NO.21 EXCESSIVE BLACK SMOKE [MZR-CD (RF Turbo)]

id0103f1821900

21

EXCESSIVE BLACK SMOKE
DESCRIPTION
•  Excessive black smoke is observed in 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
•  IAT sensor No.2 or related circuit malfunction
•  A/F sensor or related circuit malfunction
•  Fuel injector malfunction
•  Excessive fuel pressure
•  Suction control valve malfunction (built-in supply pump)
•  Fuel line clogging or restriction
•  Fuel pressure limiter malfunction (built-in common rail)
•  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
•  Intake shutter valve malfunction
•  Exhaust system and/or oxidation catalytic converter restriction or clogging
•  Fuel injection learning improper
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
Inspect the following:
•  Intake-air system clogging or restriction
•  Exhaust system and/or oxidation catalytic converter 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 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.
3
Does any other symptom exist?
Yes
Go to 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 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.
6
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.
7
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.
8
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 specification?
Yes
Go to the next step.
No
Adjust the CKP sensor position.
9
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)].)
•  IAT
•  MAP
•  RPM
•  O2S11
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.
10
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.
11
Inspect the 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, the inspection is complete.
If the concern still exists, go to the next step.
No
Go to the next step.
12
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.
13
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.
Is there any malfunction?
Yes
Replace turbocharger.
No
Go to the next step.
14
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.
15
Inspect the turbocharger compressor wheel by hand.
Does wheel turn easily and smoothly?
Yes
Go to the next step.
No
Replace the turbocharger.
16
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 the turbocharger.
No
Go to the next step.
17
Is any engine oil found inside the turbocharger compressor housing?
Yes
Wipe oil off of the vehicle and install all removed parts in Step 15. Then, go to the next step.
No
Turbocharger is normal.
Install all parts removed is Step 15. Then, go to the next step.
18
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)].)
19
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.
20
Inspect the fuel injector.
(See FUEL INJECTOR INSPECTION [MZR-CD (RF Turbo)].)
Is the fuel injector normal?
Yes
Inspect the following:
•  Boost sensor
•  Fuel pressure limiter (built-in common rail)
•  Fuel pressure sensor
•  Fuel return line restriction or clogging
Service if necessary.
If they are normal, perform fuel injection learning.
(See ENGINE TUNE-UP [MZR-CD (RF Turbo)].)
No
Repair or replace if necessary.
(See FUEL INJECTOR REMOVAL/INSTALLATION [MZR-CD (RF Turbo)].)
21
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.