NO.6 LACK OF POWER [MZ-CD 1.6]

6	Lack of power
DESCRIPTION	• Performance is poor under load. (e.g. Power down when climbing hills, starting.) • Performance is poor under load and glow indicator light is flashing.
POSSIBLE CAUSE	• PCM DTC is detected. • Fuel tank fuel level low. • Air cleaner element restriction • Loose vacuum line(s)/vacuum connections • Loose intake-air system hose(s)/hose connections • Loose intake-air system tube(s)/tube connections • Coolant leakage • Oil leakage • Fuel leakage • Visibly damaged or worn parts • Loose or missing nuts or bolts • Incorrect or contaminated fuel in fuel tank • Electrical connector, wiring harness or component damaged • Loose installation fuel gauge sender unit • Vehicle overloaded, or excessive wind resistance (roof racks, towing etc). • Brakes binding. • Clutch slipping • Incorrect engine oil. • Air ingress into the fuel lines. • EGR valve incorrect base setting • Erratic signal to PCM ― APP sensor signal malfunction ― MAF sensor signal malfunction ― ECT sensor signal malfunction ― Fuel temperature sensor signal malfunction ― Diesel particulate filter differential pressure sensor signal malfunction ― VSS signal malfunction • CKP sensor or pulse wheel malfunction • Glow plug control module malfunction • Glow plug malfunction • Fuel injector malfunction • Turbocharger wastages malfunction • EGR valve incorrect operation. • Charge air cooler blocked or cracked. • Charge air cooler pipes split or cracked. • Charge air cooler pipe retaining clips missing or loose. • Exhaust system blocked. • Diesel particulate filter blocked. • Catalytic converter blocked. • Turbocharger malfunction • Kinked or restricted fuel lines. • Fuel pressure sensor malfunction • Fuel metering valve malfunction • Supply pump malfunction • Low cylinder compression. • Incorrect valve timing. • Timing belt/timing sprocket or pulley/sprocket damaged. • PCM malfunction

Lack of power

DESCRIPTION

• Performance is poor under load. (e.g. Power down when climbing hills, starting.)

• Performance is poor under load and glow indicator light is flashing.

POSSIBLE CAUSE

• PCM DTC is detected.

• Fuel tank fuel level low.

• Air cleaner element restriction

• Loose vacuum line(s)/vacuum connections

• Loose intake-air system hose(s)/hose connections

• Loose intake-air system tube(s)/tube connections

• Coolant leakage

• Oil leakage

• Fuel leakage

• Visibly damaged or worn parts

• Loose or missing nuts or bolts

• Incorrect or contaminated fuel in fuel tank

• Electrical connector, wiring harness or component damaged

• Loose installation fuel gauge sender unit

• Vehicle overloaded, or excessive wind resistance (roof racks, towing etc).

• Brakes binding.

• Clutch slipping

• Incorrect engine oil.

• Air ingress into the fuel lines.

• EGR valve incorrect base setting

• Erratic signal to PCM

― APP sensor signal malfunction

― MAF sensor signal malfunction

― ECT sensor signal malfunction

― Fuel temperature sensor signal malfunction

― Diesel particulate filter differential pressure sensor signal malfunction

― VSS signal malfunction

• CKP sensor or pulse wheel malfunction

• Glow plug control module malfunction

• Glow plug malfunction

• Fuel injector malfunction

• Turbocharger wastages malfunction

• EGR valve incorrect operation.

• Charge air cooler blocked or cracked.

• Charge air cooler pipes split or cracked.

• Charge air cooler pipe retaining clips missing or loose.

• Exhaust system blocked.

• Diesel particulate filter blocked.

• Catalytic converter blocked.

• Turbocharger malfunction

• Kinked or restricted fuel lines.

• Fuel pressure sensor malfunction

• Fuel metering valve malfunction

• Supply pump malfunction

• Low cylinder compression.

• Incorrect valve timing.

• Timing belt/timing sprocket or pulley/sprocket damaged.

• PCM malfunction

STEP	INSPECTION	RESULTS	ACTION
1	VERIFY PCM DTC • Perform the PCM DTC inspection using the M-MDS. (See ON-BOARD DIAGNOSTIC TEST [MZ-CD 1.6].) • Are any DTCs present?	Yes	Go to the applicable DTC inspection. (See DTC TABLE [MZ-CD 1.6].)
No	Go to the next step.
2	VISUALLY INSPECT RELATED PART CONDITION • Visually inspect the following: Mechanical: ― Air cleaner element ― Vacuum line(s)/vacuum connections ― Hose(s)/hose connections ― Tube(s)/tube connections ― Coolant leaks ― Oil leaks ― Fuel level ― Fuel system leaks (Fuel filter, fuel supply line(s), fuel return line(s), high-pressure fuel supply line(s), fuel injectors, fuel rail, supply pump, fuel tank, fuel tank ventilation pipe, fuel tank filler pipe) ― Visibly damaged or worn parts ― Loose or missing nuts or bolts ― Contaminated fuel Electrical: ― Fuse(s) ― Relay(s) ― Loose or corroded connector(s) (PCM, sensor(s), switch(es)) ― Damaged or worn PCM, switch(es) and/or sensor(s) ― Wiring harness ― Fuel gauge sender unit installation • Is there any malfunction?	Yes	Repair or replace the malfunctioning part according to the inspection results. Repeat Step 2.
No	Go to the next step.
3	DETERMINE IF MALFUNCTION CAUSE IS VEHICLE OVERLOADING/EXCESSIVE WIND RESISTANCE • Verify the vehicle equipped part. • Is there any following part equipped? ― Roof lacks ― Towing	Yes	Explain to the customer that cause is overloading and/or excessive wind resistance.
No	Go to the next step.
4	INSPECT VEHICLE CONDITION • Inspect for following: ― Brake ― Clutch • Is there any malfunction?	Yes	Repair or replace the malfunctioning part according to the inspection results.
No	Go to the next step.
5	INSPECT ENGINE OIL AND RELATED PARTS CONDITION • Inspect the following: ― External leakage ― Proper dipstick ― Proper engine oil viscosity • Is there any malfunction?	Yes	Repair or replace the malfunctioning part according to the inspection results.
No	Go to the next step.
6	DETERMINE IF MALFUNCTION CAUSE IS AIR INGRESS IN FUEL LINE OR OTHER • Perform the Fuel Line Air Bleeding. (See AFTER SERVICE PRECAUTION [MZ-CD 1.6].) • Verify the symptom. • Is the symptom solved?	Yes	Troubleshooting is completed. (Air ingress into the fuel line.)
No	Go to the next step.
7	DETERMINE IF MALFUNCTION CAUSE IS AIR INGRESS IN FUEL LINE OR OTHER • Perform the “EXHAUST GAS RECIRCULATION VALVE LEARNED VALUES RESET” and “INTAKE AIR THROTTLE VALVE LEARNED VALUES RESET”. (See EXHAUST GAS RECIRCULATION VALVE LEARNED VALUES RESET [MZ-CD 1.6].) (See INTAKE AIR THROTTLE VALVE LEARNED VALUES RESET [MZ-CD 1.6].) • Verify the symptom. • Is the symptom solved?	Yes	Troubleshooting is completed. (EGR valve base setting is incorrect.)
No	Go to the next step.
8	VERIFY CURRENT INPUT SIGNAL STATUS Caution • While performing this step, always operate the vehicle in a safe and lawful manner. • When the M-MDS is used to observe monitor system status while driving, be sure to have another technician with you, or record the data in the M-MDS using the PID/DATA MONITOR AND RECORD capturing function and inspect later. • Access the following PIDs using the M-MDS: (See PCM INSPECTION [MZ-CD 1.6].) ― APP1 ― APP2 ― MAF ― ECT ― FLT ― EXHPRESS_DIF ― VSS • Monitor the each PID while driving the vehicle. • Are all PIDs normal?	Yes	Go to the next step.
No	If the APP1 or APP2 PIDs are not specified: • Inspect the APP sensor and related wiring harness. (See ACCELERATOR PEDAL POSITION (APP) SENSOR INSPECTION [MZ-CD 1.6].) If the MAF PID is not specified: • Inspect the MAF sensor and related wiring harness. (See MASS AIR FLOW (MAF) SENSOR INSPECTION [MZ-CD 1.6].) If the ECT PID is not specified: • Inspect the ECT sensor and related wiring harness. (See ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION [MZ-CD 1.6].) If the FLT PID is not specified: • Inspect the fuel temperature sensor and related wiring harness. If the EXHPRESS_DIF PID is not specified: • Inspect the sensor and related wiring harness. (See DIESEL PARTICULATE FILTER DIFFERENTIAL PRESSURE SENSOR REMOVAL/INSTALLATION [MZ-CD 1.6].) If the VSS PID is not specified: • Inspect the ABS wheel-speed sensor and related wiring harness. (See FRONT ABS WHEEL-SPEED SENSOR INSPECTION.) (See REAR ABS WHEEL-SPEED SENSOR INSPECTION.) Repair or replace malfunctioning part.
9	VISUALLY INSPECT CKP SENSOR AND PULSE WHEEL • Visually inspect the CKP sensor and teeth of the crankshaft pulley. • Is there any malfunction?	Yes	Repair or replace the malfunctioning part as necessary.
No	Go to the next step.
10	INSPECT GLOW PLUG AND GLOW PLUG CONTROL MODULE • Inspect the glow plug and glow plug control module. • Are glow plug and glow plug control module normal?	Yes	Replace the malfunctioning part. (See GLOW PLUG REMOVAL/INSTALLATION [MZ-CD 1.6].)
No	Go to the next step.
11	INSPECT FUEL INJECTOR • Inspect the fuel injector for each cylinder. (See FUEL INJECTOR INSPECTION [MZ-CD 1.6].) • Are fuel injectors normal?	Yes	Go to the next step.
No	Replace the suspected fuel injector. (See FUEL INJECTOR REMOVAL/INSTALLATION [MZ-CD 1.6].)
12	INSPECT WASTEGATE VALVE OPERATION Caution • While performing this step, always operate the vehicle in a safe and lawful manner. • When the M-MDS is used to observe monitor system status while driving, be sure to have another technician with you, or record the data in the M-MDS using the PID/DATA MONITOR AND RECORD capturing function and inspect later. • Access following PCM PIDs. ― WGC ― WG_POS (See PCM INSPECTION [MZ-CD 1.6].) • Monitor the each PID while driving the vehicle. • Are PIDs value changing according to driving conditions?	Yes	Go to the next step.
No	Inspect for following: • Wastage valve for stuck. • Wastegate valve actuator control solenoid valve • Wastegate valve actuator position sensor Repair or replace as necessary.
13	INSPECT EGR VALVE OPERATION Caution • While performing this step, always operate the vehicle in a safe and lawful manner. • When the M-MDS is used to observe monitor system status while driving, be sure to have another technician with you, or record the data in the M-MDS using the PID/DATA MONITOR AND RECORD capturing function and inspect later. • Access following PCM PIDs. ― EGRP ― SEGRP DSD (See PCM INSPECTION [MZ-CD 1.6].) • Monitor the each PID while driving the vehicle. • Are PIDs value changing according to driving conditions?	Yes	Go to the next step.
No	Inspect the EGR valve for stuck. Clean or replace the EGR valve as necessary. (See EGR VALVE REMOVAL/INSTALLATION [MZ-CD 1.6].)
14	INSPECT EGR COOLER BYPASS VALVE OPERATION Caution • While performing this step, always operate the vehicle in a safe and lawful manner. • When the M-MDS is used to observe monitor system status while driving, be sure to have another technician with you, or record the data in the M-MDS using the PID/DATA MONITOR AND RECORD capturing function and inspect later. • Access following PCM PIDs. ― EGR_C_BP ― EGR_C_BP_D (See PCM INSPECTION [MZ-CD 1.6].) • Monitor the each PID while driving the vehicle. • Are PIDs value changing according to driving conditions?	Yes	Go to the next step.
No	Inspect the EGR valve for stuck. Clean or replace the EGR valve as necessary. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZ-CD 1.6].)
15	INSPECT CHARGE AIR COOLER • Visually inspect charge air cooler core. • Are there excessive bend or collapse detected?	Yes	Replace the charge air cooler as necessary.
No	Go to the next step.
16	INSPECT CHARGE AIR COOLER PIPES • Inspect the hose bands between the following parts: ― Turbocharger compressor housing and air cleaner ― Turbocharger compressor housing and charge air cooler • Are the hose bands loose?	Yes	Retighten the hose bands. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZ-CD 1.6].)
No	Go to the next step.
17	IINSPECT EXHAUST SYSTEM • Visually inspect the following exhaust system part. ― Catalyst converter ― Diesel particulate filter (included in catalyst converter) ― Exhaust pipe • Is there any malfunction?	Yes	Repair or replace the malfunctioning part according to the inspection results.
No	Go to the next step.
18	VISUALLY INSPECT TURBOCHARGER COMPRESSOR WHEEL • Remove parts necessary to inspect the turbocharger without remove the turbocharger. • Inspect if the turbocharger compressor wheel is bent, damaged, or interfering with the housing on the vehicle. • Is there any malfunction?	Yes	Replace the turbocharger. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZ-CD 1.6].)
No	Go to the next step.
19	VISUALLY INSPECT TURBOCHARGER COMPRESSOR WHEEL LOCK BOLT • Inspect if the turbocharger compressor wheel locknut is loose or has fallen down inside the turbocharger. • Is there any malfunction?	Yes	Replace the turbocharger. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZ-CD 1.6].)
No	Go to the next step.
20	VERIFY TURBOCHARGER COMPRESSOR WHEEL ROTATION • Inspect the turbocharger compressor wheel by hand. • Does the wheel turn easily and smoothly?	Yes	Go to the next step.
No	Replace the turbocharger. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZ-CD 1.6].)
21	VISUALLY INSPECT TURBOCHARGER TURBINE WHEEL • Inspect if the turbocharger turbine wheel is damaged, cracked or interfering with the housing on the vehicle. Note • Inspect all fins on each turbine wheel. • Is there any malfunction?	Yes	Replace the turbocharger. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZ-CD 1.6].)
No	Go to the next step.
22	VISUALLY INSPECT TURBOCHARGER TURBINE HOUSING FOR OIL LEAKAGE • Is any engine oil found inside the turbocharger turbine housing?	Yes	If the excessive amount of oil is found: • Replace the turbocharger. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZ-CD 1.6].) If the small amount of oil is found: • Wipe oil off of the vehicle, then go to the next step.
No	Go to the next step.
23	VISUALLY INSPECT TURBOCHARGER COMPRESSOR HOUSING FOR OIL LEAKAGE • Is any engine oil found inside the turbocharger compressor housing?	Yes	Wipe oil off of the vehicle. • Reinstall all removed parts in Step 18, then go to the next step.
No	Turbocharger is normal. • Reinstall all removed parts in Step 18, then go to the next step.
24	INSPECT FUEL LINE FOR BLOCKAGE • Inspect the fuel line for blockage. • Is there blockage detected?	Yes	Flush the fuel system through with clean fuel.
No	Go to the next step.
25	DETERMINE IF MALFUNCTION CAUSE IS SUPPLY PUMP/FUEL METERING VALVE OR OTHER Caution • While performing this step, always operate the vehicle in a safe and lawful manner. • When the M-MDS is used to observe monitor system status while driving, be sure to have another technician with you, or record the data in the M-MDS using the PID/DATA MONITOR AND RECORD capturing function and inspect later. • Access following PCM PIDs. (See PCM INSPECTION [MZ-CD 1.6].) ― FRP ― FRP_DSD ― FUEL_V_DSD • Monitor the each PID while driving the vehicle. • Are all PIDs normal?	Yes	Go to the next step.
No	Inspect the fuel pressure sensor and related wiring harness. (See FUEL PRESSURE SENSOR INSPECTION [MZ-CD 1.6].) • If there is malfunction, repair or replace malfunctioning part. • If there is no malfunction, replace the supply pump. (See SUPPLY PUMP REMOVAL/INSTALLATION [MZ-CD 1.6].)
26	DETERMINE IF MALFUNCTION CAUSE IS VALVE OPERATION SYSTEM OR OTHER • Inspect the followings: ― Timing belt ― Pulley and sprocket ― Valve timing. (See TIMING BELT REMOVAL/INSTALLATION [MZ-CD 1.6].) • Are all items normal?	Yes	Replace the fuel. (Poor fuel quality (e.g.: include water contamination, winter/summer blend)) • Flush the fuel line as necessary.
No	Repair or replace the malfunctioning part according to the inspection results.
27	Verify test results. • If normal, return to the diagnostic index to service any additional symptoms. (See SYMPTOM DIAGNOSTIC INDEX [MZ-CD 1.6].) • If the 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

VERIFY PCM DTC

• Perform the PCM DTC inspection using the M-MDS.

(See ON-BOARD DIAGNOSTIC TEST [MZ-CD 1.6].)

• Are any DTCs present?

Yes

Go to the applicable DTC inspection.

(See DTC TABLE [MZ-CD 1.6].)

Go to the next step.

VISUALLY INSPECT RELATED PART CONDITION

• Visually inspect the following:

Mechanical:

― Air cleaner element

― Vacuum line(s)/vacuum connections

― Hose(s)/hose connections

― Tube(s)/tube connections

― Coolant leaks

― Oil leaks

― Fuel level

― Fuel system leaks (Fuel filter, fuel supply line(s), fuel return line(s), high-pressure fuel supply line(s), fuel injectors, fuel rail, supply pump, fuel tank, fuel tank ventilation pipe, fuel tank filler pipe)

― Visibly damaged or worn parts

― Loose or missing nuts or bolts

― Contaminated fuel

Electrical:

― Fuse(s)

― Relay(s)

― Loose or corroded connector(s) (PCM, sensor(s), switch(es))

― Damaged or worn PCM, switch(es) and/or sensor(s)

― Wiring harness

― Fuel gauge sender unit installation

• Is there any malfunction?

Yes

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

Repeat Step 2.

Go to the next step.

DETERMINE IF MALFUNCTION CAUSE IS VEHICLE OVERLOADING/EXCESSIVE WIND RESISTANCE

• Verify the vehicle equipped part.

• Is there any following part equipped?

― Roof lacks

― Towing

Yes

Explain to the customer that cause is overloading and/or excessive wind resistance.

Go to the next step.

INSPECT VEHICLE CONDITION

• Inspect for following:

― Brake

― Clutch

• Is there any malfunction?

Yes

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

Go to the next step.

INSPECT ENGINE OIL AND RELATED PARTS CONDITION

• Inspect the following:

― External leakage

― Proper dipstick

― Proper engine oil viscosity

• Is there any malfunction?

Yes

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

Go to the next step.

DETERMINE IF MALFUNCTION CAUSE IS AIR INGRESS IN FUEL LINE OR OTHER

• Perform the Fuel Line Air Bleeding.

(See AFTER SERVICE PRECAUTION [MZ-CD 1.6].)

• Verify the symptom.

• Is the symptom solved?

Yes

Troubleshooting is completed.

(Air ingress into the fuel line.)

Go to the next step.

DETERMINE IF MALFUNCTION CAUSE IS AIR INGRESS IN FUEL LINE OR OTHER

• Perform the “EXHAUST GAS RECIRCULATION VALVE LEARNED VALUES RESET” and “INTAKE AIR THROTTLE VALVE LEARNED VALUES RESET”.

(See EXHAUST GAS RECIRCULATION VALVE LEARNED VALUES RESET [MZ-CD 1.6].)

(See INTAKE AIR THROTTLE VALVE LEARNED VALUES RESET [MZ-CD 1.6].)

• Verify the symptom.

• Is the symptom solved?

Yes

Troubleshooting is completed.

(EGR valve base setting is incorrect.)

Go to the next step.

VERIFY CURRENT INPUT SIGNAL STATUS

Caution

• While performing this step, always operate the vehicle in a safe and lawful manner.

• When the M-MDS is used to observe monitor system status while driving, be sure to have another technician with you, or record the data in the M-MDS using the PID/DATA MONITOR AND RECORD capturing function and inspect later.

• Access the following PIDs using the M-MDS:

(See PCM INSPECTION [MZ-CD 1.6].)

― APP1

― APP2

― MAF

― ECT

― FLT

― EXHPRESS_DIF

― VSS

• Monitor the each PID while driving the vehicle.

• Are all PIDs normal?

Yes

Go to the next step.

If the APP1 or APP2 PIDs are not specified:

• Inspect the APP sensor and related wiring harness.

(See ACCELERATOR PEDAL POSITION (APP) SENSOR INSPECTION [MZ-CD 1.6].)

If the MAF PID is not specified:

• Inspect the MAF sensor and related wiring harness.

(See MASS AIR FLOW (MAF) SENSOR INSPECTION [MZ-CD 1.6].)

If the ECT PID is not specified:

• Inspect the ECT sensor and related wiring harness.

(See ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION [MZ-CD 1.6].)

If the FLT PID is not specified:

• Inspect the fuel temperature sensor and related wiring harness.

If the EXHPRESS_DIF PID is not specified:

• Inspect the sensor and related wiring harness.

(See DIESEL PARTICULATE FILTER DIFFERENTIAL PRESSURE SENSOR REMOVAL/INSTALLATION [MZ-CD 1.6].)

If the VSS PID is not specified:

• Inspect the ABS wheel-speed sensor and related wiring harness.

(See FRONT ABS WHEEL-SPEED SENSOR INSPECTION.)

(See REAR ABS WHEEL-SPEED SENSOR INSPECTION.)

Repair or replace malfunctioning part.

VISUALLY INSPECT CKP SENSOR AND PULSE WHEEL

• Visually inspect the CKP sensor and teeth of the crankshaft pulley.

• Is there any malfunction?

Yes

Repair or replace the malfunctioning part as necessary.

Go to the next step.

INSPECT GLOW PLUG AND GLOW PLUG CONTROL MODULE

• Inspect the glow plug and glow plug control module.

• Are glow plug and glow plug control module normal?

Yes

Replace the malfunctioning part.

(See GLOW PLUG REMOVAL/INSTALLATION [MZ-CD 1.6].)

Go to the next step.

INSPECT FUEL INJECTOR

• Inspect the fuel injector for each cylinder.

(See FUEL INJECTOR INSPECTION [MZ-CD 1.6].)

• Are fuel injectors normal?

Yes

Go to the next step.

Replace the suspected fuel injector.

(See FUEL INJECTOR REMOVAL/INSTALLATION [MZ-CD 1.6].)

INSPECT WASTEGATE VALVE OPERATION

Caution

• While performing this step, always operate the vehicle in a safe and lawful manner.

• Access following PCM PIDs.

― WGC

― WG_POS

(See PCM INSPECTION [MZ-CD 1.6].)

• Monitor the each PID while driving the vehicle.

• Are PIDs value changing according to driving conditions?

Yes

Go to the next step.

Inspect for following:

• Wastage valve for stuck.

• Wastegate valve actuator control solenoid valve

• Wastegate valve actuator position sensor

Repair or replace as necessary.

INSPECT EGR VALVE OPERATION

Caution

• While performing this step, always operate the vehicle in a safe and lawful manner.

• Access following PCM PIDs.

― EGRP

― SEGRP DSD

(See PCM INSPECTION [MZ-CD 1.6].)

• Monitor the each PID while driving the vehicle.

• Are PIDs value changing according to driving conditions?

Yes

Go to the next step.

Inspect the EGR valve for stuck.

Clean or replace the EGR valve as necessary.

(See EGR VALVE REMOVAL/INSTALLATION [MZ-CD 1.6].)

INSPECT EGR COOLER BYPASS VALVE OPERATION

Caution

• While performing this step, always operate the vehicle in a safe and lawful manner.

• Access following PCM PIDs.

― EGR_C_BP

― EGR_C_BP_D

(See PCM INSPECTION [MZ-CD 1.6].)

• Monitor the each PID while driving the vehicle.

• Are PIDs value changing according to driving conditions?

Yes

Go to the next step.

Inspect the EGR valve for stuck.

Clean or replace the EGR valve as necessary.

(See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZ-CD 1.6].)

INSPECT CHARGE AIR COOLER

• Visually inspect charge air cooler core.

• Are there excessive bend or collapse detected?

Yes

Replace the charge air cooler as necessary.

Go to the next step.

INSPECT CHARGE AIR COOLER PIPES

• Inspect the hose bands between the following parts:

― Turbocharger compressor housing and air cleaner

― Turbocharger compressor housing and charge air cooler

• Are the hose bands loose?

Yes

Retighten the hose bands.

(See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZ-CD 1.6].)

Go to the next step.

IINSPECT EXHAUST SYSTEM

• Visually inspect the following exhaust system part.

― Catalyst converter

― Diesel particulate filter (included in catalyst converter)

― Exhaust pipe

• Is there any malfunction?

Yes

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

Go to the next step.

VISUALLY INSPECT TURBOCHARGER COMPRESSOR WHEEL

• Remove parts necessary to inspect the turbocharger without remove the turbocharger.

• Inspect if the turbocharger compressor wheel is bent, damaged, or interfering with the housing on the vehicle.

• Is there any malfunction?

Yes

Replace the turbocharger.

(See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZ-CD 1.6].)

Go to the next step.

VISUALLY INSPECT TURBOCHARGER COMPRESSOR WHEEL LOCK BOLT

• Inspect if the turbocharger compressor wheel locknut is loose or has fallen down inside the turbocharger.

• Is there any malfunction?

Yes

Replace the turbocharger.

(See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZ-CD 1.6].)

Go to the next step.

VERIFY TURBOCHARGER COMPRESSOR WHEEL ROTATION

• Inspect the turbocharger compressor wheel by hand.

• Does the wheel turn easily and smoothly?

Yes

Go to the next step.

Replace the turbocharger.

(See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZ-CD 1.6].)

VISUALLY INSPECT TURBOCHARGER TURBINE WHEEL

• Inspect if the turbocharger turbine wheel is damaged, cracked or interfering with the housing on the vehicle.

Note

• Inspect all fins on each turbine wheel.

• Is there any malfunction?

Yes

Replace the turbocharger.

(See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZ-CD 1.6].)

Go to the next step.

VISUALLY INSPECT TURBOCHARGER TURBINE HOUSING FOR OIL LEAKAGE

• Is any engine oil found inside the turbocharger turbine housing?

Yes

If the excessive amount of oil is found:

• Replace the turbocharger.

(See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZ-CD 1.6].)

If the small amount of oil is found:

• Wipe oil off of the vehicle, then go to the next step.

Go to the next step.

VISUALLY INSPECT TURBOCHARGER COMPRESSOR HOUSING FOR OIL LEAKAGE

• Is any engine oil found inside the turbocharger compressor housing?

Yes

Wipe oil off of the vehicle.

• Reinstall all removed parts in Step 18, then go to the next step.

Turbocharger is normal.

• Reinstall all removed parts in Step 18, then go to the next step.

INSPECT FUEL LINE FOR BLOCKAGE

• Inspect the fuel line for blockage.

• Is there blockage detected?

Yes

Flush the fuel system through with clean fuel.

Go to the next step.

DETERMINE IF MALFUNCTION CAUSE IS SUPPLY PUMP/FUEL METERING VALVE OR OTHER

Caution

• While performing this step, always operate the vehicle in a safe and lawful manner.

• Access following PCM PIDs.

(See PCM INSPECTION [MZ-CD 1.6].)

― FRP

― FRP_DSD

― FUEL_V_DSD

• Monitor the each PID while driving the vehicle.

• Are all PIDs normal?

Yes

Go to the next step.

Inspect the fuel pressure sensor and related wiring harness.

(See FUEL PRESSURE SENSOR INSPECTION [MZ-CD 1.6].)

• If there is malfunction, repair or replace malfunctioning part.

• If there is no malfunction, replace the supply pump.

(See SUPPLY PUMP REMOVAL/INSTALLATION [MZ-CD 1.6].)

DETERMINE IF MALFUNCTION CAUSE IS VALVE OPERATION SYSTEM OR OTHER

• Inspect the followings:

― Timing belt

― Pulley and sprocket

― Valve timing.

(See TIMING BELT REMOVAL/INSTALLATION [MZ-CD 1.6].)

• Are all items normal?

Yes

Replace the fuel.

(Poor fuel quality (e.g.: include water contamination, winter/summer blend))

• Flush the fuel line as necessary.

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

Verify test results.

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

(See SYMPTOM DIAGNOSTIC INDEX [MZ-CD 1.6].)

• If the 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.