NO.21 EXCESSIVE BLACK SMOKE [MZR-CD 2.2]

21	EXCESSIVE BLACK SMOKE
DESCRIPTION	• Excessive black smoke is observed in exhaust gas.
POSSIBLE CAUSE	• Intake-air system clogging or restriction • Air leakage from intake-air system • Incorrect fuel injection timing • Erratic signal from CKP sensor • Boost sensor or related circuit malfunction • IAT sensor No.2 or related circuit malfunction • A/F sensor or related circuit malfunction • Fuel injector malfunction • Excessive fuel pressure ― Fuel pressure sensor or related circuit malfunction ― Fuel pressure limiter malfunction (built-in common rail) ― Suction control valve malfunction (built-in supply pump) • Fuel line clogging or restriction • Low engine compression • Improper valve timing • Base engine malfunction • EGR system malfunction • VBC system malfunction ― Guide blade actuator position sensor malfunction • Vacuum leakage • Turbocharger malfunction • Charge air cooler malfunction • Intake shutter valve malfunction • Exhaust system and/or oxidation catalytic converter restriction or clogging • Diesel particulate filter system 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].)

EXCESSIVE BLACK SMOKE

DESCRIPTION

• Excessive black smoke is observed in exhaust gas.

POSSIBLE CAUSE

• Intake-air system clogging or restriction

• Air leakage from intake-air system

• Incorrect fuel injection timing

• Erratic signal from CKP sensor

• Boost sensor or related circuit malfunction

• IAT sensor No.2 or related circuit malfunction

• A/F sensor or related circuit malfunction

• Fuel injector malfunction

• Excessive fuel pressure

― Fuel pressure sensor or related circuit malfunction

― Fuel pressure limiter malfunction (built-in common rail)

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

• Fuel line clogging or restriction

• Low engine compression

• Improper valve timing

• Base engine malfunction

• EGR system malfunction

• VBC system malfunction

― Guide blade actuator position sensor malfunction

• Vacuum leakage

• Turbocharger malfunction

• Charge air cooler malfunction

• Intake shutter valve malfunction

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

• Diesel particulate filter system 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	Inspect the following: • Intake-air system clogging or restriction • 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 1.
2	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.
3	Does any other symptom exist?	Yes	Go to the appropriate flow chart.
No	Go to the next step.
4	Inspect the air cleaner element for clogging. Is there any malfunction?	Yes	Repair or replace the air cleaner element. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR-CD 2.2].)
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 10.
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	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.
9	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].) • IAT • MAP • RPM • O2S11 ― 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.
10	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.
11	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.
12	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.
13	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.
14	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.
15	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].)
16	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.
17	Is any engine oil found inside the turbocharger compressor housing?	Yes	Wipe oil off of the vehicle. Reinstall all removed parts in Step 13, then go to the next step.
No	Turbocharger is normal. • Reinstall all removed parts in Step 13, then go to the next step.
18	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.
19	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.
20	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	Inspect the following: • Boost sensor • Fuel pressure limiter (built-in common rail) • Fuel pressure sensor • Fuel return line restriction or clogging ― If there is any malfunction: • Repair or replace the malfunctioning part according to the inspection results. ― If there is no malfunction: • Perform the fuel injection learning.
21	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

Inspect the following:

• Intake-air system clogging or restriction

• 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 1.

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.

Does any other symptom exist?

Yes

Go to the appropriate flow chart.

Go to the next step.

Inspect the air cleaner element for clogging.

Is there any malfunction?

Yes

Repair or replace the air cleaner element.

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

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 10.

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.

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].)

• IAT

• MAP

• RPM

• O2S11

― 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.

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 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 compressor housing?

Yes

Wipe oil off of the vehicle.

Reinstall all removed parts in Step 13, then go to the next step.

Turbocharger is normal.

• Reinstall all removed parts in Step 13, then 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].)

Go to the next step.

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 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].)

Inspect the following:

• Boost sensor

• Fuel pressure limiter (built-in common rail)

• Fuel pressure sensor

• Fuel return line restriction or clogging

― If there is any malfunction:

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

― If there is no malfunction:

• Perform the fuel injection learning.

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.