NO.6 HARD START/LONG CRANK/ERRATIC START/ERRATIC CRANK [MZR-CD 2.2]

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6

HARD START/LONG CRANK/ERRATIC START/ERRATIC CRANK
DESCRIPTION
•  Starter cranks the engine at the normal speed but the engine requires excessive cranking time before starting.
•  Battery is in normal condition.
POSSIBLE CAUSE
•  Poor fuel quality
•  Intake-air system restriction or clogging
•  Starting system malfunction
•  Inadequate fuel pressure
―  Fuel pressure limiter malfunction (built-in common rail)
―  Suction control valve control circuit malfunction (damaged to driver in PCM caused by short circuit to ground system)
―  Suction control valve malfunction (built-in supply pump)
―  Supply pump malfunction
•  Engine overheating
•  Glow system malfunction
•  Fuel warmer malfunction
•  Fuel filter clogging or restriction
•  Fuel line clogging or restriction
•  Fuel leakage
•  Exhaust system and/or oxidation catalytic converter restriction or clogging
•  Diesel particulate filter restriction
•  Incorrect fuel injection timing
•  Erratic signal from CKP sensor
•  Erratic signal from CMP sensor
•  ECT sensor or related circuit malfunction
•  APP sensor or related circuit malfunction
•  MAF/IAT sensor or related circuit malfunction
•  Fuel pressure sensor or related circuit malfunction
•  Fuel injector malfunction
•  Low engine compression
•  Improper valve timing
•  EGR system 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-CD 2.2].) (See AFTER SERVICE PRECAUTION [MZR-CD 2.2].)

Diagnostic Procedure

STEP

INSPECTION

RESULTS

ACTION
1
Inspect the following:
•  Fuel quality (e.g.: include water contamination, winter/summer blend)
•  Fuel line/fuel filter clogging
•  Intake-air system restriction
Are all items normal?
Yes
Go to the next step.
No
Service if necessary.
Repeat Step 1.
2
Is the engine overheating?
Yes
Go to the symptom troubleshooting “NO.19 COOLING SYSTEM CONCERNS-OVERHEATING”.
(See NO.19 COOLING SYSTEM CONCERNS-OVERHEATING [MZR-CD 2.2].)
No
Go to the next step.
3
Retrieve any PCM DTCs using the M-MDS.
(See ON-BOARD DIAGNOSTIC TEST [MZR-CD 2.2].)
Are any DTCs displayed?
Yes
DTC is displayed:
•  Go to the applicable DTC inspection.
Communication error message is displayed:
•  Open circuit in wiring harness between main relay terminal E and PCM terminal 2I
•  Open circuit in wiring harness between main relay terminal C and PCM terminals 2C, 2F
•  Main relay is stuck open.
•  Open or poor ground circuit (PCM terminals 2A, 2B, 2D and 2E)
•  Poor connection of vehicle body ground
No
Go to the next step.
4
Start and warm up the engine to normal operating temperature.
Verify the diesel particulate filter indicator light condition.
Does the diesel particulate filter indicator light illuminate or flash?
Yes
Diesel particulate filter indicator light illuminates:
•  Perform the manual diesel particulate filter regeneration procedure.
Diesel particulate filter indicator light flashes:
•  Go to the symptom troubleshooting “NO.4 DIESEL PARTICULATE FILTER INDICATOR LIGHT FLASHES”.
No
Go to the next step.
5
Does the engine start normally after warm-up?
Yes
Inspect the glow system operation.
(See ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZR-CD 2.2].)
Inspect the fuel warmer.
(See FUEL WARMER INSPECTION [MZR-CD 2.2].)
•  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
Go to the next step.
6
Is there any restriction in the exhaust system or oxidation catalytic converter?
Yes
Repair or replace if necessary.
No
Go to the next step.
7
Inspect for fuel leakage from the fuel pipe.
Is there any leakage?
Yes
Repair or replace the malfunctioning part according to the inspection results.
No
Go to the next step.
8
Inspect the APP sensor.
(See ACCELERATOR PEDAL POSITION (APP) SENSOR INSPECTION [MZR-CD 2.2].)
Is there any malfunction?
Yes
Replace the accelerator pedal component.
(See ACCELERATOR PEDAL COMPONENT REMOVAL/INSTALLATION [MZR-CD 2.2].)
No
Go to the next step.
9
Visually inspect the CKP sensor and teeth of pulse wheel.
(See CRANKSHAFT POSITION (CKP) SENSOR INSPECTION [MZR-CD 2.2].)
Are the CKP sensor and teeth of pulse wheel normal?
Yes
Go to the next step.
No
Repair or replace the malfunctioning part according to the inspection results.
10
Visually inspect the CMP sensor and teeth of pulse wheel.
(See CAMSHAFT POSITION (CMP) SENSOR INSPECTION [MZR-CD 2.2].)
Are the CMP sensor and teeth of pulse wheel normal?
Yes
Access the following PIDs using the M-MDS:
(See ON-BOARD DIAGNOSTIC TEST [MZR-CD 2.2].)
(See PCM INSPECTION [MZR-CD 2.2].)
•  ECT
•  IAT
•  MAF
•  RPM
―  If the PID value is not normal:
•  Repair or replace the malfunctioning part according to the inspection results.
―  If the PID value is normal:
•  Go to the next step.
No
Repair or replace the malfunctioning part according to the inspection results.
11
Inspect the suction control valve.
(See SUCTION CONTROL VALVE INSPECTION [MZR-CD 2.2].)
Is there any malfunction?
Yes
Replace the supply pump.
(See SUPPLY PUMP REMOVAL/INSTALLATION [MZR-CD 2.2].)
No
Go to the next step.
12
Switch the ignition to off.
Disconnect the suction control valve and PCM connectors.
Inspect for continuity between suction control valve 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. (damaged to driver in PCM caused by short circuit to ground system)
No
Go to the next step.
13
Inspect the fuel pressure sensor.
(See FUEL PRESSURE SENSOR INSPECTION [MZR-CD 2.2].)
Is there any malfunction?
Yes
Replace the common rail.
(See COMMON RAIL REMOVAL/INSTALLATION [MZR-CD 2.2].)
No
Go to the next step.
14
Inspect the engine compression.
(See COMPRESSION INSPECTION [MZR-CD 2.2].)
Is there any malfunction?
Yes
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
Service if necessary.
No
Go to the next step.
15
Inspect the fuel injector.
(See FUEL INJECTOR INSPECTION [MZR-CD 2.2].)
Is there any malfunction?
Yes
Replace the fuel injector.
(See FUEL INJECTOR REMOVAL/INSTALLATION [MZR-CD 2.2].)
No
Go to the next step.
16
Perform the EGR Valve Operation Inspection.
(See ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZR-CD 2.2].)
Is there any malfunction?
Yes
Repair or replace the malfunctioning part according to the inspection results.
No
Go to the next step.
17
Inspect the starting system.
(See STARTER INSPECTION [MZR-CD 2.2].)
Is the starting system normal?
Yes
Inspect for loose connectors or poor terminal contact.
•  If there is any malfunction:
―  Repair or replace the malfunctioning part according to the inspection results.
•  If there is no malfunction:
―  Remove the supply pump and common rail.
―  Inspect the supply pump and common rail.
―  Repair or replace the malfunctioning part according to the inspection results.
No
Repair or replace components if necessary.
18
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.