NO.19 EXCESSIVE BLACK SMOKE [MZ-CD 1.6 (Y6)]

19	EXCESSIVE BLACK SMOKE
DESCRIPTION	• Excessive black smoke is observed in the exhaust gas.
POSSIBLE CAUSE	• Intake-air system clogging or restriction • Air leakage from Intake-air system • Incorrect fuel injection timing • Erratic signal from CKP sensor • Fuel pressure sensor or related circuit malfunction • Boost sensor or related circuit malfunction • MAF/IAT sensor related circuit malfunction • Fuel injector malfunction • Excessive fuel pressure • Fuel metering valve malfunction • Fuel line clogging or restriction • Fuel pressure limiter malfunction • Low engine compression • Improper valve timing • Base engine malfunction • EGR system malfunction • Variable boost control (VBC) system malfunction • Vacuum leakage • Turbocharger malfunction • Charge air cooler malfunction • Exhaust system and/or catalyst converter restriction or clogging • 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.

EXCESSIVE BLACK SMOKE

DESCRIPTION

• Excessive black smoke is observed in the exhaust gas.

POSSIBLE CAUSE

• Intake-air system clogging or restriction

• Air leakage from Intake-air system

• Incorrect fuel injection timing

• Erratic signal from CKP sensor

• Fuel pressure sensor or related circuit malfunction

• Boost sensor or related circuit malfunction

• MAF/IAT sensor related circuit malfunction

• Fuel injector malfunction

• Excessive fuel pressure

• Fuel metering valve malfunction

• Fuel line clogging or restriction

• Fuel pressure limiter malfunction

• Low engine compression

• Improper valve timing

• Base engine malfunction

• EGR system malfunction

• Variable boost control (VBC) system malfunction

• Vacuum leakage

• Turbocharger malfunction

• Charge air cooler malfunction

• Exhaust system and/or catalyst converter restriction or clogging

• 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	Inspect for the following: • Intake-air system clogging or restriction • Exhaust system, catalyst converter and/or diesel particulate filter restriction or clogging • Charge air cooler condition (restriction or damaged) Are all items normal?	Yes	Go to the next step.
No	Service if necessary. Repeat Step 1.
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.
3	Does any other symptom exist?	Yes	Go to the appropriate flowchart.
No	Go to the next step.
4	Inspect the air cleaner element for clogging. Is the air cleaner element normal?	Yes	Go to the next step.
No	Repair or replace the air cleaner element.
5	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.
6	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.
7	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.
8	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)].) • IAT • MAP • 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.
No	Replace malfunctioning parts.
9	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.
10	Inspect hose bands between 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, inspection is completed. If the concern still exists, go to the next step.
No	Go to the next step.
11	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.
12	Remove parts necessary to inspect the turbocharger. Do not remove the turbocharger. Inspect if turbocharger compressor wheel is bent, damaged, or interfering with housing on vehicle. Is there any problem?	Yes	Replace the turbocharger.
No	Go to the next step.
13	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.
14	Inspect if turbocharger compressor wheel by hand. Does the wheel turn easily and smoothly?	Yes	Go to the next step.
No	Replace the turbocharger.
15	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.
16	Is any engine oil found inside the turbocharger compressor housing?	Yes	Wipe oil off of the vehicle and install all removed parts in Step 12. Then, go to the next step.
No	The turbocharger is normal. Install all parts removed is Step 12. Then, go to the next step.
17	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.
No	Replace the fuel pump. (See СНЯТИЕ И УСТАНОВКА ТНВД [MZ-CD 1.6 (Y6)].)
18	Is the engine compression correct?	Yes	Go to the next step. (High power-Euro 4) Go to step 24. (standard power-Euro 4)
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.
19	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.
20	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
21	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.
22	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.
23	Access following PIDs using the M-MDS. • CABVDC • CABVP • DPF_DIF 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.
24	Inspect fuel injector. (See ПРОВЕРКА ТОПЛИВНЫХ ФОРСУНОК [MZ-CD 1.6 (Y6)].) Is the fuel injector normal?	Yes	Inspect the following: • Boost sensor • Fuel pressure limiter • Fuel pressure sensor • Fuel return line restriction or clogging Service if necessary.
No	Repair or replace if necessary.
25	Verify test results. • If normal, return to 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)].)

STEP

INSPECTION

RESULTS

ACTION

Inspect for the following:

• Intake-air system clogging or restriction

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

• Charge air cooler condition (restriction or damaged)

Are all items normal?

Yes

Go to the next step.

Service if necessary.

Repeat Step 1.

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.

Does any other symptom exist?

Yes

Go to the appropriate flowchart.

Go to the next step.

Inspect the air cleaner element for clogging.

Is the air cleaner element normal?

Yes

Go to the next step.

Repair or replace the air cleaner element.

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.

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)].)

• IAT

• MAP

• 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.

Replace malfunctioning parts.

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 hose bands between 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, 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 turbocharger compressor wheel is bent, damaged, or interfering with housing on vehicle.

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 if 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 compressor housing?

Yes

Wipe oil off of the vehicle and install all removed parts in Step 12. Then, go to the next step.

The turbocharger is normal.

Install all parts removed is Step 12. Then, go to the next step.

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.

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. (High power-Euro 4)

Go to step 24. (standard power-Euro 4)

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.

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

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 fuel injector.

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

Is the fuel injector normal?

Yes

Inspect the following:

• Boost sensor

• Fuel pressure limiter

• Fuel pressure sensor

• Fuel return line restriction or clogging

Service if necessary.

Repair or replace if necessary.

Verify test results.

• If normal, return to 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)].)