NO.19 EXHAUST SMOKE [MZR 1.8, MZR 2.0, MZR 2.5]

id0103d4803900

19

EXHAUST SMOKE
DESCRIPTION
•  Blue, black, or white smoke from exhaust system.
POSSIBLE CAUSE
Blue smoke (Burning oil):
•  PCV valve malfunction
•  Engine internal oil leakage
White smoke (Water in combustion):
•  Cooling system malfunction (coolant loss)
•  Engine internal coolant leakage
Black smoke (Rich fuel mixture):
•  Air cleaner restriction
•  Intake air system is collapsed or restricted
•  Fuel return line is restricted
•  PCM DTC is stored
•  Erratic signal to PCM
―  APP sensor or related circuit malfunction
―  ECT sensor or related circuit malfunction
―  IAT sensor or related circuit malfunction
―  MAF sensor or related circuit malfunction
―  MAP sensor or related circuit malfunction
―  A/F sensor or related circuit malfunction
―  HO2S or related circuit malfunction
―  TP sensor or related circuit 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
•  CMP sensor malfunction
•  Ignition system malfunction
•  Improper engine compression
•  Improper fuel injection timing and amount
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
What color is the smoke coming from the exhaust system?
Blue
Burning oil is indicated:
•  Go to the next step.
White
Water in the combustion is indicated:
•  Go to Step 3.
Black
Rich fuel mixture is indicated:
•  Go to Step 4.
2
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 and the oil separator as a single unit, then go to the next step.
(See POSITIVE CRANKCASE VENTILATION (PCV) VALVE REMOVAL/INSTALLATION [MZR 1.8, MZR 2.0, MZR 2.5].)
No
Inspect the following:
•  Blocked oil drain passage in the cylinder head
•  Damaged cylinder bore
•  Damaged valve guide, stems or valve seals
•  Piston ring is not seated, seized or worn.
Repair or replace the malfunctioning part according to the inspection results.
•  If other drivability symptoms are present:
―  Return to the diagnostic index to service any additional symptoms.
3
Does the cooling system hold pressure?
Yes
Inspect the following:
•  Cracked or porous engine block
•  Cylinder head gasket leakage
•  Intake manifold gasket leakage
If other drivability symptoms are present:
•  Return to the diagnostic index to service any additional symptoms.
No
Inspect for cause.
Repair or replace the malfunctioning part according to the inspection results.
4
Inspect the following:
•  Air cleaner restriction
•  Collapsed or restricted intake air system
•  Restricted fuel return line
Is there any malfunction?
Yes
Repair or replace the malfunctioning part according to the inspection results.
Repeat Step 4.
No
Go to the next step.
5
Perform the PCM DTC inspection using the M-MDS.
(See ON-BOARD DIAGNOSTIC TEST [MZR 1.8, MZR 2.0, MZR 2.5].)
Are any DTCs present?
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [MZR 1.8, MZR 2.0, MZR 2.5].)
No
Go to the next step.
6
Access the following PIDs using the M-MDS:
(See ON-BOARD DIAGNOSTIC TEST [MZR 1.8, MZR 2.0, MZR 2.5].)
•  APP1
•  APP2
•  ECT
•  IAT
•  MAF
•  MAP
•  O2S11
•  O2S12
•  TP1
•  TP2
•  VSS
Monitor the PIDs under the black smoke appeared engine condition.
Do the PIDs indicate normal according to engine conditions?
(See PCM INSPECTION [MZR 1.8, MZR 2.0, MZR 2.5].)
Yes
Go to the next step.
No
APP1, APP2 PIDs are not specified:
•  Inspect if the output signal from the APP sensor changes smoothly.
ECT PID is not specified:
•  Inspect for an intermittent open circuit of the ECT sensor and the related wiring harness.
IAT PID is not specified:
•  Inspect for an intermittent open circuit of the IAT sensor and the related wiring harness.
MAF PID is not specified:
•  Inspect for an intermittent open circuit of the MAF sensor and the related wiring harness.
MAP PID is not specified:
•  Inspect for an intermittent open circuit of the MAP sensor and the related wiring harness.
O2S11 PID is not specified:
•  Inspect for an intermittent open circuit of the A/F sensor and the related wiring harness.
O2S12 PID is not specified:
•  Inspect for an intermittent open circuit of the HO2S and the related wiring harness.
TP1, TP2 PIDs are not specified:
•  Inspect if the output signal from the TP sensor changes smoothly.
VSS PID is not specified:
•  Inspect for an intermittent open circuit in the VSS and related wiring harness.
Repair or replace the malfunctioning part according to the inspection results.
7
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 same PIDs as Step 6 using the M-MDS under the trouble condition.
(See ON-BOARD DIAGNOSTIC TEST [MZR 1.8, MZR 2.0, MZR 2.5].)
Do the PIDs indicate the correct values under the trouble condition?
(See PCM INSPECTION [MZR 1.8, MZR 2.0, MZR 2.5].)
Yes
Go to the next step.
No
Repair or replace the malfunctioning part according to the inspection results.
•  If the malfunction remains:
―  Perform the “INTERMITTENT CONCERN TROUBLESHOOTING” procedure.
8
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.
9
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.
No
Repair or replace the malfunctioning part according to the inspection results.
10
Inspect the CMP sensor.
(See CAMSHAFT POSITION (CMP) 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.
11
Measure the compression pressure for each cylinder.
(See COMPRESSION INSPECTION [MZR 1.8, MZR 2.0, MZR 2.5].)
Are the compression pressures within the specification?
Yes
Inspect the fuel injector for each cylinder.
(See FUEL INJECTOR INSPECTION [MZR 1.8, MZR 2.0, MZR 2.5].)
Replace the suspected fuel injector.
(See FUEL INJECTOR REMOVAL/INSTALLATION [MZR 1.8, MZR 2.0, MZR 2.5].)
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
Repair or replace the malfunctioning part according to the inspection results.
12
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.