EXHAUST SMOKE [SKYACTIV-G (E)]

id0103s48906s7

Troubleshooting item

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):
•  Erratic signal to PCM
―  APP sensor or related circuit malfunction
―  ECT sensor No.1 or related circuit malfunction
―  ECT sensor No.2 or related circuit malfunction
―  IAT sensor No.1 (integrated in MAF sensor/IAT sensor No.1) or related circuit malfunction
―  MAF sensor or related circuit malfunction
―  MAP sensor or related circuit malfunction
―  A/F sensor or related circuit malfunction
―  HO2S or related circuit malfunction
―  TP sensor or related circuit malfunction
•  Improper fuel injection timing and amount
•  Air cleaner restriction
•  Intake-air system is collapsed or restricted
•  Leakage at engine intake manifold and/or exhaust manifold
•  Inadequate/Excessive fuel pressure
―  Fuel pressure sensor malfunction
―  High pressure fuel pump malfunction
―  Spill valve control solenoid valve control circuit malfunction (damage to driver in PCM caused by short circuit to ground system)
―  Spill valve control solenoid valve malfunction (built-into high pressure fuel pump)
―  Relief valve (built-into high pressure fuel pump) malfunction
―  Fuel line restricted or clogged
―  Fuel pump unit malfunction
•  Ignition system malfunction
―  Ignition coil malfunction
―  Spark plug malfunction
•  Improper engine compression
•  Improper intake valve timing
•  Improper exhaust valve timing
•  Injector driver (built-into PCM) malfunction
Possible cause
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.
―  Highly pressurized fuel may spray out if the fuel line is cut. Due to the following dangers occurring with a fuel spray, always complete the “Fuel Line Safety Procedure” to prevent the fuel from spraying.
•  Fuel may cause irritation if it comes in contact with skin and eyes.
•  If fuel ignites and causes a fire, it may lead to serious injury or death, and damage to property and facilities.
―  Fuel is highly flammable and dangerous. Fuel line spills and leakage can cause serious injury or death, and damage to equipment. Always refer to the “Quick Release Connector Removal/Installation (fuel system)” before performing the fuel hose installation, and execute the “Fuel Leakage Inspection” after installation.
Caution
•  Disconnecting/connecting the quick release connector without cleaning it may possibly cause damage to the 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.

Caution
•  Verify the malfunction symptom according to not only the PID value but also the symptom troubleshooting.

Related PIDs

Module

PIDs

Reference
PCM
APP1
(See PID/DATA MONITOR TABLE [PCM (SKYACTIV-G (E))].)
APP2
ECT
ECT_VOLT
ECT2
ECT2_VOLT
FUEL_PRES
IAT
LOAD_CALC
LONG_FUEL_TRIM
MAF
MAP
MAP_VOLT
A/F_SEN_CUR
HO2S_OUT_VOLT
ENG_RPM
SHRT_FUEL_TRIM
TP_RELAT
VSS

Diagnostic Procedure

Step

Inspection

Results

Action
1
VERIFY EXHAUST COLOR
•  What color is smoke coming from the exhaust system?
Blue
Burning oil is indicated.
•  Go to the next step.
White
Water in combustion is indicated.
•  Go to Step 4.
Black
Rich fuel mixture is indicated.
•  Go to Step 5.
2
INSPECT PCV VALVE FOR MALFUNCTION
•  Inspect the applicable part.
•  Is the part normal?
Yes
Go to the next step.
No
Repair or replace the malfunctioning location and perform the repair completion verification.
(See POSITIVE CRANKCASE VENTILATION (PCV) VALVE REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)
(See POSITIVE CRANKCASE VENTILATION (PCV) VALVE REMOVAL/INSTALLATION [SKYACTIV-G (WITHOUT CYLINDER DEACTIVATION (E))].)
3
INSPECT ENGINE INTERNAL PARTS
•  Inspect for the following engine internal parts:
―  Damaged valve guide, stems or valve seals
―  Blocked oil drain passage in cylinder head
―  Piston ring is not seated, seized or worn
―  Damage cylinder bore
•  Is there any malfunction?
Yes
Repair or replace the malfunctioning location and perform the repair completion verification.
No
Engine internal parts are normal.
•  If other driveability symptoms are present:
―  Return to the diagnostic index to service additional symptoms.
4
INSPECT ENGINE FOR ENGINE COOLANT LEAKAGE
•  Does the cooling system hold the coolant pressure?
Yes
Inspect the following:
•  Cylinder head gasket leakage
•  Intake manifold gasket leakage
•  Cracked or porous engine block
If there is any malfunction:
•  Repair or replace the malfunctioning location and perform the repair completion verification.
If there is no malfunction:
•  If other driveability symptoms are present:
―  Return to the diagnostic index to service additional symptoms.
No
Repair or replace the malfunctioning location and perform the repair completion verification.
5
VERIFY CURRENT INPUT SIGNAL STATUS
Warning
•  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:
―  APP1
―  APP2
―  ECT
―  ECT_VOLT
―  ECT2
―  ECT2_VOLT
―  IAT
―  MAF
―  MAP
―  MAP_VOLT
―  TP_RELAT
―  A/F_SEN_CUR
―  HO2S_OUT_VOLT
―  SHRT_FUEL_TRIM
―  LONG_FUEL_TRIM
•  Monitor the PIDs under the black smoke appeared engine condition.
•  Do the PIDs indicate normal according to engine conditions?
Yes
Go to the next step.
No
APP1, APP2 PIDs are not as specified:
•  Inspect the APP sensor No.1 and No.2.
ECT, ECT_VOLT, ECT2, ECT2_VOLT PIDs are not as specified:
•  Inspect the ECT sensor No.1 and No.2.
IAT PID is not as specified:
•  Inspect the IAT sensor No.1.
MAF PID is not as specified:
•  Inspect the MAF sensor.
MAP, MAP_VOLT PIDs are not as specified:
•  Inspect the MAP sensor.
TP_RELAT PID is not as specified:
•  Inspect the TP sensor.
A/F_SEN_CUR, SHRT_FUEL_TRIM, LONG_FUEL_TRIM PIDs are not as specified:
•  Inspect the A/F sensor.
HO2S_OUT_VOLT PID is not as specified:
•  Inspect the HO2S.
Repair or replace the malfunctioning location.
•  If the malfunction remains:
―  Perform the “Action for Non-repeatable Malfunction” procedure.
6
INSPECT FUEL INJECTOR OPERATION
•  Perform the Fuel Injector Operation Inspection.
•  Do the fuel injectors operate properly?
Yes
Go to the next step.
No
Repair or replace the malfunctioning location and perform the repair completion verification.
7
INSPECT INTAKE AIR SYSTEM
•  Inspect the following for intake-air system:
―  Air cleaner restriction
―  Collapsed or restricted air hose
―  Leakage at engine intake manifold
•  Is there any malfunction?
Yes
Repair or replace the malfunctioning location and perform the repair completion verification.
No
Go to the next step.
8
INSPECT EXHAUST SYSTEM FOR LEAKAGE
•  Visually inspect for exhaust gas leakage from exhaust manifold.
•  Is there any leakage?
Yes
Repair or replace the malfunctioning location and perform the repair completion verification.
No
Go to the next step.
9
INSPECT FUEL PRESSURE (HIGH-SIDE)
•  Start the engine and warm it up completely.
•  Access the FUEL_PRES PID using the M-MDS at idle.
•  Is the FUEL_PRES PID value within specification?
Specification:
•  Approx. 10 MPa {102 kgf/cm2, 1450 psi} (Except Thailand specs.)
•  Approx. 3 MPa {31 kgf/cm2, 435 psi} (Thailand specs.)
Yes
Go to Step 13.
No
Lower than specification:
•  Inspect the following:
―  Fuel leakage at the fuel line and fuel injector
―  Fuel pump
•  Perform the Fuel Pump (Low-pressure Side) Operation Inspection.
―  Fuel pressure sensor
―  High pressure fuel pump
•  If there is any malfunction:
―  Repair or replace the malfunctioning location and perform the repair completion verification.
•  If there is no malfunction:
―  Go to Step 12.
Higher than specification:
•  Go to the next step.
10
DETERMINE IF MALFUNCTION CAUSE IS FUEL PRESSURE SENSOR OR HIGH PRESSURE FUEL PUMP
•  Is the vehicle acceleration performance normal?
Yes
Go to the next step.
No
Go to Step 12.
11
INSPECT FUEL PRESSURE SENSOR FOR MALFUNCTION
•  Inspect the applicable part.
•  Is the part normal?
Yes
Go to Step 13.
No
Replace the fuel distributor and perform the repair completion verification.
(See FUEL INJECTOR REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)
(See FUEL INJECTOR REMOVAL/INSTALLATION [SKYACTIV-G (WITHOUT CYLINDER DEACTIVATION (E))].)
12
INSPECT SPILL VALVE CONTROL SOLENOID VALVE CONTROL CIRCUIT FOR SHORT TO GROUND
•  Inspect the applicable circuit for a short to ground.
•  Is the circuit normal?
Yes
Replace the high pressure fuel pump and perform the repair completion verification.
(See HIGH PRESSURE FUEL PUMP REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)
(See HIGH PRESSURE FUEL PUMP REMOVAL/INSTALLATION [SKYACTIV-G (WITHOUT CYLINDER DEACTIVATION (E))].)
No
Repair or replace the malfunctioning location and perform the repair completion verification.
13
INSPECT FUEL PRESSURE (LOW-SIDE)
•  Connect the fuel pressure gauge between fuel pump and high pressure fuel pump.
•  Measure the low side fuel pressure.
•  Is the low side fuel pressure within specification?
Specification:
•  475—555 kPa {4.85—5.65 kgf/cm2, 68.9—80.4 psi}
Yes
Go to the next step.
No
Inspect the following:
•  Fuel line restriction
•  Fuel filter clogged
―  If there is any malfunction:
•  Repair or replace the malfunctioning location and perform the repair completion verification.
―  If there is no malfunction:
•  Replace the fuel pump unit and perform the repair completion verification.
14
INSPECT IGNITION SYSTEM OPERATION
Note
•  Because the malfunction may have been resolved by removing the carbon adhered to the spark plug during the spark inspection for the spark plug, verify that the repairs have been completed.
•  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 location and perform the repair completion verification.
15
INSPECT ENGINE COMPRESSION
•  Measure the compression pressure for each cylinder.
•  Are compression pressures within specification?
Yes
Injector driver malfunction.
•  Replace the PCM.
If the problem remains, overhaul the engine and perform the repair completion verification.
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 intake valve timing
•  Improper exhaust valve timing
Repair or replace the malfunctioning location and perform the repair completion verification.
Repair completion verification 1
VERIFY THAT VEHICLE IS REPAIRED
•  Install/connect the part removed/disconnected during the troubleshooting procedure.
•  Has the malfunction symptom been eliminated?
Yes
Complete the symptom troubleshooting. (Explain contents of repair to customer)
No
Refer to the controller area network (CAN) malfunction diagnosis flow to inspect for a CAN communication error.
(See CONTROLLER AREA NETWORK (CAN) MALFUNCTION DIAGNOSIS FLOW [(E)].)
•  If the CAN communication is normal, perform the diagnosis from Step 1.
―  If the malfunction recurs, go to the next step.
Repair completion verification 2
VERIFY IF MALFUNCTION IS CAUSED BY NOT PERFORMING PCM REPROGRAMMING
•  Verify repair information and verify that there is a new calibration in the PCM.
•  Is there a new calibration in the PCM?
Yes
Perform the PCM reprogramming and verify if the malfunction symptom was corrected.
•  If the malfunction recurs, replace the PCM.
No
Replace the PCM.
(See PCM REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)
(See PCM REMOVAL/INSTALLATION [SKYACTIV-G (WITHOUT CYLINDER DEACTIVATION (E))].)