ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZR-CD 2.2]


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Guide Blade Actuator Operation Inspection

1.  Connect M-MDS to DLC-2.

2.  Start the engine and run it at idle.

3.  Access the PCM PIDs VBCV and VBC_POS.

4.  Command the VBCV PID from 0 to 100 % using active command mode function.

5.  Verify that the VBC_POS PID reading change according to VBCV commanded value.

•  If the VBC_POS PID cannot be verified inspect for followings;
―  Guide blade actuator (See GUIDE BLADE ACTUATOR INSPECTION [MZR-CD 2.2].)
―  Vacuum hose connection between the vacuum chamber and the guide blade actuator through the VBC solenoid valve (See INTAKE-AIR SYSTEM VACUUM HOSE ROUTING DIAGRAM [MZR-CD 2.2].)
―  Guide blade actuator position sensor (built in turbocharger)(See GUIDE BLADE ACTUATOR INSPECTION [MZR-CD 2.2].)


Glow Plug Control Operation Inspection

1.  Verify that the battery is charged fully.

2.  If not, charge the battery.

3.  Connect the M-MDS to the DLC-2.

4.  Switch the ignition to ON.

5.  Access and monitor the PCM PIDs VPWR and GPC.

6.  Verify that the VPWR PID drops 0.3 V or more while the GPC is turned on from off using the active command mode function.

•  If it cannot be verified, inspect the followings;
―  Glow plug relay
―  Glow plug
―  Wiring harness for battery positive post—glow plug relay—glow plug
―  Wiring harness for PCM terminal 1BT—glow plug relay—ground


Intake Shutter Valve Operation Inspection

1.  Connect the M-MDS to the DLC-2.

2.  Start the engine and run it at idle.

3.  Access and monitor the PCM PIDs ETC_DSD, TP and MAP.

4.  Verify that the MAP PID increases and TP PID increases linearly, while increasing the opening angle of the intake shutter valve using the active command mode function of ETC_DSD.

•  If both PIDs do not increase according to the intake shutter valve opening angle, inspect using the following steps.
1.  Remove the intake shutter valve with connector connected.
2.  Verify that the intake shutter valve opens and closes while it is operated using the active command mode function of the ETC_DSD.
―  If not verified, retest after cleaning the intake shutter valve and inspecting related wiring harness and connectors.
3.  If the intake shutter valve does not operate, replace the intake shutter valve.
•  If the MAP PID increases but TP PID does not increase linearly according to the intake shutter valve opening angle inspect using the following steps.
1.  Inspect the intake shutter valve position sensor related wiring harness and connector.
2.  Remove the intake shutter valve with the connector connected.
3.  Verify that the TP PID increases and decreases linearly while the intake shutter valve is operated using the active command mode function of ETC_DSD.
―  If the TP PID does not increase and decrease linearly, replace the intake shutter valve.
•  If the TP PID increases linearly but the MAP PID does not increase according to the intake shutter valve opening angle inspect using the following steps.
1.  Inspect air for leakage at the intake shutter valve and cylinder head.
2.  If normal, inspect and replace the MAP sensor.


Brake override system operation inspection (From GH1***-442043, GH10**-210449)

Note
•  If the brake override system operates normally after performing the following inspection, the PCM detects DTC P2299:00.

1.  Start the engine and run it is idling.

2.  Verify that the engine speed becomes approx. 1,200 rpm under the following conditions.

•  Neutral
•  Engine speed of 1,150 rpm or more other than idle
•  Brake pedal depressed
―  If the engine speed becomes approx. 1,200 rpm, clear the PCM DTC using the M-MDS. (System operation is normal.)
―  If the engine speed does not become approx. 1,200 rpm, inspect for the following parts, then repair or replace the malfunctioning part:
•  Neutral switch (See NEUTRAL SWITCH INSPECTION [MZR-CD 2.2].)
•  Brake switch No.1 (See BRAKE SWITCH INSPECTION.)
•  Brake switch No.2 (See BRAKE SWITCH INSPECTION.)


EGR Valve Operation Inspection

1.  Crank the engine and verify that the EGR valve operation (initial operation) sound is heard.

•  If the operation sound is not heard, connect the M-MDS to the DLC-2 and verify that the DTC P0403:00 is shown. Perform the DTC inspection. (See DTC TABLE [MZR-CD 2.2].)

2.  Start the engine run it at idle.

3.  Access and monitor the PCM PIDs EGRP and MAP.

4.  Verify that the MAP PID increases while increase the opening value of the EGR valve from 0 % to 100 % using the EGRP PID of active command mode function.

•  If both PIDs do not increase according to the EGR valve opening values, inspect using the following steps.
1.  Remove the EGR valve with the connector connected.
2.  Verify that the EGR valve opens and closes while it is operated using the active command mode function of EGRP.
―  If not verified, retest after cleaning the EGR valve and inspecting the related harness and connectors.
3.  If the EGR valve does not operate, replace the EGR valve.
•  If the MAP PID increases but the EGRP PID does not increase linearly according to the EGR valve opening values, inspect using the following steps.
1.  Inspect the EGR valve position sensor related harness and connector.
2.  Remove the EGR valve with the connector connected.
3.  Verify that the EGRP PID increases and decreases linearly while increasing the EGR valve steps using active command mode function of the EGRP.
―  If the EGRP PID does not increase and decrease linearly, replace the EGR valve.
•  If the EGRP PID increases linearly but MAP PID does not increase according to the EGR valve opening values, inspect using the following steps.
1.  Inspect for leakage between the exhaust manifold and surge tank.
2.  If normal, inspect and replace MAP sensor.


EGR Cooler Bypass Valve Operation Inspection

1.  Connect the M-MDS to DLC-2.

2.  Retrieve the DTC.

3.  Verify that the DTC P245C:00, P245D:00 are not displayed.

•  If the DTC P245C:00, P245D:00 is displayed, perform the suspect DTC troubleshooting procedure. (See DTC P245C:00 [MZR-CD 2.2].) (See DTC P245D:00 [MZR-CD 2.2].)

4.  Disconnect the vacuum hose at EGR cooler bypass valve actuator.

5.  Access the PCM PID EGR_C_BP.

6.  Start the engine and run it at idle.

7.  Verify that the vacuum condition is following table while the PID EGR_C_BP is ON and OFF using the active command mode function.

EGR_C_BP PID

ON

OFF

Vacuum
Applied
Not applied

•  If the vacuum condition changes are not verified, inspect and repair or replace for followings:
―  EGR cooler bypass solenoid valve (stuck)
―  Vacuum hoses between vacuum pump and EGR cooler bypass valve actuator through EGR cooler bypass solenoid valve (damage, clogging, poor connection)
•  If the vacuum condition changes are verified, inspect the EGR cooler bypass valve actuator. (See EGR COOLER BYPASS VALVE INSPECTION [MZR-CD 2.2].)


Fuel Injector Operation Inspection

1.  Connect the M-MDS to the DLC-2.

2.  Start the engine and warm it up to normal operating temperature.

3.  Perform the KOER self-test. (See KOEO/KOER SELF TEST [MZR-CD 2.2].)

4.  Verify that DTCs P0201:00, P0202:00, P0203:00 and/or P0204:00 are not shown using the KOER self-test.

•  If DTC P0201:00, P0202:00, P0203:00 and/or P0204:00 are shown, perform the DTC troubleshooting procedure. (See DTC TABLE [MZR-CD 2.2].)

5.  Verify that the engine speed drops or stalls when each cylinder fuel injector turns to off from on using the M-MDS active command mode function.

•  If it cannot be verified, inspect the following for the suspected cylinder;
―  Fuel injector (See FUEL INJECTOR INSPECTION [MZR-CD 2.2].)
―  Wiring harness for PCM—fuel injector


Cooling Fan Control System Inspection

1.  Connect the M-MDS to the DLC-2.

2.  Perform the KOEO or KOER self test and verify that DTCs P0117:00 and/or P0118:00 are not shown using the KOEO and/or KOER self test. (See KOEO/KOER SELF TEST [MZR-CD 2.2].)

•  If DTCs P0117:00 and/or P0118:00 are shown, perform the applicable DTC troubleshooting procedure. (See DTC P0117:00 [MZR-CD 2.2].) (See DTC P0118:00 [MZR-CD 2.2].)

3.  Start the engine and let it at idle with ECT is below 97 °C {207 °F}.

4.  Verify that the cooling fans are not operating when A/C switch and fan switch are turned off.

•  If the cooling fan is operating, inspect for the following based on cooling fans status:

Cooling fan status

Inspection item

Cooling fan No.1

Cooling fan No.2

Low
Stop
•  Cooling fan relay No.1 (Stuck close)
•  Wiring harness in cooling fan relay No.1—cooling fan No.1 (Short to power supply circuit)
Stop
Low
•  Cooling fan relay No.4 (Stuck close)
•  Wiring harness in cooling fan relay No.4—cooling fan No.1 (Short to power supply circuit)
Low
Low
•  Wiring harness between refrigerant pressure switch (low, high) and PCM terminal 1AF (Short to ground) (PCM PID AC_REQ is always ON)
High
Middle
•  Wiring harness between refrigerant pressure switch (low, high) and PCM terminal 1AF (Short to ground) (PCM PID AC_REQ is always ON)

5.  Using the M-MDS simulation function, turn FAN1 and FAN3 from the off position to the ON position, and verify that cooling fans No.1 and No.2 operate at low speed.

•  If the operation could not be confirmed, inspect for the following based on cooling fans status:

Cooling fan status

Inspection item

Cooling fan No.1

Cooling fan No.2

Stop
Low
•  Cooling fan relay No.1 (Stuck open)
•  Wiring harness in battery—cooling fan relay No.1—cooling fan No.1 (Open circuit, Fuse is melt by short to ground)
•  Wiring harness in cooling fan No.1—body ground (Open circuit)
•  Cooling fan No.1 (Internal circuit open)
Low
Stop
•  Cooling fan relay No.4 (Stuck open)
•  Wiring harness in battery—cooling fan relay No.4—cooling fan No.2 (Open circuit, Fuse is melt by short to ground)
•  Wiring harness in cooling fan No.2—body ground (Open circuit)
•  Cooling fan No.2 (Internal circuit open)
Middle
Middle
•  Cooling fan relay No.2 (Stuck close)
•  Wiring harness in cooling fan relay No.2—cooling fan No.1 (Short to ground)
•  Wiring harness in cooling fan relay No.2—cooling fan No.2 (Short to ground)
•  Cooling fan relay No.3 (Stuck close)
•  Wiring harness in cooling fan relay No.3—cooling fan No.1 (Short to power supply circuit)
•  Wiring harness in cooling fan relay No.3—cooling fan No.2 (Short to power supply circuit)

6.  Using the M-MDS simulation function, turn FAN1 and FAN2 from the off position to the ON position, and verify that cooling fan No.1 operates at high speed and cooling fan No.2 operates at middle speed.

•  If the operation could not be confirmed, inspect for the following based on cooling fans status:

Cooling fan status

Inspection item

Cooling fan No.1

Cooling fan No.2

High
Stop
•  Wiring harness in cooling fan relay No.3—cooling fan No.2 (Open circuit)
•  Cooling fan No.2 (Internal circuit open)
Low
Stop
•  Cooling fan relay No.3 (Stuck open)
•  Wiring harness in battery—cooling fan relay No.3—branch point between cooling fans No.1 and No.2 (Open circuit, Fuse is melt by short to ground)
•  Wiring harness in cooling fan relay No.3—cooling fan No.1 (Fuse is melt by short to ground)
•  Wiring harness in cooling fan relay No.3—cooling fan No.2 (Fuse is melt by short to ground)
Middle
Low
•  Cooling fan relay No.2 (Stuck open)
•  Wiring harness in cooling fan No.2—body ground (Open circuit)
High
Low
•  Wiring harness in cooling fan No.2—cooling fan relay No.2 (Open circuit)
•  Cooling fan No.2 (Internal circuit open)
Middle
Middle
•  Wiring harness in cooling fan No.1—cooling fan relay No.2 (Open circuit)
•  Cooling fan No.1 (Internal circuit open)

7.  Using the M-MDS simulation function, turn FAN1, FAN2, and FAN3 from the off position to the ON position, and verify that cooling fans No.1 and No.2 operate at high speed.

•  If the operation could not be confirmed, inspect for the following based on cooling fans status:

Cooling fan status

Inspection item

Cooling fan No.1

Cooling fan No.2

High
Middle/Low
•  Cooling fan No.2 (Internal circuit open)


A/C Cut-off Control System Inspection

1.  Start the engine.

2.  Turn the A/C switch and the fan switch on.

3.  Verify that the A/C compressor magnetic clutch actuates.

•  If it does not actuate, go to symptom troubleshooting “NO.25 A/C DOES NOT WORK SUFFICIENTLY”.
(See NO.25 A/C DOES NOT WORK SUFFICIENTLY [MZR-CD 2.2].)

4.  Fully open the throttle valve and verify that the A/C compressor magnetic clutch does not actuate for 2—5 s.

•  If it actuates, inspect as follows:
―  A/C relay
―  Open or short to ground circuit in wiring harness and connectors (Ignition switch (without advanced keyless entry and push button start)/block relay (with advanced keyless entry and push button start—A/C relay—PCM terminal 1BX)
―  A/C related parts
―  APP1, APP2 PIDs