NO.15 KNOCKING/PINGING [MZR-CD 2.2]

15	KNOCKING/PINGING
DESCRIPTION	• Excessive shrilly knocking sound from engine.
POSSIBLE CAUSE	• Poor fuel quality • Air leakage from intake-air system • Intake-air system restriction or clogging • VBC system malfunction ― Guide blade actuator position sensor malfunction • Intake shutter valve stuck close • Glow system malfunction • Fuel warmer malfunction • Low engine compression • Improper valve timing • Low coolant temperature • Incorrect fuel injection timing • Erratic signal from CKP sensor • Erratic signal from CMP sensor • ECT sensor or related circuit malfunction • MAF/IAT sensor or related circuit malfunction • IAT sensor No.2 or related circuit malfunction • Boost sensor or related circuit malfunction • Fuel pressure sensor or related circuit malfunction • APP sensor or related circuit malfunction • Excessive fuel pressure ― Fuel return line clogging or restriction ― Suction control valve malfunction (built-in supply pump) • EGR system malfunction • Exhaust system and/or oxidation catalytic converter restriction • Turbocharger malfunction • Charge air cooler malfunction • Fuel injection learning improper 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].)

KNOCKING/PINGING

DESCRIPTION

• Excessive shrilly knocking sound from engine.

POSSIBLE CAUSE

• Poor fuel quality

• Air leakage from intake-air system

• Intake-air system restriction or clogging

• VBC system malfunction

― Guide blade actuator position sensor malfunction

• Intake shutter valve stuck close

• Glow system malfunction

• Fuel warmer malfunction

• Low engine compression

• Improper valve timing

• Low coolant temperature

• Incorrect fuel injection timing

• Erratic signal from CKP sensor

• Erratic signal from CMP sensor

• ECT sensor or related circuit malfunction

• MAF/IAT sensor or related circuit malfunction

• IAT sensor No.2 or related circuit malfunction

• Boost sensor or related circuit malfunction

• Fuel pressure sensor or related circuit malfunction

• APP sensor or related circuit malfunction

• Excessive fuel pressure

― Fuel return line clogging or restriction

― Suction control valve malfunction (built-in supply pump)

• EGR system malfunction

• Exhaust system and/or oxidation catalytic converter restriction

• Turbocharger malfunction

• Charge air cooler malfunction

• Fuel injection learning improper

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].)

STEP	INSPECTION	RESULTS	ACTION
1	Does the engine run cold?	Yes	Go to the symptom troubleshooting “NO.20 COOLING SYSTEM CONCERNS-RUNS COLD”. (See NO.20 COOLING SYSTEM CONCERNS-RUNS COLD [MZR-CD 2.2].)
No	Go to the next step.
2	Inspect the following: • Fuel quality (e.g.: including water contamination, winter/summer blend) • Fuel return line clogging and/or restriction • Intake-air system restriction or clogging • Exhaust system and/or oxidation catalytic converter restriction or clogging • Charge air cooler condition (restriction or damaged) Are all items normal?	Yes	Go to the next step.
No	Service if necessary. Repeat Step 2.
3	Access the ECT PID using the M-MDS. (See ON-BOARD DIAGNOSTIC TEST [MZR-CD 2.2].) Is the ECT PID value is above 80 °C {176 °F}?	Yes	Go to the next step.
No	Inspect the ECT PID.
4	Perform the KOEO or KOER self test. (See KOEO/KOER SELF TEST [MZR-CD 2.2].) Are any DTCs displayed?	Yes	DTC is displayed: • Go to the applicable DTC inspection. (See DTC TABLE [MZR-CD 2.2].) 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.
5	Perform the Intake Shutter 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.
6	Access the following PIDs using the M-MDS: (See ON-BOARD DIAGNOSTIC TEST [MZR-CD 2.2].) • VBC_POS • VBCV Command VBCV PID from 0 to 100 % using the simulation function. Does the VBC_POS PID value change according to the VBCV commanded value?	Yes	Go to Step 8.
No	Go to the next step.
7	Perform the Guide Blade Actuator 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.
8	Inspect the hose bands between the following parts: • Turbocharger compressor housing and air cleaner • Turbocharger compressor housing and charge air cooler Are the hose bands loose?	Yes	Retighten the hose bands. • If the concern is resolved: ― Symptom troubleshooting is completed. • If the concern still exists: ― Go to the next step.
No	Go to the next step.
9	Inspect for improper operation, kinks, clogging or disconnection on the guide blade actuator. (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. • If the concern is resolved: ― Symptom troubleshooting is completed. • If the concern still exists: ― Turbocharger is normal. • Go to the next step.
No	Go to the next step.
10	Remove parts necessary to inspect the turbocharger. Do not remove the turbocharger. Inspect if the turbocharger compressor wheel is bent, damaged, or interfering with the housing on the vehicle. (See TURBOCHARGER INSPECTION [MZR-CD 2.2].) Is there any malfunction?	Yes	Replace the turbocharger. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR-CD 2.2].)
No	Go to the next step.
11	Inspect if the turbocharger compressor wheel locknut is loose or has fallen down inside the turbocharger. Is there any malfunction?	Yes	Replace the turbocharger. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR-CD 2.2].)
No	Go to the next step.
12	Inspect the turbocharger compressor wheel by hand. Does the wheel turn easily and smoothly?	Yes	Go to the next step.
No	Replace the turbocharger. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR-CD 2.2].)
13	Inspect if the turbocharger turbine wheel is damaged, cracked or interfering with the housing on the vehicle. Note • Inspect all fins on each turbine wheel. Is there any malfunction?	Yes	Replace the turbocharger. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR-CD 2.2].)
No	Go to the next step.
14	Is any engine oil found inside the turbocharger turbine housing?	Yes	If the excessive amount of oil is found: • Replace the turbocharger. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR-CD 2.2].) If the small amount of oil is found: • Wipe oil off of the vehicle, then go to the next step.
No	Go to the next step.
15	Is any engine oil found inside the turbocharger compressor housing?	Yes	Wipe oil off of the vehicle. Reinstall all removed parts in Step 10, then go to the next step.
No	Turbocharger is normal. • Reinstall all removed parts in Step 10, then 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 glow system operation. (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.
18	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.
19	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 • MAP • 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.
20	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.
21	Inspect the fuel warmer. (See FUEL WARMER INSPECTION [MZR-CD 2.2].) Is there any malfunction?	Yes	Replace the fuel warmer. (See FUEL FILTER COMPONENT DISASSEMBLY/ASSEMBLY [MZR-CD 2.2].)
No	Go to the next step.
22	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	Inspect the following: • Boost sensor • MAF/IAT sensor • IAT sensor No.2 • Fuel pressure sensor • APP sensor Repair or replace the malfunctioning part according to the inspection results.
23	Verify test results. • If normal, return to the diagnostic index to service any additional symptoms. (See SYMPTOM DIAGNOSTIC INDEX [MZR-CD 2.2].) • 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.

STEP

INSPECTION

RESULTS

ACTION

Does the engine run cold?

Yes

Go to the symptom troubleshooting “NO.20 COOLING SYSTEM CONCERNS-RUNS COLD”.

(See NO.20 COOLING SYSTEM CONCERNS-RUNS COLD [MZR-CD 2.2].)

Go to the next step.

Inspect the following:

• Fuel quality (e.g.: including water contamination, winter/summer blend)

• Fuel return line clogging and/or restriction

• Intake-air system restriction or clogging

• Exhaust system and/or oxidation catalytic converter restriction or clogging

• Charge air cooler condition (restriction or damaged)

Are all items normal?

Yes

Go to the next step.

Service if necessary.

Repeat Step 2.

Access the ECT PID using the M-MDS.

(See ON-BOARD DIAGNOSTIC TEST [MZR-CD 2.2].)

Is the ECT PID value is above 80 °C {176 °F}?

Yes

Go to the next step.

Inspect the ECT PID.

Perform the KOEO or KOER self test.

(See KOEO/KOER SELF TEST [MZR-CD 2.2].)

Are any DTCs displayed?

Yes

DTC is displayed:

• Go to the applicable DTC inspection.

(See DTC TABLE [MZR-CD 2.2].)

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

Go to the next step.

Perform the Intake Shutter 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.

Go to the next step.

Access the following PIDs using the M-MDS:

(See ON-BOARD DIAGNOSTIC TEST [MZR-CD 2.2].)

• VBC_POS

• VBCV

Command VBCV PID from 0 to 100 % using the simulation function.

Does the VBC_POS PID value change according to the VBCV commanded value?

Yes

Go to Step 8.

Go to the next step.

Perform the Guide Blade Actuator 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.

Go to the next step.

Inspect the hose bands between the following parts:

• Turbocharger compressor housing and air cleaner

• Turbocharger compressor housing and charge air cooler

Are the hose bands loose?

Yes

Retighten the hose bands.

• If the concern is resolved:

― Symptom troubleshooting is completed.

• If the concern still exists:

― Go to the next step.

Go to the next step.

Inspect for improper operation, kinks, clogging or disconnection on the guide blade actuator.

(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.

• If the concern is resolved:

― Symptom troubleshooting is completed.

• If the concern still exists:

― Turbocharger is normal.

• Go to the next step.

Go to the next step.

Remove parts necessary to inspect the turbocharger.

Do not remove the turbocharger.

Inspect if the turbocharger compressor wheel is bent, damaged, or interfering with the housing on the vehicle.

(See TURBOCHARGER INSPECTION [MZR-CD 2.2].)

Is there any malfunction?

Yes

Replace the turbocharger.

(See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR-CD 2.2].)

Go to the next step.

Inspect if the turbocharger compressor wheel locknut is loose or has fallen down inside the turbocharger.

Is there any malfunction?

Yes

Replace the turbocharger.

(See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR-CD 2.2].)

Go to the next step.

Inspect the turbocharger compressor wheel by hand.

Does the wheel turn easily and smoothly?

Yes

Go to the next step.

Replace the turbocharger.

(See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR-CD 2.2].)

Inspect if the turbocharger turbine wheel is damaged, cracked or interfering with the housing on the vehicle.

Note

• Inspect all fins on each turbine wheel.

Is there any malfunction?

Yes

Replace the turbocharger.

(See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR-CD 2.2].)

Go to the next step.

Is any engine oil found inside the turbocharger turbine housing?

Yes

If the excessive amount of oil is found:

• Replace the turbocharger.

(See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR-CD 2.2].)

If the small amount of oil is found:

• Wipe oil off of the vehicle, then go to the next step.

Go to the next step.

Is any engine oil found inside the turbocharger compressor housing?

Yes

Wipe oil off of the vehicle.

Reinstall all removed parts in Step 10, then go to the next step.

Turbocharger is normal.

• Reinstall all removed parts in Step 10, then go to the next step.

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.

Go to the next step.

Inspect the glow system operation.

(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.

Go to the next step.

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.

Repair or replace the malfunctioning part according to the inspection results.

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

• MAP

• 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.

Repair or replace the malfunctioning part according to the inspection results.

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.

Go to the next step.

Inspect the fuel warmer.

(See FUEL WARMER INSPECTION [MZR-CD 2.2].)

Is there any malfunction?

Yes

Replace the fuel warmer.

(See FUEL FILTER COMPONENT DISASSEMBLY/ASSEMBLY [MZR-CD 2.2].)

Go to the next step.

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].)

Inspect the following:

• Boost sensor

• MAF/IAT sensor

• IAT sensor No.2

• Fuel pressure sensor

• APP sensor

Repair or replace the malfunctioning part according to the inspection results.

Verify test results.

• If normal, return to the diagnostic index to service any additional symptoms.

(See SYMPTOM DIAGNOSTIC INDEX [MZR-CD 2.2].)

• 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.