NO.23 ENGINE NOISE [MZR-CD 2.2]

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23

ENGINE NOISE
DESCRIPTION
•  Engine noise from under bonnet.
POSSIBLE CAUSE
•  Engine internal damage
•  Improper valve timing
•  Improper engine compression
•  Timing chain displacement
•  Fuel injector malfunction
•  Loose attaching bolts or worn parts
•  Improper drive belt tension
•  Auto tensioner bearing malfunction
•  Air leakage from intake-air system
•  Incorrect injection timing
•  Erratic signal from CKP sensor
•  Erratic signal from CMP sensor
•  Fuel pressure sensor or related circuit malfunction
•  Boost sensor or related circuit malfunction
•  APP sensor or related circuit malfunction
•  MAF/IAT sensor or related circuit malfunction
•  ECT sensor or related circuit malfunction
•  IAT sensor No.2 or related circuit malfunction
•  EGR system malfunction
•  Vacuum leakage
•  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)
•  Turbocharger operating noise
•  Solenoid valve operating noise
•  Fuel injector injection amount correction improper
•  Improper valve clearance
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].)
Note
•  PCM checks fuel injection amount during a set interval while idling, and automatically corrects it to maintain engine efficiency. It is normal that engine noise and vibration might be a little louder during this process.

Diagnostic Procedure

STEP

INSPECTION

RESULTS

ACTION
1
Is there a squeal, click or chirp sound present?
Yes
Inspect the following:
•  Engine oil level
•  Drive belt tension
•  Solenoid valves installation
•  Splash shield or under cover looseness
•  Auto tensioner bearing damaged
•  Generator installation
Repair or replace the malfunctioning part according to the inspection results.
No
Go to the next step.
2
Is there a rumble or grind sound present?
Yes
Inspect the following:
•  Drive belt tension
•  Loose parts in engine compartment
―  If there is any malfunction:
•  Repair or replace the malfunctioning part according to the inspection results.
No
Go to the next step.
3
Is there a rattle sound present?
Yes
Inspect the location of the rattle for loose parts.
Repair or replace the malfunctioning part according to the inspection results.
No
Go to the next step.
4
Is there a hiss sound present?
Yes
Inspect the following:
•  Vacuum leakage
•  Intake air system leakage
Repair or replace the malfunctioning part according to the inspection results.
No
Go to the next step.
5
Is there a rap or roar sound present?
Yes
Inspect for looseness in the following:
•  Dynamic dumper
•  Intake air system
•  Exhaust system
Repair or replace the malfunctioning part according to the inspection results.
No
Go to the next step.
6
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.
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.
7
Access the ECT PID using the M-MDS.
(See ON-BOARD DIAGNOSTIC TEST [MZR-CD 2.2].)
Inspect the ECT PID value while warming up the engine.
Is the ECT PID value within the specification?
(See PCM INSPECTION [MZR-CD 2.2].)
Yes
Go to the next step.
No
Inspect the ECT sensor and related wiring harnesses.
(See ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION [MZR-CD 2.2].)
•  If there is any malfunction:
―  Repair or replace the malfunctioning part according to the inspection results.
8
Access the IAT PID using the M-MDS.
(See ON-BOARD DIAGNOSTIC TEST [MZR-CD 2.2].)
Inspect the IAT PID value while running the engine.
Is the IAT PID value within the specification?
(See PCM INSPECTION [MZR-CD 2.2].)
Yes
Go to the next step.
No
Inspect the IAT sensor and related wiring harnesses.
(See INTAKE AIR TEMPERATURE (IAT) SENSOR INSPECTION [MZR-CD 2.2].)
•  If there is any malfunction:
―  Repair or replace the malfunctioning part according to the inspection results.
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
•  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.
11
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.
12
Remove the turbocharger air inlet pipe.
(See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR-CD 2.2].)
Note
•  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.
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.
(See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR-CD 2.2].)
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.
(See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR-CD 2.2].)
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.
(See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR-CD 2.2].)
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, then go to the next step.
No
Go to the next step.
18
Is any exhaust gas leakage found around the location where the turbocharger is attached to the exhaust manifold?
Yes
Remove the turbocharger.
(See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR-CD 2.2].)
Inspect for cracks on the center housing inlet surface.
•  If there is any malfunction:
―  Replace the turbocharger.
No
Go to the next step.
19
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.
20
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.
21
Are any center housing and turbine housing attaching bolts loose?
Yes
Retighten the loose bolts.
•  If a bolt is found to be missing:
―  Attach appropriate new bolts.
No
Turbocharger is normal.
•  Reinstall all removed parts in Step 12, then go to the next step.
22
Inspect the fuel injector and fuel injector gasket.
(See FUEL INJECTOR INSPECTION [MZR-CD 2.2].)
Is there any malfunction?
Yes
Repair or replace the malfunctioning part according to the inspection results.
No
Inspect the following:
•  Metal flow
•  Bent connecting rod
•  Damaged valve seat
•  Incorrect valve clearance
―  If there is any malfunction:
•  Repair or replace the malfunctioning part according to the inspection results.
―  If there is no malfunction:
•  Perform the fuel injector injection amount correction.
•  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.
•  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.