NO.15 EMISSION COMPLIANCE [MZ-CD 1.6 (Y6)]

15	EMISSION COMPLIANCE
DESCRIPTION	• Fails the emissions test.
POSSIBLE CAUSE	• Poor fuel quality • Vacuum leakage • Air leakage from intake-air system • Intake-air system restriction or clogging • Variable boost control (VBC) system malfunction • Turbocharger malfunction • Charge air cooler malfunction • Glow system malfunction • EGR system malfunction • EGR water cooler malfunction • Low coolant temperature • Engine overheating • Inadequate fuel pressure • Fuel pressure limiter malfunction • Fuel metering control system malfunction • ECT sensor or related circuit malfunction • MAF/IAT sensor related circuit malfunction • Fuel pressure sensor or related circuit malfunction • Accelerator pedal position sensor or related circuit malfunction • Idle switch or related circuit malfunction • Fuel line clogging or restriction • Supply pump malfunction • Fuel injector malfunction • Incorrect fuel injection timing • Incorrect idle speed • Erratic signal from CKP sensor • Erratic signal from CMP sensor • Boost sensor or related circuit malfunction • Clutch pedal position switch or related circuit malfunction • VSS or related circuit malfunction • Low engine compression • Improper valve timing • Base engine malfunction • Exhaust system and/or catalyst converter restriction • Catalyst converter malfunction • Diesel particulate filter restriction or damaged (High power-Euro 4) • Diesel particulate filter system malfunction (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.

EMISSION COMPLIANCE

DESCRIPTION

• Fails the emissions test.

POSSIBLE CAUSE

• Poor fuel quality

• Vacuum leakage

• Air leakage from intake-air system

• Intake-air system restriction or clogging

• Variable boost control (VBC) system malfunction

• Turbocharger malfunction

• Charge air cooler malfunction

• Glow system malfunction

• EGR system malfunction

• EGR water cooler malfunction

• Low coolant temperature

• Engine overheating

• Inadequate fuel pressure

• Fuel pressure limiter malfunction

• Fuel metering control system malfunction

• ECT sensor or related circuit malfunction

• MAF/IAT sensor related circuit malfunction

• Fuel pressure sensor or related circuit malfunction

• Accelerator pedal position sensor or related circuit malfunction

• Idle switch or related circuit malfunction

• Fuel line clogging or restriction

• Supply pump malfunction

• Fuel injector malfunction

• Incorrect fuel injection timing

• Incorrect idle speed

• Erratic signal from CKP sensor

• Erratic signal from CMP sensor

• Boost sensor or related circuit malfunction

• Clutch pedal position switch or related circuit malfunction

• VSS or related circuit malfunction

• Low engine compression

• Improper valve timing

• Base engine malfunction

• Exhaust system and/or catalyst converter restriction

• Catalyst converter malfunction

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

• Diesel particulate filter system malfunction (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.

STEP	INSPECTION	RESULTS	ACTION
1	Is the engine overheating?	Yes	Go to symptom troubleshooting “NO.17 COOLING SYSTEM CONCERNS—OVERHEATING”.
No	Go to the next step.
2	Does the engine run cold?	Yes	Go to symptom troubleshooting “NO.18 COOLING SYSTEM CONCERNS—RUNS COLD”.
No	Go to the next step.
3	Connect the M-MDS to the DLC-2. 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
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 return line clogging and/or restriction • Charge air cooler condition (restriction or damaged) • Intake-air system restriction • Exhaust system, catalyst converter and/or diesel particulate filter^* restriction • Vacuum leakage Are all items normal?	Yes	Go to the next step.
No	Service if necessary. Repeat Step 4.
5	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 PID values normal?	Yes	Inspect for vacuum leakage.
No	Inspect and repair or replace the following part: • Accelerator pedal position sensor
6	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.
No	Replace the clutch pedal position switch.
7	Inspect guide blade valve operation. (See ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZ-CD 1.6 (Y6)].) Is there any problem?	Yes	Repair or replace if necessary.
No	Go to the next step.
8	Inspect hose bands between following parts: • Turbocharger compressor housing and air cleaner • Turbocharger compressor housing and charge air cooler Are hose bands loose?	Yes	Retighten the hose bands. If the concern is resolved, inspection is completed. If the concern still exists, go to the next step.
No	Go to the next step.
9	Inspect for improper operation, kinks, clogging or disconnection on guide blade actuator. (See ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZ-CD 1.6 (Y6)].) Is the actuator normal?	Yes	Go to the next step.
No	Repair or replace if necessary. If the concern is resolved, inspection is completed. If the concern still exists, the turbocharger is normal. Go to the next step.
10	Remove parts necessary to inspect the turbocharger. Do not remove the turbocharger. Inspect if the turbocharger compressor wheel is bent, damaged, or interfering with housing on vehicle. (See TURBOCHARGER INSPECTION [MZ-CD 1.6 (Y6)].) Is there any problem?	Yes	Replace the turbocharger.
No	Go to the next step.
11	Inspect if turbocharger compressor wheel locknut is loose or has fallen down inside turbocharger. Is there any problem?	Yes	Replace the turbocharger.
No	Go to the next step.
12	Inspect turbocharger compressor wheel by hand. Does the wheel turn easily and smoothly?	Yes	Go to the next step.
No	Replace the turbocharger.
13	Inspect if turbocharger turbine wheel is damaged, cracked or interfering with housing on vehicle. Примечание • Inspect all fins on each turbine wheel. Is there any problem?	Yes	Replace the turbocharger.
No	Go to the next step.
14	Is any engine oil found inside the turbocharger turbine housing?	Yes	Excessive amount of oil is found: Replace the turbocharger. Small amount of oil is found: Wipe oil off of the vehicle, then go to the next step.
No	Go to the next step.
15	Is any engine oil found inside the turbocharger compressor hosing?	Yes	Wipe oil off of the vehicle and install all removed parts in Step 10. Then, go to the next step.
No	The turbocharger is normal. Install all parts removed in Step10. Then, go to the next step.
16	Perform the EGR system inspection. Is the EGR system normal?	Yes	Go to the next step.
No	Repair or replace malfunctioning part according to the EGR system operation results.
17	Inspect EGR water cooler for following: • Coolant passage clogging/restriction • Exhaust gas clogging/restriction Is the EGR water cooler normal?	Yes	Go to the next step.
No	Service if necessary.
18	Inspect glow system operation. Is the glow system operation normal?	Yes	Go to the next step.
No	Repair or replace malfunctioning part according to the glow system operation results.
19	Visually inspect CKP sensor and teeth of pulse wheel. Are the CKP sensor and the teeth of pulse wheel normal?	Yes	Go to the next step.
No	Replace malfunctioning parts.
20	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 specification?	Yes	Go to the next step.
No	Adjust the CKP sensor position.
21	Visually inspect CMP sensor and teeth of pulse wheel. Are the CMP sensor and the teeth of pulse wheel normal?	Yes	Inspect the following PIDs: (See PCM INSPECTION [MZ-CD 1.6 (Y6)].) • ECT • IAT • MAF • MAP • RPM • VSS If the PID value is not as specified, repair or replace malfunctioning parts. If the PID value is normal, go to the next step.
No	Replace malfunctioning parts.
22	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.
No	Replace the common rail.
23	Inspect fuel metering valve (See ПРОВЕРКА ДОЗИРУЮЩЕГО КЛАПАНА [MZ-CD 1.6 (Y6)].) Is fuel metering valve normal?	Yes	Go to the next step.
No	Replace the fuel pump. (See СНЯТИЕ И УСТАНОВКА ТНВД [MZ-CD 1.6 (Y6)].)
24	Is the engine compression correct?	Yes	Go to the next step.
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.
25	Inspect fuel injector. (See ПРОВЕРКА ТОПЛИВНЫХ ФОРСУНОК [MZ-CD 1.6 (Y6)].) Is the fuel injector normal?	Yes	Go to the next step. (High power-Euro 4) Go to step 31. (standard power-Euro 4)
No	Repair or replace if necessary.
26	Check scheduled maintenance for following: • Fuel additive • Diesel particulate filter Are these scheduled maintenances properly?	Yes	Go to the next step.
No	Carry out the scheduled maintenance properly.
27	Inspect the fuel additive amount. Are there any fuel additives in fuel additive tank?	Yes	Go to the next step.
No	Inspect and repair or replace for following: • Fuel additive hose (Fuel additive tank - fuel additive pump - fuel tank) • Fuel tank level sensor
28	Remove the diesel particulate filter. Visually inspect for damaged at diesel particulate filter. Are there detected any damaged?	Yes	Replace the diesel particulate filter.
No	Go to the next step.
29	Perform cooling air bypass valve operation Inspection. Does the cooling air bypass valve operation properly?	Yes	Go to the next step.
No	Repair or replace malfunctioning part, according to inspection result.
30	Access following PIDs using the M-MDS. • CABVDC • CABVP • DPF_DIF • POST_CAT Monitor the PIDs. Are there any problems detected?	Yes	Inspect the suspect PID related wiring and components. If okay inspect the fuel level sensor.
No	Go to the next step.
31	Inspect timing belt for followings: • Chipping of gear teeth • Low tension • Breakage damage or cracks Is the timing belt normal?	Yes	Inspect the following: • ECT sensor • Boost sensor • MAF/IAT sensor • Catalyst converter If normal, remove and inspect the supply pump and common rail.
No	If the timing is incorrect, adjust the valve timing. If the timing belt is not normal, replace the timing belt.
32	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 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)].)

STEP

INSPECTION

RESULTS

ACTION

Is the engine overheating?

Yes

Go to symptom troubleshooting “NO.17 COOLING SYSTEM CONCERNS—OVERHEATING”.

Go to the next step.

Does the engine run cold?

Yes

Go to symptom troubleshooting “NO.18 COOLING SYSTEM CONCERNS—RUNS COLD”.

Go to the next step.

Connect the M-MDS to the DLC-2.

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

No DTC is displayed:

Go to the next step.

Inspect the following:

• Fuel quality (e.g.: including water contamination, winter/summer blend)

• Fuel return line clogging and/or restriction

• Charge air cooler condition (restriction or damaged)

• Intake-air system restriction

• Exhaust system, catalyst converter and/or diesel particulate filter^* restriction

• Vacuum leakage

Are all items normal?

Yes

Go to the next step.

Service if necessary.

Repeat Step 4.

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 PID values normal?

Yes

Inspect for vacuum leakage.

Inspect and repair or replace the following part:

• Accelerator pedal position sensor

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.

Replace the clutch pedal position switch.

Inspect guide blade valve operation.

(See ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZ-CD 1.6 (Y6)].)

Is there any problem?

Yes

Repair or replace if necessary.

Go to the next step.

Inspect hose bands between following parts:

• Turbocharger compressor housing and air cleaner

• Turbocharger compressor housing and charge air cooler

Are hose bands loose?

Yes

Retighten the hose bands.

If the concern is resolved, inspection is completed.

If the concern still exists, go to the next step.

Go to the next step.

Inspect for improper operation, kinks, clogging or disconnection on guide blade actuator.

(See ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZ-CD 1.6 (Y6)].)

Is the actuator normal?

Yes

Go to the next step.

Repair or replace if necessary.

If the concern is resolved, inspection is completed.

If the concern still exists, the turbocharger is normal.

Go to the next step.

Remove parts necessary to inspect the turbocharger.

Do not remove the turbocharger.

Inspect if the turbocharger compressor wheel is bent, damaged, or interfering with housing on vehicle.

(See TURBOCHARGER INSPECTION [MZ-CD 1.6 (Y6)].)

Is there any problem?

Yes

Replace the turbocharger.

Go to the next step.

Inspect if turbocharger compressor wheel locknut is loose or has fallen down inside turbocharger.

Is there any problem?

Yes

Replace the turbocharger.

Go to the next step.

Inspect turbocharger compressor wheel by hand.

Does the wheel turn easily and smoothly?

Yes

Go to the next step.

Replace the turbocharger.

Inspect if turbocharger turbine wheel is damaged, cracked or interfering with housing on vehicle.

Примечание

• Inspect all fins on each turbine wheel.

Is there any problem?

Yes

Replace the turbocharger.

Go to the next step.

Is any engine oil found inside the turbocharger turbine housing?

Yes

Excessive amount of oil is found:

Replace the turbocharger.

Small amount of oil is found:

Wipe oil off of the vehicle, then go to the next step.

Go to the next step.

Is any engine oil found inside the turbocharger compressor hosing?

Yes

Wipe oil off of the vehicle and install all removed parts in Step 10. Then, go to the next step.

The turbocharger is normal.

Install all parts removed in Step10.

Then, go to the next step.

Perform the EGR system inspection.

Is the EGR system normal?

Yes

Go to the next step.

Repair or replace malfunctioning part according to the EGR system operation results.

Inspect EGR water cooler for following:

• Coolant passage clogging/restriction

• Exhaust gas clogging/restriction

Is the EGR water cooler normal?

Yes

Go to the next step.

Service if necessary.

Inspect glow system operation.

Is the glow system operation normal?

Yes

Go to the next step.

Repair or replace malfunctioning part according to the glow system operation results.

Visually inspect CKP sensor and teeth of pulse wheel.

Are the CKP sensor and the teeth of pulse wheel normal?

Yes

Go to the next step.

Replace malfunctioning parts.

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 specification?

Yes

Go to the next step.

Adjust the CKP sensor position.

Visually inspect CMP sensor and teeth of pulse wheel.

Are the CMP sensor and the teeth of pulse wheel normal?

Yes

Inspect the following PIDs:

(See PCM INSPECTION [MZ-CD 1.6 (Y6)].)

• ECT

• IAT

• MAF

• MAP

• RPM

• VSS

If the PID value is not as specified, repair or replace malfunctioning parts.

If the PID value is normal, go to the next step.

Replace malfunctioning parts.

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.

Replace the common rail.

Inspect fuel metering valve

(See ПРОВЕРКА ДОЗИРУЮЩЕГО КЛАПАНА [MZ-CD 1.6 (Y6)].)

Is fuel metering valve normal?

Yes

Go to the next step.

Replace the fuel pump.

(See СНЯТИЕ И УСТАНОВКА ТНВД [MZ-CD 1.6 (Y6)].)

Is the engine compression correct?

Yes

Go to the next step.

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.

Inspect fuel injector.

(See ПРОВЕРКА ТОПЛИВНЫХ ФОРСУНОК [MZ-CD 1.6 (Y6)].)

Is the fuel injector normal?

Yes

Go to the next step. (High power-Euro 4)

Go to step 31. (standard power-Euro 4)

Repair or replace if necessary.

Check scheduled maintenance for following:

• Fuel additive

• Diesel particulate filter

Are these scheduled maintenances properly?

Yes

Go to the next step.

Carry out the scheduled maintenance properly.

Inspect the fuel additive amount.

Are there any fuel additives in fuel additive tank?

Yes

Go to the next step.

Inspect and repair or replace for following:

• Fuel additive hose (Fuel additive tank - fuel additive pump - fuel tank)

• Fuel tank level sensor

Remove the diesel particulate filter.

Visually inspect for damaged at diesel particulate filter.

Are there detected any damaged?

Yes

Replace the diesel particulate filter.

Go to the next step.

Perform cooling air bypass valve operation Inspection.

Does the cooling air bypass valve operation properly?

Yes

Go to the next step.

Repair or replace malfunctioning part, according to inspection result.

Access following PIDs using the M-MDS.

• CABVDC

• CABVP

• DPF_DIF

• POST_CAT

Monitor the PIDs.

Are there any problems detected?

Yes

Inspect the suspect PID related wiring and components.

If okay inspect the fuel level sensor.

Go to the next step.

Inspect timing belt for followings:

• Chipping of gear teeth

• Low tension

• Breakage damage or cracks

Is the timing belt normal?

Yes

Inspect the following:

• ECT sensor

• Boost sensor

• MAF/IAT sensor

• Catalyst converter

If normal, remove and inspect the supply pump and common rail.

If the timing is incorrect, adjust the valve timing.

If the timing belt is not normal, replace the timing belt.

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 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)].)