NO.5 ENGINE STALLS-AFTER START/AT IDLE [MZR 1.8, MZR 2.0, MZR 2.5]

id0103d4801100

5

ENGINE STALLS—AFTER START/AT IDLE
DESCRIPTION
•  Engine stops unexpectedly at idle and/or after start.
POSSIBLE CAUSE
•  Coil antenna connector or terminals malfunction
•  Instrument cluster or related wiring harness malfunction
•  Immobilizer system malfunction
•  Coil antenna or related wiring harness
•  Air cleaner restriction
•  Improper installation of EGR valve
•  Electrical connector disconnection
•  Poor fuel quality
•  Ignition wiring malfunction
•  Air leakage from intake air system
•  Intake air system restriction
•  Improper operation of electronic throttle control system
•  Vacuum leakage
•  APP sensor or related wiring harness malfunction
•  TP sensor or related wiring harness malfunction
•  PCM continuous memory DTC is stored
•  CKP sensor or related wiring harness malfunction
•  CKP sensor and teeth of crankshaft pulley malfunction
•  Ignition coil or related wiring harness intermittent malfunction
•  Ignition system malfunction
•  Spark plug malfunction
•  Exhaust system part malfunction
•  Excessive or insufficient fuel pressure
―  Fuel pump relay or fuel pump circuit malfunction
―  Clogging fuel line
―  Pressure regulator malfunction (built-in fuel pump unit)
―  Fuel pump unit malfunction
•  Fuel leakage from fuel system
•  Fuel injector malfunction
•  Improper operation of A/C system
•  Purge solenoid valve malfunction
•  Evaporative emission control system malfunction
•  EGR valve malfunction
•  Improper operation of variable valve timing control system (MZR 2.0, MZR 2.5)
•  Low engine compression
•  Improper valve timing
•  PCV valve malfunction
•  Immobilizer system operates
Warning
•  The following troubleshooting flow chart contains the fuel system diagnosis and repair procedures. Read the following warnings before servicing the fuel system:
―  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 injuries 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 1.8, MZR 2.0, MZR 2.5].) (See AFTER SERVICE PRECAUTION [MZR 1.8, MZR 2.0, MZR 2.5].)
Caution
•  Disconnecting/connecting the quick release connector without cleaning it may cause damage to the fuel pipe and the 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
Do the following conditions appear?
•  The engine is not completely started.
•  PCM DTC P1260:00 is displayed.
Yes
Both conditions appear:
•  Go to Step 3.
No
Either condition or other one appears:
•  Go to the next step.
2
Does the engine stall after approx. 2 s from when the engine is started?
Yes
Go to the next step.
No
Immobilizer system is normal.
•  Go to Step 10.
3
Inspect the coil antenna connector and terminals for poor connection (such as damaged/pulled-out pins, corrosion).
Is there any malfunction?
Yes
Repair or replace the connector and/or terminals.
Return to Step 2.
No
Go to the next step.
4
Does the security light flash?
Yes
Go to the next step.
No
Inspect the instrument cluster and related wiring harness.
(See INSTRUMENT CLUSTER INSPECTION.)
Repair or replace the malfunctioning part according to the inspection results.
5
Perform the immobilizer system DTC inspection.
(See DTC INSPECTION [IMMOBILIZER SYSTEM (KEYLESS ENTRY SYSTEM)].)
(See DTC INSPECTION [IMMOBILIZER SYSTEM (ADVANCED KEYLESS ENTRY AND PUSH BUTTON START SYSTEM)].)
Are any DTCs present?
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [IMMOBILIZER SYSTEM (KEYLESS ENTRY SYSTEM)].)
(See DTC TABLE [IMMOBILIZER SYSTEM (ADVANCED KEYLESS ENTRY AND PUSH BUTTON START SYSTEM)].)
No
Go to the next step.
6
Inspect the following wiring harness and connectors:
•  Vehicles without advanced keyless entry and push button start system:
―  Between coil antenna terminal C and instrument cluster terminal 2G
―  Between coil antenna terminal D and instrument cluster terminal 2E
―  Between PCM terminal 1AI and instrument cluster terminal 2W
―  Between PCM terminal 1AM and instrument cluster terminal 2X
•  Vehicles with advanced keyless entry and push button start system:
―  Between coil antenna terminal C and keyless control module terminal 2D
―  Between coil antenna terminal D and keyless control module terminal 2B
―  Between PCM terminal 1AI and keyless control module terminal 2I
―  Between PCM terminal 1AM and keyless control module terminal 2G
Is there any malfunction?
Yes
Repair or replace the suspected wiring harness and connector.
No
Go to the next step.
7
Inspect the following:
•  Air cleaner element
•  Electrical connections
•  Fuel quality (proper octane, contamination, winter/summer blend)
•  Ignition wiring
•  No air leakage from intake air system
•  No restriction of intake air system
•  Proper sealing of intake manifold and components attached to intake manifold: such as EGR valve
•  Smooth operation of throttle valve
•  Vacuum connection
Is there any malfunction?
Yes
Repair or replace the malfunctioning part according to the inspection results.
Repeat Step 7.
No
Go to the next step.
8
Access the APP1 and APP2 PIDs using the M-MDS.
(See ON-BOARD DIAGNOSTIC TEST [MZR 1.8, MZR 2.0, MZR 2.5].)
Crank the engine with the accelerator pedal released.
Are the APP1 and APP2 PIDs indicating that the accelerator pedal is in the released position?
Yes
Go to the next step.
No
Inspect the following:
•  APP sensor
•  Wiring harness between the following terminals and related connectors:
―  APP sensor terminal A—PCM terminal 1W
―  APP sensor terminal B—PCM terminal 1AP
―  APP sensor terminal C—PCM terminal 1AV
―  APP sensor terminal D—PCM terminal 1AS
―  APP sensor terminal E—PCM terminal 1AO
―  APP sensor terminal F—PCM terminal 1AL
Repair or replace the malfunctioning part according to the inspection results.
9
Access the TP_REL PID using the M-MDS.
(See ON-BOARD DIAGNOSTIC TEST [MZR 1.8, MZR 2.0, MZR 2.5].)
Crank the engine with the accelerator pedal released.
Is the TP_REL PID indicating that the accelerator pedal is in the released position?
Yes
Go to the next step.
No
Inspect the following:
•  TP sensor
•  Wiring harness between the following terminals and related connectors:
―  TP sensor terminal A—PCM terminal 2AK
―  TP sensor terminal B—PCM terminal 2AO
―  TP sensor terminal C—PCM terminal 2AL
―  TP sensor terminal D—PCM terminal 2AP
Repair or replace the malfunctioning part according to the inspection results.
10
Perform the KOEO or KOER self test using the M-MDS.
(See KOEO/KOER SELF TEST [MZR 1.8, MZR 2.0, MZR 2.5].)
•  If the engine stalls:
―  Perform the KOEO self test using the M-MDS.
Are there any continuous memory DTCs present?
Yes
Continuous memory DTC is displayed:
•  Go to the applicable DTC inspection.
Communication error message is displayed:
•  Inspect the following:
―  Open circuit in wiring harness between main relay terminal B and PCM terminal 1Q
―  Open circuit in wiring harness between main relay terminal C and PCM terminals 1A, 1B
―  Main relay is stuck open.
―  Open or short circuit in wiring harness between DLC-2 and PCM terminals 1AM and/or 1AI
―  Open or poor ground circuit (PCM terminals 1E, 1F, 1G and 1BE)
―  Poor connection of vehicle body ground
•  Repair or replace the malfunctioning part according to the inspection results.
No
Go to the next step.
11
Attempt to start the engine at part throttle.
Does the engine run smoothly at part throttle.
Yes
Inspect the electronic throttle control system operation.
(See ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZR 1.8, MZR 2.0, MZR 2.5].)
Repair or replace the malfunctioning part according to the inspection results.
No
Go to the next step.
12
Access the RPM PID using the M-MDS.
(See ON-BOARD DIAGNOSTIC TEST [MZR 1.8, MZR 2.0, MZR 2.5].)
Is the RPM PID indicating the engine speed during engine cranking?
Yes
Go to the next step.
No
Inspect the following:
•  Open or short circuit in CKP sensor
•  Open or short circuit between CKP sensor terminal A and body ground
•  Open or short circuit between CKP sensor terminal B and PCM terminal 2W
•  Open or short circuit between CKP sensor terminal C and PCM terminal 2AQ
•  CKP sensor and related wiring harness
Repair or replace the malfunctioning part according to the inspection results.
•  If the CKP sensor and wiring harness are normal:
―  Go to the next step.
13
Visually inspect the CKP sensor and teeth of the crankshaft pulley.
(See CRANKSHAFT POSITION (CKP) SENSOR INSPECTION [MZR 1.8, MZR 2.0, MZR 2.5].)
Is there any malfunction?
Yes
Repair or replace the malfunctioning part according to the inspection results.
No
Go to the next step.
14
Inspect the ignition coil related wiring harness condition (intermittent open or short circuit) for all cylinders.
(See IGNITION COIL INSPECTION [MZR 1.8, MZR 2.0, MZR 2.5].)
Is there any malfunction?
Yes
Repair or replace the suspected wiring harnesses.
No
Go to the next step.
15
Perform the Spark Test.
(See ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZR 1.8, MZR 2.0, MZR 2.5].)
Is a strong blue spark visible at each cylinder?
Yes
Go to the next step.
•  If a symptom occurs with the A/C on:
―  Go to Step 20.
No
Repair or replace the malfunctioning part according to the inspection results.
16
Verify the spark plug conditions when the spark plug removed in Step 15.
(See SPARK PLUG INSPECTION [MZR 1.8, MZR 2.0, MZR 2.5].)
Is the spark plug wet, covered with carbon or grayish white?
Yes
Spark plug is wet or covered with carbon:
•  Inspect for fuel leakage from fuel injector.
Spark plug is grayish white:
•  Inspect the fuel injector for clogging.
Repair or replace the malfunctioning part according to the inspection results.
No
Install the spark plugs on original cylinders, then go to the next step.
17
Visually inspect the exhaust system part.
(See EXHAUST SYSTEM INSPECTION [MZR 1.8, MZR 2.0, MZR 2.5].)
Is there any malfunction?
Yes
Repair or replace the malfunctioning part according to the inspection results.
No
Go to the next step.
18
Inspect the fuel line pressure.
(See FUEL LINE PRESSURE INSPECTION [MZR 1.8, MZR 2.0, MZR 2.5].)
Is there any malfunction?
Yes
Zero or low:
•  Inspect the fuel pump relay and the fuel pump circuit.
•  Inspect the fuel line for clogging.
―  If there is any malfunction:
•  Repair or replace the malfunctioning part according to the inspection results.
―  If there is no malfunction:
•  Replace the fuel pump unit.
High:
•  Replace the fuel pump unit.
No
Go to the next step.
19
Visually inspect for fuel leakage at the fuel injector O-ring and fuel line.
Is the fuel line pressure held after the ignition is off?
Yes
Go to the next step.
No
Inspect the fuel injector.
(See FUEL INJECTOR INSPECTION [MZR 1.8, MZR 2.0, MZR 2.5].)
•  If the fuel injector has malfunction:
―  Replace the fuel injector.
•  If the fuel injector is normal:
―  Replace the fuel pump unit.
20
Note
•  The following test is for stall concerns with the A/C on. If other symptoms exist, go to the next step.
Connect the pressure gauges to the A/C low side and high side pressure lines.
Turn the A/C on and measure the low side and high side pressures.
Are the pressures within the specification?
(See REFRIGERANT PRESSURE CHECK.)
Yes
Go to the next step.
No
If the A/C is always on:
•  Go to the symptom troubleshooting “NO.24 A/C IS ALWAYS ON OR A/C COMPRESSOR RUNS CONTINUOUSLY”.
For other symptoms:
•  Inspect the following:
―  Refrigerant charging amount
―  Condenser fan operation
•  Repair or replace the malfunctioning part according to the inspection results.
21
Disconnect the vacuum hose between the purge solenoid valve and the intake manifold from the purge solenoid valve side.
Plug the open end of the vacuum hose.
Switch the ignition to ON (engine off).
Is the engine stall now eliminated?
Yes
Inspect the following:
•  Purge solenoid valve
•  Evaporative emission control system
Repair or replace the malfunctioning part according to the inspection results.
No
Go to the next step.
22
Is air leakage felt or heard at the intake air system components while racing the engine to higher speed?
Yes
Repair or replace the malfunctioning part according to the inspection results.
No
Go to the next step.
23
Inspect the engine condition while tapping the EGR valve housing.
Does the engine condition improve?
Yes
Replace the EGR valve.
(See EGR VALVE REMOVAL/INSTALLATION [MZR 1.8, MZR 2.0, MZR 2.5].)
No
MZR 1.8:
•  Go to Step 25.
MZR 2.0, MZR 2.5:
•  Go to the next step.
24
Perform the Variable Valve Timing Control System Operation Inspection.
(See ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZR 1.8, MZR 2.0, MZR 2.5].)
Is there any malfunction?
Yes
Repair or replace the malfunctioning part according to the inspection results.
No
Go to the next step.
25
Inspect the engine compression.
(See COMPRESSION INSPECTION [MZR 1.8, MZR 2.0, MZR 2.5].)
Is there any malfunction?
Yes
Repair or replace the malfunctioning part according to the inspection results.
No
Go to the next step.
26
Inspect the PCV valve.
(See POSITIVE CRANKCASE VENTILATION (PCV) VALVE INSPECTION [MZR 1.8, MZR 2.0, MZR 2.5].)
Is there any malfunction?
Yes
Replace the PCV valve.
(See POSITIVE CRANKCASE VENTILATION (PCV) VALVE REMOVAL/INSTALLATION [MZR 1.8, MZR 2.0, MZR 2.5].)
No
Inspect the valve timing.
(See VARIABLE VALVE TIMING ACTUATOR INSPECTION [MZR 2.0, MZR 2.5].)
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.
•  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.