NO.6 CRANKS NORMALLY BUT WILL NOT START [MZR 2.3 DISI Turbo]

6	CRANKS NORMALLY BUT WILL NOT START
DESCRIPTION	• Starter cranks engine at normal speed but engine will not run. • Refer to symptom troubleshooting “NO.5 ENGINE STALLS” if this symptom appears after the engine stalls. • Fuel is in tank. • Battery is in normal condition.
POSSIBLE CAUSE	• Air leakage from intake-air system • Open PCM ground or vehicle body ground • Improper operation of electronic throttle control system • EGR valve malfunction • Low engine compression • Engine overheating • Vacuum leakage • Ignition system malfunction • Poor fuel quality • PCV valve malfunction • Intake-air system restriction • Improper air/fuel mixture ratio control • No signal from CKP sensor due to sensor, related wire or incorrect installation • No signal from CMP sensor due to sensor, related wire or incorrect installation • A/F sensor, HO2S or related circuit malfunction • ECT sensor or related circuit malfunction • APP sensor or related circuit malfunction • MAF sensor (integrated in MAF/IAT sensor) or related circuit malfunction • High pressure fuel pump malfunction • Exhaust system or TWC malfunction • Disconnected electrical connector • Open or short in fuel pump (low-side) body and related harness • Inadequate fuel pressure (high or low pressure side) • Fuel pressure sensor (built-in fuel delivery pipe) or related circuit malfunction • Relief valve malfunction (built-in fuel delivery pipe) • Fuel line clogging or restriction • Incorrect fuel injection timing • Fuel pump resistor or control relay malfunction • Fuel pump (low-side) mechanical malfunction • Fuel leakage • Fuel injector malfunction • Purge solenoid valve malfunction • Spark plug malfunction • Ignition coil malfunction • Improper valve timing • Improper operation of variable valve timing control system 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 injury 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 2.3 DISI Turbo].) (See AFTER SERVICE PRECAUTION [MZR 2.3 DISI Turbo].) Caution • Disconnecting/connecting the quick release connector without cleaning it may possibly cause damage to the fuel pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting, and make sure that it is free of foreign material.

CRANKS NORMALLY BUT WILL NOT START

DESCRIPTION

• Starter cranks engine at normal speed but engine will not run.

• Refer to symptom troubleshooting “NO.5 ENGINE STALLS” if this symptom appears after the engine stalls.

• Fuel is in tank.

• Battery is in normal condition.

POSSIBLE CAUSE

• Air leakage from intake-air system

• Open PCM ground or vehicle body ground

• Improper operation of electronic throttle control system

• EGR valve malfunction

• Low engine compression

• Engine overheating

• Vacuum leakage

• Ignition system malfunction

• Poor fuel quality

• PCV valve malfunction

• Intake-air system restriction

• Improper air/fuel mixture ratio control

• No signal from CKP sensor due to sensor, related wire or incorrect installation

• No signal from CMP sensor due to sensor, related wire or incorrect installation

• A/F sensor, HO2S or related circuit malfunction

• ECT sensor or related circuit malfunction

• APP sensor or related circuit malfunction

• MAF sensor (integrated in MAF/IAT sensor) or related circuit malfunction

• High pressure fuel pump malfunction

• Exhaust system or TWC malfunction

• Disconnected electrical connector

• Open or short in fuel pump (low-side) body and related harness

• Inadequate fuel pressure (high or low pressure side)

• Fuel pressure sensor (built-in fuel delivery pipe) or related circuit malfunction

• Relief valve malfunction (built-in fuel delivery pipe)

• Fuel line clogging or restriction

• Incorrect fuel injection timing

• Fuel pump resistor or control relay malfunction

• Fuel pump (low-side) mechanical malfunction

• Fuel leakage

• Fuel injector malfunction

• Purge solenoid valve malfunction

• Spark plug malfunction

• Ignition coil malfunction

• Improper valve timing

• Improper operation of variable valve timing control system

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 injury 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 2.3 DISI Turbo].) (See AFTER SERVICE PRECAUTION [MZR 2.3 DISI Turbo].)

Caution

• Disconnecting/connecting the quick release connector without cleaning it may possibly cause damage to the fuel pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting, and make sure that it is free of foreign material.

STEP	INSPECTION	RESULTS	ACTION
1	Inspect for the following: • Fuel quality (proper octane, contamination, winter/summer blend) • Intake-air system leakage and restriction • Electrical connectors • Fuses • Poor connection for PCM ground and body ground • Fuel leakage • Vacuum leakage Is there any malfunction?	Yes	Service if necessary. • Repeat this step.
No	Go to the next step.
2	Switch the ignition to ON. Retrieve any DTCs using the M-MDS. (See ON-BOARD DIAGNOSTIC TEST [MZR 2.3 DISI Turbo].) Are any DTCs present?	Yes	Go to the applicable DTC inspection. (See DTC TABLE [MZR 2.3 DISI Turbo].)
No	Go to the next step.
3	Access the ECT PID using the M-MDS. (See ON-BOARD DIAGNOSTIC TEST [MZR 2.3 DISI Turbo].) Verify that the ECT PID value is less than 116 °C {241 °F} during driving. Is the ECT PID value less than specified? (See PCM INSPECTION [MZR 2.3 DISI Turbo].)	Yes	Go to the next step.
No	The cause of this concern could be from the cooling system overheating. • Perform the symptom troubleshooting “NO.17 COOLING SYSTEM CONCERNS-OVERHEATING”. (See NO.17 COOLING SYSTEM CONCERNS-OVERHEATING [MZR 2.3 DISI Turbo].)
4	Does the engine start with throttle close?	Yes	Go to the next step.
No	Go to Step 10.
5	Will the engine start and run smoothly at part throttle?	Yes	Go to the next step.
No	Go to Step 8.
6	Perform the TP sweep inspection. (See ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZR 2.3 DISI Turbo].) Does the electronic throttle control system work properly?	Yes	Visually inspect the throttle body (damage/scratching). • If normal: ― Go to the next step. • If not: ― Repair or replace the malfunctioning parts according to the inspection results.
No	Repair or replace the malfunctioning parts according to the inspection results.
7	Access the RPM PID using the M-MDS. (See ON-BOARD DIAGNOSTIC TEST [MZR 2.3 DISI Turbo].) Is the RPM PID value indicating engine speed when the cranking engine.	Yes	Go to the next step.
No	Inspect the CKP sensor for following: • Installation condition (See CRANKSHAFT POSITION (CKP) SENSOR REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo].) • Damaged trigger wheel and camshaft • Open or short circuit in wiring harnesses Repair or replace the malfunctioning parts according to the inspection results.
8	Inspect CMP sensor for the following: • Installation condition (See CAMSHAFT POSITION (CMP) SENSOR REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo].) • Damaged trigger wheel and camshaft • Open or short circuit in wiring harnesses Is there any malfunction?	Yes	Repair or replace the malfunctioning parts according to the inspection results.
No	Go to the next step.
9	Disconnect the vacuum hose between purge solenoid valve and intake manifold from the purge solenoid valve side. Plug the open end of the vacuum hose. Start the engine. Is the engine stall now eliminated?	Yes	Inspect the following: • Purge solenoid valve (See PURGE SOLENOID VALVE INSPECTION [MZR 2.3 DISI Turbo].) • EVAP system Repair or replace the malfunctioning parts according to the inspection results.
No	Go to the next step.
10	Inspect the engine condition while tapping the EGR valve housing. Does the engine condition improve?	Yes	Replace the EGR valve. (See EGR VALVE REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo].)
No	Go to the next step.
11	Access the following PIDs using the M-MDS: (See ON-BOARD DIAGNOSTIC TEST [MZR 2.3 DISI Turbo].) • ECT • APP1 • APP2 • MAF • O2S11 • O2S12 • LONGFT1 • SHTFT1 Do the PID values indicate the correct values under the trouble condition? (See PCM INSPECTION [MZR 2.3 DISI Turbo].)	Yes	Go to the next step.
No	Inspect the suspected parts and related wiring harness. • If normal: ― Perform the “INTERMITTENT CONCERN TROUBLESHOOTING. (See INTERMITTENT CONCERN TROUBLESHOOTING [MZR 2.3 DISI Turbo].) • If not: ― Repair or replace the malfunctioning parts according to the inspection results.
12	Inspect for restriction in the exhaust system and TWC. Is there any restriction?	Yes	Repair or replace the malfunctioning parts according to the inspection results.
No	Go to the next step.
13	Perform the Spark Test. (See ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZR 2.3 DISI Turbo].) Is a strong blue spark visible at each cylinder?	Yes	Go to the next step.
No	Repair or replace the malfunctioning parts according to the inspection results.
14	Access the FUEL_PRES PID using the M-MDS. (See ON-BOARD DIAGNOSTIC TEST [MZR 2.3 DISI Turbo].) Crank the engine. Does the FUEL_PRES PID value increase? (See PCM INSPECTION [MZR 2.3 DISI Turbo].)	Yes	Go to Step 17.
No	Go to the next step.
15	Replace the high pressure fuel pump. (See HIGH PRESSURE FUEL PUMP REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo].) Access the FUEL_PRES PID using the M-MDS. (See ON-BOARD DIAGNOSTIC TEST [MZR 2.3 DISI Turbo].) Crank the engine. Does the FUEL_PRES PID value increase? (See PCM INSPECTION [MZR 2.3 DISI Turbo].)	Yes	High-pressure fuel pump or spill valve control solenoid valve (built-in high pressure fuel pump or fuel pressure sensor) malfunction.
No	Relief valve or fuel pressure sensor malfunction. • Replace the fuel delivery pipe. (See FUEL INJECTOR REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo].)
16	Connect the fuel pressure gauge between the fuel pump and the high pressure fuel pump. Measure the fuel pressure line of the low pressure side. (See FUEL LINE PRESSURE INSPECTION [MZR 2.3 DISI Turbo].) Is the fuel pressure within the specification?	Yes	Go to the next step.
No	Inspect for the following: • Fuel line restriction • Fuel filter clogging ― If normal: • Replace the fuel pump unit. (See FUEL PUMP UNIT REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo].) ― If not: • Repair or replace the malfunctioning parts according to the inspection results.
17	Measure the compression pressure for each cylinder. (See COMPRESSION INSPECTION [MZR 2.3 DISI Turbo].) Does the starting system work properly?	Yes	Go to the next step.
No	Inspect for the following: • Damaged valve seat • Worn valve stem and valve guide • Worn or stuck piston ring • Worn piston, piston ring or cylinder • Improper valve timing Repair or replace the malfunctioning parts according to the inspection results.
18	Disconnect the fuel injector connectors. Connect the NOID light to the fuel injector harness-side terminals. Inspect the NOID light dim during cranking. Does the NOID light illuminate?	Yes	Go to the next step.
No	Inspect the fuel injector wiring harnesses. • If normal: ― Replace the PCM (injector driver circuit malfunction). (See PCM REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo].) • If not: ― Repair or replace the suspected wiring harness.
19	Perform the Variable Valve Timing Control System Operation Inspection. (See ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZR 2.3 DISI Turbo].) Does the variable valve timing control system work properly?	Yes	Go to the next step.
No	Repair or replace the malfunctioning parts according to the inspection results.
20	Inspect the PCV valve. (See POSITIVE CRANKCASE VENTILATION (PCV) VALVE INSPECTION [MZR 2.3 DISI Turbo].) Is the PCV valve normal?	Yes	Replace the fuel injector. (See FUEL INJECTOR REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo].) If a malfunction remains: • Repair or replace the malfunctioning part according to the inspection results.
No	Replace the PCV valve. (See POSITIVE CRANKCASE VENTILATION (PCV) VALVE REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo].)
21	Verify test results. • If normal, return to the diagnostic index to service any additional symptoms. • 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, reprogram the PCM if a later calibration is available. Retest.

STEP

INSPECTION

RESULTS

ACTION

Inspect for the following:

• Fuel quality (proper octane, contamination, winter/summer blend)

• Intake-air system leakage and restriction

• Electrical connectors

• Fuses

• Poor connection for PCM ground and body ground

• Fuel leakage

• Vacuum leakage

Is there any malfunction?

Yes

Service if necessary.

• Repeat this step.

Go to the next step.

Switch the ignition to ON.

Retrieve any DTCs using the M-MDS.

(See ON-BOARD DIAGNOSTIC TEST [MZR 2.3 DISI Turbo].)

Are any DTCs present?

Yes

Go to the applicable DTC inspection.

(See DTC TABLE [MZR 2.3 DISI Turbo].)

Go to the next step.

Access the ECT PID using the M-MDS.

(See ON-BOARD DIAGNOSTIC TEST [MZR 2.3 DISI Turbo].)

Verify that the ECT PID value is less than 116 °C {241 °F} during driving.

Is the ECT PID value less than specified?

(See PCM INSPECTION [MZR 2.3 DISI Turbo].)

Yes

Go to the next step.

The cause of this concern could be from the cooling system overheating.

• Perform the symptom troubleshooting “NO.17 COOLING SYSTEM CONCERNS-OVERHEATING”.

(See NO.17 COOLING SYSTEM CONCERNS-OVERHEATING [MZR 2.3 DISI Turbo].)

Does the engine start with throttle close?

Yes

Go to the next step.

Go to Step 10.

Will the engine start and run smoothly at part throttle?

Yes

Go to the next step.

Go to Step 8.

Perform the TP sweep inspection.

(See ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZR 2.3 DISI Turbo].)

Does the electronic throttle control system work properly?

Yes

Visually inspect the throttle body (damage/scratching).

• If normal:

― Go to the next step.

• If not:

― Repair or replace the malfunctioning parts according to the inspection results.

Repair or replace the malfunctioning parts according to the inspection results.

Access the RPM PID using the M-MDS.

(See ON-BOARD DIAGNOSTIC TEST [MZR 2.3 DISI Turbo].)

Is the RPM PID value indicating engine speed when the cranking engine.

Yes

Go to the next step.

Inspect the CKP sensor for following:

• Installation condition

(See CRANKSHAFT POSITION (CKP) SENSOR REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo].)

• Damaged trigger wheel and camshaft

• Open or short circuit in wiring harnesses

Repair or replace the malfunctioning parts according to the inspection results.

Inspect CMP sensor for the following:

• Installation condition

(See CAMSHAFT POSITION (CMP) SENSOR REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo].)

• Damaged trigger wheel and camshaft

• Open or short circuit in wiring harnesses

Is there any malfunction?

Yes

Repair or replace the malfunctioning parts according to the inspection results.

Go to the next step.

Disconnect the vacuum hose between purge solenoid valve and intake manifold from the purge solenoid valve side.

Plug the open end of the vacuum hose.

Start the engine.

Is the engine stall now eliminated?

Yes

Inspect the following:

• Purge solenoid valve

(See PURGE SOLENOID VALVE INSPECTION [MZR 2.3 DISI Turbo].)

• EVAP system

Repair or replace the malfunctioning parts according to the inspection results.

Go to the next step.

Inspect the engine condition while tapping the EGR valve housing.

Does the engine condition improve?

Yes

Replace the EGR valve.

(See EGR VALVE REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo].)

Go to the next step.

Access the following PIDs using the M-MDS:

(See ON-BOARD DIAGNOSTIC TEST [MZR 2.3 DISI Turbo].)

• ECT

• APP1

• APP2

• MAF

• O2S11

• O2S12

• LONGFT1

• SHTFT1

Do the PID values indicate the correct values under the trouble condition?

(See PCM INSPECTION [MZR 2.3 DISI Turbo].)

Yes

Go to the next step.

Inspect the suspected parts and related wiring harness.

• If normal:

― Perform the “INTERMITTENT CONCERN TROUBLESHOOTING.

(See INTERMITTENT CONCERN TROUBLESHOOTING [MZR 2.3 DISI Turbo].)

• If not:

― Repair or replace the malfunctioning parts according to the inspection results.

Inspect for restriction in the exhaust system and TWC.

Is there any restriction?

Yes

Repair or replace the malfunctioning parts according to the inspection results.

Go to the next step.

Perform the Spark Test.

(See ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZR 2.3 DISI Turbo].)

Is a strong blue spark visible at each cylinder?

Yes

Go to the next step.

Repair or replace the malfunctioning parts according to the inspection results.

Access the FUEL_PRES PID using the M-MDS.

(See ON-BOARD DIAGNOSTIC TEST [MZR 2.3 DISI Turbo].)

Crank the engine.

Does the FUEL_PRES PID value increase?

(See PCM INSPECTION [MZR 2.3 DISI Turbo].)

Yes

Go to Step 17.

Go to the next step.

Replace the high pressure fuel pump.

(See HIGH PRESSURE FUEL PUMP REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo].)

Access the FUEL_PRES PID using the M-MDS.

(See ON-BOARD DIAGNOSTIC TEST [MZR 2.3 DISI Turbo].)

Crank the engine.

Does the FUEL_PRES PID value increase?

(See PCM INSPECTION [MZR 2.3 DISI Turbo].)

Yes

High-pressure fuel pump or spill valve control solenoid valve (built-in high pressure fuel pump or fuel pressure sensor) malfunction.

Relief valve or fuel pressure sensor malfunction.

• Replace the fuel delivery pipe.

(See FUEL INJECTOR REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo].)

Connect the fuel pressure gauge between the fuel pump and the high pressure fuel pump.

Measure the fuel pressure line of the low pressure side.

(See FUEL LINE PRESSURE INSPECTION [MZR 2.3 DISI Turbo].)

Is the fuel pressure within the specification?

Yes

Go to the next step.

Inspect for the following:

• Fuel line restriction

• Fuel filter clogging

― If normal:

• Replace the fuel pump unit.

(See FUEL PUMP UNIT REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo].)

― If not:

• Repair or replace the malfunctioning parts according to the inspection results.

Measure the compression pressure for each cylinder.

(See COMPRESSION INSPECTION [MZR 2.3 DISI Turbo].)

Does the starting system work properly?

Yes

Go to the next step.

Inspect for the following:

• Damaged valve seat

• Worn valve stem and valve guide

• Worn or stuck piston ring

• Worn piston, piston ring or cylinder

• Improper valve timing

Repair or replace the malfunctioning parts according to the inspection results.

Disconnect the fuel injector connectors.

Connect the NOID light to the fuel injector harness-side terminals.

Inspect the NOID light dim during cranking.

Does the NOID light illuminate?

Yes

Go to the next step.

Inspect the fuel injector wiring harnesses.

• If normal:

― Replace the PCM (injector driver circuit malfunction).

(See PCM REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo].)

• If not:

― Repair or replace the suspected wiring harness.

Perform the Variable Valve Timing Control System Operation Inspection.

(See ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZR 2.3 DISI Turbo].)

Does the variable valve timing control system work properly?

Yes

Go to the next step.

Repair or replace the malfunctioning parts according to the inspection results.

Inspect the PCV valve.

(See POSITIVE CRANKCASE VENTILATION (PCV) VALVE INSPECTION [MZR 2.3 DISI Turbo].)

Is the PCV valve normal?

Yes

Replace the fuel injector.

(See FUEL INJECTOR REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo].)

If a malfunction remains:

• Repair or replace the malfunctioning part according to the inspection results.

Replace the PCV valve.

(See POSITIVE CRANKCASE VENTILATION (PCV) VALVE REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo].)

Verify test results.

• If normal, return to the diagnostic index to service any additional symptoms.

• 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, reprogram the PCM if a later calibration is available. Retest.