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 pedal 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 SERVICE PRECAUTION" and "AFTER SERVICE PRECAUTION" described in this manual. (See BEFORE SERVICE PRECAUTION [MZR-CD (RF Turbo)].) (See AFTER SERVICE PRECAUTION [MZR-CD (RF Turbo)].)


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