NO.15 EMISSION COMPLIANCE [MZR 2.0, MZR 2.5]

id0103e1802100

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
•  EGR valve malfunction
•  Exhaust system clogging
•  Fuel tank ventilation system malfunction
•  Fuel-filler cap malfunction
•  Charcoal canister damage
•  Air cleaner element clogging or restriction
•  Throttle body malfunction
•  Erratic signal to ignition coil
•  Improper air/fuel mixture ratio control operation
•  Bend or open circuit A/F sensor wiring harness
•  Catalyst converter malfunction
•  Engine internal parts malfunction
•  Excessive carbon is built up in combustion chamber
•  Improper engine compression
•  Improper valve timing
•  PCV valve malfunction or incorrect valve installation
•  PCM malfunction
Warning
The following troubleshooting flow chart contains fuel system diagnosis and repair procedures. Read following warnings before servicing fuel system:
•  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 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 lines for leakage or blockage
•  Electrical connections
•  Proper maintenance schedule followed
•  Intake air system and air cleaner element concerns: obstructions, leakage or soiling
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.
Switch the ignition to ON (engine off).
Retrieve any DTCs.
(See ON-BOARD DIAGNOSTIC TEST [MZR 2.0, MZR 2.5].)
Are any DTCs present?
Yes
Go to the appropriate DTC inspection.
(See DTC TABLE [MZR 2.0, MZR 2.5].)
No
Go to the next step.
3
Is any other driveability concern present?
Yes
Go to the appropriate symptom troubleshooting.
(See QUICK DIAGNOSTIC CHART [MZR 2.0, MZR 2.5].)
No
Go to the next step.
4
Connect the M-MDS to the DLC-2.
Access the ECT PID using the M-MDS.
(See ON-BOARD DIAGNOSTIC TEST [MZR 2.0, MZR 2.5].)
Warm up the engine and idle it.
Is the ECT PID value normal?
(See PCM INSPECTION [MZR 2.0, MZR 2.5].)
Yes
Go to the next step.
No
Inspect for coolant leakage, and inspect the cooling fan and condenser fan operation or thermostat operation.
Repair or replace the malfunctioning part according to the inspection results.
5
Inspect the fuel-filler cap.
Is there any leakage at the fuel-filler cap?
Yes
Replace the fuel-filler cap.
No
Go to the next step.
6
Inspect the A/F sensor.
(See AIR FUEL RATIO (A/F) SENSOR INSPECTION [MZR 2.0, MZR 2.5].)
Is there any malfunction?
Yes
Inspect for following:
•  Exhaust gas leakage between exhaust manifold and A/F sensor
•  Loose installation of A/F sensor
―  If there are no malfunctions detected:
•  Replace the A/F sensor
―  If there are malfunctions detected:
•  Repair or replace the malfunctioning part according to the inspection results.
No
Go to the next step.
7
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 the inspection results.
8
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
Low:
•  Inspect the fuel line for clogging.
―  If there is no malfunction:
•  Replace the fuel pump unit.
High:
•  Replace the fuel pump unit.
9
Inspect for fuel saturation inside the charcoal canister.
Is there an excess amount of liquid fuel present in canister?
Yes
Replace the charcoal canister.
(See CHARCOAL CANISTER REMOVAL/INSTALLATION [MZR 2.0, MZR 2.5].)
No
Inspect the fuel tank vent system, then go to the next step.
(See FUEL TANK INSPECTION [MZR 2.0, MZR 2.5].)
10
Visually inspect the exhaust system parts.
Are there any deformed exhaust system parts?
Yes
Repair or replace the malfunctioning part according to the inspection results.
No
Go to the next step.
11
Inspect the TWC.
Is there any malfunction?
Yes
Replace the TWC.
(See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR 2.0, MZR 2.5].)
No
Go to the next step.
12
Perform the EGR Control System Inspection.
(See ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZR 2.0, MZR 2.5].)
Is there any malfunction?
Yes
Repair or replace the malfunctioning part according to the inspection results.
No
Replace the PCV valve and oil separator as a single unit.
(See POSITIVE CRANKCASE VENTILATION (PCV) VALVE REMOVAL/INSTALLATION [MZR 2.0, MZR 2.5].)
13
•  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].)