NO.14 EXHAUST SMOKE [MZ-CD 1.6]

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14

Exhaust smoke
DESCRIPTION
•  Black smoke at cruising speeds.
•  Black smoke at cruising speeds and glow indicator light is flashing.
•  Black smoke at idle.
•  Black smoke at idle and glow indicator light is flashing.
•  Excessive black smoke during acceleration.
•  Blue smoke.
•  Blue smoke and glow indicator light is flashing.
•  White smoke.
•  White smoke and glow indicator light is flashing.
POSSIBLE CAUSE
Black smoke:
•  PCM DTC is detected.
•  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
•  Fuel leakage
•  Visibly damaged or worn parts
•  Loose or missing nuts or bolts
•  Incorrect or contaminated fuel in fuel tank
•  EGR valve incorrect base setting
•  Erratic signal to PCM
―  APP sensor signal malfunction
―  MAF sensor signal malfunction
―  ECT sensor signal malfunction
•  CKP sensor or pulse wheel malfunction
•  Fuel injector malfunction
•  EGR valve incorrect operation.
•  Charge air cooler bend collapse
•  Charge air cooler improper installation
•  Catalytic converter blocked.
•  Turbocharger malfunction
•  Fuel pressure sensor malfunction
•  Supply pump malfunction
•  Incorrect valve timing.
•  PCM malfunction
Blue smoke:
•  PCM DTC is detected.
•  Oil leakage
•  Incorrect or contaminated fuel in fuel tank
•  Burning engine oil.
•  PCV system malfunction
•  Turbocharger malfunction
―  Turbocharger oil seals leaking.
―  Turbocharger oil return tube blocked or damaged.
•  Worn or damaged valve guide(s), piston ring(s), cylinder bore(s), cylinder head or gasket.
White smoke:
•  PCM DTC is detected.
•  Water in fuel.
•  Coolant leakage
•  Diesel particulate filter blocked.
•  Coolant in the combustion chamber.
•  Incorrect valve timing.

Diagnostic procedure

STEP

INSPECTION

RESULTS

ACTION
1
VERIFY PCM DTC
•  Perform the PCM DTC inspection using the M-MDS.
•  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
―  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)
―  Contaminated fuel
•  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
VERIFY EXHAUST GAS COLOR
•  What color is the smoke coming from the exhaust system?
Black
Go to the next step.
Blue
Go to Step 20.
White
Go to Step 25.
4
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”.
•   Verify the symptom.
•   Is the symptom solved?
Yes
Troubleshooting is completed.
(EGR valve base setting is incorrect.)
No
Go to the next step.
5
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:
―  APP1
―  APP2
―  MAF
―  ECT
•  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.
If the MAF PID is not specified:
•  Inspect the MAF sensor and related wiring harness.
If the ECT PID is not specified:
•  Inspect the ECT sensor and related wiring harness.
Repair or replace malfunctioning part.
6
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.
7
INSPECT FUEL INJECTOR
•  Inspect the fuel injector for each cylinder.
•  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].)
8
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
•  Monitor the MAF 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].)
9
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
•  Monitor the MAF PID while driving the vehicle.
•  Are PIDs value changing according to driving conditions?
Yes
Go to the next step.
No
Inspect the EGR cooler bypass valve for stuck.
Clean or replace the EGR cooler bypass valve as necessary.
(See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZ-CD 1.6].)
10
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.
11
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.
12
INSPECT EXHAUST SYSTEM
•  Visually inspect the following exhaust system part.
―  Catalyst converter
―  Diesel particulate filter (included in catalyst converter)
•  Is there any malfunction?
Yes
Repair or replace the malfunctioning part according to the inspection results.
No
Go to the next step.
13
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.
14
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.
15
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.
(SeeEXHAUST SYSTEM REMOVAL/INSTALLATION [MZ-CD 1.6].)
16
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.
17
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.
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.
18
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 13, then go to the next step.
No
Turbocharger is normal.
Reinstall all removed parts in Step 13, then go to the next step.
19
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 the following PID using the M-MDS:
―  FRP
―  FRP_DSD
―  FUEL_V_DSD
•  Monitor the each PID while driving the vehicle.
•  Are all PIDs normal?
Yes
Inspect the valve timing.
(See TIMING BELT REMOVAL/INSTALLATION [MZ-CD 1.6].)
•  If the valve timing is not normal, repair or replace the malfunctioning part according to the inspection results.
If the small amount of oil is found:
•  If the valve timing is normal, replace the fuel.(Poor fuel quality (e.g.: include water contamination, winter/summer blend))
―  Flush the fuel line as necessary.
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.
20
INSPECT PCV VALVE
•  Inspect the PCV valve.
•  Is the PCV valve normal?
Yes
Go to the next step.
No
Clean or replace the upper cylinder head cover.
(See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZ-CD 1.6].)
21
INSPECT TURBOCHARGER OIL RETURN LINE FOR BLOCKAGE
•  Inspect the turbocharger oil return tube blocked or damaged.
•  Is there any blocked or damaged in oil return tube?
Yes
Repair or replace malfunctioning part.
No
Go to the next step.
22
VISUALLY INSPECT TURBOCHARGER TURBINE HOUSING FOR OIL LEAKAGE
•  Remove parts necessary to inspect the turbocharger without remove the turbocharger.
•  Is any engine oil found inside the turbocharger turbine housing?
Yes
If the excessive amount of oil is found:
•  Replace the turbocharger.
If the excessive 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 21, then go to the next step.
No
Turbocharger is normal.
•  Reinstall all removed parts in Step 21, then go to the next step.
24
INSPECT CYLINDER HEAD GASKET
•  Remove the cylinder head.
•  Visually inspect cylinder head gasket and mating surface.
•  Is there any damaged or mating face wrapped?
Yes
Replace the cylinder head gasket, and/or clean the mating surface as necessary.
No
Go to the symptom troubleshooting “NO.10 HIGH ENGINE OIL CONSUMPTION”.
(See NO.10 HIGH ENGINE OIL CONSUMPTION [MZ-CD 1.6].)
25
DETERMINE IF MALFUNCTION CAUSE IS WATER IN FUEL OR OTHER
•  Perform the fuel filter water draining.
•  Verify the symptom.
•  Is the symptom solved?
Yes
Troubleshooting is completed.
(Water into the fuel line.)
No
Go to the next step.
26
INSPECT FOR ENGINE COOLANT LEAKAGE
•  Perform the ENGINE COOLANT LEAKAGE INSPECTION.
•  Is there any leakage detected?
Yes
Repair or replace the applicable part.
No
Go to the next step.
27
INSPECT FUEL LINE FOR CONTAMINATION
•  Flush the fuel system through with clean fuel.
•  Is the symptom solved?
Yes
Troubleshooting is completed.
(Contaminated fuel into the fuel line.)
No
Go to the next step.
28
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.
If the malfunction is remains, overhaul the engine and repair or replace malfunctioning part.
(Engine internal coolant passage is malfunction.)
No
Repair or replace the malfunctioning part according to the inspection results.
29
Verify test results.
•  If normal, return to the diagnostic index to service any additional symptoms.
•  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.