ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZR-CD 2.2]

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Guide Blade Actuator Operation Inspection

1.  Connect M-MDS to DLC-2.

2.  Start the engine and run it at idle.

3.  Access the VBCV and VBCV_POS PIDs.

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

5.  Verify that the VBCV_POS PID reading change according to VBCV commanded value.

•  If the VBCV_POS PID cannot be verified inspect for followings;

―  Guide blade actuator (See GUIDE BLADE ACTUATOR INSPECTION [MZR-CD 2.2].)

―  Vacuum hose connection between the vacuum chamber and the guide blade actuator through the VBC solenoid valve (See INTAKE-AIR SYSTEM VACUUM HOSE ROUTING DIAGRAM [MZR-CD 2.2].)

―  VBC solenoid valve (See VARIABLE BOOST CONTROL (VBC) SOLENOID VALVE INSPECTION [MZR-CD 2.2].)

―  Guide blade actuator position sensor (built in turbocharger)(See GUIDE BLADE ACTUATOR INSPECTION [MZR-CD 2.2].)

Glow Plug Control Operation Inspection

1.  Verify that the battery is charged fully.

2.  If not, charge the battery.

3.  Connect the M-MDS to the DLC-2.

4.  Switch the ignition to ON.

5.  Access and monitor the VPWR and GPC PIDs.

6.  Verify that the VPWR PID drops 0.3 V or more while the GPC is turned on from off using the simulation function.

•  If it cannot be verified, inspect the followings;

―  Glow plug relay

―  Glow plug

―  Wiring harness for battery positive post—glow plug relay—glow plug

―  Wiring harness for PCM terminal 1BT—glow plug relay—ground

Intake Shutter Valve Operation Inspection

1.  Connect the M-MDS to the DLC-2.

2.  Start the engine and run it at idle.

3.  Access and monitor the ETC_DSD, TP and MAP PIDs.

4.  Verify that the MAP PID increases and TP PID increases linearly, while increasing the opening angle of the intake shutter valve using the simulation function of ETC_DSD.

•  If both PIDs do not increase according to the intake shutter valve opening angle, inspect using the following steps.

1.  Remove the intake shutter valve with connector connected.

2.  Verify that the intake shutter valve opens and closes while it is operated using the simulation function of the ETC_DSD.

―  If not verified, retest after cleaning the intake shutter valve and inspecting related wiring harness and connectors.

3.  If the intake shutter valve does not operate, replace the intake shutter valve.

•  If the MAP PID increases but TP PID does not increase linearly according to the intake shutter valve opening angle inspect using the following steps.

1.  Inspect the intake shutter valve position sensor related wiring harness and connector.

2.  Remove the intake shutter valve with the connector connected.

3.  Verify that the TP PID increases and decreases linearly while the intake shutter valve is operated using the simulation function of ETC_DSD.

―  If the TP PID does not increase and decrease linearly, replace the intake shutter valve.

•  If the TP PID increases linearly but the MAP PID does not increase according to the intake shutter valve opening angle inspect using the following steps.

1.  Inspect air for leakage at the intake shutter valve and cylinder head.

2.  If normal, inspect and replace the MAP sensor.

EGR Valve Operation Inspection

1.  Crank the engine and verify that the EGR valve operation (initial operation) sound is heard.

•  If the operation sound is not heard, connect the M-MDS to the DLC-2 and verify that the DTC P0403:00 is shown. Perform the DTC inspection. (See DTC TABLE [MZR-CD 2.2].)

2.  Start the engine run it at idle.

3.  Access and monitor EGRP and MAP PIDs.

4.  Verify that the MAP PID increases while increase the opening value of the EGR valve from 0 % to 100 % using the EGRP PID of simulation function.

•  If both PIDs do not increase according to the EGR valve opening values, inspect using the following steps.

1.  Remove the EGR valve with the connector connected.

2.  Verify that the EGR valve opens and closes while it is operated using the simulation function of EGRP.

―  If not verified, retest after cleaning the EGR valve and inspecting the related harness and connectors.

3.  If the EGR valve does not operate, replace the EGR valve.

•  If the MAP PID increases but the EGRP PID does not increase linearly according to the EGR valve opening values, inspect using the following steps.

1.  Inspect the EGR valve position sensor related harness and connector.

2.  Remove the EGR valve with the connector connected.

3.  Verify that the EGRP PID increases and decreases linearly while increasing the EGR valve steps using simulation function of the EGRP.

―  If the EGRP PID does not increase and decrease linearly, replace the EGR valve.

•  If the EGRP PID increases linearly but MAP PID does not increase according to the EGR valve opening values, inspect using the following steps.

1.  Inspect for leakage between the exhaust manifold and surge tank.

2.  If normal, inspect and replace MAP sensor.

EGR Cooler Bypass Valve Operation Inspection

1.  Connect the M-MDS to DLC-2.

2.  Retrieve the DTC.

3.  Verify that the DTC P245C:00, P245D:00 are not displayed.

•  If the DTC P245C:00, P245D:00 is displayed, perform the suspect DTC troubleshooting procedure. (See DTC P245C:00 [MZR-CD 2.2].)(See DTC P245D:00 [MZR-CD 2.2].)

4.  Disconnect the vacuum hose at EGR cooler bypass valve actuator.

5.  Access the PCM PID EGR_C_BP.

6.  Start the engine and run it at idle.

7.  Verify that the vacuum condition is following table while the PID EGR_C_BP is ON and OFF using the simulation function.

EGR_C_BP PID	ON	OFF
Vacuum	Applied	Not applied

•  If the vacuum condition changes are not verified, inspect and repair or replace for followings:

―  EGR cooler bypass solenoid valve (stuck)

―  Vacuum hoses between vacuum pump and EGR cooler bypass valve actuator through EGR cooler bypass solenoid valve (damage, clogging, poor connection)

•  If the vacuum condition changes are verified, inspect the EGR cooler bypass valve actuator. (See EGR COOLER BYPASS VALVE INSPECTION [MZR-CD 2.2].)

Fuel Injector Operation Inspection

1.  Connect the M-MDS to the DLC-2.

2.  Start the engine and warm it up to normal operating temperature.

3.  Perform the KOER self-test. (See KOEO/KOER SELF TEST [MZR-CD 2.2].)

4.  Verify that DTCs P0201:00, P0202:00, P0203:00 and/or P0204:00 are not shown using the KOER self-test.

•  If DTC P0201:00, P0202:00, P0203:00 and/or P0204:00 are shown, perform the DTC troubleshooting procedure. (See DTC TABLE [MZR-CD 2.2].)

5.  Verify that the engine speed drops or stalls when each cylinder fuel injector turns to off from on using the M-MDS simulation function.

•  If it cannot be verified, inspect the following for the suspected cylinder;

―  Fuel injector (See FUEL INJECTOR INSPECTION [MZR-CD 2.2].)

―  Wiring harness for PCM—fuel injector

Cooling Fan Control System Inspection

Cooling fan system operation

1.  Connect M-MDS to DLC-2.

2.  Verify that ECT PID is below cooling fan operating temperature.

3.  Verify that the A/C switch and fan switch are off.

4.  Start the engine and let it at idle.

5.  Verify that the cooling fans are not operating.

•  If the cooling fan is operating low speed, inspect for the following:

―  Short to ground circuit between PCM terminal 1CA and cooling fan relay No.1

―  Cooling fan relay No.1 stuck in closed position

•  If the cooling fans are operating high speed, inspect for the following:

―  DTC for ECT sensor (P0117:00, P0118:00)

•  If the cooling fan motor No.1 is not operating and cooling fan motor No.2 is operating, inspect for the following:

―  Short to ground circuit between PCM terminal 1CF and cooling fan relay No.2

―  Cooling fan relay No.2 stuck OFF

―  Short to ground circuit between PCM terminal 1BW and cooling fan relay No.4

―  Cooling fan relay No.4 stuck OFF

6.  Start the engine.

7.  Verify that the cooling fans are operating low speed when ECT PID is above 100°C {212°F}.

•  If the cooling fan motor No.1 does not operate, perform the following:

1.  Select FAN3 PID.

2.  Operate cooling fan relay No.1 by sending ON command.

3.  Inspect the operation sound is heard from cooling fan relay No.1.

―  If the operation sound is heard, inspect wiring harnesses, connectors and cooling fan motor No.1.

―  If the operation sound is not heard, inspect cooling fan relay No.1 and open circuit between PCM terminal 1CA and cooling fan relay No.1 wiring harness and connectors.

•  Inspect the cooling fan is operating high speed, inspect the following:

―  Short to ground circuit between PCM terminal 1CF and cooling fan relay No.2/cooling fan relay No.3.

8.  Turn A/C switch and fan switch are on.

9.  Verify that the ACCS PID is ON.

•  If the ACCS PID is not ON, inspect for the following:

―  A/C switch

―  Fan switch

―  Refrigerant pressure switch

―  Open circuit PCM 1AF related harnesses and connectors

10.  Access the COLP PID.

11.  Verify that the cooling fan motor No.1 is operating high speed and cooling fan motor No.2 is operating low speed, while the COLP PID is ON.

•  If the cooling fan motor No.1 does not operate high speed, perform the following:

1.  Select FAN1 PID.

2.  Operate cooling fan relay No.2 and cooling fan relay No.3 by sending ON command.

3.  Inspect the operation sound is heard from cooling fan relay No.2 and cooling fan relay No.3.

―  If the operation sound is not heard from cooling fan relay No.3, inspect cooling fan relay No.3 and open circuit between PCM 1CF and cooling fan relay No.3 wiring harnesses and connectors.

―  If the operation sound is not heard from cooling fan relay No.2, inspect cooling fan relay No.2 and between PCM terminal 1CF and cooling fan relay No.2 wiring harnesses and connector.

―  If the operation sound is heard from cooling fan relay No.2 and cooling fan relay No.3, inspect wiring harnesses and connectors.

•  If the cooling fan motor No.2 does not operate, perform the following:

―  Inspect cooling fan motor No.2 and related wiring harnesses and connectors

•  If the cooling fan motor No.2 does not operate, perform the following:

1.  Select FAN2 PID.

2.  Operate cooling fan relay No.4 by sending ON command.

3.  Inspect the operation sound is heard from cooling fan relay No.4.

―  If the operation sound is heard, inspect wiring harnesses and connectors.

―  If the operation sound is not heard, inspect cooling fan relay No.4 and open circuit wiring harnesses and connectors between PCM terminal 1BW and cooling fan relay No.4.

A/C Cut-off Control System Inspection

1.  Start the engine.

2.  Turn the A/C switch and the fan switch on.

3.  Verify that the A/C compressor magnetic clutch actuates.

•  If it does not actuate, go to symptom troubleshooting “No.25 A/C does not work sufficiently”.

4.  Fully open the throttle valve and verify that the A/C compressor magnetic clutch does not actuate for 2—5 s.

•  If it actuates, inspect as follows:

―  A/C relay

―  Open or short to ground circuit in wiring harness and connectors (Ignition switch (without advanced keyless entry and push button start)/block relay (with advanced keyless entry and push button start—A/C relay—PCM terminal 1BX)

―  A/C related parts

―  APP1, APP2 PIDs