NO.15 EMISSION COMPLIANCE [MZR 2.3 DISI Turbo]

id0103e2802100

15

EMISSION COMPLIANCE
DESCRIPTION
•  Fails emissions test.
POSSIBLE CAUSE
•  Poor fuel quality
•  Vacuum lines leakage or blockage
•  Cooling system malfunction
•  Engine overheating
•  Spark plug malfunction
•  Air leakage from intake-air system
•  Variable swirl system malfunction
•  Improper operation of wastegate control system
•  Turbocharger malfunction
•  Charge air cooler malfunction
•  Inadequate fuel pressure (high-pressure side)
•  PCV valve malfunction or incorrect valve installation
•  EGR system malfunction
•  Exhaust system and/or TWC restriction
•  Fuel tank ventilation system malfunction
•  Charcoal canister damage
•  Air cleaner element clogging or restriction
•  Throttle body malfunction
•  Improper operation of electronic throttle control system
•  Relief valve malfunction (built-in fuel delivery pipe)
•  Spill valve control solenoid valve malfunction (built-in high pressure fuel pump)
•  Improper air/fuel mixture ratio control operation
•  Erratic or no signal from CMP sensor
•  Erratic signal from CKP sensor
•  A/F sensor, HO2S or related circuit malfunction
•  ECT sensor or related circuit malfunction
•  MAF sensor (integrated in MAF/IAT sensor) or related circuit malfunction
•  IAT sensor (integrated in MAF/IAT sensor) or related circuit malfunction
•  Boost air temperature sensor (integrated in MAP sensor/boost air temperature sensor) or related circuit malfunction
•  Fuel pressure sensor (built-in fuel delivery pipe) malfunction
•  APP sensor or related circuit malfunction
•  TP sensor or related circuit malfunction
•  MAP sensor (integrated in MAP sensor/boost air temperature sensor) or related circuit malfunction
•  VSS or related circuit malfunction
•  CPP switch or related circuit malfunction
•  Neutral switch or related circuit malfunction
•  Fuel line restriction
•  High pressure fuel pump malfunction
•  Fuel injector or related circuit malfunction
•  Incorrect fuel injection timing
•  TWC 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 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.

Diagnostic procedure

STEP

INSPECTION

RESULTS

ACTION
1
Is the engine overheating?
Yes
Perform the symptom troubleshooting “NO.17 COOLING SYSTEM CONCERNS-OVERHEATING”.
(See NO.17 COOLING SYSTEM CONCERNS-OVERHEATING [MZR 2.3 DISI Turbo].)
No
Go to the next step.
2
Is the engine runs cold?
Yes
Perform the symptom troubleshooting “NO.18 COOLING SYSTEM CONCERNS-RUNS COLD”.
(See NO.18 COOLING SYSTEM CONCERNS-RUNS COLD [MZR 2.3 DISI Turbo].)
No
Go to the next step.
3
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.
4
Inspect for the following:
•  Fuel quality (proper octane, contamination, winter/summer blend)
•  Charge air cooler condition (restriction or damaged)
•  Air cleaner element (clogging or restriction)
•  Intake-air system leakage
•  PCV valve installation
•  Vacuum line leakage or blockage
•  Fuel leakage at fuel system
•  Charcoal canister damaged
•  Exhaust system and/or TWC restriction
Is there any malfunction?
Yes
Service if necessary.
•  Repeat this step.
No
Go to the next step.
5
Perform the EGR Control System Inspection.
(See ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZR 2.3 DISI Turbo].)
Does the EGR system operate properly?
Yes
Go to the next step.
No
Repair or replace the malfunctioning parts according to the inspection results.
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
Perform the Variable Swirl System Operation Inspection.
(See ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZR 2.3 DISI Turbo].)
Does the variable swirl system work properly?
Yes
Go to the next step.
No
Repair or replace the malfunctioning parts according to the inspection results.
8
Perform the Wastegate Control System Operation Inspection.
(See ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZR 2.3 DISI Turbo].)
Does the wastegate control system work properly?
Yes
Go to the next step.
No
Repair or replace the malfunctioning parts according to the inspection results.
9
Perform the Evaporative Emission (EVAP) System Leak Inspection.
(See ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZR 2.3 DISI Turbo].)
Is the EVAP system normal?
Yes
Go to the next step.
No
Repair or replace the malfunctioning parts according to the inspection results.
10
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.
11
Inspect the CMP sensor and CKP sensor for the following:
•  Installation condition
•  Damaged trigger wheel and camshaft
•  Open or short circuit in the wiring harnesses
Is there any malfunction?
Yes
Repair or replace the malfunctioning parts according to the inspection results.
No
Go to the next step.
12
Access the following PIDs using the M-MDS:
(See ON-BOARD DIAGNOSTIC TEST [MZR 2.3 DISI Turbo].)
•  APP1
•  APP2
•  BAT
•  ECT
•  MAF
•  IAT
•  TP REL
•  MAP
•  VSS
•  CPP
•  CPP/PNP
•  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.
•  If not:
―  Repair or replace the malfunctioning parts according to the inspection results.
13
Access the FUEL_PRES PID using the M-MDS.
(See ON-BOARD DIAGNOSTIC TEST [MZR 2.3 DISI Turbo].)
Is the FUEL_PRES PID value within the specification?
(See PCM INSPECTION [MZR 2.3 DISI Turbo].)
Yes
Go to Step 17.
No
Go to the next step.
14
Is the vehicle accelerate performance normally?
Yes
Go to the next step.
No
Go to Step 16.
15
Inspect the fuel pressure sensor.
(See FUEL PRESSURE SENSOR INSPECTION [MZR 2.3 DISI Turbo].)
Is there any malfunction?
Yes
Replace the fuel delivery pipe.
(See FUEL INJECTOR REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo].)
No
Go to Step 17.
16
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].)
Is the FUEL_PRES PID value within the specified?
(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) malfunction.
•  Go to Step 22.
No
Relief valve or fuel pressure sensor malfunction.
•  Replace the fuel delivery pipe.
17
Inspect the turbocharger.
(See TURBOCHARGER INSPECTION [MZR 2.3 DISI Turbo].)
Is there any malfunction?
Yes
Replace the turbocharger.
(See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo].)
No
Go to the next step.
18
Inspect the TWC.
Is there any malfunction?
Yes
Replace the TWC.
(See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo].)
No
Go to the next step.
19
Perform the Fuel Injector Operation Inspection.
(See ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZR 2.3 DISI Turbo].)
Do the fuel injectors operate normally?
Yes
Go to the next step.
No
Repair or replace the malfunctioning parts according to the inspection results.
20
Measure the compression pressure for each cylinder.
(See COMPRESSION INSPECTION [MZR 2.3 DISI Turbo].)
Are compression pressures within the specification?
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.
21
Inspect the PCV valve.
(See POSITIVE CRANKCASE VENTILATION (PCV) VALVE INSPECTION [MZR 2.3 DISI Turbo].)
Is there any malfunction?
Yes
Replace the PCV valve.
(See POSITIVE CRANKCASE VENTILATION (PCV) VALVE REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo].)
No
Replace the PCM (injector driver circuit malfunction).
(See PCM REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo].)
•  If a malfunction remains:
―  Repair or replace the malfunctioning part according to the inspection results.
22
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.