NO.6 CRANKS NORMALLY BUT WILL NOT START [MZR 1.3, MZR 1.5]

id0103d7801200

6

CRANKS NORMALLY BUT WILL NOT START
DESCRIPTION
•  The starter cranks the engine at normal speed but the engine will not run.
―  Refer to the symptom troubleshooting “NO.5 ENGINE STALLS-AFTER START/AT IDLE” if this symptom appears after engine stall.
―  Fuel is in the tank.
―  Battery is in normal condition.
POSSIBLE CAUSE
•  Continuous memory DTC is stored
•  Air leakage from intake-air system
•  Electrical connector disconnected
•  Poor fuel quality
•  Fuse malfunction
•  Ignition wiring malfunction
•  Intake-air system restriction
•  Vacuum leakage
•  Improper operation of drive-by-wire control system
•  CKP sensor and related wiring harness malfunction
•  Improper operation of fuel injector
•  Improper operation of fuel pump
•  Improper operation of ignition system
―  Ignition coil malfunction
―  Spark plug malfunction
•  Inadequate fuel pressure
―  Fuel pump relay or fuel pump circuit malfunction
―  Restriction in fuel line
―  Pressure regulator malfunction (built-into fuel pump unit)
―  Fuel pump mechanical malfunction
―  Fuel leakage from fuel system
•  EVAP control system malfunction
•  Improper operation of EGR control system
•  Improper operation of A/C system
•  Restriction in exhaust system
•  Improper operation of variable valve timing control system
•  Low engine compression
•  PCV valve malfunction
•  Valve timing malfunction
•  PCM 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 injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete “BEFORE SERVICE PRECAUTION” and “AFTER SERVICE PRECAUTION” described in this manual. (See BEFORE SERVICE PRECAUTION [MZR 1.3, MZR 1.5].) (See AFTER SERVICE PRECAUTION [MZR 1.3, MZR 1.5].)
Caution
•  Disconnecting/connecting the quick release connector without cleaning it may possibly cause damage to fuel pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting, and make sure that it is free of foreign material.

Diagnostic procedure

STEP

INSPECTION

RESULTS

ACTION
1
VERIFY PCM DTC
•  Retrieve any continuous memory DTCs using the M-MDS.
―  If the engine stalls:
•  Perform the KOEO self test.
―  If the engine does not stall:
•  Perform the KOEO and KOER self test.
•  Are there any continuous memory DTCs displayed?
Yes
Continuous memory DTC is displayed:
•  Go to the applicable DTC inspection.
Communication error message is displayed:
•  Inspect the following:
―  Open circuit in wiring harness between main relay terminal B and PCM terminal 1AJ
―  Open circuit in wiring harness between main relay terminal D and PCM terminals 1BB
―  Open circuit in wiring harness between main relay terminal D and PCM terminals 1BG (ATX)
―  Main relay is stuck open.
―  Open or short circuit in wiring harness between DLC-2 and PCM terminals 1AE and 1AI
―  Open or poor PCM ground circuit (PCM terminals 2AZ, 2BA, 2BB, 2BD and 2BH)
―  Poor connection of vehicle body ground
•  Repair or replace the malfunctioning part according to the inspection results.
No
Go to the next step.
2
INSPECT RELATED PART CONDITION
•  Inspect the following:
―  Air leakage from intake-air system
―  Electrical connections
―  Fuel quality (proper octane, contamination, winter/summer blend)
―  Fuses
―  Ignition wiring
―  Intake-air system restriction (such as air cleaner element, fresh air duct)
―  Proper sealing of intake manifold and components attached to intake manifold: such as EGR valve
―  Vacuum connection
•  Is there any malfunction?
Yes
Repair or replace the malfunctioning part according to the inspection results.
Repeat Step 1.
No
Go to the next step.
3
DETERMINE IF MALFUNCTION CAUSE IS DRIVE-BY-WIRE CONTROL SYSTEM OR OTHER
•  Attempt to start the engine at part throttle.
•  Does the engine run smoothly at part throttle?
Yes
Inspect the drive-by-wire control system operation.
(See ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZR 1.3, MZR 1.5].)
Repair or replace the malfunctioning part according to the inspection results.
No
Go to the next step.
4
DETERMINE IF MALFUNCTION CAUSE IS CKP SENSOR WIRING HARNESS OR OTHER
•  Access the RPM PID using the M-MDS.
•  Is the RPM PID indicating the engine speed during engine cranking?
Yes
Go to the next step.
No
Inspect the CKP sensor and related wiring harness.
(See CRANKSHAFT POSITION (CKP) SENSOR INSPECTION [MZR 1.3, MZR 1.5].)
•  If there is any malfunction:
―  Repair or replace the malfunctioning part according to the inspection results.
•  If there is no malfunction:
―  Go to the next step.
5
INSPECT FUEL INJECTOR OPERATION
•  Perform the Fuel Injector Operation Inspection.
•  Is there any malfunction?
Yes
Repair or replace the malfunctioning part according to the inspection results.
No
Go to the next step.
6
INSPECT FUEL PUMP OPERATION
•  Perform the Fuel Pump Operation Inspection.
•  Is there any malfunction?
Yes
Repair or replace the malfunctioning part according to the inspection results.
No
Go to the next step.
7
INSPECT IGNITION SYSTEM OPERATION
•  Perform the Spark Test.
•  Is a strong blue spark visible at each cylinder?
Yes
Go to the next step.
No
Repair or replace the malfunctioning part according to the inspection results.
8
VERIFY SPARK PLUG CONDITION
•  Verify the spark plug conditions when the spark plug removed in Step 7.
•  Is the spark plug wet, covered with carbon or grayish white?
Yes
Spark plug is wet or covered with carbon:
•  Inspect for fuel leakage from fuel injector.
Spark plug is grayish white:
•  Inspect the fuel injector for restriction.
Repair or replace the malfunctioning part according to the inspection results.
No
Install the spark plugs on original cylinders, then go to the next step.
9
INSPECT EXHAUST SYSTEM
•  Visually inspect the exhaust system part.
•  Is there any malfunction?
Yes
Repair or replace the malfunctioning part according to the inspection results.
No
Go to the next step.
10
INSPECT FUEL LINE PRESSURE
•  Inspect the fuel line pressure.
•  Is there any malfunction?
Yes
Zero or low:
•  Inspect the fuel pump relay and the fuel pump circuit.
•  Inspect the fuel line for restriction.
―  If there is any malfunction:
•  Repair or replace the malfunctioning part according to the inspection results.
―  If there is no malfunction:
•  Replace the fuel pump unit. (pressure regulator or fuel pump malfunction)
High:
•  Replace the fuel pump unit. (pressure regulator malfunction)
No
Go to the next step.
11
DETERMINE IF MALFUNCTION CAUSE IS EVAPORATIVE EMISSION CONTROL SYSTEM OR OTHER
•  Disconnect the vacuum hose between purge solenoid valve and intake manifold from purge solenoid valve side.
•  Plug the open end of the vacuum hose.
•  Turn the ignition switch to the ON position (engine off).
•  Is the engine stall now eliminated?
Yes
Inspect the following:
•  Purge solenoid valve
•  Evaporative emission control system
Repair or replace the malfunctioning part according to the inspection results.
No
Go to the next step.
12
DETERMINE IF MALFUNCTION CAUSE IS A/C SYSTEM OR OTHER
Note
•  The following test is for stall concerns with the A/C on. If other symptoms exist, go to the next step.
•  Inspect the refrigerant pressure.
•  Are the pressures within the specification?
Yes
Go to the next step.
No
If the A/C is always on:
•  Go to the symptom troubleshooting “NO.24 A/C IS ALWAYS ON OR A/C COMPRESSOR RUNS CONTINUOUSLY”.
For other symptoms:
•  Inspect the following:
―  Refrigerant charging amount
―  Condenser fan operation
•  Repair or replace the malfunctioning part according to the inspection results.
13
INSPECT EGR VALVE FOR STUCK
•  Inspect the engine condition while tapping the EGR valve housing.
•  Does the engine condition improve?
Yes
Replace the EGR valve.
(See EGR VALVE REMOVAL/INSTALLATION [MZR 1.3, MZR 1.5].)
No
Go to the next step.
14
INSPECT VARIABLE VALVE TIMING CONTROL SYSTEM OPERATION
•  Perform the Variable Valve Timing Control System Operation Inspection.
•  Is there any malfunction?
Yes
Repair or replace the malfunctioning part according to the inspection results.
No
Go to the next step.
15
INSPECT ENGINE COMPRESSION
•  Inspect the engine compression.
•  Is there any malfunction?
Yes
Repair or replace the malfunctioning part according to the inspection results.
No
Go to the next step.
16
INSPECT IF MALFUNCTION CAUSE IS PCV VALVE OR VALVE TIMING
•  Inspect the PCV valve operation.
•  Is there any malfunction?
Yes
Replace the PCV valve and the oil separator as a single unit.
(See POSITIVE CRANKCASE VENTILATION (PCV) VALVE REMOVAL/INSTALLATION [MZR 1.3, MZR 1.5].)
No
Inspect the valve timing.
(See VARIABLE VALVE TIMING ACTUATOR INSPECTION [MZR 1.3, MZR 1.5].)
Repair or replace the malfunctioning part according to the inspection results.
17
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 the 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.