NO.15 EMISSION COMPLIANCE [ZJ, ZY, Z6]

id0103b1802100


Without Throttle Valve Actuator

15

EMISSION COMPLIANCE
DESCRIPTION
Fails emissions test.
POSSIBLE CAUSE
•  Vacuum lines leakage or blockage
•  Cooling system malfunction
•  Spark plug malfunction
•  Leakage from intake manifold
•  Erratic or no signal from CMP sensor
•  Inadequate fuel pressure
•  PCV valve malfunction or incorrect valve installation
•  Exhaust system clogging
•  Fuel tank ventilation system malfunction
•  Charcoal canister damage
•  Air cleaner element clogging or restriction
•  Throttle body malfunction
•  Spark leakage from high-tension leads
•  Improper air/fuel mixture ratio control operation
•  Bend or open circuit front HO2S or rear HO2S wiring harness
•  Catalyst converter malfunction
•  Engine internal parts malfunction
•  Excessive carbon is built up in combustion chamber
•  Improper engine compression
•  Improper valve timing
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 the "BEFORE SERVICE PRECAUTION" and "AFTER SERVICE PRECAUTION" described in this manual.
Caution
•  If there is foreign material on the connecting area of the quick release connector, it might damage the connector or fuel pipe. To prevent this, disconnect the connector and clean the connecting area before connecting.

Diagnostic procedure

STEP

INSPECTION

RESULTS

ACTION
1
Inspect for following:
•  Vacuum lines for leakage or blockage
•  Electrical connections
•  Proper maintenance schedule followed
•  Intake-air system and air cleaner element concerns: obstructions, leakage or dirtiness
Are all items normal?
Yes
Go to the next step.
No
Service if necessary.
Repeat Step 1.
2
Connect the M-MDS to the DLC-2.
Retrieve any continuous memory, KOEO and KOER DTCs using M-MDS.
Are there any DTCs displayed?
Yes
DTC is displayed:
Go to the appropriate DTC inspection.
(See DTC TABLE[ZJ, ZY, Z6].)
No
No DTC is displayed:
Go to the next step.
3
Is any other drivability concern present?
Yes
Go to appropriate symptom troubleshooting.
No
Go to the next step.
4
Connect the M-MDS to the DLC-2.
Access ECT PID.
Warm-up the engine and idle it.
Verify ECT PID is correct.
(See PCM INSPECTION[ZJ, ZY, Z6].)
Is ECT PID correct?
Yes
Go to the next step.
No
Inspect for coolant leakage, cooling fan and thermostat operation.
5
Connect the M-MDS to DLC-2.
Warm up the engine and idle it.
Access O2S11 PID.
Is O2S11 PID normal?
•  More than 0.45 V when accelerator pedal is suddenly depressed: rich condition.
•  Less than 0.45 V during fuel cut: lean condition
Yes
Go to the next step.
No
Inspect and repair or replace front HO2S, wiring harness, connector or terminal, then go to the next step.
(See FRONT HEATED OXYGEN SENSOR (HO2S) INSPECTION[ZJ, ZY, Z6].)
6
Perform the spark test.
(See ENGINE CONTROL SYSTEM OPERATION INSPECTION[ZJ, ZY, Z6].)
Is strong blue spark visible at each cylinder?
Yes
Go to the next step.
No
Repair or replace the malfunctioning part according to spark test results.
7
Install fuel pressure gauge between the fuel pipe and the fuel distributor.
Start the engine and idle it.
Measure fuel line pressure during idle.
Is fuel line pressure correct during idle?
(See FUEL LINE PRESSURE INSPECTION[ZJ, ZY, Z6].)
Yes
Go to the next step.
No
Low:
Inspect for clogged fuel line.
•  If normal, replace fuel pump unit.
High:
Replace fuel pump unit.
(See FUEL PUMP UNIT REMOVAL/INSTALLATION[ZJ, ZY, Z6].)
8
Remove and shake the PCV valve.
Does the PCV valve rattle?
Yes
Go to the next step.
No
Replace the PCV valve.
9
Inspect inside charcoal canister for fuel saturation.
Is excess amount of liquid fuel present in the charcoal canister?
Yes
Replace the charcoal canister.
No
Inspect fuel tank vent system.
(See FUEL TANK INSPECTION[ZJ, ZY, Z6].)
Then, go to the next step.
10
Visually inspect the exhaust system part. Is there any defective exhaust system part?
Yes
Replace the suspected part.
No
Go to the next step.
11
Inspect the three way catalytic converter.
(See EXHAUST SYSTEM INSPECTION[ZJ, ZY, Z6].)
Is the three way catalytic converter normal?
Yes
Go to the next step.
No
Replace the three way catalytic converter.
12
Verify test results.
•  If normal, return to diagnostic index to service any additional symptoms.
•  If malfunction remains, inspect related Service information perform repair or diagnosis.
―  If vehicle repaired, troubleshooting completed.
―  If vehicle not repaired or additional diagnostic information not available, replace the PCM.


With Throttle Valve Actuator

15

EMISSION COMPLIANCE
DESCRIPTION
Fails emissions test.
POSSIBLE CAUSE
•  Vacuum lines leakage or blockage
•  Cooling system malfunction
•  Spark plug malfunction
•  Leakage from intake manifold
•  Erratic or no signal from CMP sensor
•  Inadequate fuel pressure
•  PCV valve malfunction or incorrect valve installation
•  EGR valve malfunction
•  Exhaust system clogging
•  Fuel tank ventilation system malfunction
•  Charcoal canister damage
•  Air cleaner element clogging or restriction
•  Throttle body malfunction
•  Spark leakage from high-tension leads
•  Improper air/fuel mixture ratio control operation
•  Bend or open circuit front HO2S or rear HO2S wiring harness
•  Catalyst converter malfunction
•  Engine internal parts malfunction
•  Excessive carbon is built up in combustion chamber
•  Improper engine compression
•  Improper valve timing
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 the "BEFORE SERVICE PRECAUTION" and "AFTER SERVICE PRECAUTION" described in this manual.
Caution
•  If there is foreign material on the connecting area of the quick release connector, it might damage the connector or fuel pipe. To prevent this, disconnect the connector and clean the connecting area before connecting.

Diagnostic procedure

STEP

INSPECTION

RESULTS

ACTION
1
Inspect for following:
•  Vacuum lines for leakage or blockage
•  Electrical connections
•  Proper maintenance schedule followed
•  Intake-air system and air cleaner element concerns: obstructions, leakage or dirtiness
Are all items normal?
Yes
Go to the next step.
No
Service if necessary.
Repeat Step 1.
2
Connect the M-MDS to the DLC-2.
Retrieve any continuous memory, KOEO and KOER DTCs using M-MDS.
Are there any DTCs displayed?
Yes
DTC is displayed:
Go to the appropriate DTC inspection.
(See DTC TABLE[ZJ, ZY, Z6].)
No
No DTC is displayed:
Go to the next step.
3
Is any other drivability concern present?
Yes
Go to appropriate symptom troubleshooting.
No
Go to the next step.
4
Connect the M-MDS to the DLC-2.
Access ECT PID.
Warm-up the engine and idle it.
Verify ECT PID is correct.
(See PCM INSPECTION[ZJ, ZY, Z6].)
Is ECT PID correct?
Yes
Go to the next step.
No
Inspect for coolant leakage, cooling fan and thermostat operation.
5
Connect the M-MDS to DLC-2.
Warm up the engine and idle it.
Access O2S11 PID.
Is O2S11 PID normal?
•  Less than 1.0mA when accelerator pedal is suddenly depressed: rich condition.
•  More than 1.0 mA during fuel cut: lean condition
Yes
Go to the next step.
No
Inspect and repair or replace front HO2S, wiring harness, connector or terminal, then go to the next step.
(See FRONT HEATED OXYGEN SENSOR (HO2S) INSPECTION[ZJ, ZY, Z6].)
6
Perform the spark test.
(See ENGINE CONTROL SYSTEM OPERATION INSPECTION[ZJ, ZY, Z6].)
Is strong blue spark visible at each cylinder?
Yes
Go to the next step.
No
Repair or replace the malfunctioning part according to spark test results.
7
Install fuel pressure gauge between the fuel pipe and the fuel distributor.
Start the engine and idle it.
Measure fuel line pressure during idle.
Is fuel line pressure correct during idle?
(See FUEL LINE PRESSURE INSPECTION[ZJ, ZY, Z6].)
Yes
Go to the next step.
No
Low:
Inspect for clogged fuel line.
•  If normal, replace fuel pump unit.
High:
Replace fuel pump unit.
(See FUEL PUMP UNIT REMOVAL/INSTALLATION[ZJ, ZY, Z6].)
8
Remove and shake the PCV valve.
Does the PCV valve rattle?
Yes
Go to the next step.
No
Replace the PCV valve.
9
Inspect inside charcoal canister for fuel saturation.
Is excess amount of liquid fuel present in the charcoal canister?
Yes
Replace the charcoal canister.
No
Inspect fuel tank vent system.
(See FUEL TANK INSPECTION[ZJ, ZY, Z6].)
Then, go to the next step.
10
Visually inspect the exhaust system part. Is there any defective exhaust system part?
Yes
Replace the suspected part.
No
Go to the next step.
11
Inspect the three way catalytic converter.
(SeeEXHAUST SYSTEM INSPECTION[ZJ, ZY, Z6].)
Is the three way catalytic converter normal?
Yes
Inspect the EGR system.
(SeeENGINE CONTROL SYSTEM OPERATION INSPECTION[ZJ, ZY, Z6].)
No
Replace the three way catalytic converter.
12
Verify test results.
•  If normal, return to diagnostic index to service any additional symptoms.
•  If malfunction remains, inspect related Service information perform repair or diagnosis.
―  If vehicle repaired, troubleshooting completed.
―  If vehicle not repaired or additional diagnostic information not available, replace the PCM.