NO.22 FUEL ODOR (IN ENGINE COMPARTMENT) [MZR-CD 2.2]

22	FUEL ODOR (IN ENGINE COMPARTMENT)
DESCRIPTION	• Fuel smell or visible leakage.
POSSIBLE CAUSE	• Excessive fuel pressure • Suction control valve malfunction (built-in supply pump) • Fuel pressure limiter malfunction (built-in common rail) • Fuel pressure sensor or related circuit malfunction • Fuel leakage • Fuel filter damaged or cracks 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].)

FUEL ODOR (IN ENGINE COMPARTMENT)

DESCRIPTION

• Fuel smell or visible leakage.

POSSIBLE CAUSE

• Excessive fuel pressure

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

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

• Fuel pressure sensor or related circuit malfunction

• Fuel leakage

• Fuel filter damaged or cracks

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	Visually inspect for fuel leakage at the fuel injector and fuel line. Is there any fuel leakage?	Yes	Service if necessary.
No	Go to the next step.
2	Visually inspect for a damaged or cracked fuel filter. Is the fuel filter normal?	Yes	Go to the next step.
No	Replace the fuel filter. (See FUEL FILTER REMOVAL/INSTALLATION [MZR-CD 2.2].)
3	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].)
4	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].)
5	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: Remove and inspect common rail.
6	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

Visually inspect for fuel leakage at the fuel injector and fuel line.

Is there any fuel leakage?

Yes

Service if necessary.

Go to the next step.

Visually inspect for a damaged or cracked fuel filter.

Is the fuel filter normal?

Yes

Go to the next step.

Replace the fuel filter.

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

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].)

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:

Remove and inspect common rail.

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.