NO.17 EMISSION COMPLIANCE [MZR-CD 2.2]
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17 |
EMISSION COMPLIANCE |
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DESCRIPTION
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• Fails emissions test.
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POSSIBLE CAUSE
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• Poor fuel quality
• Vacuum leakage
• Air leakage from intake-air system
• Intake-air system restriction or clogging
• VBC system malfunction
• Intake shutter valve stuck close
• Turbocharger malfunction
• Charge air cooler malfunction
• Glow system malfunction
• EGR system malfunction
• EGR cooler malfunction
• Improper operation of EGR cooler bypass valve
• Low coolant temperature
• Engine overheating
• Inadequate fuel pressure
• ECT sensor or related circuit malfunction
• MAF/IAT sensor related circuit malfunction
• IAT sensor No.2 or related circuit malfunction
• APP sensor or related circuit malfunction
• Fuel line clogging or restriction
• Fuel injector malfunction
• Incorrect fuel injection timing
• Incorrect idle speed
• Erratic signal from CKP sensor
• Erratic signal from CMP sensor
• Boost sensor or related circuit malfunction
• Neutral switch or related circuit malfunction
• VSS or related circuit malfunction
• Low engine compression
• Improper valve timing
• Base engine malfunction
• Exhaust system and/or oxidation catalytic converter restriction
• Oxidation catalytic converter malfunction
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Diagnostic Procedure
STEP |
INSPECTION |
RESULTS |
ACTION |
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1
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Is the engine overheating?
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Yes
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Go to the symptom troubleshooting “NO.19 COOLING SYSTEM CONCERNS-OVERHEATING”.
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No
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Go to the next step.
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2
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Does the engine run cold?
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Yes
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Go to the symptom troubleshooting “NO.20 COOLING SYSTEM CONCERNS-RUNS COLD”.
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No
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Go to the next step.
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3
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Perform the KOEO or KOER self test.
Are any DTCs displayed?
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Yes
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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
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No
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Go to the next step.
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4
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Inspect the following:
• Fuel quality (e.g.: including water contamination, winter/summer blend)
• Fuel return line clogging and/or restriction
• Charge air cooler condition (restriction or damaged)
• Intake-air system restriction
• Exhaust system and/or oxidation catalytic converter restriction
• Vacuum leakage
Are all items normal?
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Yes
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Go to the next step.
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No
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Service if necessary.
Repeat Step 4.
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5
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Inspect the APP sensor.
Is there any malfunction?
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Yes
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Replace the accelerator pedal component.
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No
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Go to the next step.
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6
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Inspect the neutral switch.
Is there any malfunction?
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Yes
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Replace the neutral switch.
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No
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Go to the next step.
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7
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Perform the Intake Shutter Valve Operation Inspection.
Is there any malfunction?
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Yes
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Repair or replace the malfunctioning part according to the inspection results.
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No
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Go to the next step.
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8
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Access the following PIDs using the M-MDS:
• 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?
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Yes
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Go to Step 10.
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No
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Go to the next step.
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9
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Perform the Guide Blade Actuator Operation Inspection.
Is there any malfunction?
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Yes
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Repair or replace the malfunctioning part according to the inspection results.
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No
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Go to the next step.
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10
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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?
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Yes
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Retighten the hose bands.
• If the concern is resolved:
• If the concern still exists:
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No
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Go to the next step.
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11
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Inspect for improper operation, kinks, clogging or disconnection on the guide blade actuator.
Is there any malfunction?
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Yes
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Repair or replace the malfunctioning part according to the inspection results.
• If the concern is resolved:
• If the concern still exists:
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No
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Go to the next step.
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12
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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.
Is there any malfunction?
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Yes
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Replace the turbocharger.
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No
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Go to the next step.
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13
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Inspect if the turbocharger compressor wheel locknut is loose or has fallen down inside the turbocharger.
Is there any malfunction?
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Yes
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Replace the turbocharger.
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No
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Go to the next step.
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14
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Inspect the turbocharger compressor wheel by hand.
Does the wheel turn easily and smoothly?
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Yes
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Go to the next step.
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No
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Replace the turbocharger.
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15
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Inspect if the turbocharger turbine wheel is damaged, cracked or interfering with the housing on the vehicle.
Is there any malfunction?
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Yes
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Replace the turbocharger.
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No
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Go to the next step.
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16
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Is any engine oil found inside the turbocharger turbine housing?
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Yes
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If the excessive amount of oil is found:
• Replace the turbocharger.
If the small amount of oil is found:
• Wipe oil off of the vehicle, then go to the next step.
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No
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Go to the next step.
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17
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Is any engine oil found inside the turbocharger compressor housing?
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Yes
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Wipe oil off of the vehicle.
Reinstall all removed parts in Step 12, then go to the next step.
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No
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Turbocharger is normal.
• Reinstall all removed parts in Step 12, then go to the next step.
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18
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Perform the EGR Valve Operation Inspection.
Is there any malfunction?
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Yes
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Repair or replace the malfunctioning part according to the inspection results.
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No
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Go to the next step.
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19
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Perform the EGR Cooler Bypass Valve Operation Inspection.
Is there any malfunction?
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Yes
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Repair or replace the malfunctioning part according to the inspection results.
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No
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Go to the next step.
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20
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Inspect the glow system operation.
Is there any malfunction?
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Yes
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Repair or replace the malfunctioning part according to the inspection results.
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No
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Go to the next step.
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21
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Visually inspect the CKP sensor and teeth of pulse wheel.
Are the CKP sensor and teeth of pulse wheel normal?
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Yes
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Go to the next step.
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No
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Repair or replace the malfunctioning part according to the inspection results.
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22
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Visually inspect the CMP sensor and teeth of pulse wheel.
Are the CMP sensor and teeth of pulse wheel normal?
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Yes
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Access the following PIDs using the M-MDS:
(See PCM INSPECTION [MZR-CD 2.2].)
• ECT
• IAT
• MAF
• MAP
• RPM
• VSS
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No
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Repair or replace the malfunctioning part according to the inspection results.
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23
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Inspect the suction control valve.
Is there any malfunction?
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Yes
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Replace the supply pump.
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No
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Go to the next step.
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24
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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?
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Yes
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Repair or replace the wiring harness for a possible short to ground.
• If the malfunction remains:
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No
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Go to the next step.
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25
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Inspect the fuel pressure sensor.
Is there any malfunction?
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Yes
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Replace the common rail.
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No
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Go to the next step.
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26
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Inspect the engine compression.
Is there any malfunction?
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Yes
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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.
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No
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Go to the next step.
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27
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Inspect the fuel injector.
Is there any malfunction?
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Yes
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Replace the fuel injector.
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No
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Go to the next step.
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28
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Inspect the EGR cooler for the following:
• Coolant passage clogging/restriction
• Exhaust gas clogging/restriction
Is there any malfunction?
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Yes
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Repair or replace the malfunctioning part according to the inspection results.
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No
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Go to the next step.
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29
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Inspect the timing chain for the following:
• Chipping of gear teeth
• Low tension
• Breakage damage or cracks
Is there any malfunction?
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Yes
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If the valve timing is incorrect:
• Adjust the valve timing.
If the timing chain is not normal:
• Replace the timing chain.
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No
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Inspect the following:
• ECT sensor
• Boost sensor
• MAF/IAT sensor
• Oxidation catalytic converter
• Fuel warmer
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30
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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.
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