NO.17 EMISSION COMPLIANCE [MZR-CD (RF Turbo)]

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17

EMISSION COMPLIANCE
DESCRIPTION
•  Fails 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
•  Intake shutter valve stuck close
•  Turbocharger malfunction
•  Guide blade valve 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 (built-in common rail)
•  Suction control valve inspection (built-in supply pump)
•  ECT sensor or related circuit malfunction
•  MAF/IAT sensor related circuit malfunction
•  IAT sensor No.2 or related circuit malfunction
•  Fuel pressure sensor or related circuit malfunction
•  APP sensor 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
•  Neutral switch or related circuit malfunction
•  VSS or related circuit malfunction
•  Low engine compression
•  Improper valve timing
•  Base engine malfunction
•  Exhaust system and/or oxidation catalytic converter restriction
•  Oxidation catalytic converter malfunction
Warning
The following troubleshooting flow chart contains the fuel system diagnosis and repair procedures. Read the following warnings before performing the fuel system services:
•  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 engine overheating?
Yes
Go to the symptom troubleshooting “NO.19 COOLING SYSTEM CONCERNS—OVERHEATING [MZR-CD (RF-Turbo)]”.
(See NO.19 COOLING SYSTEM CONCERNS-OVERHEATING [MZR-CD (RF Turbo)].)
No
Go to the next step.
2
Does the engine run cold?
Yes
Go to the symptom troubleshooting “NO.20 COOLING SYSTEM CONCERNS—RUNS COLD [MZR-CD (RF-Turbo)]”.
(See NO.20 COOLING SYSTEM CONCERNS-RUNS COLD [MZR-CD (RF Turbo)].)
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 DTCs.
Are any DTCs displayed?
Yes
DTC is displayed:
Go to the appropriate DTC test.
(See DTC TABLE [MZR-CD (RF Turbo)].)
Communication error message is displayed:
Inspect the following:
•  Open circuit between PCM control relay and PCM terminal 119 or 120
•  Open circuit PCM control relay and PCM terminal 105
•  PCM control relay stuck open
•  Open or poor ground circuit (PCM terminal 1, 2, 3, 114 or 117)
•  Poor connection to 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 and/or oxidation catalytic converter restriction
•  Vacuum leakage
Are all items normal?
Yes
Go to the next step.
No
Service if necessary.
Repeat Step 4.
5
Inspect the APP sensor.
(See ACCELERATOR PEDAL POSITION (APP) SENSOR INSPECTION [MZR-CD (RF Turbo)].)
Is the APP sensor normal?
Yes
Go to the next step.
No
Replace the accelerator pedal component.
(See ACCELERATOR PEDAL REMOVAL/INSTALLATION [MZR-CD (RF Turbo)].)
6
Inspect the adjustment of neutral switch.
(See NEUTRAL SWITCH INSPECTION [MZR-CD (RF Turbo)].)
Is the neutral switch adjusted correctly?
Yes
Go to the next step.
No
Adjust the neutral switch correctly.
7
Inspect the intake shutter valve operation.
(See ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZR-CD (RF Turbo)].)
Is there any malfunction?
Yes
Repair or replace if necessary.
No
Go to the next step.
8
Inspect the guide blade valve operation.
(See ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZR-CD (RF Turbo)].)
Is there any malfunction?
Yes
Repair or replace if necessary.
No
Go to the next step.
9
Inspect the 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 complete.
If the concern still exists, go to the next step.
No
Go to the next step.
10
Inspect for improper operation, kinks, clogging or disconnection on guide blade actuator.
(See ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZR-CD (RF Turbo)].)
Is the actuator normal?
Yes
Go to the next step.
No
Repair or replace if necessary.
If the concern is resolved, the inspection is complete.
If the concern still exists, turbocharger is normal.
Go to the next step.
11
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 [MZR-CD (RF Turbo)].)
Is there any malfunction?
Yes
Replace turbocharger.
No
Go to the next step.
12
Inspect if the turbocharger compressor wheel locknut is loose or has fallen down inside the turbocharger.
Is there any malfunction?
Yes
Replace the turbocharger.
No
Go to the next step.
13
Inspect the turbocharger compressor wheel by hand.
Does the wheel turn easily and smoothly?
Yes
Go to the next step.
No
Replace the turbocharger.
14
Inspect if the turbocharger turbine wheel is damaged, cracked or interfering with the housing on vehicle.
Note
•  Inspect all fins on each turbine wheel.
Is there any malfunction?
Yes
Replace turbocharger.
No
Go to the next step.
15
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.
16
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
Turbocharger is normal.
Install all parts removed in Step10.
Then, go to the next step.
17
Perform the EGR system inspection.
Is the EGR system normal?
Yes
Go to the next step.
No
Repair or replace the malfunctioning part according to EGR system operation results.
18
Inspect the EGR water cooler for the 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.
19
Inspect the glow system operation.
(See RELAY INSPECTION.)
Is the glow system operation normal?
Yes
Go to the next step.
No
Repair or replace the malfunctioning part according to glow system operation results.
20
Visually inspect the CKP sensor and the teeth of the pulse wheel.
Are the CKP sensor and the teeth of the pulse wheel normal?
Yes
Go to the next step.
No
Replace malfunctioning parts.
21
Measure the gap between the CKP sensor and the teeth of the 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.
No
Adjust the CKP sensor position.
22
Visually inspect the CMP sensor and the teeth of the pulse wheel.
Are the CMP sensor and the teeth of the pulse wheel normal?
Yes
Inspect the following PIDs:
(See PCM INSPECTION [MZR-CD (RF Turbo)].)
•  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.
23
Inspect the fuel pressure sensor.
(See FUEL PRESSURE SENSOR INSPECTION [MZR-CD (RF Turbo)].)
Is the fuel pressure normal?
Yes
Go to the next step.
No
Replace the common rail.
(See SUPPLY PUMP REMOVAL/INSTALLATION [MZR-CD (RF Turbo)].)
24
Inspect the suction control valve.
(See SUCTION CONTROL VALVE INSPECTION [MZR-CD (RF Turbo)].)
Is the suction control valve normal?
Yes
Go to the next step.
No
Replace the supply pump.
(See SUPPLY PUMP REMOVAL/INSTALLATION [MZR-CD (RF Turbo)].)
25
Is the engine compression correct?
(See COMPRESSION INSPECTION [MZR-CD (RF Turbo)].)
Yes
Go to the next step.
No
Inspect 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.
26
Inspect the fuel injector.
(See FUEL INJECTOR INSPECTION [MZR-CD (RF Turbo)].)
Is the fuel injector normal?
Yes
Go to the next step.
No
Repair or replace if necessary.
(See FUEL INJECTOR REMOVAL/INSTALLATION [MZR-CD (RF Turbo)].)
27
Inspect the timing belt for the following:
•  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
•  Oxidation catalytic converter
If normal, remove and inspect the supply pump and common rail.
No
If the timing is incorrect, adjust the valve the timing.
If the timing belt is not normal, replace the timing belt.
28
Verify test results.
•  If normal, return to the diagnostic index to service any additional symptoms.
•  If the malfunction remains, inspect the related Service Information and perform repair or diagnosis.
―  If the vehicle is repaired, troubleshooting completed.
―  If the vehicle is not repaired or additional diagnostic information is not available, reprogram the PCM if later calibration is available. Retest.