NO.15 EMISSION COMPLIANCE [MZR 1.3, MZR 1.5]

id0103d7802100

15

EMISSION COMPLIANCE
DESCRIPTION
•  Fails emissions test.
POSSIBLE CAUSE
•  Electrical connector disconnected
•  Intake-air system clogging or restriction
•  Air cleaner element clogging or restriction
•  Vacuum lines leakage or blockage
•  Continuous memory DTC is stored
•  Cooling system malfunction
•  Fuel-filler cap malfunction
•  Improper operation of air/fuel mixture ratio control
•  Bend or open circuit A/F sensor or HO2S wiring harness
•  Exhaust gas leakage from exhaust system
•  Ignition system malfunction
―  Spark plug malfunction
―  Ignition coil and related wiring harness 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
•  Charcoal canister damage
•  Fuel tank ventilation system malfunction
•  Restriction in exhaust system
•  TWC malfunction
•  Improper operation of EGR control system
•  Improper 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
INSPECT RELATED PART CONDITION
•  Inspect the following:
―  Electrical connections
―  Intake-air system and air cleaner element concerns: obstructions, leakage or soiling
―  Proper maintenance schedule followed
―  Vacuum lines for leakage or blockage
―  Fuel-filler cap (looseness, damaged)
•  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.
2
VERIFY PCM DTC
•  Perform the PCM DTC inspection using the M-MDS.
•  Are any DTCs present?
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [MZR 1.3, MZR 1.5].)
No
Go to the next step.
3
VERIFY IF MALFUNCTION INCLUDES DRIVEABILITY
•  Is any other driveability concern present?
Yes
Go to the applicable symptom troubleshooting.
(See SYMPTOM DIAGNOSTIC INDEX [MZR 1.3, MZR 1.5].)
No
Go to the next step.
4
INSPECT COOLING SYSTEM FOR MALFUNCTION
Caution
•  While performing this step, always operate the vehicle in a safe and lawful manner.
•  When the M-MDS is used to observe monitor system status while driving, be sure to have another technician with you, or record the data in the M-MDS using the PID/DATA MONITOR AND RECORD capturing function and inspect later.
•  Access the ECT PID using the M-MDS.
•  Warm-up the engine and idle it.
•  Is the ECT PID value within the specification?
Yes
Go to the next step.
No
Inspect the following:
•  Coolant leakage
•  Cooling fan operation
•  Thermostat operation
Repair or replace the malfunctioning part according to the inspection results.
5
INSPECT FUEL CAP
•  Inspect the fuel-filler cap.
•  Is there any leakage at the fuel-filler cap?
Yes
Replace the fuel-filler cap.
No
Go to the next step.
6
INSPECT CURRENT A/F SENSOR SIGNAL
•  Inspect the A/F sensor.
•  Is there any malfunction?
Yes
Inspect the following:
•  Exhaust gas leakage between exhaust manifold and A/F sensor
•  Loose installation of A/F sensor
―  If there is any malfunction:
•  Repair or replace the malfunctioning part according to the inspection results.
―  If there is no malfunction:
•  Replace the A/F sensor.
No
Go to the next step.
7
INSPECT CURRENT HO2S SIGNAL
•  Inspect the HO2S.
•  Is there any malfunction?
Yes
Inspect the following:
•  Exhaust gas leakage between A/F sensor and HO2S
•  Loose installation of HO2S
―  If there is any malfunction:
•  Repair or replace the malfunctioning part according to the inspection results.
―  If there is no malfunction:
•  Replace the HO2S.
No
Go to the next step.
8
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.
9
INSPECT FUEL LINE PRESSURE
•  Install the fuel pressure gauge between fuel pipe and fuel distributor.
•  Start the engine and idle it.
•  Measure the fuel line pressure during idle.
•  Is there any malfunction?
Yes
Low:
•  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 mechanical malfunction)
High:
•  Replace the fuel pump unit. (pressure regulator malfunction)
No
Go to the next step.
10
DETERMINE IF MALFUNCTION CAUSE IS CHARCOAL CANISTER OR FUEL TANK VENT SYSTEM
•  Inspect for fuel saturation inside the charcoal canister.
•  Is there an excess amount of liquid fuel present in charcoal canister?
Yes
Replace the charcoal canister.
(See CHARCOAL CANISTER REMOVAL/INSTALLATION [MZR 1.3, MZR 1.5].)
No
Inspect the fuel tank vent system.
(See FUEL TANK INSPECTION [MZR 1.3, MZR 1.5].)
Repair or replace the malfunctioning part according to the inspection results, then go to the next step.
11
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.
12
INSPECT TWC
•  Inspect the TWC.
•  Is there any malfunction?
Yes
Replace the TWC.
(See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR 1.3, MZR 1.5].)
No
Go to the next step.
13
INSPECT EGR VALVE OPERATION
•  Perform the EGR Control System Inspection.
•  Is there any malfunction?
Yes
Repair or replace the malfunctioning part according to the inspection results.
No
Go to the next step.
14
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.
15
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.
16
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.