NO.11 ENGINE STALLS/QUITS, ENGINE RUNS ROUGH, MISSES, BUCK/JERK, HESITATION/STUMBLE, SURGES [MZ-CD 1.6 (Y6)]

id0103b3801700

11

ENGINE STALLS/QUITS, ENGINE RUNS ROUGH, MISSES, BUCK/JERK, HESITATION/STUMBLE, SURGES

DESCRIPTION

•  The engine stops unexpectedly at the beginning of acceleration or while cruising.

•  The engine stops unexpectedly while cruising.

•  The engine speed fluctuates during acceleration or cruising.

•  The engine misses during acceleration or cruising.

•  The vehicle bucks/jerks during acceleration or deceleration.

•  Momentary pause at beginning of acceleration or during acceleration.

•  Momentary minor irregularity in engine output.

POSSIBLE CAUSE

•  Poor fuel quality

•  Glow system malfunction

•  Air leakage from intake-air system

•  Intake-air system restriction or clogging

•  Engine overheating

•  A/C system improper operation

•  Turbocharger malfunction

•  EGR system malfunction

•  Clutch pedal position switch or related circuit malfunction

•  Cooling fan seat is improper

•  Fuel line clogging or restriction

•  Fuel filter clogging or restriction

•  Fuel warmer system malfunction

•  Incorrect fuel injection timing

•  Erratic signal from CKP sensor

•  Erratic signal from CMP sensor

•  ECT sensor or related circuit malfunction

•  Boost sensor or related circuit malfunction

•  Accelerator pedal position sensor or related circuit malfunction

•  Idle switch or related circuit malfunction

•  MAF/IAT sensor or related circuit malfunction

•  VSS or related circuit malfunction

•  Incorrect idle speed

•  Inadequate fuel pressure

•  Fuel pressure sensor or related circuit malfunction

•  Fuel metering valve malfunction

•  Fuel pressure limiter malfunction

•  Supply pump malfunction

•  Fuel injector malfunction

•  Low engine compression

•  Improper valve timing

•  Exhaust system and/or catalyst converter restriction

•  Clutch slippage

•  diesel particulate filter restriction or damaged (High power-Euro 4)

Предупреждение

The following troubleshooting flow chart contains the fuel system diagnosis and repair procedures. Read the following warnings before servicing the fuel system:

•  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	Is the idle speed stable?	Yes	Go to the next step.
1	Is the idle speed stable?	No	Go to symptom troubleshooting “NO.8 ENGINE RUNS ROUGH/ROLLING IDLE”.
2	Is the engine overheating?	Yes	Go to symptom troubleshooting “NO.17 COOLING SYSTEM CONCERNS—OVERHEATING”.
2	Is the engine overheating?	No	Go to the next step.
3	Perform the self-test function using the M-MDS. Turn the engine switch to the ON position. Retrieve any DTC. Are DTCs displayed?	Yes	DTC is displayed: Go to the appropriate DTC test. Communication error message is displayed: Inspect for the following: • Open circuit between PCM control relay and PCM terminal 236 or 231 • Open circuit between PCM control relay and PCM terminal 241 • PCM control relay stuck open • Open or poor ground circuit (PCM terminal 307, 308 or 332) • Poorly connected vehicle body ground
3		No	No DTC is displayed: Go to the next step.
4	Inspect the following: • Fuel quality (e.g.: including water contamination, winter/summer blend) • Fuel line/fuel filter clogging and/or restriction • Intake-air system restriction or clogging • Exhaust system, catalyst converter and/or diesel particulate filter^* restriction • Cooling fan seat Are all items normal?	Yes	Go to the next step.
4		No	Service if necessary. Repeat Step 4.
5	Does the engine run normal after warm-up?	Yes	Go to the next step.
5	Does the engine run normal after warm-up?	No	Go to Step 8.
6	Inspect glow system operation. Is the glow system operation normal?	Yes	Go to the next step.
6		No	Repair or replace malfunctioning parts according to the glow system operation inspection results.
7	Inspect fuel warmer system operation. Is the fuel warmer system operation normal?	Yes	Go to the next step.
7		No	Repair or replace malfunctioning parts according to the fuel warmer system operation inspection results.
8	Примечание • The following test should be performed on vehicles with the A/C system. If the following test cannot be performed due to engine stalling, go to the next step. • Go to the next step for the vehicles without A/C system. Connect the pressure gauge to the A/C line. Turn the blower and A/C switches on. Is the pressure within specification?	Yes	Go to the next step.
8		No	A/C is always on: Go to symptom troubleshooting “NO.24 A/C ALWAYS ON OR A/C COMPRESSOR RUNS CONTINUITY”. Other symptoms: Inspect the following: • Refrigerant charging amount • Cooling fan operation
9	Inspect hose bands between the following parts: • Turbocharger compressor housing and air cleaner • Turbocharger compressor housing and charge air cooler Are the hose bands loose?	Yes	Retighten the hose bands. If the concern is resolved, the inspection is completed. If the concern still exists, go to the next step.
9		No	Go to the next step.
10	Inspect for improper operation, kinks, clogging or disconnection on the guide blade actuator. Is the guide blade actuator normal?	Yes	The turbocharger is normal. Go to the next step.
10		No	Repair or replace if necessary. If the concern is resolved, the inspection is completed. If the concern still exists, the turbocharger is normal. Go to the next step.
11	Perform the EGR system inspection. Is the EGR system normal?	Yes	Go to the next step.
11		No	Repair or replace malfunctioning parts according to the EGR system operation results.
12	Inspect idle speed. Is the idle speed correct?	Yes	Go to the next step.
12	Inspect idle speed. Is the idle speed correct?	No	Repair or replace malfunctioning parts according to the idle speed inspection results.
13	Connect the M-MDS to the DLC-2. Access the following PID. • APP Verify that the PID value when the accelerator pedal is depressed and/or released. Is the PID value normal?	Yes	Go to the next step.
13		No	Inspect and repair or replace the following part:. • Accelerator pedal position sensor
14	Inspect the clutch pedal position switch. (See CLUTCH PEDAL POSITION (CPP) SWITCH INSPECTION [MZ-CD 1.6 (Y6)].) Is the clutch pedal position switch normal?	Yes	Go to the next step.
14		No	Replace the clutch pedal position switch.
15	Visually inspect CKP sensor and teeth of pulse wheel. Are the CKP sensor and the teeth of the pulse wheel normal?	Yes	Go to the next step.
15		No	Replace malfunctioning parts.
16	Measure gap between CKP sensor and teeth of pulse wheel. Specification 1.5—2.5 mm {0.059—0.098 in} Is the gap within the specification?	Yes	Go to the next step.
16		No	Adjust the CKP sensor position.
17	Visually inspect CMP sensor and teeth of pulse wheel. Are the CMP sensor and the teeth of the pulse wheel normal?	Yes	Inspect the following PIDs: (See PCM INSPECTION [MZ-CD 1.6 (Y6)].) • ECT • IAT • MAF • RPM If the PID value is not as specified, repair or replace malfunctioning parts. If the PID value is normal, go to the next step.
17		No	Replace malfunctioning parts.
18	Inspect fuel pressure sensor. (See FUEL PRESSURE SENSOR INSPECTION [MZ-CD 1.6 (Y6)].) Is the fuel pressure normal?	Yes	Go to the next step.
18		No	Replace the common rail.
19	Inspect fuel metering valve. (See ПРОВЕРКА ДОЗИРУЮЩЕГО КЛАПАНА [MZ-CD 1.6 (Y6)].) Is the fuel metering valve normal?	Yes	Go to the next step.
19		No	Replace the fuel pump. (See СНЯТИЕ И УСТАНОВКА ТНВД [MZ-CD 1.6 (Y6)].)
20	Is the engine compression correct?	Yes	Go to the next step.
20	Is the engine compression correct?	No	Inspect for the following: • Damaged valve seat • Worn valve stem and valve guide • Worn or stuck piston ring • Worn piston, piston ring or cylinder • Improper valve timing Service if necessary.
21	Inspect fuel injector. (See ПРОВЕРКА ТОПЛИВНЫХ ФОРСУНОК [MZ-CD 1.6 (Y6)].) Is the fuel injector normal?	Yes	Go to the next step.
21		No	Repair or replace if necessary.
22	Inspect timing belt for following: • Chipping of gear teeth • Low tension • Breakage or cracks Is the timing belt normal?	Yes	Inspect the following: • Clutch slippage • CKP sensor • VSS If normal, remove and inspect the supply pump and common rail.
22		No	If the timing is incorrect, adjust the valve timing. If the timing belt is not normal, replace the timing belt.
23	Verify test results. • If normal, return to the diagnostic index to service any additional symptoms. (See SYMPTOM DIAGNOSTIC INDEX [MZ-CD 1.6 (Y6)].) • If the malfunction remains, inspect related Service Information and perform repair or diagnosis. ― If the vehicle is repaired, troubleshooting is completed. ― If the vehicle is not repaired or additional diagnostic information is not available, replace the PCM. (See PCM REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)

* :High power-Euro 4

11	ENGINE STALLS/QUITS, ENGINE RUNS ROUGH, MISSES, BUCK/JERK, HESITATION/STUMBLE, SURGES
DESCRIPTION	• The engine stops unexpectedly at the beginning of acceleration or while cruising. • The engine stops unexpectedly while cruising. • The engine speed fluctuates during acceleration or cruising. • The engine misses during acceleration or cruising. • The vehicle bucks/jerks during acceleration or deceleration. • Momentary pause at beginning of acceleration or during acceleration. • Momentary minor irregularity in engine output.
POSSIBLE CAUSE	• Poor fuel quality • Glow system malfunction • Air leakage from intake-air system • Intake-air system restriction or clogging • Engine overheating • A/C system improper operation • Turbocharger malfunction • EGR system malfunction • Clutch pedal position switch or related circuit malfunction • Cooling fan seat is improper • Fuel line clogging or restriction • Fuel filter clogging or restriction • Fuel warmer system malfunction • Incorrect fuel injection timing • Erratic signal from CKP sensor • Erratic signal from CMP sensor • ECT sensor or related circuit malfunction • Boost sensor or related circuit malfunction • Accelerator pedal position sensor or related circuit malfunction • Idle switch or related circuit malfunction • MAF/IAT sensor or related circuit malfunction • VSS or related circuit malfunction • Incorrect idle speed • Inadequate fuel pressure • Fuel pressure sensor or related circuit malfunction • Fuel metering valve malfunction • Fuel pressure limiter malfunction • Supply pump malfunction • Fuel injector malfunction • Low engine compression • Improper valve timing • Exhaust system and/or catalyst converter restriction • Clutch slippage • diesel particulate filter restriction or damaged (High power-Euro 4) Предупреждение The following troubleshooting flow chart contains the fuel system diagnosis and repair procedures. Read the following warnings before servicing the fuel system: • 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.