NO.19 POOR FUEL ECONOMY [SKYACTIV-D 1.5]

id0103q2898600

19	POOR FUEL ECONOMY
DESCRIPTION	•  Fuel economy is unsatisfactory.
POSSIBLE CAUSE	•  PCM DTC is stored. •  Fuel system malfunction (leak in supply system) •  A/C relay malfunction •  Fan control module No.1 malfunction •  Fan control module No.2 malfunction •  ATX malfunction (ATX) •  Air cleaner malfunction (non-genuine part installed) •  Brake dragging •  Tire air pressure malfunction •  Turbocharger solenoid valve malfunction •  Turbocharger actuator malfunction •  LP-EGR control valve malfunction •  Exhaust shutter valve malfunction •  Electric water pump malfunction •  Water-cooled charge air cooler malfunction •  Generator control malfunction •  Poor fuel quality •  EGR filter clogged •  Mechanical (engine) malfunction ―  Large mechanical resistance ―  Improper engine compression ―  Improper valve timing ―  Engine oil malfunction (oil working up or down) 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 1.5].) ―  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 1.5].)

Diagnostic Procedure

STEP	INSPECTION	RESULTS	ACTION
1	VERIFY PCM DTC •  Retrieve PCM DTCs using the M-MDS. (See ON-BOARD DIAGNOSTIC TEST [PCM (SKYACTIV-D 1.5)].) •  Are any DTCs present?	Yes	Go to the applicable DTC inspection. (See DTC TABLE [PCM (SKYACTIV-D 1.5)].)
		No	Go to the next step.
2	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 Step 25.
3	INSPECT A/C RELAY •  Switch the ignition off. •  Remove the A/C relay. (See RELAY LOCATION.) •  Inspect the A/C relay. (See RELAY INSPECTION.) •  Is the A/C relay normal?	Yes	Go to the next step.
		No	Replace the A/C relay, then go to Step 25.
4	INSPECT FAN CONTROL MODULE NO.1 •  Inspect the fan control module No.1. (See FAN CONTROL MODULE INSPECTION [SKYACTIV-D 1.5].) •  Is the fan control module No.1 normal?	Yes	Go to the next step.
		No	Replace the fan control module No.1, then go to Step 25. (See COOLING FAN MOTOR REMOVAL/INSTALLATION [SKYACTIV-D 1.5].)
5	INSPECT FAN CONTROL MODULE NO.2 •  Inspect the fan control module No.2. (See FAN CONTROL MODULE INSPECTION [SKYACTIV-D 1.5].) •  Is the fan control module No.2 normal?	Yes	ATX: •  Go to the next step. MTX: •  Go to Step 8.
		No	Replace the fan control module No.2, then go to Step 25. (See COOLING FAN MOTOR REMOVAL/INSTALLATION [SKYACTIV-D 1.5].)
6	VERIFY ATX RELATED DTC •  Retrieve TCM DTCs using the M-MDS. (See ON-BOARD DIAGNOSTIC SYSTEM DTC INSPECTION [TCM (EW6A-EL)].) •  Are any DTCs present?	Yes	Go to the applicable DTC inspection. (See ON-BOARD DIAGNOSTIC SYSTEM DTC TABLE [TCM (EW6A-EL)].)
		No	Go to the next step.
7	VERIFY MALFUNCTION SYMPTOM RELATED TO ATX •  Verify the malfunction symptom related to the ATX. (See SYMPTOM TROUBLESHOOTING ITEM TABLE [EW6A-EL].) •  Is a malfunction occurring which is applicable to the symptom diagnostic index?	Yes	Go to the applicable symptom troubleshooting. (See SYMPTOM TROUBLESHOOTING ITEM TABLE [EW6A-EL].)
		No	Go to the next step.
8	INSPECT AIR CLEANER FOR NON-GENUINE AIR CLEANER INSTALLATION •  Remove the non-genuine air cleaner. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 1.5].) •  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 Step 25.
		No	Install the removed parts correctly, then go to the next step. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 1.5].)
9	INSPECT RELATED PART CONDITION •  Inspect the following: ―  Brake dragging ―  Tire air pressure •  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 Step 25.
10	INSPECT GENERATOR •  Inspect the generator. (See GENERATOR INSPECTION [SKYACTIV-D 1.5].) •  Is the generator normal?	Yes	Go to the next step.
		No	Repair or replace the malfunctioning part according to the inspection results, then go to Step 25. (See GENERATOR REMOVAL/INSTALLATION [SKYACTIV-D 1.5].)
11	INSPECT TURBOCHARGER SOLENOID VALVE •  Inspect the turbocharger solenoid valve. (See TURBOCHARGER SOLENOID VALVE INSPECTION [SKYACTIV-D 1.5].) •  Is there any malfunction?	Yes	Replace the turbocharger solenoid valve, then go to Step 25. (See TURBOCHARGER SOLENOID VALVE REMOVAL/INSTALLATION [SKYACTIV-D 1.5].)
		No	Go to the next step.
12	INSPECT TURBOCHARGER ACTUATOR •  Start the engine and idle it. •  Access the PID/DATA monitor item VGTURB_ACT and simulation item VGTURB_DSD using the M-MDS. (See ON-BOARD DIAGNOSTIC TEST [PCM (SKYACTIV-D 1.5)].) •  Verify the turbocharger actuator operation when the simulation item VGTURB_DSD increases from 0 % to 100 %. •  Does the VGTURB_ACT value change according to the simulation function operation?	Yes	Go to the next step.
		No	Replace the turbocharger with variable turbine geometry, then go to Step 25. (See TURBOCHARGER WITH VARIABLE TURBINE GEOMETRY REMOVAL/INSTALLATION [SKYACTIV-D 1.5].)
13	INSPECT LP-EGR CONTROL VALVE •  Inspect the LP-EGR control valve. (See LP-EGR CONTROL VALVE INSPECTION [SKYACTIV-D 1.5].) •  Is there any malfunction?	Yes	Replace the LP-EGR control valve, then go to Step 25. (See LP-EGR CONTROL VALVE REMOVAL/INSTALLATION [SKYACTIV-D 1.5].)
		No	Go to the next step.
14	INSPECT EXHAUST SHUTTER VALVE •  Switch the ignition off. •  Reconnect all disconnected connectors. •  Inspect the exhaust shutter valve. (See EXHAUST SHUTTER VALVE INSPECTION [SKYACTIV-D 1.5].) •  Is there any malfunction?	Yes	Repair or replace the malfunctioning part according to the inspection results, then go to Step 25. (See EXHAUST SHUTTER VALVE REMOVAL/INSTALLATION [SKYACTIV-D 1.5].) (See EXHAUST SHUTTER VALVE ACTUATOR REMOVAL/INSTALLATION [SKYACTIV-D 1.5].)
		No	Go to the next step.
15	DETERMINE IF MALFUNCTION IS DUE TO ELECTRIC WATER PUMP STUCK •  Access the PID/DATA monitor item E_WP and simulation item E_WP using the M-MDS. (See ON-BOARD DIAGNOSTIC TEST [PCM (SKYACTIV-D 1.5)].) •  Does the electric water pump operation sound change according to the simulation function operation?	Yes	Go to the next step.
		No	Replace the electric water pump, then go to Step 25. (See ELECTRIC WATER PUMP REMOVAL/INSTALLATION [SKYACTIV-D 1.5].)
16	INSPECT SEALING OF WATER-COOLED CHARGE AIR COOLANT PASSAGE •  Perform the “WATER-COOLED CHARGE AIR COOLER COOLANT LEAKAGE INSPECTION”. (See WATER-COOLED CHARGE AIR COOLER COOLANT LEAKAGE INSPECTION [SKYACTIV-D 1.5].) •  Does the radiator cap tester needle drop even though there is no engine coolant leakage from the radiator or the hoses?	Yes	Repair or replace the malfunctioning part according to the inspection results, then go to Step 25.
		No	Go to the next step.
17	INSPECT FOR RESTRICTION IN WATER-COOLED CHARGE AIR COOLER PASSAGE •  Inspect restrict in water-cooled charge air cooler coolant passage. •  Is there any restriction?	Yes	Repair or replace the malfunctioning part according to the inspection results, then go to Step 25.
		No	Go to the next step.
18	INSPECT FOR MALFUNCTION DUE TO POOR FUEL •  Replace the fuel. (See FUEL DRAINING PROCEDURE [SKYACTIV-D 1.5].) •  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
19	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 1.5].) •  Can bolts be rotated?	Yes	Go to Step 21.
		No	Go to the next step.
20	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 1.5].) 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 Step 25. (Large mechanical resistance in engine accessories.)
		No	Go to the next step.
21	INSPECT EGR FILTER •  Inspect the EGR filter for clogging. •  Is there any malfunction?	Yes	Clean or replace EGR filter, then go to Step 25. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 1.5].)
		No	Go to the next step.
22	INSPECT ENGINE COMPRESSION •  Inspect the engine compression. (See COMPRESSION INSPECTION [SKYACTIV-D 1.5].) •  Are compression pressures within specification?	Yes	Go to Step 25.
		No	Go to the next step.
23	INSPECT FOR MALFUNCTION DUE TO DEVIATED VALVE TIMING •  Inspect the valve timing (timing chain installation condition). (See TIMING CHAIN REMOVAL/INSTALLATION [SKYACTIV-D 1.5].) •  Is the valve timing normal?	Yes	Go to the next step.
		No	Adjust the valve timing to the correct timing, then go to Step 25.
24	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	Engine internal parts are normal. •  If other driveability symptoms are present: ―  Return to the diagnostic index to service additional symptoms. (See SYMPTOM DIAGNOSTIC INDEX [SKYACTIV-D 1.5].)
		No	Repair or replace the malfunctioning part according to the inspection results, then go to the next step.
25	Verify the test results. •  If normal, return to the diagnostic index to service any additional symptoms. (See SYMPTOM DIAGNOSTIC INDEX [SKYACTIV-D 1.5].) •  If a 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, replace the PCM. (See PCM REMOVAL/INSTALLATION [SKYACTIV-D 1.5].)