NO.4 ENGINE STALL [MZ-CD 1.6 (Y6) (EURO5 emission level)]

4	Engine stall
DESCRIPTION	• Engine starts but immediately stops. • Engine starts but immediately stops and glow indicator light is flashing. • Engine cuts out during hard acceleration.
POSSIBLE CAUSE	• PCM DTC is detected. • Fuel tank fuel level low. • Air cleaner element restriction • Loose vacuum line(s)/vacuum connections • Loose intake-air system hose(s)/hose connections • Loose intake-air system tube(s)/tube connections • Coolant leakage • Oil leakage • Fuel leakage • Visibly damaged or worn parts • Loose or missing nuts or bolts • Incorrect or contaminated fuel in fuel tank • Electrical connector, wiring harness or component damaged • Loose installation fuel gauge sender unit • Main relay malfunction • Air ingress into the fuel lines • Erratic signal to PCM ― MAF sensor signal malfunction ― ECT sensor signal malfunction • CKP sensor or pulse wheel malfunction • CMP sensor or pulse wheel malfunction • Fuel pressure sensor malfunction • Fuel metering valve malfunction • Supply pump malfunction • PCM malfunction

Engine stall

DESCRIPTION

• Engine starts but immediately stops.

• Engine starts but immediately stops and glow indicator light is flashing.

• Engine cuts out during hard acceleration.

POSSIBLE CAUSE

• PCM DTC is detected.

• Fuel tank fuel level low.

• Air cleaner element restriction

• Loose vacuum line(s)/vacuum connections

• Loose intake-air system hose(s)/hose connections

• Loose intake-air system tube(s)/tube connections

• Coolant leakage

• Oil leakage

• Fuel leakage

• Visibly damaged or worn parts

• Loose or missing nuts or bolts

• Incorrect or contaminated fuel in fuel tank

• Electrical connector, wiring harness or component damaged

• Loose installation fuel gauge sender unit

• Main relay malfunction

• Air ingress into the fuel lines

• Erratic signal to PCM

― MAF sensor signal malfunction

― ECT sensor signal malfunction

• CKP sensor or pulse wheel malfunction

• CMP sensor or pulse wheel malfunction

• Fuel pressure sensor malfunction

• Fuel metering valve malfunction

• Supply pump malfunction

• PCM malfunction

STEP	INSPECTION	RESULTS	ACTION
1	VERIFY PCM DTC • Perform the PCM DTC inspection using the M-MDS. (See ON-BOARD DIAGNOSTIC TEST [MZ-CD 1.6 (Y6) (EURO5 emission level)].) • Are any DTCs present?	Yes	Go to the applicable DTC inspection. (See DTC TABLE [MZ-CD 1.6 (Y6) (EURO5 emission level)].)
No	Go to the next step.
2	VISUALLY INSPECT RELATED PART CONDITION • Visually inspect the following: Mechanical: ― Fuel level ― Air cleaner element ― Vacuum line(s)/vacuum connections ― Hose(s)/hose connections ― Tube(s)/tube connections ― Fuel leak(s) (Fuel filter, fuel supply line(s), fuel return line(s), high-pressure fuel supply line(s), fuel injectors, fuel rail, supply pump, fuel tank, fuel tank ventilation pipe, fuel tank filler pipe) ― Contaminated fuel Electrical: ― Fuse(s) ― Relay(s) ― Loose or corroded connector(s) (PCM, sensor(s), switch(es)) ― Damaged or worn PCM, switch(es) and/or sensor(s) ― Wiring harness ― Fuel gauge sender unit installation • Is there any malfunction?	Yes	Repair or replace the malfunctioning part according to the inspection results. Repeat Step 2.
No	Go to the next step.
3	INSPECT MAIN RELAY • Switch the ignition to ON (engine off). • Tap the main relay. • Does the main relay turn off?	Yes	Inspect the main relay terminal connection. • If there is malfunction in terminal, repair or replace malfunctioning part • If there is no malfunction, replace the main relay.
No	Go to the next step.
4	DETERMINE IF MALFUNCTION CAUSE IS AIR INGRESS IN FUEL LINE OR OTHER • Perform the Fuel Line Air Bleeding. (See AFTER SERVICE PRECAUTION [MZ-CD 1.6 (Y6)].) • Verify the symptom. • Is the symptom solved?	Yes	Troubleshooting is completed. (Air ingress into the fuel line.)
No	Go to the next step.
5	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 PCM INSPECTION [MZ-CD 1.6 (Y6) (EURO5 emission level)].) ― MAF ― ECT • Monitor the each PID while driving the vehicle. • Are all PIDs normal?	Yes	Go to the next step.
No	If the MAF PID is not specified: • Inspect the MAF sensor and related wiring harness. (See MASS AIR FLOW (MAF) SENSOR INSPECTION [MZ-CD 1.6 (Y6) (EURO5 emission level)].) If the ECT PID is not specified: • Inspect the ECT sensor and related wiring harness. (See ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION [MZ-CD 1.6 (Y6) (EURO5 emission level)].) Repair or replace malfunctioning part.
6	VISUALLY INSPECT CKP SENSOR AND PULSE WHEEL • Visually inspect the CKP sensor and teeth of the crankshaft pulley. • Is there any malfunction?	Yes	Repair or replace the malfunctioning part as necessary.
No	Go to the next step.
7	VISUALLY INSPECT CMP SENSOR AND PULSE WHEEL • Visually inspect the CMP sensor and teeth of the camshaft pulley. • Is there any malfunction?	Yes	Repair or replace the malfunctioning part as necessary.
No	Go to the next step.
8	DETERMINE IF MALFUNCTION CAUSE IS SUPPLY PUMP/FUEL METERING VALVE OR OTHER 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 PCM INSPECTION [MZ-CD 1.6 (Y6) (EURO5 emission level)].) ― FRP ― FRP_DSD ― FUEL_V_DSD • Monitor the each PID while driving the vehicle. • Are all PIDs normal?	Yes	Replace the fuel. (Poor fuel quality (e.g.: include water contamination, winter/summer blend))
No	Inspect the fuel pressure sensor and related wiring harness. (See FUEL PRESSURE SENSOR INSPECTION [MZ-CD 1.6 (Y6) (EURO5 emission level)].) • If there is malfunction, repair or replace malfunctioning part. • If there is no malfunction, replace the supply pump. (See SUPPLY PUMP REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)
9	Verify test results. • If normal, return to the diagnostic index to service any additional symptoms. (See SYMPTOM DIAGNOSTIC INDEX [MZ-CD 1.6 (Y6) (EURO5 emission level)].) • 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, reprogram the PCM if a later calibration is available. Retest.

STEP

INSPECTION

RESULTS

ACTION

VERIFY PCM DTC

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

(See ON-BOARD DIAGNOSTIC TEST [MZ-CD 1.6 (Y6) (EURO5 emission level)].)

• Are any DTCs present?

Yes

Go to the applicable DTC inspection.

(See DTC TABLE [MZ-CD 1.6 (Y6) (EURO5 emission level)].)

Go to the next step.

VISUALLY INSPECT RELATED PART CONDITION

• Visually inspect the following:

Mechanical:

― Fuel level

― Air cleaner element

― Vacuum line(s)/vacuum connections

― Hose(s)/hose connections

― Tube(s)/tube connections

― Fuel leak(s) (Fuel filter, fuel supply line(s), fuel return line(s), high-pressure fuel supply line(s), fuel injectors, fuel rail, supply pump, fuel tank, fuel tank ventilation pipe, fuel tank filler pipe)

― Contaminated fuel

Electrical:

― Fuse(s)

― Relay(s)

― Loose or corroded connector(s) (PCM, sensor(s), switch(es))

― Damaged or worn PCM, switch(es) and/or sensor(s)

― Wiring harness

― Fuel gauge sender unit installation

• Is there any malfunction?

Yes

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

Repeat Step 2.

Go to the next step.

INSPECT MAIN RELAY

• Switch the ignition to ON (engine off).

• Tap the main relay.

• Does the main relay turn off?

Yes

Inspect the main relay terminal connection.

• If there is malfunction in terminal, repair or replace malfunctioning part

• If there is no malfunction, replace the main relay.

Go to the next step.

DETERMINE IF MALFUNCTION CAUSE IS AIR INGRESS IN FUEL LINE OR OTHER

• Perform the Fuel Line Air Bleeding.

(See AFTER SERVICE PRECAUTION [MZ-CD 1.6 (Y6)].)

• Verify the symptom.

• Is the symptom solved?

Yes

Troubleshooting is completed.

(Air ingress into the fuel line.)

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 PCM INSPECTION [MZ-CD 1.6 (Y6) (EURO5 emission level)].)

― MAF

― ECT

• Monitor the each PID while driving the vehicle.

• Are all PIDs normal?

Yes

Go to the next step.

If the MAF PID is not specified:

• Inspect the MAF sensor and related wiring harness.

(See MASS AIR FLOW (MAF) SENSOR INSPECTION [MZ-CD 1.6 (Y6) (EURO5 emission level)].)

If the ECT PID is not specified:

• Inspect the ECT sensor and related wiring harness.

(See ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION [MZ-CD 1.6 (Y6) (EURO5 emission level)].)

Repair or replace malfunctioning part.

VISUALLY INSPECT CKP SENSOR AND PULSE WHEEL

• Visually inspect the CKP sensor and teeth of the crankshaft pulley.

• Is there any malfunction?

Yes

Repair or replace the malfunctioning part as necessary.

Go to the next step.

VISUALLY INSPECT CMP SENSOR AND PULSE WHEEL

• Visually inspect the CMP sensor and teeth of the camshaft pulley.

• Is there any malfunction?

Yes

Repair or replace the malfunctioning part as necessary.

Go to the next step.

DETERMINE IF MALFUNCTION CAUSE IS SUPPLY PUMP/FUEL METERING VALVE OR OTHER

Caution

• While performing this step, always operate the vehicle in a safe and lawful manner.

• Access the following PIDs using the M-MDS:

(See PCM INSPECTION [MZ-CD 1.6 (Y6) (EURO5 emission level)].)

― FRP

― FRP_DSD

― FUEL_V_DSD

• Monitor the each PID while driving the vehicle.

• Are all PIDs normal?

Yes

Replace the fuel.

(Poor fuel quality (e.g.: include water contamination, winter/summer blend))

Inspect the fuel pressure sensor and related wiring harness.

(See FUEL PRESSURE SENSOR INSPECTION [MZ-CD 1.6 (Y6) (EURO5 emission level)].)

• If there is malfunction, repair or replace malfunctioning part.

• If there is no malfunction, replace the supply pump.

(See SUPPLY PUMP REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)

Verify test results.

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

(See SYMPTOM DIAGNOSTIC INDEX [MZ-CD 1.6 (Y6) (EURO5 emission level)].)

• 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, reprogram the PCM if a later calibration is available. Retest.