NO.17 EMISSION COMPLIANCE [MZR-CD 2.2]


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17

EMISSION COMPLIANCE

DESCRIPTION
•  Fails emissions test.
POSSIBLE CAUSE
•  Poor fuel quality
•  Vacuum leakage
•  Air leakage from intake-air system
•  Intake-air system restriction or clogging
•  VBC system malfunction
―  Guide blade actuator malfunction
―  Guide blade actuator position sensor 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
―  Fuel pressure sensor or related circuit malfunction
―  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
•  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
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
Is the engine overheating?
Yes
Go to the symptom troubleshooting “NO.19 COOLING SYSTEM CONCERNS-OVERHEATING”.
No
Go to the next step.
2
Does the engine run cold?
Yes
Go to the symptom troubleshooting “NO.20 COOLING SYSTEM CONCERNS-RUNS COLD”.
No
Go to the next step.
3
Perform the KOEO or KOER self test.
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
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?
Yes
Go to the next step.
No
Service if necessary.
Repeat Step 4.
5
Inspect the APP sensor.
Is there any malfunction?
Yes
Replace the accelerator pedal component.
No
Go to the next step.
6
Inspect the neutral switch.
Is there any malfunction?
Yes
Replace the neutral switch.
No
Go to the next step.
7
Perform the Intake Shutter Valve Operation Inspection.
Is there any malfunction?
Yes
Repair or replace the malfunctioning part according to the inspection results.
No
Go to the next step.
8
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?
Yes
Go to Step 10.
No
Go to the next step.
9
Perform the Guide Blade Actuator Operation Inspection.
Is there any malfunction?
Yes
Repair or replace the malfunctioning part according to the inspection results.
No
Go to the next step.
10
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.
11
Inspect for improper operation, kinks, clogging or disconnection on the guide blade actuator.
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.
12
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?
Yes
Replace the turbocharger.
No
Go to the next step.
13
Inspect if the turbocharger compressor wheel locknut is loose or has fallen down inside the turbocharger.
Is there any malfunction?
Yes
Replace the turbocharger.
No
Go to the next step.
14
Inspect the turbocharger compressor wheel by hand.
Does the wheel turn easily and smoothly?
Yes
Go to the next step.
No
Replace the turbocharger.
15
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.
No
Go to the next step.
16
Is any engine oil found inside the turbocharger turbine housing?
Yes
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.
No
Go to the next step.
17
Is any engine oil found inside the turbocharger compressor housing?
Yes
Wipe oil off of the vehicle.
Reinstall all removed parts in Step 12, then go to the next step.
No
Turbocharger is normal.
•  Reinstall all removed parts in Step 12, then go to the next step.
18
Perform the EGR Valve Operation Inspection.
Is there any malfunction?
Yes
Repair or replace the malfunctioning part according to the inspection results.
No
Go to the next step.
19
Perform the EGR Cooler Bypass Valve Operation Inspection.
Is there any malfunction?
Yes
Repair or replace the malfunctioning part according to the inspection results.
No
Go to the next step.
20
Inspect the glow system operation.
Is there any malfunction?
Yes
Repair or replace the malfunctioning part according to the inspection results.
No
Go to the next step.
21
Visually inspect the CKP sensor and teeth of pulse wheel.
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.
22
Visually inspect the CMP sensor and teeth of pulse wheel.
Are the CMP sensor and teeth of pulse wheel normal?
Yes
Access the following PIDs using the M-MDS:
•  ECT
•  IAT
•  MAF
•  MAP
•  RPM
•  VSS
―  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.
23
Inspect the suction control valve.
Is there any malfunction?
Yes
Replace the supply pump.
No
Go to the next step.
24
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.
25
Inspect the fuel pressure sensor.
Is there any malfunction?
Yes
Replace the common rail.
No
Go to the next step.
26
Inspect the engine compression.
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.
27
Inspect the fuel injector.
Is there any malfunction?
Yes
Replace the fuel injector.
No
Go to the next step.
28
Inspect the EGR cooler for the following:
•  Coolant passage clogging/restriction
•  Exhaust gas clogging/restriction
Is there any malfunction?
Yes
Repair or replace the malfunctioning part according to the inspection results.
No
Go to the next step.
29
Inspect the timing chain for the following:
•  Chipping of gear teeth
•  Low tension
•  Breakage damage or cracks
Is there any malfunction?
Yes
If the valve timing is incorrect:
•  Adjust the valve timing.
If the timing chain is not normal:
•  Replace the timing chain.
No
Inspect the following:
•  ECT sensor
•  Boost sensor
•  MAF/IAT sensor
•  Oxidation catalytic converter
•  Fuel warmer
―  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.
30
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.