NO.15 EMISSION COMPLIANCE [MZR 1.8, MZR 2.0, MZR 2.5]


id0103d4802100

15

EMISSION COMPLIANCE

DESCRIPTION
•  Fails emissions test.
POSSIBLE CAUSE
•  Electrical connector disconnection
•  Intake air system and air cleaner element malfunction
•  Vacuum lines leakage or blockage
•  PCM DTC is stored
•  Cooling system malfunction
•  Fuel-filler cap malfunction
•  A/F sensor malfunction
•  Spark plug malfunction
•  Improper operation of ignition system
•  Erratic or no signal from CMP sensor
•  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
•  Charcoal canister malfunction
•  Exhaust system clogging
•  TWC malfunction
•  EGR system malfunction
•  Base engine malfunction
•  Improper engine compression
•  Improper valve timing
•  PCV valve malfunction
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
Inspect the following:
•  Electrical connections
•  Intake air system and air cleaner element concerns: obstructions, leakage or soiling
•  Proper maintenance schedule followed
•  Vacuum lines for leakage or blockage
Is there any malfunction?
Yes
Repair or replace the malfunctioning part according to the inspection results.
Repeat Step 1.
No
Go to the next step.
2
Perform the PCM DTC inspection using the M-MDS.
Are any DTCs present?
Yes
Go to the applicable DTC inspection.
No
Go to the next step.
3
Is any other driveability concern present?
Yes
Go to the applicable symptom troubleshooting.
No
Go to the next step.
4
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 ECT PID using the M-MDS.
Drive the vehicle while monitoring the ECT PID.
Is the ECT PID value within the specification?
Yes
Go to the next step.
No
Inspect the following:
•  Coolant leakage
•  Cooling fan and condenser fan operation
•  Thermostat operation
Repair or replace the malfunctioning part according to the inspection results.
5
Inspect the fuel-filler cap.
Is there any leakage at the fuel-filler cap?
Yes
Replace the fuel-filler cap.
No
Go to the next step.
6
Inspect the A/F sensor.
Is there any malfunction?
Yes
Inspect for followings:
•  Exhaust gas leakage between exhaust manifold and A/F sensor
•  Loose installation of A/F sensor
―  If there is any malfunction:
•  Repair or replace the malfunctioning part according to the inspection results.
―  If there is no malfunction:
No
Go to the next step.
7
Perform the Spark Test.
Is a strong blue spark visible at each cylinder?
Yes
Go to the next step.
No
Repair or replace the malfunctioning part according to the inspection results.
8
Inspect the fuel line pressure.
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.
9
Inspect for fuel saturation inside the charcoal canister.
Is there an excess amount of liquid fuel present in canister?
Yes
Replace the charcoal canister.
No
Inspect the fuel tank vent system, then go to the next step.
10
Visually inspect the exhaust system parts.
Are there any deformed exhaust system parts?
Yes
Repair or replace the malfunctioning part according to the inspection results.
No
Go to the next step.
11
Inspect the TWC.
Is there any malfunction?
Yes
Replace the TWC.
No
Go to the next step.
12
Perform the EGR Control System Inspection.
Is there any malfunction?
Yes
Repair or replace the malfunctioning part according to the inspection results.
No
Go to the next step.
13
Inspect the engine compression.
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 PCV valve.
Is there any malfunction?
Yes
Replace the PCV valve and the oil separator as a single unit, then go to the next step.
No
Inspect the valve timing.
Repair or replace the malfunctioning part according to the inspection results.
15
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.