NO.15 EMISSION COMPLIANCE [MZR 2.0 DISI]

id0103d5802100

15

EMISSION COMPLIANCE
DESCRIPTION
•  Fails emissions test.
POSSIBLE CAUSE
•  Engine overheating
•  Cooling system malfunction
•  PCM DTC is stored
•  Poor fuel quality
•  Air cleaner element clogging or restriction
•  Air leakage from intake-air system
•  Vacuum lines leakage or blockage
•  Fuel leakage
•  Charcoal canister damage
•  Exhaust system and/or TWC restriction
•  Clutch slippage (MTX)
•  EGR system malfunction
•  Improper operation of electronic throttle control system
•  Throttle body malfunction
•  Variable swirl system malfunction
•  Spark plug malfunction
•  Erratic or no signal from CMP sensor
•  Erratic signal from CKP sensor
•  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
―  Improper air/fuel mixture ratio control operation
―  TP sensor or related circuit malfunction
•  Inadequate fuel pressure (high-pressure side)
―  Fuel pressure sensor or related circuit malfunction
―  High pressure fuel pump malfunction
―  Spill valve control solenoid valve control circuit malfunction (damage to driver in PCM caused by short circuit to ground system)
―  Spill valve control solenoid valve (built-in high pressure fuel pump) malfunction
―  Relief valve (built-in fuel delivery pipe) malfunction
―  Fuel line restriction
―  Fuel pump unit malfunction
•  TWC malfunction
•  Incorrect fuel injection timing
•  Fuel injector or related circuit malfunction
•  Improper engine compression
•  Engine internal parts malfunction
•  Excessive carbon is built-up in combustion chamber
•  Improper valve timing
•  PCV valve malfunction or incorrect valve installation
•  Injector driver (built-in PCM) 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 SERVICE PRECAUTION” and “AFTER SERVICE PRECAUTION” described in this manual. (See BEFORE SERVICE PRECAUTION [MZR 2.0 DISI].) (See AFTER SERVICE PRECAUTION [MZR 2.0 DISI].)
Caution
•  Disconnecting/connecting the quick release connector without cleaning it may possibly cause damage to the fuel pipe and 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
Is the engine overheating?
Yes
Perform the symptom troubleshooting “NO.17 COOLING SYSTEM CONCERNS-OVERHEATING”.
(See NO.17 COOLING SYSTEM CONCERNS-OVERHEATING [MZR 2.0 DISI].)
No
Go to the next step.
2
Is the engine runs cold?
Yes
Perform the symptom troubleshooting “NO.18 COOLING SYSTEM CONCERNS-RUNS COLD”.
(See NO.18 COOLING SYSTEM CONCERNS-RUNS COLD [MZR 2.0 DISI].)
No
Go to the next step.
3
Retrieve any PCM DTCs using the M-MDS.
(See ON-BOARD DIAGNOSTIC TEST [MZR 2.0 DISI].)
Are any DTCs present?
Yes
Go to the applicable DTC inspection.
(See DTC TABLE [MZR 2.0 DISI].)
No
Go to the next step.
4
Inspect for following:
•  Fuel quality (proper octane, contamination, winter/summer blend)
•  Air cleaner element (clogging or restriction)
•  Intake-air system leakage
•  Vacuum line leakage or blockage
•  Fuel leakage at fuel system
•  Charcoal canister damaged
•  Exhaust system and/or TWC restriction
•  Clutch slippage (MTX)
Is there any malfunction?
Yes
Service if necessary.
•  Repeat this step.
No
Go to the next step.
5
Perform the EGR Control System Inspection.
(See ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZR 2.0 DISI].)
Does the EGR system operate properly?
Yes
Go to the next step.
No
Repair or replace the malfunctioning part according to the inspection results.
6
Perform the TP sweep inspection.
(See ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZR 2.0 DISI].)
Does the electronic throttle control system work properly?
Yes
Visually inspect the throttle body (damage/scratching).
•  If there is any malfunction:
―  Repair or replace the malfunctioning part according to the inspection results.
•  If there is no malfunction:
―  Go to the next step.
No
Repair or replace the malfunctioning part according to the inspection results.
7
Perform the Variable Swirl System Operation Inspection.
(See ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZR 2.0 DISI].)
Does the variable swirl system work properly?
Yes
Go to the next step.
No
Repair or replace the malfunctioning part according to the inspection results.
8
Perform the Spark Test.
(See ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZR 2.0 DISI].)
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.
9
Inspect the CMP sensor and CKP sensor for the following:
•  Installation condition
•  Damaged trigger wheel and camshaft
•  Open or short circuit in related circuit
Is there any malfunction?
Yes
Repair or replace the malfunctioning part according to the inspection results.
No
Go to the next step.
10
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 following PIDs using the M-MDS:
(See ON-BOARD DIAGNOSTIC TEST [MZR 2.0 DISI].)
•  APP
•  ECT
•  IAT
•  LONGFT1
•  MAF
•  MAP
•  O2S11
•  O2S12
•  SHTFT1
•  TP
•  VSS
Do the PIDs indicate the correct values under the trouble condition?
(See PCM INSPECTION [MZR 2.0 DISI].)
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.
11
Access the FUEL_PRES PID using the M-MDS.
(See ON-BOARD DIAGNOSTIC TEST [MZR 2.0 DISI].)
Is the FUEL_PRES PID value within the specification?
(See PCM INSPECTION [MZR 2.0 DISI].)
Yes
Go to Step 16.
No
Go to the next step.
12
Is the vehicle accelerate performance normally?
Yes
Go to the next step.
No
Go to Step 14.
13
Inspect the fuel pressure sensor.
(See FUEL PRESSURE SENSOR INSPECTION [MZR 2.0 DISI].)
Is there any malfunction?
Yes
Replace the fuel delivery pipe.
(See FUEL INJECTOR REMOVAL/INSTALLATION [MZR 2.0 DISI].)
No
Go to Step 16.
14
Switch the ignition to off.
Disconnect the high pressure fuel pump and PCM connectors.
Inspect for continuity between high pressure fuel pump terminal A (wiring harness-side) and body ground.
Is there continuity?
Yes
Repair or replace the wiring harness for a possible short to ground.
•  If the malfunction remains:
―  Replace the PCM. (damage to driver in PCM)
No
Go to the next step.
15
Replace the high pressure fuel pump.
(See HIGH PRESSURE FUEL PUMP REMOVAL/INSTALLATION [MZR 2.0 DISI].)
Access the FUEL_PRES PID using the M-MDS.
(See ON-BOARD DIAGNOSTIC TEST [MZR 2.0 DISI].)
Is the FUEL_PRES PID value within the specification?
(See PCM INSPECTION [MZR 2.0 DISI].)
Yes
High pressure fuel pump or spill valve control solenoid valve (built-in high pressure fuel pump) malfunction.
•  Symptom troubleshooting is completed.
•  Go to Step 21.
No
Relief valve (built-in fuel delivery pipe) malfunction.
•  Replace the fuel delivery pipe.
16
Connect the fuel pressure gauge between fuel pump and high pressure fuel pump.
Measure the low side fuel pressure.
(See FUEL LINE PRESSURE INSPECTION [MZR 2.0 DISI].)
Is the low side fuel pressure within the specification?
Yes
Go to the next step.
No
Inspect for following:
•  Fuel line restriction
•  Fuel filter 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.
17
Inspect the TWC.
(See EXHAUST SYSTEM INSPECTION [MZR 2.0 DISI].)
Is there any malfunction?
Yes
Replace the TWC.
(See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR 2.0 DISI].)
No
Go to the next step.
18
Perform the Fuel Injector Operation Inspection.
(See ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZR 2.0 DISI].)
Do the fuel injectors operate properly?
Yes
Go to the next step.
No
Repair or replace the malfunctioning part according to the inspection results.
19
Measure the compression pressure for each cylinder.
(See COMPRESSION INSPECTION [MZR 2.0 DISI].)
Are the compression pressures within the specification?
Yes
Go to the next step.
No
Inspect for 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.
20
Inspect the PCV valve.
(See POSITIVE CRANKCASE VENTILATION (PCV) VALVE INSPECTION [MZR 2.0 DISI].)
Is there any malfunction?
Yes
Replace the PCV valve.
(See POSITIVE CRANKCASE VENTILATION (PCV) VALVE REMOVAL/INSTALLATION [MZR 2.0 DISI].)
No
Injector driver is malfunction.
•  Replace the PCM.
If the malfunction remains:
•  Overhaul the engine.
21
Verify the test results.
•  If normal, return to the diagnostic index to service any additional symptoms. (See SYMPTOM DIAGNOSTIC INDEX [MZR 2.0 DISI].)
•  If a 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, replace the PCM. (See PCM REMOVAL/INSTALLATION [MZR 2.0 DISI].)