NO.17 EMISSION COMPLIANCE [MZR-CD 2.2]

17	EMISSION COMPLIANCE
DESCRIPTION	• Fails emissions test.
POSSIBLE CAUSE	• Poor fuel quality • Vacuum leakage • Air leakage from intake-air system • Intake-air system restriction or clogging • Variable boost control (VBC) system malfunction • Guide blade actuator position sensor malfunction • Intake shutter valve stuck close • Turbocharger malfunction • Guide blade valve malfunction • Charge air cooler malfunction • Glow system malfunction • EGR system malfunction • EGR cooler malfunction • EGR cooler bypass valve improper operation • Low coolant temperature • Engine overheating • Inadequate fuel pressure • Fuel pressure limiter malfunction (built-in common rail) • Suction control valve inspection (built-in supply pump) • ECT sensor or related circuit malfunction • MAF/IAT sensor related circuit malfunction • IAT sensor No.2 or related circuit malfunction • Fuel pressure sensor or related circuit malfunction • APP sensor or related circuit malfunction • Fuel line clogging or restriction • Supply pump malfunction • Fuel injector malfunction • Incorrect fuel injection timing • Incorrect idle speed • Erratic signal from CKP sensor • Erratic signal from CMP sensor • Boost sensor or related circuit malfunction • Neutral switch or related circuit malfunction • VSS or related circuit malfunction • Low engine compression • Improper valve timing • Base engine malfunction • Exhaust system and/or oxidation catalytic converter restriction • Oxidation catalytic converter malfunction 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 REPAIR PROCEDURE” and “AFTER REPAIR PROCEDURE” described in this manual. (See BEFORE SERVICE PRECAUTION [MZR-CD 2.2].) (See AFTER SERVICE PRECAUTION [MZR-CD 2.2].)

EMISSION COMPLIANCE

DESCRIPTION

• Fails emissions test.

POSSIBLE CAUSE

• Poor fuel quality

• Vacuum leakage

• Air leakage from intake-air system

• Intake-air system restriction or clogging

• Variable boost control (VBC) system malfunction

• Guide blade actuator position sensor malfunction

• Intake shutter valve stuck close

• Turbocharger malfunction

• Guide blade valve malfunction

• Charge air cooler malfunction

• Glow system malfunction

• EGR system malfunction

• EGR cooler malfunction

• EGR cooler bypass valve improper operation

• Low coolant temperature

• Engine overheating

• Inadequate fuel pressure

• Fuel pressure limiter malfunction (built-in common rail)

• Suction control valve inspection (built-in supply pump)

• ECT sensor or related circuit malfunction

• MAF/IAT sensor related circuit malfunction

• IAT sensor No.2 or related circuit malfunction

• Fuel pressure sensor or related circuit malfunction

• APP sensor or related circuit malfunction

• Fuel line clogging or restriction

• Supply pump malfunction

• Fuel injector malfunction

• Incorrect fuel injection timing

• Incorrect idle speed

• Erratic signal from CKP sensor

• Erratic signal from CMP sensor

• Boost sensor or related circuit malfunction

• Neutral switch or related circuit malfunction

• VSS or related circuit malfunction

• Low engine compression

• Improper valve timing

• Base engine malfunction

• Exhaust system and/or oxidation catalytic converter restriction

• Oxidation catalytic converter malfunction

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 REPAIR PROCEDURE” and “AFTER REPAIR PROCEDURE” described in this manual.

(See BEFORE SERVICE PRECAUTION [MZR-CD 2.2].)

(See AFTER SERVICE PRECAUTION [MZR-CD 2.2].)

STEP	INSPECTION	RESULTS	ACTION
1	Is the engine overheating?	Yes	Go to the symptom troubleshooting “NO.19 COOLING SYSTEM CONCERNS—OVERHEATING”. (See NO.19 COOLING SYSTEM CONCERNS-OVERHEATING [MZR-CD 2.2].)
No	Go to the next step.
2	Does the engine run cold?	Yes	Go to the symptom troubleshooting “NO.20 COOLING SYSTEM CONCERNS—RUNS COLD”. (See NO.20 COOLING SYSTEM CONCERNS-RUNS COLD [MZR-CD 2.2].)
No	Go to the next step.
3	Connect the M-MDS to the DLC-2. Perform the self-test function using the M-MDS. Switch the ignition to ON. Retrieve any DTCs. Are any DTCs displayed?	Yes	DTC is displayed: Go to the appropriate DTC test. (See DTC TABLE [MZR-CD 2.2].) Communication error message is displayed: Inspect the following: • Open circuit between main relay and PCM terminal 2C or 2F • Open circuit main relay and PCM terminal 2I • Main relay stuck open • Open or poor ground circuit (PCM terminal 2B, 2E, 2A or 2D) • Poor connection to vehicle body ground
No	No DTC is displayed: Go to the next step.
4	Inspect the following: • Fuel quality (e.g.: including water contamination, winter/summer blend) • Fuel return line clogging and/or restriction • Charge air cooler condition (restriction or damaged) • Intake-air system restriction • Exhaust system and/or oxidation catalytic converter restriction • Vacuum leakage Are all items normal?	Yes	Go to the next step.
No	Service if necessary. Repeat Step 4.
5	Inspect the APP sensor. (See ACCELERATOR PEDAL POSITION (APP) SENSOR INSPECTION [MZR-CD 2.2].) Is the APP sensor normal?	Yes	Go to the next step.
No	Replace the accelerator pedal component. (See ACCELERATOR PEDAL COMPONENT REMOVAL/INSTALLATION [MZR-CD 2.2].)
6	Inspect the neutral switch. (See NEUTRAL SWITCH INSPECTION [MZR-CD 2.2].) Is the neutral switch normal?	Yes	Go to the next step.
No	Repair or replace the malfunctioning part.
7	Inspect the intake shutter valve operation. (See ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZR-CD 2.2].) Is there any malfunction?	Yes	Repair or replace if necessary.
No	Go to the next step.
8	Access and monitor the guide blade actuator position sensor and VBCV PIDs using the M-MDS. Monitor the VBCV_POS using the M-MDS. Command VBCV PID from 0 to 100 % using simulation function. Does the VBCV_POS PID reading change according to VBCV commanded value?	Yes	Go to Step 10.
No	Go to the next step.
9	Inspect the guide blade actuator operation. (See ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZR-CD 2.2].) Is there any malfunction?	Yes	Repair or replace if necessary.
No	Go to the next step.
10	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. If the concern is resolved, the inspection is complete. If the concern still exists, go to the next step.
No	Go to the next step.
11	Inspect for improper operation, kinks, clogging or disconnection on guide blade actuator. (See ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZR-CD 2.2].) Is the actuator normal?	Yes	Go to the next step.
No	Repair or replace if necessary. If the concern is resolved, the inspection is complete. If the concern still exists, turbocharger is normal. Go to the next step.
12	Remove parts necessary to inspect the turbocharger. Do not remove the turbocharger. Inspect if the turbocharger compressor wheel is bent, damaged, or interfering with housing on vehicle. (See TURBOCHARGER INSPECTION [MZR-CD 2.2].) Is there any malfunction?	Yes	Replace the turbocharger. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR-CD 2.2].)
No	Go to the next step.
13	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 [MZR-CD 2.2].)
No	Go to the next step.
14	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 [MZR-CD 2.2].)
15	Inspect if the turbocharger turbine wheel is damaged, cracked or interfering with the housing on vehicle. Note • Inspect all fins on each turbine wheel. Is there any malfunction?	Yes	Replace the turbocharger. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR-CD 2.2].)
No	Go to the next step.
16	Is any engine oil found inside the turbocharger turbine housing?	Yes	Excessive amount of oil is found: Replace the turbocharger. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR-CD 2.2].) Small amount of oil is found: Wipe oil off of the vehicle, then go to the next step.
No	Go to the next step.
17	Is any engine oil found inside the turbocharger compressor hosing?	Yes	Wipe oil off of the vehicle and install all removed parts in Step 12. Then, go to the next step.
No	Turbocharger is normal. Install all parts removed in Step 12. Then, go to the next step.
18	Perform the EGR system inspection. (See ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZR-CD 2.2].) Is the EGR system normal?	Yes	Go to the next step.
No	Repair or replace the malfunctioning part according to EGR valve operation inspection results.
19	Perform the EGR cooler bypass valve operation inspection. (See ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZR-CD 2.2].) Is the EGR bypass valve normal?	Yes	Go to the next step.
No	Repair or replace the malfunctioning part according to EGR bypass valve operation inspection results.
20	Inspect the glow system operation. (See ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZR-CD 2.2].) Is the glow system operation normal?	Yes	Go to the next step.
No	Repair or replace the malfunctioning part according to glow system operation results.
21	Visually inspect the CKP sensor and the teeth of the pulse wheel. (See CRANKSHAFT POSITION (CKP) SENSOR INSPECTION [MZR-CD 2.2].) Are the CKP sensor and the teeth of the pulse wheel normal?	Yes	Go to the next step.
No	Replace malfunctioning parts.
22	Visually inspect the CMP sensor and the teeth of the pulse wheel. (See CAMSHAFT POSITION (CMP) SENSOR INSPECTION [MZR-CD 2.2].) Are the CMP sensor and the teeth of the pulse wheel normal?	Yes	Inspect the following PIDs: (See PCM INSPECTION [MZR-CD 2.2].) • ECT • IAT • MAF • MAP • RPM • VSS If the PID value is not as specified, repair or replace malfunctioning parts. If the PID value is normal, go to the next step.
No	Replace malfunctioning parts.
23	Inspect the fuel pressure sensor. (See FUEL PRESSURE SENSOR INSPECTION [MZR-CD 2.2].) Is the fuel pressure normal?	Yes	Go to the next step.
No	Replace the common rail. (See COMMON RAIL REMOVAL/INSTALLATION [MZR-CD 2.2].)
24	Inspect the suction control valve. (See SUCTION CONTROL VALVE INSPECTION [MZR-CD 2.2].) Is the suction control valve normal?	Yes	Go to the next step.
No	Replace the supply pump. (See SUPPLY PUMP REMOVAL/INSTALLATION [MZR-CD 2.2].)
25	Is the engine compression correct? (See COMPRESSION INSPECTION [MZR-CD 2.2].)	Yes	Go to the next step.
No	Inspect 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 Service if necessary.
26	Inspect the fuel injector. (See FUEL INJECTOR INSPECTION [MZR-CD 2.2].) Is the fuel injector normal?	Yes	Go to the next step.
No	Repair or replace if necessary. (See FUEL INJECTOR REMOVAL/INSTALLATION [MZR-CD 2.2].)
27	Inspect the EGR cooler for the following: • Coolant passage clogging/restriction • Exhaust gas clogging/restriction Is the EGR cooler normal?	Yes	Go to the next step.
No	Service if necessary.
28	Inspect the timing chain for the following: • Chipping of gear teeth • Low tension • Breakage damage or cracks Is the timing chain normal?	Yes	Inspect the following: • ECT sensor • Boost sensor • MAF/IAT sensor • Oxidation catalytic converter • Fuel warmer If normal, remove and inspect the supply pump and common rail.
No	If the timing is incorrect, adjust the valve timing. If the timing chain is not normal, replace the timing chain. (See TIMING CHAIN REMOVAL/INSTALLATION [MZR-CD 2.2].)
29	Verify test results. • If normal, return to the diagnostic index to service any additional symptoms. (See SYMPTOM DIAGNOSTIC INDEX [MZR-CD 2.2].) • If the malfunction remains, inspect the related Service Information and perform repair or diagnosis. ― If the vehicle is repaired, troubleshooting completed. ― If the vehicle is not repaired or additional diagnostic information is not available, reprogram the PCM if later calibration is available. Retest.

STEP

INSPECTION

RESULTS

ACTION

Is the engine overheating?

Yes

Go to the symptom troubleshooting “NO.19 COOLING SYSTEM CONCERNS—OVERHEATING”.

(See NO.19 COOLING SYSTEM CONCERNS-OVERHEATING [MZR-CD 2.2].)

Go to the next step.

Does the engine run cold?

Yes

Go to the symptom troubleshooting “NO.20 COOLING SYSTEM CONCERNS—RUNS COLD”.

(See NO.20 COOLING SYSTEM CONCERNS-RUNS COLD [MZR-CD 2.2].)

Go to the next step.

Connect the M-MDS to the DLC-2.

Perform the self-test function using the M-MDS.

Switch the ignition to ON.

Retrieve any DTCs.

Are any DTCs displayed?

Yes

DTC is displayed:

Go to the appropriate DTC test.

(See DTC TABLE [MZR-CD 2.2].)

Communication error message is displayed:

Inspect the following:

• Open circuit between main relay and PCM terminal 2C or 2F

• Open circuit main relay and PCM terminal 2I

• Main relay stuck open

• Open or poor ground circuit (PCM terminal 2B, 2E, 2A or 2D)

• Poor connection to vehicle body ground

No DTC is displayed:

Go to the next step.

Inspect the following:

• Fuel quality (e.g.: including water contamination, winter/summer blend)

• Fuel return line clogging and/or restriction

• Charge air cooler condition (restriction or damaged)

• Intake-air system restriction

• Exhaust system and/or oxidation catalytic converter restriction

• Vacuum leakage

Are all items normal?

Yes

Go to the next step.

Service if necessary.

Repeat Step 4.

Inspect the APP sensor.

(See ACCELERATOR PEDAL POSITION (APP) SENSOR INSPECTION [MZR-CD 2.2].)

Is the APP sensor normal?

Yes

Go to the next step.

Replace the accelerator pedal component.

(See ACCELERATOR PEDAL COMPONENT REMOVAL/INSTALLATION [MZR-CD 2.2].)

Inspect the neutral switch.

(See NEUTRAL SWITCH INSPECTION [MZR-CD 2.2].)

Is the neutral switch normal?

Yes

Go to the next step.

Repair or replace the malfunctioning part.

Inspect the intake shutter valve operation.

(See ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZR-CD 2.2].)

Is there any malfunction?

Yes

Repair or replace if necessary.

Go to the next step.

Access and monitor the guide blade actuator position sensor and VBCV PIDs using the M-MDS.

Monitor the VBCV_POS using the M-MDS.

Command VBCV PID from 0 to 100 % using simulation function.

Does the VBCV_POS PID reading change according to VBCV commanded value?

Yes

Go to Step 10.

Go to the next step.

Inspect the guide blade actuator operation.

(See ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZR-CD 2.2].)

Is there any malfunction?

Yes

Repair or replace if necessary.

Go to the next step.

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.

If the concern is resolved, the inspection is complete.

If the concern still exists, go to the next step.

Go to the next step.

Inspect for improper operation, kinks, clogging or disconnection on guide blade actuator.

(See ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZR-CD 2.2].)

Is the actuator normal?

Yes

Go to the next step.

Repair or replace if necessary.

If the concern is resolved, the inspection is complete.

If the concern still exists, turbocharger is normal.

Go to the next step.

Remove parts necessary to inspect the turbocharger.

Do not remove the turbocharger.

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

(See TURBOCHARGER INSPECTION [MZR-CD 2.2].)

Is there any malfunction?

Yes

Replace the turbocharger.

(See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR-CD 2.2].)

Go to the next step.

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 [MZR-CD 2.2].)

Go to the next step.

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 [MZR-CD 2.2].)

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

Note

• Inspect all fins on each turbine wheel.

Is there any malfunction?

Yes

Replace the turbocharger.

(See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR-CD 2.2].)

Go to the next step.

Is any engine oil found inside the turbocharger turbine housing?

Yes

Excessive amount of oil is found:

Replace the turbocharger.

(See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR-CD 2.2].)

Small amount of oil is found:

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

Go to the next step.

Is any engine oil found inside the turbocharger compressor hosing?

Yes

Wipe oil off of the vehicle and install all removed parts in Step 12. Then, go to the next step.

Turbocharger is normal.

Install all parts removed in Step 12.

Then, go to the next step.

Perform the EGR system inspection.

(See ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZR-CD 2.2].)

Is the EGR system normal?

Yes

Go to the next step.

Repair or replace the malfunctioning part according to EGR valve operation inspection results.

Perform the EGR cooler bypass valve operation inspection.

(See ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZR-CD 2.2].)

Is the EGR bypass valve normal?

Yes

Go to the next step.

Repair or replace the malfunctioning part according to EGR bypass valve operation inspection results.

Inspect the glow system operation.

(See ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZR-CD 2.2].)

Is the glow system operation normal?

Yes

Go to the next step.

Repair or replace the malfunctioning part according to glow system operation results.

Visually inspect the CKP sensor and the teeth of the pulse wheel.

(See CRANKSHAFT POSITION (CKP) SENSOR INSPECTION [MZR-CD 2.2].)

Are the CKP sensor and the teeth of the pulse wheel normal?

Yes

Go to the next step.

Replace malfunctioning parts.

Visually inspect the CMP sensor and the teeth of the pulse wheel.

(See CAMSHAFT POSITION (CMP) SENSOR INSPECTION [MZR-CD 2.2].)

Are the CMP sensor and the teeth of the pulse wheel normal?

Yes

Inspect the following PIDs:

(See PCM INSPECTION [MZR-CD 2.2].)

• ECT

• IAT

• MAF

• MAP

• RPM

• VSS

If the PID value is not as specified, repair or replace malfunctioning parts.

If the PID value is normal, go to the next step.

Replace malfunctioning parts.

Inspect the fuel pressure sensor.

(See FUEL PRESSURE SENSOR INSPECTION [MZR-CD 2.2].)

Is the fuel pressure normal?

Yes

Go to the next step.

Replace the common rail.

(See COMMON RAIL REMOVAL/INSTALLATION [MZR-CD 2.2].)

Inspect the suction control valve.

(See SUCTION CONTROL VALVE INSPECTION [MZR-CD 2.2].)

Is the suction control valve normal?

Yes

Go to the next step.

Replace the supply pump.

(See SUPPLY PUMP REMOVAL/INSTALLATION [MZR-CD 2.2].)

Is the engine compression correct?

(See COMPRESSION INSPECTION [MZR-CD 2.2].)

Yes

Go to the next step.

Inspect 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

Service if necessary.

Inspect the fuel injector.

(See FUEL INJECTOR INSPECTION [MZR-CD 2.2].)

Is the fuel injector normal?

Yes

Go to the next step.

Repair or replace if necessary.

(See FUEL INJECTOR REMOVAL/INSTALLATION [MZR-CD 2.2].)

Inspect the EGR cooler for the following:

• Coolant passage clogging/restriction

• Exhaust gas clogging/restriction

Is the EGR cooler normal?

Yes

Go to the next step.

Service if necessary.

Inspect the timing chain for the following:

• Chipping of gear teeth

• Low tension

• Breakage damage or cracks

Is the timing chain normal?

Yes

Inspect the following:

• ECT sensor

• Boost sensor

• MAF/IAT sensor

• Oxidation catalytic converter

• Fuel warmer

If normal, remove and inspect the supply pump and common rail.

If the timing is incorrect, adjust the valve timing.

If the timing chain is not normal, replace the timing chain.

(See TIMING CHAIN REMOVAL/INSTALLATION [MZR-CD 2.2].)

Verify test results.

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

(See SYMPTOM DIAGNOSTIC INDEX [MZR-CD 2.2].)

• If the malfunction remains, inspect the related Service Information and perform repair or diagnosis.

― If the vehicle is repaired, troubleshooting completed.

― If the vehicle is not repaired or additional diagnostic information is not available, reprogram the PCM if later calibration is available. Retest.