NO.8 HARD START/LONG CRANK/ERRATIC START/ERRATIC CRANK [MZR-CD 2.2]

8	HARD START/LONG CRANK/ERRATIC START/ERRATIC CRANK
DESCRIPTION	• Starter cranks engine at the normal speed but the engine requires excessive cranking time before starting. • Battery is in normal condition.
POSSIBLE CAUSE	• Poor fuel quality • Intake-air system restriction or clogging • Starting system malfunction • Inadequate fuel pressure • Fuel pressure limiter malfunction (built-in common rail) • Suction control valve malfunction (built-in supply pump) • Engine overheating • Glow system malfunction • Fuel warmer malfunction (With fuel warmer) • Fuel filter clogging or restriction • Fuel line clogging or restriction • Fuel leakage • Exhaust system and/or oxidation catalytic converter restriction or clogging • Incorrect fuel injection timing • Erratic signal from CKP sensor • Erratic signal from CMP sensor • ECT sensor or related circuit malfunction • Accelerator pedal position (APP) sensor or related circuit malfunction • MAF/IAT sensor or related circuit malfunction • Fuel pressure sensor or related circuit malfunction • Supply pump malfunction • Fuel injector malfunction • Low engine compression • Improper valve timing • EGR system 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. (See BEFORE SERVICE PRECAUTION [MZR-CD 2.2].) (See AFTER SERVICE PRECAUTION [MZR-CD 2.2].)

HARD START/LONG CRANK/ERRATIC START/ERRATIC CRANK

DESCRIPTION

• Starter cranks engine at the normal speed but the engine requires excessive cranking time before starting.

• Battery is in normal condition.

POSSIBLE CAUSE

• Poor fuel quality

• Intake-air system restriction or clogging

• Starting system malfunction

• Inadequate fuel pressure

• Fuel pressure limiter malfunction (built-in common rail)

• Suction control valve malfunction (built-in supply pump)

• Engine overheating

• Glow system malfunction

• Fuel warmer malfunction (With fuel warmer)

• Fuel filter clogging or restriction

• Fuel line clogging or restriction

• Fuel leakage

• Exhaust system and/or oxidation catalytic converter restriction or clogging

• Incorrect fuel injection timing

• Erratic signal from CKP sensor

• Erratic signal from CMP sensor

• ECT sensor or related circuit malfunction

• Accelerator pedal position (APP) sensor or related circuit malfunction

• MAF/IAT sensor or related circuit malfunction

• Fuel pressure sensor or related circuit malfunction

• Supply pump malfunction

• Fuel injector malfunction

• Low engine compression

• Improper valve timing

• EGR system 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. (See BEFORE SERVICE PRECAUTION [MZR-CD 2.2].) (See AFTER SERVICE PRECAUTION [MZR-CD 2.2].)

STEP	INSPECTION	RESULTS	ACTION
1	Inspect the following: • Fuel quality (e.g.: include water contamination, winter/summer blend) • Fuel line/fuel filter clogging • Intake-air system restriction Are all items normal?	Yes	Go to the next step.
No	Service if necessary. Repeat Step 1.
2	Is the engine overheating?	Yes	Go to the symptom troubleshooting “NO.21 COOLING SYSTEM CONCERNS-OVERHEATING”. (See NO.21 COOLING SYSTEM CONCERNS-OVERHEATING [MZR-CD 2.2].)
No	Go to the next step.
3	Connect the M-MDS to the DLC-2. Switch the ignition to ON. Retrieve any DTCs. Are any DTCs displayed?	Yes	DTC is displayed: Go to the appropriate DTC test. (See DTC TABLE [MZR-CD 2.2].) Communication error message is displayed: Inspect the following: • Open circuit between main relay and PCM terminal 2C or 2F • Open circuit main relay and PCM terminal 2I • Main relay stuck open • Open or poor ground circuit (PCM terminal 2B, 2E, 2A or 2D) • Poor connection to vehicle body ground
No	No DTC is displayed: Go to the next step.
4	Start the engine and warm up to normal operation temperature. Verify the diesel particulate filter indicator light condition. Does the diesel particulate filter indicator light illuminate or flash?	Yes	Diesel particulate filter indicator light illuminates: Perform the manual diesel particulate filter regeneration procedure. (See DIESEL PARTICULATE FILTER REGENERATION [MZR-CD 2.2].) Diesel particulate filter indicator light flashes: Go to symptom troubleshooting “NO.4 DIESEL PARTICULATE FILTER INDICATOR LIGHT FLASHES”. (See NO.4 DIESEL PARTICULATE FILTER INDICATOR LIGHT FLASHES [MZR-CD 2.2].)
No	Go to the next step.
5	Does the engine start normally after warm-up?	Yes	Inspect the glow system operation. (See ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZR-CD 2.2].) Inspect the fuel warmer. (With fuel warmer) (See FUEL WARMER INSPECTION [MZR-CD 2.2].) Replace any malfunctioning part if necessary. If the glow system and fuel warmer are normal, go to the next step.
No	Go to the next step.
6	Is there any restriction in the exhaust system or oxidation catalytic converter?	Yes	Repair or replace if necessary.
No	Go to the next step.
7	Inspect for fuel leakage from the fuel pipe. Is any fuel leakage found on the fuel pipe?	Yes	Repair or replace if necessary.
No	Go to the next step.
8	Inspect the APP sensor. (See ACCELERATOR PEDAL POSITION (APP) SENSOR INSPECTION [MZR-CD 2.2].) Is the APP sensor normal?	Yes	Go to the next step.
No	Replace the accelerator pedal component. (See ACCELERATOR PEDAL COMPONENT REMOVAL/INSTALLATION [MZR-CD 2.2].)
9	Visually inspect the CKP sensor and the teeth of the pulse wheel. (See CRANKSHAFT POSITION (CKP) SENSOR INSPECTION [MZR-CD 2.2].) Are the CKP sensor and teeth of pulse wheel normal?	Yes	Go to the next step.
No	Replace the malfunctioning parts.
10	Visually inspect the CMP sensor and teeth of pulse wheel. (See CAMSHAFT POSITION (CMP) SENSOR INSPECTION [MZR-CD 2.2].) Are CMP sensor and teeth of pulse wheel normal?	Yes	Inspect following PIDs: (See PCM INSPECTION [MZR-CD 2.2].) • ECT • IAT • MAF • RPM If the PID value is not as specified, repair or replace the malfunctioning parts. If the PID value is normal, go to the next step.
No	Replace malfunctioning parts.
11	Inspect fuel pressure sensor. (See FUEL PRESSURE SENSOR INSPECTION [MZR-CD 2.2].) Is fuel pressure normal?	Yes	Go to the next step.
No	Replace the common rail. (See COMMON RAIL REMOVAL/INSTALLATION [MZR-CD 2.2].)
12	Inspect suction control valve. (See SUCTION CONTROL VALVE INSPECTION [MZR-CD 2.2].) Is suction control valve normal?	Yes	Go to the next step.
No	Replace the supply pump. (See SUPPLY PUMP REMOVAL/INSTALLATION [MZR-CD 2.2].)
13	Is engine compression correct? (See COMPRESSION INSPECTION [MZR-CD 2.2].)	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.
14	Inspect fuel injector. (See FUEL INJECTOR INSPECTION [MZR-CD 2.2].) Is fuel injector normal?	Yes	Go to the next step.
No	Replace if necessary. (See FUEL INJECTOR REMOVAL/INSTALLATION [MZR-CD 2.2].)
15	Inspect the EGR system operation. (See ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZR-CD 2.2].) Is the EGR system operation normal?	Yes	Go to the next step.
No	Repair or replace the malfunctioning part according to the EGR system operation results.
16	Inspect starting system. (See STARTER INSPECTION [MZR-CD 2.2].) Is the starting system normal?	Yes	Inspect for loose connectors or poor terminal contact. If normal, remove and inspect supply pump and common rail. (See SUPPLY PUMP REMOVAL/INSTALLATION [MZR-CD 2.2].) (See COMMON RAIL REMOVAL/INSTALLATION [MZR-CD 2.2].)
No	Repair or replace components as required.
17	Verify test results. • If normal, return to the diagnostic index to service any additional symptoms. (See SYMPTOM DIAGNOSTIC INDEX [MZR-CD 2.2].) • 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.

STEP

INSPECTION

RESULTS

ACTION

Inspect the following:

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

• Fuel line/fuel filter clogging

• Intake-air system restriction

Are all items normal?

Yes

Go to the next step.

Service if necessary.

Repeat Step 1.

Is the engine overheating?

Yes

Go to the symptom troubleshooting “NO.21 COOLING SYSTEM CONCERNS-OVERHEATING”.

(See NO.21 COOLING SYSTEM CONCERNS-OVERHEATING [MZR-CD 2.2].)

Go to the next step.

Connect the M-MDS to the DLC-2.

Switch the ignition to ON.

Retrieve any DTCs.

Are any DTCs displayed?

Yes

DTC is displayed:

Go to the appropriate DTC test.

(See DTC TABLE [MZR-CD 2.2].)

Communication error message is displayed:

Inspect the following:

• Open circuit between main relay and PCM terminal 2C or 2F

• Open circuit main relay and PCM terminal 2I

• Main relay stuck open

• Open or poor ground circuit (PCM terminal 2B, 2E, 2A or 2D)

• Poor connection to vehicle body ground

No DTC is displayed:

Go to the next step.

Start the engine and warm up to normal operation temperature.

Verify the diesel particulate filter indicator light condition.

Does the diesel particulate filter indicator light illuminate or flash?

Yes

Diesel particulate filter indicator light illuminates:

Perform the manual diesel particulate filter regeneration procedure.

(See DIESEL PARTICULATE FILTER REGENERATION [MZR-CD 2.2].)

Diesel particulate filter indicator light flashes:

Go to symptom troubleshooting “NO.4 DIESEL PARTICULATE FILTER INDICATOR LIGHT FLASHES”.

(See NO.4 DIESEL PARTICULATE FILTER INDICATOR LIGHT FLASHES [MZR-CD 2.2].)

Go to the next step.

Does the engine start normally after warm-up?

Yes

Inspect the glow system operation.

(See ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZR-CD 2.2].)

Inspect the fuel warmer. (With fuel warmer)

(See FUEL WARMER INSPECTION [MZR-CD 2.2].)

Replace any malfunctioning part if necessary.

If the glow system and fuel warmer are normal, go to the next step.

Go to the next step.

Is there any restriction in the exhaust system or oxidation catalytic converter?

Yes

Repair or replace if necessary.

Go to the next step.

Inspect for fuel leakage from the fuel pipe.

Is any fuel leakage found on the fuel pipe?

Yes

Repair or replace if necessary.

Go to the next step.

Inspect the APP sensor.

(See ACCELERATOR PEDAL POSITION (APP) SENSOR INSPECTION [MZR-CD 2.2].)

Is the APP sensor normal?

Yes

Go to the next step.

Replace the accelerator pedal component.

(See ACCELERATOR PEDAL COMPONENT REMOVAL/INSTALLATION [MZR-CD 2.2].)

Visually inspect the CKP sensor and the teeth of the pulse wheel.

(See CRANKSHAFT POSITION (CKP) SENSOR INSPECTION [MZR-CD 2.2].)

Are the CKP sensor and teeth of pulse wheel normal?

Yes

Go to the next step.

Replace the malfunctioning parts.

Visually inspect the CMP sensor and teeth of pulse wheel.

(See CAMSHAFT POSITION (CMP) SENSOR INSPECTION [MZR-CD 2.2].)

Are CMP sensor and teeth of pulse wheel normal?

Yes

Inspect following PIDs:

(See PCM INSPECTION [MZR-CD 2.2].)

• ECT

• IAT

• MAF

• RPM

If the PID value is not as specified, repair or replace the 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 [MZR-CD 2.2].)

Is fuel pressure normal?

Yes

Go to the next step.

Replace the common rail.

(See COMMON RAIL REMOVAL/INSTALLATION [MZR-CD 2.2].)

Inspect suction control valve.

(See SUCTION CONTROL VALVE INSPECTION [MZR-CD 2.2].)

Is suction control valve normal?

Yes

Go to the next step.

Replace the supply pump.

(See SUPPLY PUMP REMOVAL/INSTALLATION [MZR-CD 2.2].)

Is engine compression correct?

(See COMPRESSION INSPECTION [MZR-CD 2.2].)

Yes

Go to the next step.

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.

Inspect fuel injector.

(See FUEL INJECTOR INSPECTION [MZR-CD 2.2].)

Is fuel injector normal?

Yes

Go to the next step.

Replace if necessary.

(See FUEL INJECTOR REMOVAL/INSTALLATION [MZR-CD 2.2].)

Inspect the EGR system operation.

(See ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZR-CD 2.2].)

Is the EGR system operation normal?

Yes

Go to the next step.

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

Inspect starting system.

(See STARTER INSPECTION [MZR-CD 2.2].)

Is the starting system normal?

Yes

Inspect for loose connectors or poor terminal contact.

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

(See SUPPLY PUMP REMOVAL/INSTALLATION [MZR-CD 2.2].)

(See COMMON RAIL REMOVAL/INSTALLATION [MZR-CD 2.2].)

Repair or replace components as required.

Verify test results.

• If normal, return to the diagnostic index to service any additional symptoms. (See SYMPTOM DIAGNOSTIC INDEX [MZR-CD 2.2].)

• 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.