EMISSION COMPLIANCE [SKYACTIV-D]

Troubleshooting item	EMISSION COMPLIANCE
Description	• Fails emissions test.
Possible cause	Note • If NOx concentration is excessive, a lean A/F or NSC deterioration can be considered the cause. • If the HC concentration is normal and the CO concentration is excessive, a rich A/F can be considered the cause. • If the CO concentration is normal and the HC concentration is excessive, a A/F lean can be considered the cause. • If the CO concentration and HC concentration are excessive, incomplete combustion, a rich A/F, or NSC deterioration can be considered the cause. • PCM DTC is stored. • Air cleaner malfunction (non-genuine part installed) • Cooling system malfunction ― Coolant control valve malfunction • Fuel injector injection amount correction procedure has not been completed. • Fuel injection system malfunction ― Fuel leakage from fuel system ― Common rail malfunction ― Supply pump malfunction ― Suction control valve malfunction ― Fuel injector malfunction ― Fuel pressure relief valve malfunction • Poor fuel quality • EGR cooler, EGR pipe and EGR filter clogging • Mechanical (engine) malfunction ― Large mechanical resistance ― Engine compression malfunction ― Valve timing malfunction ― Engine oil malfunction (oil working up or down) • Catalytic converter (NOx strage catalyst) deterioration or loss Warning • The following troubleshooting flow chart contains the fuel system diagnosis and repair procedures. Read the following warnings before performing the fuel system services: ― Always keep sparks and flames away from fuel. Fuel can be easily ignited which could cause serious injury or death, and damage to equipment. ― Fuel line spills and leakage from the pressurized fuel system are dangerous. Fuel can ignite and cause serious injury or death, and damage to property and facilities. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure", while referring to the "BEFORE SERVICE PRECAUTION". (See BEFORE SERVICE PRECAUTION [SKYACTIV-D 1.8].) ― Fuel is highly flammable and dangerous. Fuel line spills and leakage can cause serious injury or death, and damage to equipment. When installing the fuel hose, always refer to the "AFTER SERVICE PRECAUTION" and perform the "Fuel Hose Installation Procedure". (See AFTER SERVICE PRECAUTION [SKYACTIV-D 1.8].)
System wiring diagram	• Not applicable
Connector diagram	• Not applicable

Troubleshooting item

EMISSION COMPLIANCE

Description

• Fails emissions test.

Possible cause

Note

• If NOx concentration is excessive, a lean A/F or NSC deterioration can be considered the cause.

• If the HC concentration is normal and the CO concentration is excessive, a rich A/F can be considered the cause.

• If the CO concentration is normal and the HC concentration is excessive, a A/F lean can be considered the cause.

• If the CO concentration and HC concentration are excessive, incomplete combustion, a rich A/F, or NSC deterioration can be considered the cause.

• PCM DTC is stored.

• Air cleaner malfunction (non-genuine part installed)

• Cooling system malfunction

― Coolant control valve malfunction

• Fuel injector injection amount correction procedure has not been completed.

• Fuel injection system malfunction

― Fuel leakage from fuel system

― Common rail malfunction

― Supply pump malfunction

― Suction control valve malfunction

― Fuel injector malfunction

― Fuel pressure relief valve malfunction

• Poor fuel quality

• EGR cooler, EGR pipe and EGR filter clogging

• Mechanical (engine) malfunction

― Large mechanical resistance

― Engine compression malfunction

― Valve timing malfunction

― Engine oil malfunction (oil working up or down)

• Catalytic converter (NOx strage catalyst) deterioration or loss

Warning

• The following troubleshooting flow chart contains the fuel system diagnosis and repair procedures. Read the following warnings before performing the fuel system services:

― Always keep sparks and flames away from fuel. Fuel can be easily ignited which could cause serious injury or death, and damage to equipment.

― Fuel line spills and leakage from the pressurized fuel system are dangerous. Fuel can ignite and cause serious injury or death, and damage to property and facilities. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure", while referring to the "BEFORE SERVICE PRECAUTION". (See BEFORE SERVICE PRECAUTION [SKYACTIV-D 1.8].)

― Fuel is highly flammable and dangerous. Fuel line spills and leakage can cause serious injury or death, and damage to equipment. When installing the fuel hose, always refer to the "AFTER SERVICE PRECAUTION" and perform the "Fuel Hose Installation Procedure". (See AFTER SERVICE PRECAUTION [SKYACTIV-D 1.8].)

System wiring diagram

• Not applicable

Connector diagram

• Not applicable

Step	Inspection	Results	Action
1	VERIFY PCM DTC • Retrieve PCM DTCs using the M-MDS. (See DTC INSPECTION.) • Are any DTCs present?	Yes	Go to the applicable DTC inspection. (See DTC TABLE [PCM (SKYACTIV-D)].)
No	Go to the next step.
2	INSPECT AIR CLEANER FOR NON-GENUINE AIR CLEANER INSTALLATION • Remove the non-genuine air cleaner. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 1.8].) • Verify the symptom. • Does the symptom disappear?	Yes	Explain to the customer that a malfunction occurred due to the installation of a non-genuine air cleaner. • Go to repair completion verification.
No	Install the removed parts correctly, then go to the next step. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)
3	DETERMINE IF MALFUNCTION CAUSE IS THERMOSTAT OR OTHER • Verify the radiator hose tension. Warning • To prevent burns, use a cloth with your hand to verify the tension of the radiator hose. • After the engine warms up, does the engine coolant circulate to the radiator hose?	Yes	Go to Step 5.
No	Go to the next step.
4	INSPECT COOLANT CONTROL VALVE FOR MALFUNCTION • Inspect the applicable part. (See COOLANT CONTROL VALVE INSPECTION [SKYACTIV-D 1.8].) • Is the part normal?	Yes	Go to the next step.
No	Repair or replace the malfunctioning location and perform the repair completion verification. (See COOLANT CONTROL VALVE REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)
5	VERIFY THAT FUEL INJECTION AMOUNT CORRECTION IS CORRECTLY COMPLETED • Perform the “FUEL INJECTOR INJECTION AMOUNT CORRECTION”. (See FUEL INJECTOR INJECTION AMOUNT CORRECTION [SKYACTIV-D 1.8].) • Start the engine. • Verify the glow indicator light. • Does the glow indicator light illuminate?	Yes	Re-perform the PCM fuel injection amount adjustment. (Perform the “FUEL INJECTOR DATA RESET” and “FUEL INJECTOR CODE PROGRAM” using the M-MDS.) (See FUEL INJECTOR DATA RESET [SKYACTIV-D 1.8].) • If a malfunction occurs, change the learning method (use/do not use M-MDS), and re-implement the “FUEL INJECTOR INJECTION AMOUNT CORRECTION”. (See FUEL INJECTOR INJECTION AMOUNT CORRECTION [SKYACTIV-D 1.8].) Go to repair completion verification.
No	Go to the next step.
6	INSPECT FOR FUEL LEAKAGE FROM FUEL SYSTEM • Visually inspect the following: ― Fuel leakage from the fuel tank, fuel pump, hose, pipe, fuel injector, supply pump, common rail ― Cracking and damage in fuel hose and pipe ― Clamp installation condition for each hose and pipe ― Fuel pipe securing condition due to deterioration such as rubber of clamp • Are all items normal?	Yes	Go to the next step.
No	Repair or replace the malfunctioning part according to the inspection results, then go to repair completion verification.
7	INSPECT FUEL INJECTION RELATED PARTS • Inspect the following parts: ― Common rail (See COMMON RAIL INSPECTION [SKYACTIV-D 1.8].) ― Supply pump (See SUPPLY PUMP INSPECTION [SKYACTIV-D 1.8].) ― Suction control valve (See SUCTION CONTROL VALVE INSPECTION [SKYACTIV-D 1.8].) ― Fuel injector (See FUEL INJECTOR INSPECTION [SKYACTIV-D 1.8].) ― Fuel pressure relief valve (See FUEL PRESSURE RELIEF VALVE INSPECTION [SKYACTIV-D 1.8].) • Are all items normal?	Yes	Go to the next step.
No	Repair or replace the malfunctioning part according to the inspection results, then go to repair completion verification.
8	INSPECT FOR MALFUNCTION DUE TO POOR FUEL • Replace the fuel. (See FUEL DRAINING PROCEDURE [SKYACTIV-D 1.8].) • Does the symptom disappear?	Yes	Advise the customer as to the change in the fuel used.
No	Remove the accumulated matter in the cylinder head using the following procedure, then go to the next step. • Carbon remover • Overhauling
9	INSPECT EGR COOLER, EGR PIPE AND EGR FILTER • Inspect for clogging in the EGR cooler, EGR pipe and EGR filter. • Are the EGR cooler and EGR pipe normal?	Yes	Go to the next step.
No	Repair or replace the malfunctioning part according to the inspection results, then go to repair completion verification.
10	DETERMINE IF MALFUNCTION IS DUE TO EXCESSIVE ENGINE SPEED RESISTANCE • Rotate the crankshaft pulley lock bolt clockwise using a wrench. (See FRONT OIL SEAL REPLACEMENT [SKYACTIV-D 1.8].) • Can bolts be rotated?	Yes	Go to Step 12.
No	Go to the next step.
11	INSPECT FOR MALFUNCTION DUE TO EXCESSIVE MECHANICAL RESISTANCE OF ENGINE ACCESSORIES • Remove all drive belts from engine accessories. (See DRIVE BELT REMOVAL/INSTALLATION [SKYACTIV-D 1.8].) Caution • Do not run the engine for long periods with the drive belts of engine accessories removed. Otherwise the engine could be damaged from overheating. • Start the engine. • Is cranking possible? (Does the engine start?)	Yes	Repair or replace the malfunctioning part according to the inspection results, then go to repair completion verification. (Large mechanical resistance in engine accessories.)
No	Go to the next step.
12	INSPECT ENGINE COMPRESSION • Inspect the engine compression. (See COMPRESSION INSPECTION [SKYACTIV-D 1.8].) • Are compression pressures within specification? Specification: • Compression ― Standard: 2150—2350 kPa {21.93—23.96 kgf/cm², 311.9—340.8 psi} (200 rpm) ― Minimum: 1800 kPa {18.35 kgf/cm², 261.1 psi} (200 rpm) ― Maximum difference between cylinders: 150 kPa {1.53 kgf/cm², 21.8 psi} (200 rpm)	Yes	Go to repair completion verification.
No	Go to the next step.
13	INSPECT FOR MALFUNCTION DUE TO DEVIATED VALVE TIMING • Inspect the valve timing (timing chain installation condition). (See TIMING CHAIN REMOVAL/INSTALLATION [SKYACTIV-D 1.8].) • Is the valve timing normal?	Yes	Go to the next step.
No	Adjust the valve timing to the correct timing, then go to repair completion verification.
14	INSPECT FOR MALFUNCTION DUE TO INTERNAL ENGINE WEAR, DAMAGE • Inspect for the following engine internal parts: ― Cylinder ― Piston ring ― Intake valve ― Exhaust valve ― Such as cylinder head gasket • Are all items normal?	Yes	Replace the catalytic converter (oxidation catalyst/NOx strage catalyst.), then go to the next step. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)
No	Repair or replace the malfunctioning part according to the inspection results, then go to repair completion verification..
15	DETERMINE IF MALFUNCTION IS CAUSED BY DETERIORATION OF CATALYTIC CONVERTER • Replace the lower case. (See LOWER CASE REMOVAL/INSTALLATION [SKYACTIV-D 1.8].) • Measure CO, HC, and NOx concentration again. • Is CO, HC, and NOx concentration within the specification?	Yes	Lower case malfunction. Explain the repair contents to the customer and complete the symptom troubleshooting.
No	Replace the catalytic converter (oxidation catalyst/NOx strage catalyst.), then go to the next step. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)
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. (See PCM REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)
No	Replace the PCM. (See PCM REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

Step

Inspection

Results

Action

VERIFY PCM DTC

• Retrieve PCM DTCs using the M-MDS.

(See DTC INSPECTION.)

• Are any DTCs present?

Yes

Go to the applicable DTC inspection.

(See DTC TABLE [PCM (SKYACTIV-D)].)

Go to the next step.

INSPECT AIR CLEANER FOR NON-GENUINE AIR CLEANER INSTALLATION

• Remove the non-genuine air cleaner.

(See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

• Verify the symptom.

• Does the symptom disappear?

Yes

Explain to the customer that a malfunction occurred due to the installation of a non-genuine air cleaner.

• Go to repair completion verification.

Install the removed parts correctly, then go to the next step.

(See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

DETERMINE IF MALFUNCTION CAUSE IS THERMOSTAT OR OTHER

• Verify the radiator hose tension.

Warning

• To prevent burns, use a cloth with your hand to verify the tension of the radiator hose.

• After the engine warms up, does the engine coolant circulate to the radiator hose?

Yes

Go to Step 5.

Go to the next step.

INSPECT COOLANT CONTROL VALVE FOR MALFUNCTION

• Inspect the applicable part.

(See COOLANT CONTROL VALVE INSPECTION [SKYACTIV-D 1.8].)

• Is the part normal?

Yes

Go to the next step.

Repair or replace the malfunctioning location and perform the repair completion verification.

(See COOLANT CONTROL VALVE REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

VERIFY THAT FUEL INJECTION AMOUNT CORRECTION IS CORRECTLY COMPLETED

• Perform the “FUEL INJECTOR INJECTION AMOUNT CORRECTION”.

(See FUEL INJECTOR INJECTION AMOUNT CORRECTION [SKYACTIV-D 1.8].)

• Start the engine.

• Verify the glow indicator light.

• Does the glow indicator light illuminate?

Yes

Re-perform the PCM fuel injection amount adjustment. (Perform the “FUEL INJECTOR DATA RESET” and “FUEL INJECTOR CODE PROGRAM” using the M-MDS.)

(See FUEL INJECTOR DATA RESET [SKYACTIV-D 1.8].)

• If a malfunction occurs, change the learning method (use/do not use M-MDS), and re-implement the “FUEL INJECTOR INJECTION AMOUNT CORRECTION”.

(See FUEL INJECTOR INJECTION AMOUNT CORRECTION [SKYACTIV-D 1.8].)

Go to repair completion verification.

Go to the next step.

INSPECT FOR FUEL LEAKAGE FROM FUEL SYSTEM

• Visually inspect the following:

― Fuel leakage from the fuel tank, fuel pump, hose, pipe, fuel injector, supply pump, common rail

― Cracking and damage in fuel hose and pipe

― Clamp installation condition for each hose and pipe

― Fuel pipe securing condition due to deterioration such as rubber of clamp

• Are all items normal?

Yes

Go to the next step.

Repair or replace the malfunctioning part according to the inspection results, then go to repair completion verification.

INSPECT FUEL INJECTION RELATED PARTS

• Inspect the following parts:

― Common rail

(See COMMON RAIL INSPECTION [SKYACTIV-D 1.8].)

― Supply pump

(See SUPPLY PUMP INSPECTION [SKYACTIV-D 1.8].)

― Suction control valve

(See SUCTION CONTROL VALVE INSPECTION [SKYACTIV-D 1.8].)

― Fuel injector

(See FUEL INJECTOR INSPECTION [SKYACTIV-D 1.8].)

― Fuel pressure relief valve

(See FUEL PRESSURE RELIEF VALVE INSPECTION [SKYACTIV-D 1.8].)

• Are all items normal?

Yes

Go to the next step.

Repair or replace the malfunctioning part according to the inspection results, then go to repair completion verification.

INSPECT FOR MALFUNCTION DUE TO POOR FUEL

• Replace the fuel.

(See FUEL DRAINING PROCEDURE [SKYACTIV-D 1.8].)

• Does the symptom disappear?

Yes

Advise the customer as to the change in the fuel used.

Remove the accumulated matter in the cylinder head using the following procedure, then go to the next step.

• Carbon remover

• Overhauling

INSPECT EGR COOLER, EGR PIPE AND EGR FILTER

• Inspect for clogging in the EGR cooler, EGR pipe and EGR filter.

• Are the EGR cooler and EGR pipe normal?

Yes

Go to the next step.

Repair or replace the malfunctioning part according to the inspection results, then go to repair completion verification.

DETERMINE IF MALFUNCTION IS DUE TO EXCESSIVE ENGINE SPEED RESISTANCE

• Rotate the crankshaft pulley lock bolt clockwise using a wrench.

(See FRONT OIL SEAL REPLACEMENT [SKYACTIV-D 1.8].)

• Can bolts be rotated?

Yes

Go to Step 12.

Go to the next step.

INSPECT FOR MALFUNCTION DUE TO EXCESSIVE MECHANICAL RESISTANCE OF ENGINE ACCESSORIES

• Remove all drive belts from engine accessories.

(See DRIVE BELT REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

Caution

• Do not run the engine for long periods with the drive belts of engine accessories removed. Otherwise the engine could be damaged from overheating.

• Start the engine.

• Is cranking possible? (Does the engine start?)

Yes

Repair or replace the malfunctioning part according to the inspection results, then go to repair completion verification. (Large mechanical resistance in engine accessories.)

Go to the next step.

INSPECT ENGINE COMPRESSION

• Inspect the engine compression.

(See COMPRESSION INSPECTION [SKYACTIV-D 1.8].)

• Are compression pressures within specification?

Specification:

• Compression

― Standard: 2150—2350 kPa {21.93—23.96 kgf/cm², 311.9—340.8 psi} (200 rpm)

― Minimum: 1800 kPa {18.35 kgf/cm², 261.1 psi} (200 rpm)

― Maximum difference between cylinders: 150 kPa {1.53 kgf/cm², 21.8 psi} (200 rpm)

Yes

Go to repair completion verification.

Go to the next step.

INSPECT FOR MALFUNCTION DUE TO DEVIATED VALVE TIMING

• Inspect the valve timing (timing chain installation condition).

(See TIMING CHAIN REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

• Is the valve timing normal?

Yes

Go to the next step.

Adjust the valve timing to the correct timing, then go to repair completion verification.

INSPECT FOR MALFUNCTION DUE TO INTERNAL ENGINE WEAR, DAMAGE

• Inspect for the following engine internal parts:

― Cylinder

― Piston ring

― Intake valve

― Exhaust valve

― Such as cylinder head gasket

• Are all items normal?

Yes

Replace the catalytic converter (oxidation catalyst/NOx strage catalyst.), then go to the next step.

(See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

Repair or replace the malfunctioning part according to the inspection results, then go to repair completion verification..

DETERMINE IF MALFUNCTION IS CAUSED BY DETERIORATION OF CATALYTIC CONVERTER

• Replace the lower case.

(See LOWER CASE REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

• Measure CO, HC, and NOx concentration again.

• Is CO, HC, and NOx concentration within the specification?

Yes

Lower case malfunction.

Explain the repair contents to the customer and complete the symptom troubleshooting.

Replace the catalytic converter (oxidation catalyst/NOx strage catalyst.), then go to the next step.

(See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

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)

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.

(See PCM REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

Replace the PCM.

(See PCM REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)