NO.15 EMISSION COMPLIANCE [MZR-CD (RF Turbo)]


15	EMISSION COMPLIANCE
DESCRIPTION	• Fails emissions test.
POSSIBLE CAUSE	• Poor fuel quality • Vacuum leakage • Air leakage from intake-air system • Intake-air system restriction • Variable swirl control (VSC) system malfunction • Variable boost control (VBC) system malfunction • Intake shutter valve stuck close • VSC valve stuck close • Turbocharger malfunction • Guide blade valve malfunction • Charge air cooler malfunction • Glow system malfunction • EGR system malfunction • EGR water cooler malfunction • Low coolant temperature • Engine overheating • Inadequate fuel pressure • Fuel pressure limiter malfunction (built-in common rail) • Suction control valve inspection (built-in supply pump) • ECT sensor or related circuit malfunction • MAF/IAT sensor related circuit malfunction • IAT sensor No.2 or related circuit malfunction • Fuel pressure sensor or related circuit malfunction • Incorrect adjustment accelerator position sensor and/or idle switch • Accelerator position sensor or related circuit malfunction • Fuel line restriction • Supply pump malfunction • Fuel injector malfunction • Incorrect fuel injection timing • Incorrect fuel idle speed • Erratic signal from CKP sensor • Erratic signal from CMP sensor • ECT sensor malfunction • Boost sensor or related circuit malfunction • MAF sensor malfunction • Neutral switch or related circuit malfunction • VSS or related circuit malfunction • Low engine compression • Improper valve timing • Exhaust system and/or catalyst converter restriction • Catalyst converter 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	Is engine overheating?	Yes	Go to symptom troubleshooting "NO.17 COOLING SYSTEM CONCERNS-OVERHEATING".
1	Is engine overheating?	No	Go to next step.
2	Does engine run cold?	Yes	Go to symptom troubleshooting "NO.18 COOLING SYSTEM CONCERNS-RUNS COLD".
2	Does engine run cold?	No	Go to next step.
3	Connect WDS or equivalent to DLC-2. Perform self-test function using WDS or equivalent. 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
3		No	No DTC is displayed: Go to next step.
4	Inspect for following: • Fuel quality (e.g.: including water contamination, winter/summer blend) • Fuel return line clogging and/or restriction • Charge air cooler condition (restriction or damaged) • Intake-air system restriction • Exhaust system and/or catalyst converter restriction • Vacuum leakage Are all items okay?	Yes	Go to next step.
4		No	Service as necessary. Repeat Step 4.
5	Inspect adjustment of accelerator position sensor and idle switch. (See ACCELERATOR POSITION SENSOR INSPECTION [MZR-CD (RF Turbo)].) (See IDLE SWITCH INSPECTION [MZR-CD (RF Turbo)].) Are accelerator position sensor and idle switch adjusted correctly?	Yes	Go to next step.
5		No	Adjust accelerator position sensor and idle switch correctly. (See ACCELERATOR POSITION SENSOR ADJUSTMENT [MZR-CD (RF Turbo)].) (See IDLE SWITCH ADJUSTMENT [MZR-CD (RF Turbo)].)
6	Inspect adjustment of neutral switch. (See NEUTRAL SWITCH INSPECTION [MZR-CD (RF Turbo)].) Is neutral switch adjusted correctly?	Yes	Go to next step.
6		No	Adjust neutral switch correctly.
7	Inspect intake shutter valve and VSC valve operations. (See ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZR-CD (RF Turbo)].) Is there any problem?	Yes	Repair or replace as necessary.
7		No	Go to next step.
8	Inspect guide blade valve operation. (See ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZR-CD (RF Turbo)].) Is there any problem?	Yes	Repair or replace as necessary.
8		No	Go to next step.
9	Inspect hose bands between following parts: • Turbocharger compressor housing and air cleaner • Turbocharger compressor housing and charge air cooler Are hose bands loose?	Yes	Retighten hose bands. If concern is resolved, complete inspection. If concern still exists, go to next step.
9		No	Go to next step.
10	Inspect for improper operation, kinks, clogging or disconnection on guide blade actuator. (See ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZR-CD (RF Turbo)].) Is actuator okay?	Yes	Go to next step.
10		No	Repair or replace as necessary. If concern is resolved, complete inspection. If concern still exists, turbocharger is okay. Go to next step.
11	Remove parts necessary to inspect turbocharger. Do not remove turbocharger. Inspect if turbocharger compressor wheel is bent, damaged, or interfering with housing on vehicle. (See TURBOCHARGER INSPECTION [MZR-CD (RF Turbo)].) Is there any problem?	Yes	Replace turbocharger.
11		No	Go to next step.
12	Inspect if turbocharger compressor wheel locknut is loose or has fallen down inside turbocharger. Is there any problem?	Yes	Replace turbocharger.
12		No	Go to next step.
13	Inspect turbocharger compressor wheel by hand. Does wheel turn easily and smoothly?	Yes	Go to next step.
13		No	Replace turbocharger.
14	Inspect if turbocharger turbine wheel is damaged, cracked or interfering with housing on vehicle. Note • Inspect all fins on each turbine wheel. Is there any problem?	Yes	Replace turbocharger.
14		No	Go to next step.
15	Is any engine oil found inside turbocharger turbine housing?	Yes	Excessive amount of oil is found: Replace turbocharger. Small amount of oil is found: Wipe oil off of vehicle, then go to next step.
15		No	Go to next step.
16	Is any engine oil found inside turbocharger compressor hosing?	Yes	Wipe oil off of vehicle and install all removed parts in Step 10. Then, go to next step.
16		No	Turbocharger is okay. Install all parts removed in Step10. Then, go to next step.
17	Perform EGR system inspection. Is EGR system okay?	Yes	Go to next step.
17	Perform EGR system inspection. Is EGR system okay?	No	Repair or replace malfunctioning part according to EGR system operation results.
18	Inspect EGR water cooler for following: • Coolant passage clogging/restriction • Exhaust gas clogging/restriction Is EGR water cooler okay?	Yes	Go to next step.
18		No	Service as necessary.
19	Inspect glow system operation. (See RELAY INSPECTION.) Is glow system operation normal?	Yes	Go to next step.
19		No	Repair or replace malfunctioning part according to glow system operation results.
20	Visually inspect CKP sensor and teeth of pulse wheel. Are CKP sensor and teeth of pulse wheel okay?	Yes	Go to next step.
20		No	Replace malfunctioning parts.
21	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.
21		No	Adjust CKP sensor position.
22	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 • MAP • RPM • VSS If PID value is not as specified, repair or replace malfunctioning parts. If PID value is okay, go to next step.
22		No	Replace malfunctioning parts.
23	Inspect fuel pressure sensor. (See FUEL PRESSURE SENSOR INSPECTION [MZR-CD (RF Turbo)].) Is fuel pressure okay?	Yes	Go to next step.
23		No	Replace common rail.
24	Inspect suction control valve. (See SUCTION CONTROL VALVE INSPECTION [MZR-CD (RF Turbo)].) Is suction control valve okay?	Yes	Go to next step.
24		No	Repair supply pump. (See SUPPLY PUMP INSPECTION [MZR-CD (RF Turbo)].)
25	Is engine compression correct? (See COMPRESSION INSPECTION [MZR-CD (RF Turbo)].)	Yes	Go to next step.
25		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.
26	Inspect fuel injector. (See FUEL INJECTOR INSPECTION [MZR-CD (RF Turbo)].) Is fuel injector okay?	Yes	Go to next step.
26		No	Repair or replace as necessary.
27	Inspect timing belt for followings: • Chipping of gear teeth • Low tension • Breakage damage or cracks Is timing belt okay?	Yes	Inspect following: • ECT sensor • Boost sensor • MAF/IAT sensor • Catalyst converter If okay, remove and inspect supply pump and common rail.
27		No	If timing is incorrect, adjust valve timing. If timing belt is not okay, replace timing belt.
28	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)].)