NO.19 EXCESSIVE BLACK SMOKE [MZR-CD (RF Turbo)]


19	EXCESSIVE BLACK SMOKE
DESCRIPTION	• Excessive black smoke is observed in exhaust gas.
POSSIBLE CAUSE	• Air cleaner element restriction • Incorrect fuel injection timing • Erratic signal from CKP sensor • Erratic signal from CMP sensor • Fuel pressure sensor or related circuit malfunction • ECT sensor or related circuit malfunction • Boost sensor or related circuit malfunction • Accelerator position sensor or related circuit malfunction • MAF/IAT sensor or related circuit malfunction • IAT sensor No.2 or related circuit malfunction • Fuel injector malfunction • Excessive fuel pressure • Suction control valve malfunction (built-in supply pump) • Fuel line restriction • Fuel pressure limiter malfunction (built-in common rail) • Low engine compression • Improper valve timing • EGR system malfunction • EGR water cooler malfunction • Vacuum leakage • Intake shutter valve malfunction • VSC valve 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	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
1		No	No DTC is displayed: Go to next step.
2	Does any other symptom exist?	Yes	Go to appropriate flowchart.
2	Does any other symptom exist?	No	Go to next step.
3	Inspect for air cleaner element for clogging. Is air cleaner element okay?	Yes	Go to next step.
3		No	Repair or replace air cleaner element.
4	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.
4		No	Go to next step.
5	Visually inspect CKP sensor and teeth of pulse wheel. Are CKP sensor and teeth of pulse wheel okay?	Yes	Go to next step.
5		No	Replace malfunctioning parts.
6	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.
6		No	Adjust CKP sensor position.
7	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 If PID value is not as specified, repair or replace malfunctioning parts. If PID value is okay, go to next step.
7		No	Replace malfunctioning parts.
8	Perform EGR system inspection. Is EGR system okay?	Yes	Go to next step.
8	Perform EGR system inspection. Is EGR system okay?	No	Repair or replace malfunctioning part according to EGR system operation results.
9	Inspect EGR water cooler for following: • Coolant passage clogging/restriction • Exhaust gas clogging/restriction Is EGR water cooler okay?	Yes	Go to next step.
9		No	Service as necessary.
10	Inspect VSC system operation. Does VSC system operate properly?	Yes	Go to next step.
10		No	Repair or replace malfunctioning part according to VSC system operation inspection results.
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	Inspect following: • Boost sensor • Fuel pressure limiter (built-in common rail) • Fuel pressure sensor • Fuel return line restriction Service as necessary.
13		No	Repair or replace as necessary.
14	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)].)