NO.4 HARD START/LONG CRANK/ERRATIC START/ERRATIC CRANK [MZR-CD (RF Turbo)]


4	HARD START/LONG CRANK/ERRATIC START/ERRATIC CRANK
DESCRIPTION	• Starter cranks engine at normal speed but engine requires excessive cranking time before starting. • Battery is in normal condition.
POSSIBLE CAUSE	• Poor fuel quality • Intake-air system restriction • Starting system malfunction • Inadequate fuel pressure • Fuel pressure limiter malfunction (built-in common rail) • Suction control valve malfunction (built-in supply pump) • Engine overheating • Glow system malfunction • Fuel filter clogging • Fuel line restriction • Fuel leakage • Exhaust system and/or catalyst converter restriction • Incorrect fuel injection timing • Erratic signal from CKP sensor • Erratic signal from CMP sensor • ECT sensor or related circuit malfunction • Accelerator position sensor or related circuit malfunction • MAF/IAT sensor or related circuit malfunction • Fuel pressure sensor or related circuit malfunction • Supply pump malfunction • Fuel injector malfunction • Low engine compression • Improper valve timing • IDM or related circuit malfunction • EGR system malfunction • Vacuum leakage 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 REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual.


STEP	INSPECTION	RESULTS	ACTION
1	Inspect for following: • Fuel quality (e.g.: include water contamination, winter/summer blend) • Fuel line/fuel filter clogging • Intake-air system restriction Are all items okay?	Yes	Go to next step.
1		No	Service as necessary. Repeat Step 1.
2	Is engine overheating?	Yes	Go to symptom troubleshooting "NO.17 COOLING SYSTEM CONCERNS-OVERHEATING".
2	Is engine overheating?	No	Go to next step.
3	Connect WDS or equivalent to DLC-2. Turn engine switch to ON. Retrieve any DTC. Is DTC displayed?	Yes	DTC is displayed: Go to appropriate DTC test. Communication error message is displayed: Inspect followings: • Open circuit between PCM control relay and PCM terminal 53 or 79 • Open circuit PCM control relay and PCM terminal 69 • PCM control relay stuck open • Open or poor GND circuit (PCM terminal 65, 85, 103 or 104) • Poor connection vehicle body GND
3		No	No DTC is displayed: Go to next step.
4	Does engine start normally after warm-up?	Yes	Inspect glow system operation. (See RELAY INSPECTION.) Replace any malfunctioning part as necessary. If glow system is okay, go to next step.
4	Does engine start normally after warm-up?	No	Go to next step.
5	Is there any restriction in exhaust system or catalyst converter?	Yes	Repair or replace as necessary.
5		No	Go to next step.
6	Inspect for fuel leakage from fuel pipe. Is any fuel leakage found on fuel pipe?	Yes	Repair or replace as necessary.
6		No	Go to next step.
7	Visually inspect CKP sensor and teeth of pulse wheel. Are CKP sensor and teeth of pulse wheel okay?	Yes	Go to next step.
7		No	Replace malfunctioning parts.
8	Measure gap between CKP sensor and teeth of pulse wheel. Specification 1.5-2.5 mm {0.059-0.098 in} Is gap within specification?	Yes	Go to next step.
8		No	Adjust CKP sensor position.
9	Visually inspect CMP sensor and teeth of pulse wheel. Are CMP sensor and teeth of pulse wheel okay?	Yes	Inspect following PIDs: (See PCM INSPECTION [MZR-CD (RF Turbo)].) • ECT • IAT • MAF • RPM If PID value is not as specified, repair or replace malfunctioning parts. If PID value is okay, go to next step.
9		No	Replace malfunctioning parts.
10	Inspect fuel pressure sensor. (See FUEL PRESSURE SENSOR INSPECTION [MZR-CD (RF Turbo)].) Is fuel pressure okay?	Yes	Go to next step.
10		No	Replace common rail.
11	Inspect suction control valve. (See SUCTION CONTROL VALVE INSPECTION [MZR-CD (RF Turbo)].) Is suction control valve okay?	Yes	Go to next step.
11		No	Repair supply pump. (See SUPPLY PUMP INSPECTION [MZR-CD (RF Turbo)].)
12	Is engine compression correct? (See COMPRESSION INSPECTION [MZR-CD (RF Turbo)].)	Yes	Go to next step.
12		No	Inspect for 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 as necessary.
13	Inspect fuel injector. (See FUEL INJECTOR INSPECTION [MZR-CD (RF Turbo)].) Is fuel injector okay?	Yes	Go to next step.
13		No	Repair or replace as necessary.
14	Inspect EGR system operation. Is EGR system operation normal?	Yes	Go to next step.
14		No	Repair or replace malfunctioning part according to EGR system operation results.
15	Inspect starting system. Is starting system normal?	Yes	Inspect for loose connectors or poor terminal contact. If okay, remove and inspect supply pump and common rail.
15	Inspect starting system. Is starting system normal?	No	Repair or replace components as required.
16	Verify test results. • If okay, return to diagnostic index to service any additional symptoms. • If malfunction remains, replace PCM. (See PCM REMOVAL/INSTALLATION [MZR-CD (RF Turbo)].)