DTC P0616:24 [START STOP UNIT]

id0902p6022500

Description

Circuit malfunction on downstream side of starter relay

Detection condition

•  Start stop unit detects an open circuit in the starter relay downstream circuit continuously for 0.5 s or more for a continuous 5 times.

Fail-safe function

Not applicable

Possible cause

•  DTCs are stored in the PCM.

•  Start stop unit connector or terminal malfunction

•  PCM connector or terminal malfunction

•  Open circuit in wiring harness between the following terminals:

―  Start stop unit terminal 1D—PCM terminal 2AZ (SKYACTIV-G 1.5, SKYACTIV-G 2.0, SKYACTIV-G 2.5)

―  Start stop unit terminal 1D—PCM terminal 2BF (SKYACTIV-D 1.5, SKYACTIV-D 2.2)

―  Start stop unit terminal 1D—PCM terminal 1F (MZR 1.6)

•  PCM malfunction

•  Start stop unit malfunction

Description	Circuit malfunction on downstream side of starter relay
Detection condition	• Start stop unit detects an open circuit in the starter relay downstream circuit continuously for 0.5 s or more for a continuous 5 times.
Fail-safe function	Not applicable
Possible cause	• DTCs are stored in the PCM. • Start stop unit connector or terminal malfunction • PCM connector or terminal malfunction • Open circuit in wiring harness between the following terminals: ― Start stop unit terminal 1D—PCM terminal 2AZ (SKYACTIV-G 1.5, SKYACTIV-G 2.0, SKYACTIV-G 2.5) ― Start stop unit terminal 1D—PCM terminal 2BF (SKYACTIV-D 1.5, SKYACTIV-D 2.2) ― Start stop unit terminal 1D—PCM terminal 1F (MZR 1.6) • PCM malfunction • Start stop unit malfunction

Diagnostic Procedure

Step	Inspection		Action
1	VERIFY PCM DTCs • Retrieve the PCM DTCs using the M-MDS. (See ON-BOARD DIAGNOSTIC TEST [SKYACTIV-G 1.5, SKYACTIV-G 2.0, SKYACTIV-G 2.5].) (See ON-BOARD DIAGNOSTIC TEST [SKYACTIV-D 1.5].) (See ON-BOARD DIAGNOSTIC TEST [SKYACTIV-D 2.2].) (See ON-BOARD DIAGNOSTIC TEST [MZR 1.6].) • Are any DTCs displayed?	Yes	Repair or replace the malfunctioning part according to the applicable DTC troubleshooting. (See DTC TABLE [SKYACTIV-G 1.5, SKYACTIV-G 2.0, SKYACTIV-G 2.5].) (See DTC TABLE [SKYACTIV-D 1.5].) (See DTC TABLE [SKYACTIV-D 2.2].) (See DTC TABLE [MZR 1.6].)
1		No	Go to the next step.
2	INSPECT START STOP UNIT CONNECTOR CONDITION • Switch the ignition off. • Disconnect the negative battery cable. (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [SKYACTIV-G 1.5, SKYACTIV-G 2.0, SKYACTIV-G 2.5].) (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [SKYACTIV-D 1.5].) (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [SKYACTIV-D 2.2].) (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [MZR 1.6].) • Disconnect the start stop unit connector. • Inspect the connector engagement and connection condition and inspect the terminals for damage, deformation, corrosion, or disconnection. • Is the connector normal?	Yes	Go to the next step.
2		No	Repair or replace the connector, then go to Step 6.
3	INSPECT PCM CONNECTOR CONDITION • Disconnect the PCM connector. • Inspect the connector engagement and connection condition and inspect the terminals for damage, deformation, corrosion, or disconnection. • Is the connector normal?	Yes	Go to the next step.
3		No	Repair or replace the connector, then go to Step 6.
4	INSPECT FOR OPEN CIRCUIT IN DOWNSTREAM SIDE OF STARTER RELAY CIRCUIT • Verify that the start stop unit and PCM connectors are disconnected. • Inspect for continuity between the following terminals (wiring harness-side): ― Start stop unit terminal 1D—PCM terminal 2AZ (SKYACTIV-G 1.5, SKYACTIV-G 2.0, SKYACTIV-G 2.5) ― Start stop unit terminal 1D—PCM terminal 2BF (SKYACTIV-D 1.5, SKYACTIV-D 2.2) ― Start stop unit terminal 1D—PCM terminal 1F (MZR 1.6) • Is there continuity?	Yes	Go to the next step.
4		No	Refer to the wiring diagram and verify whether or not there is a common connector between the following terminals: • Start stop unit terminal 1D—PCM terminal 2AZ (SKYACTIV-G 1.5, SKYACTIV-G 2.0, SKYACTIV-G 2.5) • Start stop unit terminal 1D—PCM terminal 2BF (SKYACTIV-D 1.5, SKYACTIV-D 2.2) • Start stop unit terminal 1D—PCM terminal 1F (MZR 1.6) If there is a common connector: • Determine the malfunctioning part by inspecting the common connector and the terminal for corrosion, damage, or pin disconnection, and the common wiring harness for an open circuit. • Repair or replace the malfunctioning part. If there is no common connector: • Repair or replace the wiring harness which has an open circuit. Go to Step 6.
5	PERFORM DTC INSPECTION AND VERIFY PCM MALFUNCTION • Always reconnect all disconnected connectors. • Reconnect the negative battery cable. (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [SKYACTIV-G 1.5, SKYACTIV-G 2.0, SKYACTIV-G 2.5].) (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [SKYACTIV-D 1.5].) (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [SKYACTIV-D 2.2].) (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [MZR 1.6].) • Clear the DTC for the start stop unit using the M-MDS. (See CLEARING DTC [START STOP UNIT].) • With the programmed remote transmitter in the vehicle, switch the ignition ON (engine off). • Perform the following work 5 times or more. ― Depress the clutch pedal. (MTX) ― Operate the selector lever to P or N position from other than P and N position and hold for 1 s or more. (ATX) • Retrieve the start stop unit DTCs using the M-MDS. (See DTC INSPECTION [START STOP UNIT].) • Is the same DTC displayed?	Yes	Replace the PCM, then go to the next step. (See PCM REMOVAL/INSTALLATION [SKYACTIV-G 1.5, SKYACTIV-G 2.0, SKYACTIV-G 2.5].) (See PCM REMOVAL/INSTALLATION [SKYACTIV-D 1.5].) (See PCM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].) (See PCM REMOVAL/INSTALLATION [MZR 1.6].)
5		No	Go to Step 7.
6	VERIFY THAT REPAIRS HAVE BEEN COMPLETED • Always reconnect all disconnected connectors. • Reconnect the negative battery cable. (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [SKYACTIV-G 1.5, SKYACTIV-G 2.0, SKYACTIV-G 2.5].) (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [SKYACTIV-D 1.5].) (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [SKYACTIV-D 2.2].) (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [MZR 1.6].) • Clear the DTC for the start stop unit using the M-MDS. (See CLEARING DTC [START STOP UNIT].) • With the programmed remote transmitter in the vehicle, switch the ignition ON (engine off). • Perform the following work 5 times or more. ― Depress the clutch pedal. (MTX) ― Operate the selector lever to P or N position from other than P and N position and hold for 1 s or more. (ATX) • Retrieve the start stop unit DTCs using the M-MDS. (See DTC INSPECTION [START STOP UNIT].) • Is the same DTC displayed?	Yes	Repeat the inspection from Step 1. • If the malfunction recurs, replace the start stop unit. (See START STOP UNIT REMOVAL/INSTALLATION.) Go to the next step.
6		No	Go to the next step.
7	VERIFY IF OTHER DTCs DISPLAYED • Are any other DTCs displayed?	Yes	Repair or replace the malfunctioning part according to the applicable DTC troubleshooting. (See DTC TABLE [START STOP UNIT].)
7		No	DTC troubleshooting completed.