NO.5 ENGINE STALLS-AFTER START/AT IDLE [MZR-CD (RF Turbo)]


5	ENGINE STALLS-AFTER START/AT IDLE
DESCRIPTION	• Engine stops unexpectedly.
POSSIBLE CAUSE	• Poor fuel quality • Intake-air system restriction • Air leakage from intake-air system • Engine overheating • A/C system improper operation • Immobilizer system and/or circuit malfunction • PCM control relay malfunction • Glow system malfunction • Inadequate fuel pressure • Fuel pressure sensor related circuit malfunction • Suction control valve malfunction (built-in supply pump) • Fuel pressure limiter malfunction (built-in common rail) • Fuel leakage • Fuel line restriction • Fuel filter clogging • Incorrect fuel injection timing • Erratic signal from CKP sensor • Erratic signal from CMP sensor • Supply pump malfunction • Fuel injector malfunction • Low engine compression • Improper valve timing • Exhaust system and/or catalyst converter restriction or clogging • EGR system malfunction • ECT sensor or related circuit malfunction • Accelerator positions sensor or related circuit malfunction • MAF/IAT sensor or related circuit malfunction • V-reference voltage supply circuit malfunction • IDM or related circuit 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 REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual.


STEP	INSPECTION	RESULTS	ACTION
1	Note • The following test should be performed on vehicles with immobilizer system. Go to Step 12 for vehicles without immobilizer system. Connect WDS or equivalent to DLC-2. Do following conditions appear? • Engine is not completely started. • DTC P1624 is displayed.	Yes	Both conditions appear: Go to Step 4.
1		No	Either condition or some other condition appears: Go to next step.
2	Does engine stall approx. 2 s after engine is started?	Yes	Go to next step.
2	Does engine stall approx. 2 s after engine is started?	No	Immobilizer system is okay. Go to Step 12.
3	Is immobilizer unit connector securely connected to immobilizer unit?	Yes	Go to next step.
3		No	Connect immobilizer unit connector securely. Return to Step 2.
4	Does security light flash and indicate any of following immobilizer system DTCs? DTC 02, 03, 11, 21	Yes	Go to "ON-BOARD DIAGNOSTIC FUNCTION" of immobilizer system.
4		No	Go to next step.
5	Does security light illuminate?	Yes	Go to Step 8.
5	Does security light illuminate?	No	Go to next step.
6	Does security light flash and indicate either of following immobilizer system DTCs more than 135 s after engine switch is turned to ON? DTC 24, 30	Yes	Go to "ON-BOARD DIAGNOSTIC FUNCTION" of immobilizer system.
6		No	Go to next step.
7	Turn engine switch to OFF. Disconnect immobilizer unit connector. Connect jumper wire between immobilizer unit connector terminal M and GND. Turn engine switch to ON. Does security light illuminate?	Yes	Reconnect immobilizer unit connector. Go to next step.
7		No	Inspect for open circuit between immobilizer unit connector terminal M and instrument cluster. If okay, inspect security light bulb. Repair or replace if necessary. Reconnect immobilizer unit connector, then return to Step 4.
8	Connect WDS or equivalent to DLC-2 and retrieve DTC. Is any following DTCs displayed? DTC P1602, P1603, P1604, P1621, P1622, P1624	Yes	Go to appropriate DTC test.
8		No	Go to next step.
9	Disconnect accelerator position sensor connector. Inspect continuity between GND terminal at accelerator position sensor vehicle harness connector and body GND. Is there continuity?	Yes	Go to next step.
9		No	Access PCM connector. Inspect for continuity between PCM connector 65 and 85 terminals and body GND. Repair or replace as necessary.
10	Turn engine switch to ON. Access VPWR PID. Is VPWR PID okay? VPWR PID Battery positive voltage	Yes	Go to next step.
10		No	Repair or replace wiring harness.
11	Disconnect immobilizer unit connector. Turn engine switch to ON. Is there battery voltage at immobilizer unit harness-side terminal J?	Yes	Inspect for following: • Open or short circuit between immobilizer unit terminal A and PCM terminal 54
11		No	Go to next step.
12	Inspect for following: • Fuel quality (e.g.: include water contamination, winter/summer blend) • Fuel line/fuel filter clogging • Cracks on intake-air system parts • Intake-air system restriction Are all items okay?	Yes	Go to next step.
12		No	Service as necessary. Repeat Step 12.
13	Is engine overheating?	Yes	Go to symptom troubleshooting "NO.17 COOLING SYSTEM CONCERNS-OVERHEATING".
13	Is engine overheating?	No	Go to next step.
14	Note • Ignore DTC P0122, P0123, P0222 or P0223 while performing this test. Disconnect accelerator position sensor connector. Measure voltage at accelerator position sensor connector VREF terminal (terminal D) with engine switch ON. Specification 4.5-5.5 V Is voltage okay?	Yes	Go to next step.
14		No	Go to symptom troubleshooting "NO.26 CONSTANT VOLTAGE".
15	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 for following: • 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
15		No	No DTC is displayed: Go to next step.
16	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.
16	Does engine start normally after warm-up?	No	Go to next step.
17	Is there any restriction in exhaust system or catalyst converter?	Yes	Repair or replace as necessary.
17		No	Go to next step.
18	Access RPM PID. Is RPM PID indicating engine speed during cranking engine?	Yes	Go to next step.
18		No	Go to Step 20.
19	Note • The following test should be performed on the vehicles with A/C system. If the following test cannot be performed due to engine stalling, go to next step. • Go to next step for the vehicle without A/C system. Connect pressure gauge to A/C line. Turn blower and A/C switches on. Is pressure within specifications?	Yes	Go to next step.
19		No	A/C is always on: Go to symptom troubleshooting "NO.24 A/C ALWAYS ON OR A/C COMPRESSOR RUNS CONTINUOUSLY". Other symptoms: Inspect following: • Refrigerant charging amount • Main fan and/or additional fan operation
20	Depress accelerator pedal slightly. Crank engine. Does engine start now?	Yes	Inspect idle speed. (See IDLE SPEED INSPECTION [MZR-CD (RF Turbo)].)
20		No	Go to next step.
21	Inspect for fuel leakage from fuel pipe. Is any fuel leakage found on fuel pipe?	Yes	Repair or replace as necessary.
21		No	Go to next step.
22	Visually inspect CKP sensor and teeth of pulse wheel. Are CKP sensor and teeth of pulse wheel okay?	Yes	Go to next step.
22		No	Replace malfunctioning parts.
23	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.
23		No	Adjust CKP sensor position.
24	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.
24		No	Replace malfunctioning parts.
25	Inspect fuel pressure sensor. (See FUEL PRESSURE SENSOR INSPECTION [MZR-CD (RF Turbo)].) Is fuel pressure okay?	Yes	Go to next step.
25		No	Replace common rail.
26	Inspect suction control valve. (See SUCTION CONTROL VALVE INSPECTION [MZR-CD (RF Turbo)].) Is suction control valve okay?	Yes	Go to next step.
26		No	Repair supply pump. (See SUPPLY PUMP INSPECTION [MZR-CD (RF Turbo)].)
27	Is engine compression correct? (See COMPRESSION INSPECTION [MZR-CD (RF Turbo)].)	Yes	Go to next step.
27		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.
28	Inspect fuel injector. (See FUEL INJECTOR INSPECTION [MZR-CD (RF Turbo)].) Is fuel injector okay?	Yes	Go to next step.
28		No	Repair or replace as necessary.
29	Inspect EGR system operation. Is EGR system operation normal?	Yes	Remove and inspect supply pump and common rail.
29		No	Repair or replace malfunctioning part according to EGR system operation results.
30	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)].)