short in fuel pump assembly (for high pressure side) circuit detected 60 times or more (1 trip detection logic).	Open or short in fuel pump assembly (for high pressure side) circuit Fuel pump assembly (for high pressure side) ECM	Comes on	DTC stored	SAE Code: P1235

MONITOR DESCRIPTION

If an open or short in the fuel pump assembly (for high pressure side) circuit is detected after the engine is started, the ECM will illuminate the MIL and store this DTC.

MONITOR STRATEGY

Related DTCs	P1235: Fuel pump (for high pressure side) circuit/open
Required Sensors/Components (Main)	Fuel pump assembly (for high pressure side)
Required Sensors/Components (Related)	Injector driver (ECM)
Frequency of Operation	Continuous
Duration	-
MIL Operation	Immediate
Sequence of Operation	None

TYPICAL ENABLING CONDITIONS

Monitor runs whenever the following DTCs are not stored	None
All of the following conditions are met	-
Time after engine start	5 seconds or more
Command to injector driver relay	On
Output duty cycle	5 to 95%
Battery voltage	10.5 V or higher
Engine switch	On (IG)
Starter	Off
Engine	Running

TYPICAL MALFUNCTION THRESHOLDS

One of the following conditions is met	1, 2, 3, 4 or 5
1. Both of the following conditions are met	-
Following condition is met	60 time or more
High pressure fuel pump voltage	4.8 V or higher
2. Both of the following conditions are met	-
Following condition is met	60 time or more
High pressure fuel pump voltage	1.2 V or less
3. Both of the following conditions are met	-
Following condition is met	60 time or more
High pressure fuel pump current	15 A or higher
4. Both of the following conditions are met	-
Following condition is met	60 time or more
High pressure fuel pump drive MOSFET current	12 A or higher
5. Both of the following conditions are met	-
Following condition is met	60 time or more
High pressure fuel pump drive MOSFET voltage	0.02 V or less

CONFIRMATION DRIVING PATTERN

HINT:

After repair has been completed, clear the DTC and then check that the vehicle has returned to normal by performing the following All Readiness check procedure.
Click here
When clearing the permanent DTCs, refer to the "CLEAR PERMANENT DTC" procedure.
Click here

Connect the Techstream to the DLC3.
Turn the engine switch on (IG).
Turn the Techstream on.
Clear the DTCs (even if no DTCs are stored, perform the clear DTC procedure).
Turn the engine switch off and wait for at least 30 seconds.
Start the engine [A].
Idle the engine for 10 seconds [B].
Turn the Techstream on.
Enter the following menus: Powertrain / Engine / Trouble Codes [C].
Read the pending DTCs.
HINT:
- If a pending DTC is output, the system is malfunctioning.
- If a pending DTC is not output, perform the following procedure.
Enter the following menus: Powertrain / Engine / Utility / All Readiness.
Input the DTC: P123513.

Check the DTC judgment result.

Techstream Display	Description
NORMAL	DTC judgment completed System normal
ABNORMAL	DTC judgment completed System abnormal
INCOMPLETE	DTC judgment not completed Perform driving pattern after confirming DTC enabling conditions

HINT:

If the judgment result is NORMAL, the system is normal.
If the judgment result is ABNORMAL, the system has a malfunction.
If the judgment result is INCOMPLETE, perform steps [B] through [C] again.
[A] to [C]: Normal judgment procedure.
The normal judgment procedure is used to complete DTC judgment and also used when clearing permanent DTCs.
When clearing the permanent DTCs, do not disconnect the cable from the battery terminal or attempt to clear the DTCs during this procedure, as doing so will clear the universal trip and normal judgment histories.

WIRING DIAGRAM

CAUTION / NOTICE / HINT

HINT:

If the current from the D INJ relay is cut because DTC P062D13 is stored, DTC P123513 will be stored even if the fuel pump assembly (for high pressure side) is normal.
Read freeze frame data using the Techstream. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the air fuel ratio was lean or rich, and other data from the time the malfunction occurred.

PROCEDURE

1.	INSPECT FUEL PUMP ASSEMBLY (FOR HIGH PRESSURE SIDE)

(a) Inspect the fuel pump assembly (for high pressure side).

Click here

HINT:

Perform "Inspection After Repair" after replacing the fuel pump assembly (for high pressure side).

Click here

REPLACE FUEL PUMP ASSEMBLY (FOR HIGH PRESSURE SIDE)

2.	CHECK HARNESS AND CONNECTOR (FUEL PUMP ASSEMBLY (FOR HIGH PRESSURE SIDE) - ECM)

(a) Disconnect the fuel pump assembly (for high pressure side) connector.

(b) Disconnect the ECM connector.

Standard Resistance:

Tester Connection	Condition	Specified Condition
C30-1 (FP+) - C56-23 (FP1+)	Always	Below 1 Ω
C30-2 (FP-) - C56-22 (FP1-)	Always	Below 1 Ω
C30-1 (FP+) or C56-23 (FP1+) - Body ground and other terminals	Always	10 kΩ or higher
C30-2 (FP-) or C56-22 (FP1-) - Body ground and other terminals	Always	10 kΩ or higher

REPLACE ECM

REPAIR OR REPLACE HARNESS OR CONNECTOR

Engine Stall History (P160300)

DESCRIPTION

After starting the engine, this DTC is stored when the engine stops without the engine switch being operated.

Using the Techstream, the conditions present when the DTC was stored can be confirmed by referring to the freeze frame data. Freeze frame data records engine conditions when a malfunction occurs. This information can be useful when troubleshooting.

It is necessary to check if the vehicle has run out of fuel before performing troubleshooting, as this DTC is also stored when the engine stalls due to running out of fuel.

DTC No.	Detection Item	DTC Detection Condition	MIL	Memory	Note
P160300	Engine Stall History	After monitoring for startability problems (P160400) finishes and 2 seconds or more have elapsed after starting the engine, with the engine running, the engine stops (the engine speed drops to 200 rpm or less) without the engine switch being operated for 0.5 seconds or more (1 trip detection logic).	Does not come on	DTC stored	SAE Code: P1603

Trouble Area
Ignition system	Spark plug Ignition coil assembly
Fuel system	Fuel injector assembly (for port injection) Fuel injector assembly (for direct injection) Fuel pump (for low pressure side) Fuel pump assembly (for high pressure side) Fuel pump control circuit Fuel line Purge VSV system Fuel quality (existence of foreign matter, degradation)
Intake and exhaust systems	Mass air flow meter sub-assembly Intake system (Air leaks or deposit accumulation) Throttle body with motor assembly Air fuel ratio sensor Heated oxygen sensor Cam timing oil control solenoid assembly Camshaft timing oil control valve assembly Variable Valve Timing system (VVT system)
Other control systems	ECM Wire harness or connector Knock control sensor Engine coolant temperature sensor
Engine	Water inlet with thermostat sub-assembly Engine assembly
High load from another system	Air conditioning system Power steering system Electrical load signal system A/T system

CAUTION / NOTICE / HINT

HINT:

DTC P160300
- In contrast to normal malfunction diagnosis for components, circuits and systems, DTC P160300 is used to determine the malfunctioning area from the problem symptoms and freeze frame data when the user mentions problems such as engine stall.
  As this DTC can be stored as a result of certain user actions, even if the DTC is output, if the customer makes no mention of problems, clear the DTC without performing any troubleshooting and return the vehicle to the customer.
- As DTCs may be stored when an Active Test or learning is performed, make sure to clear the DTCs before returning the vehicle to the customer.
- DTCs related to engine stall problems may be detected due to operations performed by the user. The following are a few examples. Ask questions to the user about how the vehicle is operated and give advice as necessary.
  - Ran out of fuel
  - Rolled down on a slope and engine stalls (backed up in D, moved forward in R)
- If any other DTCs are output, perform troubleshooting for those DTCs first.

CUSTOMER PROBLEM ANALYSIS

Use any information from the customer problem analysis about the condition of the vehicle at the time when the problem occurred (how the engine stopped, conditions when the engine was restarted, etc.) as a reference.

Symptom	Suspected Area
Engine vibration occurs and engine stops	Abnormal mass air flow meter sub-assembly output due to existence of foreign matter Abnormal air fuel ratio due to malfunction of air fuel ratio sensor or heated oxygen sensor, air leaks in intake system or insufficient fuel supply
Engine stops with no engine vibration	Ignition system, injection stoppage, high load from external parts
Engine can be started with accelerator pedal depressed	Insufficient air volume
Engine stalls or is difficult to start immediately after engine stalled, regardless of whether engine is cold or warm	Deposits in intake system or combustion chamber caught temporarily on intake or exhaust valve

FREEZE FRAME DATA
- Read freeze frame data using the Techstream. Freeze frame data records engine conditions when a malfunction occurs. This information can be useful when troubleshooting.
- When confirming the freeze frame data, be sure to check all multi freeze frame data.
  Click here
- When confirming the freeze frame data, if there are multiple items related to the cause of the malfunction, perform troubleshooting for all related items.
- Try to operate the vehicle under the conditions recorded in the freeze frame data which were present when the malfunction occurred. Confirm the data at this time and the data when the engine is idling (engine warmed up, no load, and shift lever in D or N) and compare this data with the freeze frame data.
PRECAUTIONS
- Inspections take into account the fact that the malfunction may not have recurred and place emphasis on checking the vehicle conditions present at the time when the malfunction occurred.
- When performing inspections, jiggle the relevant wire harnesses and connectors in an attempt to reproduce malfunctions that do not always occur.

PROCEDURE

1.	CHECK FOR ANY OTHER DTCS OUTPUT

(a) Connect the Techstream to the DLC3.

(b) Turn the engine switch on (IG).

(d) Enter the following menus: Powertrain / Engine / Trouble Codes.

(e) Read the DTCs.

Powertrain > Engine > Trouble Codes

Result	Proceed to
Only DTC P160300 is output	A
DTCs other than P160300 are output	B

HINT:

When DTC P160300 and P160500 are output simultaneously, perform the troubleshooting for P160500 first.
Using freeze frame data, confirm the conditions the moment the DTC was stored and after the DTC was stored. This information can be useful when troubleshooting.

GO TO DTC CHART

2.	READ FREEZE FRAME DATA (ISC F/B LEARN TORQUE)

(a) Connect the Techstream to the DLC3.

(b) Turn the engine switch on (IG).

(d) Using the Techstream, confirm the vehicle conditions recorded in the freeze frame data which were present when the DTC was stored.

Click here

Freeze Frame Data Item for DTC P160300	Result	Suspected Area	Action	Proceed to
ISC F/B Learn Torque	Less than 30 Nm	-	Go to the next step	A
ISC F/B Learn Torque	30 Nm or higher	Throttle body with motor assembly	Go to ENGINE STALLS (from step 11)	B

GO TO ENGINE STALLS

3.	READ FREEZE FRAME DATA (A/F (O2) SENSOR VOLTAGE, SHORT FT AND LONG FT)

(a) Connect the Techstream to the DLC3.

(b) Turn the engine switch on (IG).

(d) Using the Techstream, confirm the vehicle conditions recorded in the freeze frame data which were present when the DTC was stored.

Click here

Freeze Frame Data Item for DTC P160300			Suspected Area	Action	Proceed to
A/F (O2) Sensor Voltage B1S1 and A/F (O2) Sensor Voltage B2S1	Short FT B1S1 and Short FT B2S1	Long FT B1S1 and Long FT B2S1	Suspected Area	Action	Proceed to
2.8 V to 3.8 V	-15% to 15%	-15% to 15%	-	Go to ENGINE STALLS	NEXT
3.8 V or higher	15% or higher	-	Fuel pump	Go to ENGINE STALLS (from step 20)
Less than 2.8 V, or 3.8 V or higher	Less than -15%, or 15% or higher	Less than -15%, or 15% or higher	Mass air flow meter sub-assembly Air fuel ratio sensor Fuel pump	Go to ENGINE STALLS (from step 15)*

HINT:

*: If the value of A/F (O2) Sensor Voltage B1S1, A/F (O2) Sensor Voltage B2S1, Short FT B1S1, Short FT B2S1, Long FT B1S1 or Long FT B2S1 is as specified, malfunction of a component listed in the "Suspected Area" column of the table is suspected.

GO TO ENGINE STALLS

Startability Malfunction (P160400)

DESCRIPTION

This DTC is stored when the engine does not start even though the STA signal is input or when the engine takes a long time to start, and when the engine speed is low or the engine stalls just after the engine starts.

It is necessary to check if the vehicle ran out of fuel before performing troubleshooting, as this DTC is also stored when there is engine starting trouble due to running out of fuel.

DTC No.	Detection Item	DTC Detection Condition	MIL	Memory	Note
P160400	Startability Malfunction	Either conditions is met (1 trip detection logic): The engine speed is below 500 rpm with the STA signal on for a certain amount of time (refer to the illustration below). After the engine starts (engine speed is 500 rpm or more), the engine speed drops to 200 rpm or less within approximately 2 seconds.	Does not come on	DTC stored	SAE Code: P1604

DTC No.

Detection Item

DTC Detection Condition

MIL

Memory

Note

P160400

Startability Malfunction

Either conditions is met (1 trip detection logic):

The engine speed is below 500 rpm with the STA signal on for a certain amount of time (refer to the illustration below).
After the engine starts (engine speed is 500 rpm or more), the engine speed drops to 200 rpm or less within approximately 2 seconds.

Does not come on

DTC stored

SAE Code: P1604

Trouble Area
Ignition system	Spark plug Ignition coil assembly
Fuel system	Fuel injector assembly (for direct injection) Fuel injector assembly (for port injection) Fuel pump assembly (for high pressure side) Fuel pump (for low pressure side) Fuel pump control circuit Fuel suction plate sub-assembly Fuel main valve assembly Fuel line Purge VSV system Fuel quality (existence of foreign matter, degradation)
Intake and exhaust systems	Mass air flow meter sub-assembly Intake system (Air leaks or deposit accumulation) Throttle body with motor assembly Air fuel ratio sensor Heated oxygen sensor Cam timing oil control solenoid assembly Camshaft timing oil control valve assembly Variable Valve Timing system (VVT system)
Other control systems	ECM Wire harness or connector Knock control sensor Engine coolant temperature sensor
Engine	Water inlet with thermostat sub-assembly Engine assembly
High load from another system	Air conditioning system Power steering system Electrical load signal system A/T system

CAUTION / NOTICE / HINT

HINT:

DTC P160400
- In contrast to normal malfunction diagnosis for components, circuits and systems, DTC P160400 is used to determine the malfunctioning area from the problem symptoms and freeze frame data when the user mentions problems such as starting difficulty.
  As this DTC can be stored as a result of certain user actions, even if the DTC is output, if the customer makes no mention of problems, clear the DTC without performing any troubleshooting and return the vehicle to the customer.
- As DTCs may be stored when an Active Test or learning is performed, make sure to clear the DTCs before returning the vehicle to the customer.
- If any other DTCs are output, perform troubleshooting for those DTCs first.
DATA LIST / FREEZE FRAME DATA
- When this Data List item "Immobiliser Communication" is OFF or "Immobiliser Fuel Cut Status" is ON, the engine cannot be started.
- Read freeze frame data using the Techstream. Freeze frame data records engine conditions when a malfunction occurs. This information can be useful when troubleshooting.
- When confirming the freeze frame data, be sure to check all multi freeze frame data.
  Click here
- When confirming the freeze frame data, if there are multiple items related to the cause of the malfunction, perform troubleshooting for all related items.
- Try to start the vehicle under the conditions recorded in the freeze frame data which were present when the malfunction occurred. Confirm the data at this time and compare it with the freeze frame data.
- If the malfunction does not recur, carefully check the vehicle conditions from when the malfunction occurred using freeze frame data.
PRECAUTIONS
- When performing inspections, jiggle the relevant wire harnesses and connectors in an attempt to reproduce malfunctions that do not always occur.
- If the same inspection or replacement procedure appears 2 times when performing an inspection procedure, it is not necessary to repeat the procedure the second time.

PROCEDURE

1.	CHECK FOR ANY OTHER DTCS OUTPUT

(a) Connect the Techstream to the DLC3.

(b) Turn the engine switch on (IG).

(d) Enter the following menus: Powertrain / Engine / Trouble Codes.

(e) Read the DTCs.

Powertrain > Engine > Trouble Codes

Result	Proceed to
DTC P160400 is output	A
DTC P160400 and other DTCs are output	B

HINT:

If any DTCs other than P160400 is output, troubleshoot those DTCs first.
Using freeze frame data, confirm the conditions the moment the DTC was stored and after the DTC was stored. This information can be useful when troubleshooting.

GO TO DTC CHART

2.	READ FREEZE FRAME DATA (IMMOBILISER COMMUNICATION AND IMMOBILISER FUEL CUT STATUS)

(a) Connect the Techstream to the DLC3.

(b) Turn the engine switch on (IG).

(d) Using the Techstream, confirm the vehicle conditions recorded in the freeze frame data which were present when the DTC was stored.

Click here

OK:

Data List Item	Techstream Display
Immobiliser Communication	ON
Immobiliser Fuel Cut Status	OFF

HINT:

If the engine is started immediately after reconnecting the battery terminal, the engine may stall immediately after it starts due to the intercommunication process between each ECU. For this reason, when starting the engine after reconnecting the battery terminal, first turn the engine switch on (IG) and then wait several seconds for the communication process to complete before starting the engine.
When this operation causes DTC P160400 to be stored, this is due to normal operation of the immobiliser system and does not indicate a malfunction, so clear the DTC and return the vehicle to the customer.

CHECK IMMOBILISER SYSTEM

3.	READ FREEZE FRAME DATA (ISC F/B LEARN TORQUE)

(a) Connect the Techstream to the DLC3.

(b) Turn the engine switch on (IG).

(d) Using the Techstream, confirm the vehicle conditions recorded in the freeze frame data which were present when the DTC was stored.

Click here

Freeze Frame Data Item	Result	Suspected Area	Action	Proceed to
ISC F/B Learn Torque	Less than 30 Nm	-	Go to the next step	A
ISC F/B Learn Torque	30 Nm or higher	Throttle body with motor assembly	Go to ENGINE DIFFICULT TO START (from step 15)	B

GO TO ENGINE DIFFICULT TO START

4.	READ FREEZE FRAME DATA (ENGINE SPEED)

(a) Connect the Techstream to the DLC3.

(b) Turn the engine switch on (IG).

(d) Using the Techstream, confirm the vehicle conditions recorded in the freeze frame data which were present when the DTC was stored.

Click here

Freeze Frame Data Item	Result	Suspected Area	Action	Proceed to
Engine Speed	All 5 sets of freeze frame data are 0 rpm (engine did not crank or engine speed was not detected properly)	Starter signal circuit Crankshaft position sensor system Battery fully depleted	Go to ENGINE DIFFICULT TO START (from step 5)	A
100 to 500 rpm (engine cranked but initial combustion did not occur or was delayed)	Fuel pump Leaking fuel injector assembly Spark plug Ignition coil assembly	Go to the next step	B
500 rpm or higher (engine speed dropped immediately after initial combustion) (Low Revolution for Engine Start is ON)	Spark plug Ignition coil assembly

Freeze Frame Data Item

Result

Suspected Area

Action

Proceed to

Engine Speed

All 5 sets of freeze frame data are 0 rpm (engine did not crank or engine speed was not detected properly)

Starter signal circuit
Crankshaft position sensor system
Battery fully depleted

Go to ENGINE DIFFICULT TO START (from step 5)

100 to 500 rpm (engine cranked but initial combustion did not occur or was delayed)

Fuel pump
Leaking fuel injector assembly
Spark plug
Ignition coil assembly

Go to the next step

500 rpm or higher (engine speed dropped immediately after initial combustion)

(Low Revolution for Engine Start is ON)

Spark plug
Ignition coil assembly

GO TO ENGINE DIFFICULT TO START

5.	INTERVIEW THE CUSTOMER

(a) Interview the customer for details about the conditions when the malfunction occurred.

HINT:

If the engine is difficult to start only when the vehicle has been left as is for a long time, a leaking fuel injector assembly is suspected.

Result	Suspected Area	Action	Proceed to
Engine is difficult to start only when the vehicle has been left as is for a long time (1 hour or more)	Leaking fuel injector assembly	Go to ENGINE DIFFICULT TO START (from step 4)	A
Other than above	Fuel pump Spark plug Ignition coil assembly	Go to the next step	B

GO TO ENGINE DIFFICULT TO START

6.	INTERVIEW THE CUSTOMER

(a) Interview the customer for details about the conditions when the malfunction occurred.

HINT:

If the vehicle is mostly driven for short distances, deposits may have accumulated on the spark plugs, causing starting difficulty.

Result	Suspected Area	Action	Proceed to
Mostly driven short distances	Spark plug Ignition coil assembly	Go to ENGINE DIFFICULT TO START (from step 13)	NEXT
Not mostly driven short distances	Fuel pump Spark plug Ignition coil assembly	Go to ENGINE DIFFICULT TO START (from step 9)	NEXT

GO TO ENGINE DIFFICULT TO START

Transmission Range Sensor "A" Circuit Open (P070513,P070562)

Rough Idling (P160500). Cruise Control Input Processor (P160700). Throttle Actuator "A" Control Motor Circuit Short to Ground or Open (P210014,P210015)

See More:

Toyota Avalon (XX50) 2019-2022 Service & Repair Manual > Hybrid Control System: Vehicle Control History
VEHICLE CONTROL HISTORY CHECK VEHICLE CONTROL HISTORY (HYBRID CONTROL SYSTEM) (a) Connect the Techstream to the DLC3. (b) Turn the power switch on (IG). (c) Turn the Techstream on. (d) Enter the following menus: Powertrain / Hybrid Control / Utility / Vehicle Control History (RoB). Powertrain > H ...