Hard start when hot, intermittent codes

AntleredRuin

New member
1999 LTD V6, 2wd, non-Cali emissions

OK, so I have some weird backstory; not sure if it's all related, but every detail helps, right?



I'd been getting a P0505 code for my IAC off and on for about a year. It would come on, then go away within a few minutes, and stay off for months at a time. More and more often, the 4Runner would stall when sitting still like in traffic, maybe once every other week. Started back up just fine though.

Then the IAC code stuck and didn't go away, and I got another code, the P0171 lean code, and the 4Runner started getting hard to start when hot. If it was on, and I turned it off and right back on again, it would work, but if I waited maybe 15-20 minutes, it would crank and stumble its way to life, and run rough for about 30 seconds to a minutes during which I had to give it gas or it might stall. If I cut it off and tried to start it again, it wouldn't start at all. If I waited 45 minutes or so, it'd start up just fine.

I'd cleaned the IAC when I first bought the 4runner over 3 years ago, and had read that often when you have an IAC CEL, cleaning it sometimes only temporarily fixes the problem; you'll need a new one soon.

So I figured I'd get a new one, cause why not? I found one on Amazon. It was NOT OEM Denso, but had nearly 5 stars for over 50 reviews, so at $40, I figured it was worth a shot.

I installed the new IAC, cleaned my MAF with MAF cleaner (I clean it a few times a year), cleaned the TB out (it was pretty black), and installed a new air filter.
Cranked it up, and it started fine, but the idle was never right. It was always too high, even when warmed up. It'd sit around 800RPM when in Drive, and over 1500RPM when in Park. I adjusted the linkages for the TB, reset the EFI relay, pulled the battery, etc. Nothing fixed it.
The new IAC made the P0505 code go away, but the P0171 came back, and I also got a P0125 (insufficient coolant temp). The coolant amount is fine, and I read that the MAF can throw that sometimes while it's relearning, so I pulled the battery to reset the codes, but they came back again. Also, the hard starts were still there.

After a few days of this (to see if the ECM would relearn), around 150 miles, I decided to reinstall the old IAC (after a thorough cleaning). I also replaced the large air inlet hose connecting the air baffle to the TB because it was pretty cracked (Duct tape had held it together for years, but it was time)


The idle returned to normal, the P0505 code stayed away, and the P0171 came back. I've driven it for a week like this, and yesterday, the P0125 came on for one drive, but turned back off the next. The P0125 code is currently off.

The hard starts are still happening, but seem better. Now it can start when warm, multiple times in a row, but it sputters a bit while doing so, but once on it idles smooth.

So I'm kinda stumped, but I have some ideas. I almost don't care about the P0171, but the hard starts can be potentially dangerous and stranding. The most obvious ones are the MAF and the O2 sensors. The MAF is not new, but I've traded in a non-OEM spare that's currently working fine in my wife's 2003 Rav4 (same part number), and the issues remain, so I put my original one back in. So MAF could still be the issue, but I don't think so. I'd have to buy a brand new one to be sure.

I've read that the upstream O2 sensor could cause a P0171 code and a P0125 code so I'm leaning that direction, as mine has almost 200k on it. Really needs to be done anyways. Could a bad O2 sensor 'overheat' and cause hard starts until it cools down?


I'm just mostly confused about the warm hard starts. Research shows these are usually mostly fuel pressure related, but the timing with my other codes seems to indicate otherwise. It cranks fine, so not a battery or starter issue. It just stumbles like it doesn't have the proper fuel mixture, but only when warm.

I read somewhere that someone's fuel injector cracked internally and was releasing fuel pressure. I also read that the Jeep guys used to wrap their injectors with reflective insulation to prevent heat-soak and vapor-lock.

Any ideas?


Edit: No gas smells at all, and it drives great once started. I had a bad FPR a few years ago, and the symptoms were different.
 
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Try checking the fuel pressure from the pump.....you can use an auto parts free loaner program. Might have a tired fuel pump or clogged filter. Or like me with an 80 I had the fuel pump partially came apart in the tank and caused all kinds of weird issues. When I ran the fuel pressure test it failed as soon as I shut the key off.....it wouldn't hold pressure at all.
GOOD LUCK! WITH IT!
 
Try checking the fuel pressure from the pump.....you can use an auto parts free loaner program. Might have a tired fuel pump or clogged filter. Or like me with an 80 I had the fuel pump partially came apart in the tank and caused all kinds of weird issues. When I ran the fuel pressure test it failed as soon as I shut the key off.....it wouldn't hold pressure at all.
GOOD LUCK! WITH IT!

Sorry for the late reply; I actually forgot I made this post! The issue was not really prevalent in my day-to-day life, as I very rarely do a lot of stop and go errands. I'm usually at my destinations for an hour or more, so I was not really affected by this.

HOWEVER...last Monday, I stopped by a client for about 20 minutes. I started it up, and it stumbled to life, but as I backed out of the parking spot, it died, and I had to push it back in. I waited for another 20 minutes before trying again, but no go. I had to walk to the nearest gas station and get some starting fluid. Sprayed it in the intake and it started right up.

I started researching the issue again and came across these threads:
Part 1:
96 4Runner Hard start when engine warm/hot (long/detailed) | IH8MUD Forum
Part2:
Fuel rail pressure when starting? Real Time Help please... | IH8MUD Forum

The symptoms sound exactly like mine, so I started thinking the fuel pump as well (or at least the wiring, like in the threads above). Then, I got another CEL that pointed directly to the front O2 sensor (I forget the code), so I bought a new Denso O2 sensor (PN = 234-4162).



This weekend, I rented a fuel pressure 'master' kit from Autozone, but of course it didn't have the exact fittings to tap into the fuel line (the 5VZFE doesn't have a schraeder valve built in; you have to splice into the high pressure line couplers at the drivers side of the engine bay). I also tried to splice in right before the fuel filter underneath, but again, the line size was wrong. I even tried to get some adapters from Home Depot, but nothing fit. So, a waste of time.
I also replaced the O2 sensor with the new Denso that just came in.

I patched it all back up (having done no real work other than replace the O2 sensor) and...it works better. A lot better. I've gone on several test drives and TRIED to make it stall out after sitting warm for a few minutes, and I can't. It starts up every time, without fail.


The O2 sensor CEL is gone, but the P0171 still remains. It does still take a little longer to start than I think it should, and it appears to stumble a bit still, so I'll try another fuel pressure tester.
I actually ordered a Denso Fuel Pump (PN = 950-0100) and new Wix fuel filter (PN = 33319) anyways, as the pump is original at almost 200k and the fuel filter has about 70k. I figured for a little over $100 total, it's worth it regardless, but I'd like to try another pressure tester and see the numbers for myself, first.

So that one's confusing. I know it's probably in conjunction with less than ideal fuel pressure, etc, but I've never heard of a O2 sensor that went bad and caused near impossible starting when it was warm. That just makes no sense to me. I inspected the wiring, and it all looks solid, just a little dirty. I don't think it was shorting out anywhere. That's a mystery.
 
0171 excessive lean = too much air and/or not enough fuel.

If the 2nd part of that equation is OK then look for too much air getting in thru a crack and/or loose rubber to metal connection after the MAF and before the metal intake. If the leak is there then the IAC & intake get extra dirty extra fast too. :cowboy:
 
Yeah, the main issue was the hard warm starting, but the P0171 is definitely a clue, albeit a vague one.
I've just never heard of an O2 sensor that affected startability like that. Or it was a red herring; we'll see.


I've inspected all my hoses and replaced the ones that looked iffy, but still have the P0171 code.

Addition: today I ran an errand during lunch. Exactly 20 minutes from arrival to restarting the truck. It started up, but had to crank significantly longer and it stuttered slightly for a few seconds. Not near as bad as it used to but it's still there.

Waiting on the fuel pump. Should be here by this weekend.




Horrible timing too, because I have to drive to Dallas on Friday for work (4 hours one way) and I really probably shouldn't take a car with a failing fuel pump, so I'm gonna have to drive my wife's '03 Rav4. I hate driving that thing; it just begs to be made fun of. Plus, the difference in interior quality is insane. I drive the Rav4, then drive the 4Runner and am just blown away by how much more solid it feels (even with my suspension squeaks).
 
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I had a lazy upstream and downstream O2 sensor on my dad's truck that would cause hard starts sometimes after a drive cycle, regardless if the money light had been tripped or not. Changed out all four O2 sensors, no more hard hot starts or money light.

A bad coolant temp sensor I have heard can cause the same.

If it were me I would change the rear 02 sensor with a Denso and a coolant with an OEM one. I would also look to see if the IAC per FSM specs are good or not.
 
I replaced the fuel pump per this write-up:
https://www.toyota-4runner.org/3rd-...removal-step-step-diy-w-pics.html#post3215685
OEM unit: Denso 950-0100

I also replaced the fuel filter with a Wix unit.

So far, so good. (now I jinxed it). It feels much more powerful and has not failed to start once. The P0171 code is gone, too.

I got a Coolant Temp Sensor as well, just in case. Not OEM, but a well rated model for $10 from Amazon. I did not replace it, but I'll do so if necessary.

I still could not find a fuel pressure tester without piecing together different kits, etc, so I'm not sure of the PSI, but id definitely feels better overall.

I read somewhere that the Fuel Pump itself has a check valve that (when it goes bad) starts to close after it's been shut off for a few minutes, which effectively chokes the system of fuel(?) I'm not sure if this is accurate, but it makes as much sense to me as anything else.
 
I replaced the fuel pump...
I read somewhere that the Fuel Pump itself has a check valve that (when it goes bad) starts to close after it's been shut off for a few minutes, which effectively chokes the system of fuel(?) I'm not sure if this is accurate, but it makes as much sense to me as anything else.

The check valve is a one-way valve allowing fuel to flow out from tank forward but not back into tank. When the valve begins to fail it will allow fuel to flow back into tank usually after sitting a while (could be 1/2 hour or more) causing hard starts due to fuel starvation.

Good you solved your issue - enjoy that Runner. :cowboy:
 
The check valve is a one-way valve allowing fuel to flow out from tank forward but not back into tank. When the valve begins to fail it will allow fuel to flow back into tank usually after sitting a while (could be 1/2 hour or more) causing hard starts due to fuel starvation.

Good you solved your issue - enjoy that Runner. :cowboy:

That makes perfect sense. It started being hard to start after around 20 minutes of sitting, but started fine again after roughly 45-60 minutes.

Thanks!



Be wary of using a non OEM sensor. If the PO125 code doesn’t come back, drive on.

Yeah, I didn't install the sensor yet. I'm not gonna touch it if the codes stay away, which they have so far. At the very least, I have a $10 spare if I ever need one. (my $13 eBay special MAF was a godsend almost 3 years after I bought it)



Why Toyota didn't make the hole under the passenger seat large enough to pull the pump is beyond me. That hole is completely useless, except for to remove the plug from the fuel pump directly. There's plenty more room under that seat to have the hole easily 4x as big, which would mean the tank would not have to drop at all. Stupid planning. (or rather, a planned failure that requires a dealership visit?)
 
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