NO.19 EXHAUST SMOKE [MZR 1.3, MZR 1.5]

19	EXHAUST SMOKE
DESCRIPTION	• Blue, black, or white smoke from exhaust system.
POSSIBLE CAUSE	Blue smoke (Burning oil): • PCV valve malfunction • Engine internal oil leakage White smoke (Water in combustion): • Cooling system malfunction (coolant loss) • Engine internal coolant leakage Black smoke (Rich fuel mixture): • Air cleaner restriction • Intake-air system is collapsed or restricted • Fuel return line is restricted • Continuous memory DTC is stored • Erratic signal to PCM ― APP sensor or related wiring harness malfunction ― ECT sensor or related wiring harness malfunction ― IAT sensor or related wiring harness malfunction ― MAF sensor or related wiring harness malfunction ― MAP sensor or related wiring harness malfunction ― A/F sensor or related wiring harness malfunction ― HO2S or related wiring harness malfunction ― TP sensor or related wiring harness malfunction ― VSS or related wiring harness malfunction (ATX) • Injector fuel leakage • Excessive fuel pressure ― Restriction in fuel line ― Pressure regulator malfunction (built-into fuel pump unit) ― Fuel pump mechanical malfunction • Ignition system malfunction ― Spark plug malfunction ― Ignition coil and related wiring harness malfunction • CMP sensor malfunction • Improper engine compression • Improper fuel injection timing and amount • 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.

EXHAUST SMOKE

DESCRIPTION

• Blue, black, or white smoke from exhaust system.

POSSIBLE CAUSE

Blue smoke (Burning oil):

• PCV valve malfunction

• Engine internal oil leakage

White smoke (Water in combustion):

• Cooling system malfunction (coolant loss)

• Engine internal coolant leakage

Black smoke (Rich fuel mixture):

• Air cleaner restriction

• Intake-air system is collapsed or restricted

• Fuel return line is restricted

• Continuous memory DTC is stored

• Erratic signal to PCM

― APP sensor or related wiring harness malfunction

― ECT sensor or related wiring harness malfunction

― IAT sensor or related wiring harness malfunction

― MAF sensor or related wiring harness malfunction

― MAP sensor or related wiring harness malfunction

― A/F sensor or related wiring harness malfunction

― HO2S or related wiring harness malfunction

― TP sensor or related wiring harness malfunction

― VSS or related wiring harness malfunction (ATX)

• Injector fuel leakage

• Excessive fuel pressure

― Restriction in fuel line

― Pressure regulator malfunction (built-into fuel pump unit)

― Fuel pump mechanical malfunction

• Ignition system malfunction

― Spark plug malfunction

― Ignition coil and related wiring harness malfunction

• CMP sensor malfunction

• Improper engine compression

• Improper fuel injection timing and amount

• 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.

STEP	INSPECTION	RESULTS	ACTION
1	VERIFY EXHAUST GAS COLOR • What color is the smoke coming from the exhaust system?	Blue	Burning oil is indicated: • Go to the next step.
White	Water in the combustion is indicated: • Go to Step 3.
Black	Rich fuel mixture is indicated: • Go to Step 4.
2	INSPECT IF MALFUNCTION CAUSE IS PCV VALVE OR OTHER • Inspect the PCV valve operation. (See POSITIVE CRANKCASE VENTILATION (PCV) VALVE INSPECTION [MZR 1.3, MZR 1.5].) • 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 following: • Blocked oil drain passage in the cylinder head • Damaged cylinder bore • Damaged valve guide, stems or valve seals • Piston ring is not seated, seized or worn. Repair or replace the malfunctioning part according to the inspection results. • If other drivability symptoms are present: ― Return to the diagnostic index to service any additional symptoms.
3	INSPECT COOLING SYSTEM FOR LEAKAGE • Does the cooling system hold pressure?	Yes	Inspect the following: • Cracked or porous engine block • Cylinder head gasket leakage • Intake manifold gasket leakage Repair or replace the malfunctioning part according to the inspection results. • If other drivability symptoms are present: ― Return to the diagnostic index to service any additional symptoms.
No	Inspect for cause. Repair or replace the malfunctioning part according to the inspection results.
4	INSPECT INTAKE-AIR SYSTEM • Inspect the following: ― Air cleaner restriction ― Collapsed or restricted intake-air system ― Restricted fuel return line • Is there any malfunction?	Yes	Repair or replace the malfunctioning part according to the inspection results. Repeat Step 4.
No	Go to the next step.
5	VERIFY PCM DTC • Perform the PCM DTC inspection using the M-MDS. (See ON-BOARD DIAGNOSTIC TEST [MZR 1.3, MZR 1.5].) • 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.
6	VERIFY CURRENT INPUT SIGNAL STATUS 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 following PIDs using the M-MDS: (See ON-BOARD DIAGNOSTIC TEST [MZR 1.3, MZR 1.5].) ― APP1 ― APP2 ― ECT ― IAT ― MAF ― MAP ― O2S11 ― O2S12 ― TP1 ― TP2 ― VSS • Monitor the PIDs under the black smoke appeared engine condition. • Do the PIDs indicate normal according to engine conditions? (See PCM INSPECTION [MZR 1.3, MZR 1.5].)	Yes	Go to the next step.
No	APP1, APP2 PIDs are not as specified: • Inspect if the output signal from the APP sensor changes smoothly. (See ACCELERATOR PEDAL POSITION (APP) SENSOR INSPECTION [MZR 1.3, MZR 1.5].) ECT PID is not as specified: • Inspect for an intermittent open circuit of the ECT sensor and the related wiring harness. (See ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION [MZR 1.3, MZR 1.5].) IAT PID is not as specified: • Inspect for an intermittent open circuit of the IAT sensor and the related wiring harness. (See INTAKE AIR TEMPERATURE (IAT) SENSOR INSPECTION [MZR 1.3, MZR 1.5].) MAF PID is not as specified: • Inspect for an intermittent open circuit of the MAF sensor and the related wiring harness. (See MASS AIR FLOW (MAF) SENSOR INSPECTION [MZR 1.3, MZR 1.5].) MAP PID is not as specified: • Inspect for an intermittent open circuit of the MAP sensor and the related wiring harness. (See MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR INSPECTION [MZR 1.3, MZR 1.5].) O2S11 PID is not as specified: • Inspect for an intermittent open circuit of the A/F sensor and the related wiring harness. (See AIR FUEL RATIO (A/F) SENSOR INSPECTION [MZR 1.3, MZR 1.5].) O2S12 PID is not as specified: • Inspect for an intermittent open circuit of the HO2S and the related wiring harness. (See HEATED OXYGEN SENSOR (HO2S) INSPECTION [MZR 1.3, MZR 1.5].) TP1, TP2 PIDs are not as specified: • Inspect if the output signal from the TP sensor changes smoothly. (See THROTTLE POSITION (TP) SENSOR INSPECTION [MZR 1.3, MZR 1.5].) VSS PID is not as specified: • Inspect for an intermittent open circuit of the VSS and related wiring harness. (ATX) (See VEHICLE SPEED SENSOR (VSS) INSPECTION [FN4A-EL].) • Inspect the ABS wheel-speed sensor. (MTX, CVT) (See FRONT ABS WHEEL-SPEED SENSOR INSPECTION.) (See REAR ABS WHEEL-SPEED SENSOR INSPECTION.) Repair or replace the malfunctioning part according to the inspection results.
7	VERIFY CURRENT INPUT SIGNAL STATUS • Access the same PIDs as Step 6 using the M-MDS under the trouble condition. (See ON-BOARD DIAGNOSTIC TEST [MZR 1.3, MZR 1.5].) • Do the PIDs indicate the correct values under the trouble condition? (See PCM INSPECTION [MZR 1.3, MZR 1.5].)	Yes	Go to the next step.
No	Repair or replace the malfunctioning part according to the inspection results. • If the malfunction remains: ― Perform the “INTERMITTENT CONCERN TROUBLESHOOTING” procedure. (See INTERMITTENT CONCERN TROUBLESHOOTING [MZR 1.3, MZR 1.5].)
8	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. (See FUEL LINE PRESSURE INSPECTION [MZR 1.3, MZR 1.5].) • 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) (See FUEL PUMP UNIT REMOVAL/INSTALLATION [MZR 1.3, MZR 1.5].) High: • Replace the fuel pump unit. (pressure regulator malfunction) (See FUEL PUMP UNIT REMOVAL/INSTALLATION [MZR 1.3, MZR 1.5].)
No	Go to the next step.
9	INSPECT IGNITION SYSTEM OPERATION • Perform the Spark Test. (See ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZR 1.3, MZR 1.5].) • 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.
10	INSPECT CMP SENSOR • Inspect the CMP sensor. (See CAMSHAFT POSITION (CMP) SENSOR INSPECTION [MZR 1.3, MZR 1.5].) • Is there any malfunction?	Yes	Repair or replace the malfunctioning part according to the inspection results.
No	Go to the next step.
11	INSPECT IF MALFUNCTION CAUSE IS ENGINE COMPRESSION OR FUEL INJECTOR • Measure the compression pressure for each cylinder. (See COMPRESSION INSPECTION [MZR 1.3, MZR 1.5].) • Are the compression pressures within the specification?	Yes	Inspect the fuel injector for each cylinder. (See FUEL INJECTOR INSPECTION [MZR 1.3, MZR 1.5].) Replace the suspected fuel injector. (See FUEL INJECTOR REMOVAL/INSTALLATION [MZR 1.3, MZR 1.5].)
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 Repair or replace the malfunctioning part according to the inspection results.
12	Verify test results. • If normal, return to the diagnostic index to service any additional symptoms. (See SYMPTOM DIAGNOSTIC INDEX [MZR 1.3, MZR 1.5].) • 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. (See PCM REMOVAL/INSTALLATION [MZR 1.3, MZR 1.5].)

STEP

INSPECTION

RESULTS

ACTION

VERIFY EXHAUST GAS COLOR

• What color is the smoke coming from the exhaust system?

Blue

Burning oil is indicated:

• Go to the next step.

White

Water in the combustion is indicated:

• Go to Step 3.

Black

Rich fuel mixture is indicated:

• Go to Step 4.

INSPECT IF MALFUNCTION CAUSE IS PCV VALVE OR OTHER

• Inspect the PCV valve operation.

(See POSITIVE CRANKCASE VENTILATION (PCV) VALVE INSPECTION [MZR 1.3, MZR 1.5].)

• 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].)

Inspect the following:

• Blocked oil drain passage in the cylinder head

• Damaged cylinder bore

• Damaged valve guide, stems or valve seals

• Piston ring is not seated, seized or worn.

Repair or replace the malfunctioning part according to the inspection results.

• If other drivability symptoms are present:

― Return to the diagnostic index to service any additional symptoms.

INSPECT COOLING SYSTEM FOR LEAKAGE

• Does the cooling system hold pressure?

Yes

Inspect the following:

• Cracked or porous engine block

• Cylinder head gasket leakage

• Intake manifold gasket leakage

Repair or replace the malfunctioning part according to the inspection results.

• If other drivability symptoms are present:

― Return to the diagnostic index to service any additional symptoms.

Inspect for cause.

Repair or replace the malfunctioning part according to the inspection results.

INSPECT INTAKE-AIR SYSTEM

• Inspect the following:

― Air cleaner restriction

― Collapsed or restricted intake-air system

― Restricted fuel return line

• Is there any malfunction?

Yes

Repair or replace the malfunctioning part according to the inspection results.

Repeat Step 4.

Go to the next step.

VERIFY PCM DTC

• Perform the PCM DTC inspection using the M-MDS.

(See ON-BOARD DIAGNOSTIC TEST [MZR 1.3, MZR 1.5].)

• Are any DTCs present?

Yes

Go to the applicable DTC inspection.

(See DTC TABLE [MZR 1.3, MZR 1.5].)

Go to the next step.

VERIFY CURRENT INPUT SIGNAL STATUS

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 following PIDs using the M-MDS:

(See ON-BOARD DIAGNOSTIC TEST [MZR 1.3, MZR 1.5].)

― APP1

― APP2

― ECT

― IAT

― MAF

― MAP

― O2S11

― O2S12

― TP1

― TP2

― VSS

• Monitor the PIDs under the black smoke appeared engine condition.

• Do the PIDs indicate normal according to engine conditions?

(See PCM INSPECTION [MZR 1.3, MZR 1.5].)

Yes

Go to the next step.

APP1, APP2 PIDs are not as specified:

• Inspect if the output signal from the APP sensor changes smoothly.

(See ACCELERATOR PEDAL POSITION (APP) SENSOR INSPECTION [MZR 1.3, MZR 1.5].)

ECT PID is not as specified:

• Inspect for an intermittent open circuit of the ECT sensor and the related wiring harness.

(See ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION [MZR 1.3, MZR 1.5].)

IAT PID is not as specified:

• Inspect for an intermittent open circuit of the IAT sensor and the related wiring harness.

(See INTAKE AIR TEMPERATURE (IAT) SENSOR INSPECTION [MZR 1.3, MZR 1.5].)

MAF PID is not as specified:

• Inspect for an intermittent open circuit of the MAF sensor and the related wiring harness.

(See MASS AIR FLOW (MAF) SENSOR INSPECTION [MZR 1.3, MZR 1.5].)

MAP PID is not as specified:

• Inspect for an intermittent open circuit of the MAP sensor and the related wiring harness.

(See MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR INSPECTION [MZR 1.3, MZR 1.5].)

O2S11 PID is not as specified:

• Inspect for an intermittent open circuit of the A/F sensor and the related wiring harness.

(See AIR FUEL RATIO (A/F) SENSOR INSPECTION [MZR 1.3, MZR 1.5].)

O2S12 PID is not as specified:

• Inspect for an intermittent open circuit of the HO2S and the related wiring harness.

(See HEATED OXYGEN SENSOR (HO2S) INSPECTION [MZR 1.3, MZR 1.5].)

TP1, TP2 PIDs are not as specified:

• Inspect if the output signal from the TP sensor changes smoothly.

(See THROTTLE POSITION (TP) SENSOR INSPECTION [MZR 1.3, MZR 1.5].)

VSS PID is not as specified:

• Inspect for an intermittent open circuit of the VSS and related wiring harness. (ATX)

(See VEHICLE SPEED SENSOR (VSS) INSPECTION [FN4A-EL].)

• Inspect the ABS wheel-speed sensor. (MTX, CVT)

(See FRONT ABS WHEEL-SPEED SENSOR INSPECTION.)

(See REAR ABS WHEEL-SPEED SENSOR INSPECTION.)

Repair or replace the malfunctioning part according to the inspection results.

VERIFY CURRENT INPUT SIGNAL STATUS

• Access the same PIDs as Step 6 using the M-MDS under the trouble condition.

(See ON-BOARD DIAGNOSTIC TEST [MZR 1.3, MZR 1.5].)

• Do the PIDs indicate the correct values under the trouble condition?

(See PCM INSPECTION [MZR 1.3, MZR 1.5].)

Yes

Go to the next step.

Repair or replace the malfunctioning part according to the inspection results.

• If the malfunction remains:

― Perform the “INTERMITTENT CONCERN TROUBLESHOOTING” procedure.

(See INTERMITTENT CONCERN TROUBLESHOOTING [MZR 1.3, MZR 1.5].)

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.

(See FUEL LINE PRESSURE INSPECTION [MZR 1.3, MZR 1.5].)

• 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)

(See FUEL PUMP UNIT REMOVAL/INSTALLATION [MZR 1.3, MZR 1.5].)

High:

• Replace the fuel pump unit. (pressure regulator malfunction)

(See FUEL PUMP UNIT REMOVAL/INSTALLATION [MZR 1.3, MZR 1.5].)

Go to the next step.

INSPECT IGNITION SYSTEM OPERATION

• Perform the Spark Test.

(See ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZR 1.3, MZR 1.5].)

• Is a strong blue spark visible at each cylinder?

Yes

Go to the next step.

Repair or replace the malfunctioning part according to the inspection results.

INSPECT CMP SENSOR

• Inspect the CMP sensor.

(See CAMSHAFT POSITION (CMP) SENSOR INSPECTION [MZR 1.3, MZR 1.5].)

• Is there any malfunction?

Yes

Repair or replace the malfunctioning part according to the inspection results.

Go to the next step.

INSPECT IF MALFUNCTION CAUSE IS ENGINE COMPRESSION OR FUEL INJECTOR

• Measure the compression pressure for each cylinder.

(See COMPRESSION INSPECTION [MZR 1.3, MZR 1.5].)

• Are the compression pressures within the specification?

Yes

Inspect the fuel injector for each cylinder.

(See FUEL INJECTOR INSPECTION [MZR 1.3, MZR 1.5].)

Replace the suspected fuel injector.

(See FUEL INJECTOR REMOVAL/INSTALLATION [MZR 1.3, MZR 1.5].)

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

Repair or replace the malfunctioning part according to the inspection results.

Verify test results.

• If normal, return to the diagnostic index to service any additional symptoms.

(See SYMPTOM DIAGNOSTIC INDEX [MZR 1.3, MZR 1.5].)

• 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.

(See PCM REMOVAL/INSTALLATION [MZR 1.3, MZR 1.5].)