ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZR-CD 2.2]

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Guide Blade Actuator Operation Inspection

1.  Connect M-MDS to DLC-2.

2.  Start the engine and run it at idle.

3.  Access the VBCV and VBCV_POS PIDs.

4.  Command the VBCV PID from 0 to 100 % using active command mode function.

5.  Verify that the VBC_POS PID reading change according to VBCV commanded value.

•  If the VBC_POS PID cannot be verified inspect for followings;
―  Guide blade actuator (See GUIDE BLADE ACTUATOR INSPECTION [MZR-CD 2.2].)
―  Vacuum hose connection between the vacuum chamber and the guide blade actuator through the VBC solenoid valve (See INTAKE-AIR SYSTEM VACUUM HOSE ROUTING DIAGRAM [MZR-CD 2.2].)
―  VBC solenoid valve (See VARIABLE BOOST CONTROL (VBC) SOLENOID VALVE INSPECTION [MZR-CD 2.2].)
―  Guide blade actuator position sensor (built in turbocharger) (See GUIDE BLADE ACTUATOR INSPECTION [MZR-CD 2.2].)


Glow Plug Control Operation Inspection

1.  Verify that the battery is charged fully.

2.  If not, charge the battery.

3.  Connect the M-MDS to the DLC-2.

4.  Switch the ignition to ON.

5.  Access and monitor the VPWR and GPC PIDs.

6.  Verify that the VPWR PID drops 0.3 V or more while the GPC is turned on from off using the active command mode function.

•  If it cannot be verified, inspect the followings;
―  Glow plug relay
―  Glow plug
―  Wiring harness for battery positive post—glow plug relay—glow plug
―  Wiring harness for PCM terminal 1BT—glow plug relay—ground


Intake Shutter Valve Operation Inspection

1.  Connect the M-MDS to the DLC-2.

2.  Start the engine and run it at idle.

3.  Access and monitor the ETC_DSD, TP and MAP PIDs.

4.  Verify that the MAP PID increases and TP PID increases linearly, while increasing the opening angle of the intake shutter valve using the active command mode function of ETC_DSD.

•  If both PIDs do not increase according to the intake shutter valve opening angle, inspect using the following steps.
1.  Remove the intake shutter valve with connector connected.
2.  Verify that the intake shutter valve opens and closes while it is operated using the active command mode function of the ETC_DSD.
―  If not verified, retest after cleaning the intake shutter valve and inspecting related wiring harness and connectors.
3.  If the intake shutter valve does not operate, replace the intake shutter valve.
•  If the MAP PID increases but TP PID does not increase linearly according to the intake shutter valve opening angle inspect using the following steps.
1.  Inspect the intake shutter valve position sensor related wiring harness and connector.
2.  Remove the intake shutter valve with the connector connected.
3.  Verify that the TP PID increases and decreases linearly while the intake shutter valve is operated using the active command mode function of ETC_DSD.
―  If the TP PID does not increase and decrease linearly, replace the intake shutter valve.
•  If the TP PID increases linearly but the MAP PID does not increase according to the intake shutter valve opening angle inspect using the following steps.
1.  Inspect air for leakage at the intake shutter valve and cylinder head.
2.  If normal, inspect and replace the MAP sensor.


Brake override system operation inspection (From BL****-198281, BL1***-239890)

Note
•  If the brake override system operates normally after performing the following inspection, the PCM detects DTC P2299:00.

1.  Start the engine and run it is idling.

2.  Verify that the engine speed becomes approx. 1,200 rpm under the following conditions.

•  Neutral
•  Engine speed of 1,150 rpm or more other than idle
•  Brake pedal depressed
―  If the engine speed becomes approx. 1,200 rpm, clear the PCM DTC using the M-MDS. (System operation is normal.)
―  If the engine speed does not become approx. 1,200 rpm, inspect for the following parts, then repair or replace the malfunctioning part:
•  APP sensor (See ACCELERATOR PEDAL POSITION (APP) SENSOR INSPECTION [MZR-CD 2.2].)
•  Neutral switch (See NEUTRAL SWITCH INSPECTION [MZR-CD 2.2].)
•  Clutch switch (See CLUTCH PEDAL POSITION (CPP) SWITCH INSPECTION [MZR-CD 2.2].)
•  Brake switch No.1 (See BRAKE SWITCH INSPECTION.)
•  Brake switch No.2 (See BRAKE SWITCH INSPECTION.)


EGR Valve Operation Inspection

1.  Crank the engine and verify that the EGR valve operation (initial operation) sound is heard.

•  If the operation sound is not heard, connect the M-MDS to the DLC-2 and verify that the DTC P0403:00 is shown. Perform the DTC inspection. (See DTC TABLE [MZR-CD 2.2].)

2.  Start the engine run it at idle.

3.  Access and monitor EGRP and MAP PIDs.

4.  Verify that the MAP PID increases while increase the opening value of the EGR valve from 0 % to 100 % using the EGRP PID of active command mode function.

•  If both PIDs do not increase according to the EGR valve opening values, inspect using the following steps.
1.  Remove the EGR valve with the connector connected.
2.  Verify that the EGR valve opens and closes while it is operated using the active command mode function of EGRP.
―  If not verified, retest after cleaning the EGR valve and inspecting the related harness and connectors.
3.  If the EGR valve does not operate, replace the EGR valve.
•  If the MAP PID increases but the EGRP PID does not increase linearly according to the EGR valve opening values, inspect using the following steps.
1.  Inspect the EGR valve position sensor related harness and connector.
2.  Remove the EGR valve with the connector connected.
3.  Verify that the EGRP PID increases and decreases linearly while increasing the EGR valve steps using active command mode function of the EGRP.
―  If the EGRP PID does not increase and decrease linearly, replace the EGR valve.
•  If the EGRP PID increases linearly but MAP PID does not increase according to the EGR valve opening values, inspect using the following steps.
1.  Inspect for leakage between the exhaust manifold and surge tank.
2.  If normal, inspect and replace MAP sensor.


EGR Cooler Bypass Valve Operation Inspection

1.  Connect the M-MDS to DLC-2.

2.  Retrieve the DTC.

3.  Verify that the DTC P245C:00, P245D:00 are not displayed.

•  If the DTC P245C:00, P245D:00 is displayed, perform the suspect DTC troubleshooting procedure. (See DTC P245C:00 [MZR-CD 2.2].)(See DTC P245D:00 [MZR-CD 2.2].)

4.  Disconnect the vacuum hose at EGR cooler bypass valve actuator.

5.  Access the PCM PID EGR_C_BP.

6.  Start the engine and run it at idle.

7.  Verify that the vacuum condition is following table while the PID EGR_C_BP is ON and OFF using the active command mode function.

EGR_C_BP PID

ON

OFF
Vacuum
Applied
Not applied

•  If the vacuum condition changes are not verified, inspect and repair or replace for followings:
―  EGR cooler bypass solenoid valve (stuck)
―  Vacuum hoses between vacuum pump and EGR cooler bypass valve actuator through EGR cooler bypass solenoid valve (damage, clogging, poor connection)
•  If the vacuum condition changes are verified, inspect the EGR cooler bypass valve actuator. (See EGR COOLER BYPASS VALVE INSPECTION [MZR-CD 2.2].)


Fuel Injector Operation Inspection

1.  Connect the M-MDS to the DLC-2.

2.  Start the engine and warm it up to normal operating temperature.

3.  Perform the KOER self-test. (See KOEO/KOER SELF TEST [MZR-CD 2.2].)

4.  Verify that DTCs P0201:00, P0202:00, P0203:00 and/or P0204:00 are not shown using the KOER self-test.

•  If DTC P0201:00, P0202:00, P0203:00 and/or P0204:00 are shown, perform the DTC troubleshooting procedure. (See DTC TABLE [MZR-CD 2.2].)

5.  Verify that the engine speed drops or stalls when each cylinder fuel injector turns to off from on using the M-MDS active command mode function.

•  If it cannot be verified, inspect the following for the suspected cylinder;
―  Fuel injector (See FUEL INJECTOR INSPECTION [MZR-CD 2.2].)
―  Wiring harness for PCM—fuel injector


Cooling Fan Control System Inspection

1.  Verify that the battery voltage is above 12.4 V.

•  If the battery voltage is below 12.4 V, charge the battery or connect the external power supply.

2.  Connect the M-MDS to the DLC-2.

3.  Access the following PIDs.

•  ECT
•  AC_REQ

4.  Turn the A/C switch to off.

5.  Verify that ECT PID is below 98 °C {209 °F} and the AC_REQ is off.

•  If the ECT PID is below 98 °C {209 °F}, inspect the ECT sensor.
•  If the AC_REQ PID is on, perform the A/C symptom troubleshooting NO.26 A/C ALWAYS ON OR A/C COMPRESSOR RUNS CONTINUOUSLY.
(See NO.26 A/C ALWAYS ON OR A/C COMPRESSOR RUNS CONTINUOUSLY [MZR-CD 2.2].)

6.  Turn the ignition switch to the ON position while the temperature is below 98 °C {209 °F} with the ignition switch in the ON position.

7.  Verify that the cooling fan is not operating.

•  If the cooling fan is operating inspect the following:
1.  Verify that the FAN DUTY PID is 0 %.
•  If the FAN DUTY PID is not 0 %, inspect the following PID and related parts.
―  ECT (ECT sensor)
―  AC_REQ (Climate control unit, refrigerant pressure switch, evaporator temperature sensor and instrument cluster)
―  VSS (Vehicle speed sensor)
―  ACCS (A/C magnetic clutch)
•  If the FAN DUTY PID is 0 %, replace cooling fan component.

8.  Turn the A/C switch to on.

9.  Verify that the cooling fan is operating while the ECT PID is below 98 °C {209 °F}.

•  If the cooling fan does not operate, inspect for the following:
―  A/C refrigerant pressure switch
―  Open or short circuit in wiring harness between refrigerant pressure switch and PCM terminal 1X
―  Climate control unit (A/C switch and fan switch)
―  Communication error between instrument cluster and PCM
―  Communication error between climate control unit and instrument cluster
―  Fan control module power supply circuit (open or short circuit)
―  Fan control module ground circuit (open or short circuit)
―  Fan control module control signal circuit (open or short circuit between fan control module terminal 1C and PCM terminal 2Q)
―  Fan control module

10.  Turn the A/C switch to the off position.

11.  Start the engine and idle it.

12.  Verify that the cooling fan operating speed increases relative to the ECT PID increase.

•  If the cooling fan speed does not increase inspect the following:
―  ECT sensor (characteristic).
―  Fan control signal circuit (between fan control module terminal 1C and PCM terminal 2Q)
•  If the all items are normal, replace the cooling fan component.


A/C Cut-off Control System Inspection

1.  Start the engine.

2.  Turn the A/C switch and the fan switch on.

3.  Verify that the A/C compressor magnetic clutch actuates.

•  If it does not actuate, go to symptom troubleshooting “NO.25 A/C DOES NOT WORK SUFFICIENTLY”.
(See NO.25 A/C DOES NOT WORK SUFFICIENTLY [MZR-CD 2.2].)

4.  Fully open the throttle valve and verify that the A/C compressor magnetic clutch does not actuate for 2—5 s.

•  If it actuates, inspect as follows:
―  A/C relay
―  Open or short to ground circuit in wiring harness and connectors (Ignition switch (without advanced keyless entry and push button start)/block relay (with advanced keyless entry and push button start—A/C relay—PCM terminal 1BX)
―  A/C related parts
―  APP1, APP2 PIDs