NO.6 CRANKS NORMALLY BUT WILL NOT START [MZR 2.0, MZR 2.5]

id0103e1801200

6

CRANKS NORMALLY BUT WILL NOT START
DESCRIPTION
•  The starter cranks the engine at normal speed but the engine will not run.
―  Refer to the symptom troubleshooting “NO.5 ENGINE STALLS-AFTER START/AT IDLE” if this symptom appears after engine stall.
―  Fuel is in the tank.
―  Battery is in normal condition.
POSSIBLE CAUSE
•  No battery power supply to PCM
•  Air leakage from intake air system
•  Open PCM ground or vehicle body ground
•  Improper operation of electronic throttle control system
•  EGR valve malfunction
•  No signal from CKP sensor due to sensor, related wiring harness or incorrect installation
•  No signal from CMP sensor due to sensor, related wiring harness or incorrect installation
•  Low engine compression
•  Engine overheating
•  Vacuum leakage
•  Erratic signal to ignition coil
•  Improper air/fuel mixture ratio control
•  Poor fuel quality
•  Restriction in intake air system
•  Restriction in exhaust system
•  Disconnected electrical connector
•  Open or short circuit in fuel pump body and related wiring harness
•  Inadequate fuel pressure
•  Fuel pump mechanical malfunction
•  Fuel leakage from injector
•  Fuel injector is clogged
•  Purge solenoid valve malfunction
•  Spark plug malfunction
•  Ignition coil malfunction
•  Improper operation of variable valve timing control system
•  Improper valve timing
•  Pressure regulator malfunction
•  PCM malfunction
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 "BEFORE SERVICE PRECAUTION" and "AFTER SERVICE PRECAUTION" described in this manual. (See BEFORE SERVICE PRECAUTION [MZR 2.0, MZR 2.5].) (See AFTER SERVICE PRECAUTION [MZR 2.0, MZR 2.5].)
Caution
•  Disconnecting/connecting the quick release connector without cleaning it may possibly cause damage to the fuel pipe and the quick release connector. Always clean the quick release connector joint area before disconnecting/connecting, and make sure that it is free of foreign material.

Diagnostic procedure

STEP

INSPECTION

RESULTS

ACTION
1
Inspect the following:
•  Vacuum connection
•  External fuel shut off or accessory (such as kill switch, alarm)
•  Fuel quality: proper octane, contamination, winter/summer blend
•  No air leakage from intake air system
•  Intake air system restriction (such as air cleaner element, fresh air duct)
•  Proper sealing of intake manifold and components attached to intake manifold: EGR valve
•  Ignition wiring
•  Electrical connections
•  Fuses
•  Smooth operation of throttle valve
Are all items normal?
Yes
Go to the next step.
No
Repair or replace the malfunctioning part according to the inspection results.
Repeat Step 1.
2
Connect the M-MDS to the DLC-2.
Access the APP1 and APP2 PIDs using the M-MDS.
(See ON-BOARD DIAGNOSTIC TEST [MZR 2.0, MZR 2.5].)
Crank the engine with the accelerator pedal released.
Are the APP1 and APP2 PIDs indicating that the accelerator pedal is in the released position?
Yes
Go to the next step.
No
Inspect for the following:
•  APP sensor
•  Wiring harness and connector for the following:
―  APP sensor terminal A—Main relay terminal C
―  APP sensor terminal B—PCM terminal 1X
―  APP sensor terminal C—Body ground
―  APP sensor terminal D—PCM terminal 1AJ
―  APP sensor terminal E—PCM terminal 1AP
―  APP sensor terminal F—PCM terminal 1AE
Repair or replace the malfunctioning part according to the inspection results.
3
Connect the M-MDS to the DLC-2.
Access the TP REL PID using M-MDS.
(See ON-BOARD DIAGNOSTIC TEST [MZR 2.0, MZR 2.5].)
Crank the engine with the accelerator pedal released.
Is the TP REL PID indicating that the accelerator pedal is in the released position?
Yes
Go to the next step.
No
Inspect the following:
•  TP sensor
•  Wiring harness and connector for the following:
―  TP sensor terminal A—PCM terminal 2AK
―  TP sensor terminal B—PCM terminal 2AR
―  TP sensor terminal C—PCM terminal 2AL
―  TP sensor terminal D—PCM terminal 2AN
Repair or replace the malfunctioning part according to the inspection results.
4
Connect the M-MDS to the DLC-2.
Retrieve any continuous memory and KOEO DTCs using the M-MDS.
(See KOEO/KOER SELF TEST [MZR 2.0, MZR 2.5].)
Are any DTCs present?
Yes
DTC is displayed:
•  Go to the appropriate DTC inspection.
Communication error message is displayed:
•  Inspect for the following:
―  Open circuit in the wiring harness between main relay terminal B and PCM terminal 1Q
―  Open circuit in the wiring harness between main relay terminal C and PCM terminal 1A
―  Main relay is stuck open
―  Open or short circuit the in wiring harness between the DLC-2 and PCM terminals 1AM or 1AI
―  Open or poor ground circuit (PCM terminal 1E, 1F, 1G and 1BE)
―  Poor connection of vehicle body ground
Repair or replace the malfunctioning part according to the inspection results.
No
Go to the next step.
5
Will the engine start and run smoothly at part throttle?
Yes
Perform the Electronic Throttle Control System Inspection.
(See ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZR 2.0, MZR 2.5].)
Repair or replace the malfunctioning part according to the inspection results.
No
Go to the next step.
6
Connect the M-MDS to the DLC-2.
Access the RPM PID using the M-MDS.
(See ON-BOARD DIAGNOSTIC TEST [MZR 2.0, MZR 2.5].)
Is the RPM PID indicating the engine speed during engine cranking?
Yes
Go to the next step.
No
Inspect for the following:
•  Open or short circuit in CKP sensor
•  Open or short circuit between CKP sensor terminal A and body ground
•  Open or short circuit between CKP sensor terminal B and PCM terminal 2W
•  Open or short circuit between CKP sensor terminal C and PCM terminal 2AQ
Repair or replace the malfunctioning part according to the inspection results.
•  If the CKP sensor and wiring harness are normal:
―  Go to the next step.
7
Visually inspect the CKP sensor and teeth of the crankshaft pulley.
Is there any malfunction?
Yes
Repair or replace the malfunctioning part according to the inspection results.
No
Go to the next step.
8
Inspect the ignition coil related wiring harness condition (intermittent open or short circuit) for all cylinders.
Is there any malfunction?
Yes
Repair or replace the suspected wiring harness.
No
Go to the next step.
9
Inspect the spark plug condition.
(See SPARK PLUG INSPECTION [MZR 2.0, MZR 2.5].)
Is the spark plug wet, covered with carbon or grayish white?
Yes
Spark plug is wet or covered with carbon:
•  Inspect for fuel leakage from the injector.
Spark plug is grayish white:
•  Inspect for a clogged fuel injector.
Repair or replace the malfunctioning part according to the inspection results.
No
Go to the next step.
10
Perform the Spark Test.
(See ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZR 2.0, MZR 2.5].)
Is a strong blue spark visible at each cylinder?
Yes
Go to the next step.
No
Repair or replace the malfunctioning part according to spark test result.
11
Visually inspect the exhaust system part.
Is there any deformed exhaust system part?
Yes
Repair or replace the malfunctioning part according to the inspection results.
No
Go to the next step.
12
Inspect the fuel line pressure.
(See FUEL LINE PRESSURE INSPECTION [MZR 2.0, MZR 2.5].)
Is the fuel line pressure correct?
Yes
Go to the next step.
No
Zero or low:
•  Inspect for the following:
―  Fuel pump relay, fuel pump circuit
―  Fuel line for clogging
•  If there is a malfunction, repair or replace the malfunctioning part according to the inspection results.
•  If there is no malfunction, replace the fuel pump unit.
High:
•  Replace the fuel pump unit.
13
Visually inspect for fuel leakage at the fuel injector O-ring and fuel line.
Repair or replace the malfunctioning part according to the inspection results.
Is the fuel line pressure held after the ignition is off?
Yes
Go to the next step.
No
Inspect the fuel injector.
(See FUEL INJECTOR INSPECTION [MZR 2.0, MZR 2.5].)
•  If the fuel injector has a malfunction:
―  Replace the fuel injector.
•  If the fuel injector is normal:
―  Replace the fuel pump unit.
14
Disconnect the vacuum hose between the purge solenoid valve and the intake manifold from the purge solenoid valve side.
Plug the open end of the vacuum hose.
Start the engine.
Is the starting condition improved?
Yes
Inspect the following:
•  Purge solenoid valve
•  Evaporative emission control system
Repair or replace the malfunctioning part according to the inspection results.
No
Go to the next step.
15
Is the air leakage felt or heard at the intake air system components while racing the engine to higher speed?
Yes
Repair or replace the malfunctioning part according to the inspection results.
No
Go to the next step.
16
Inspect the engine condition while tapping the EGR valve housing.
Is the engine condition improved?
Yes
Replace the EGR valve.
(See EGR VALVE REMOVAL/INSTALLATION [MZR 2.0, MZR 2.5].)
No
Go to the next step.
17
Perform the Variable Valve Timing Control System Operation Inspection.
(See ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZR 2.0, MZR 2.5].)
Does the variable valve timing control system operate properly?
Yes
Go to the next step.
No
Repair or replace malfunctioning part according to inspection results.
18
Is the engine compression correct?
(See COMPRESSION INSPECTION [MZR 2.0, MZR 2.5].)
Yes
Inspect the valve timing.
Repair or replace malfunctioning part according to inspection results.
No
Inspect the cause.
Repair or replace malfunctioning part according to inspection results.
19
•  Verify the test results.
―  If normal, return to the diagnostic index to service any additional symptoms. (See SYMPTOM DIAGNOSTIC INDEX [MZR 2.0, MZR 2.5].)
―  If a malfunction remains, inspect the related Service Information perform repair or diagnosis.
•  If the vehicle repaired, troubleshooting is completed.
•  If the vehicle not repaired or additional diagnostic information not available, replace the PCM. (See PCM REMOVAL/INSTALLATION [MZR 2.0, MZR 2.5].)