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

BME010300103276

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 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)].)

Diagnostic Procedure

STEP

INSPECTION

RESULTS

ACTION

1
Note
• The following test should be performed on vehicles with the immobilizer system. Go to Step 12 for the vehicles without the immobilizer system.
Connect the WDS or equivalent to the DLC-2.
Do the following conditions appear?
• Engine is not completely started.
• DTC P1624 is displayed.
Yes

Both conditions appear:

Go to Step 4.
No

Either condition or some other condition appears:

Go to the next step.
2
Does the engine stall approx. 2 s after the engine is started?
Yes
Go to the next step.
No
The immobilizer system is normal.
Go to Step 12.
3
Is the immobilizer control module connector securely connected to the immobilizer control module?
Yes
Go to the next step.
No
Connect the immobilizer control module connector securely.
Return to Step 2.
4
Does the security light flash and indicate any of the following immobilizer system DTCs?

DTC

02, 03, 11, 21

Yes
Go to "ON-BOARD DIAGNOSTIC FUNCTION" of the immobilizer system.
No
Go to the next step.
5
Does the security light illuminate?
Yes
Go to Step 8.
No
Go to the next step.
6
Does the security light flash and indicate either of the following immobilizer system DTCs more than 135 s after the engine switch is turned the to ON?

DTC

24, 30

Yes
Go to "ON-BOARD DIAGNOSTIC FUNCTION" of the immobilizer system.
No
Go to the next step.
7
Turn the engine switch off.
Disconnect the immobilizer control module connector.
Connect a jumper wire between immobilizer control module connector terminal M and GND.
Turn the engine switch to the ON position.
Does the security light illuminate?
Yes
Reconnect the immobilizer control module connector.
Go to the next step.
No
Inspect for open circuit between immobilizer control module connector terminal M and instrument cluster.
If normal, inspect the security light bulb. Repair or replace if necessary. Reconnect the immobilizer control module connector, then return to Step 4.
8
Connect the WDS or equivalent to DLC-2 and retrieve DTC.
Is any the following DTCs displayed?

DTC

P1602, P1603, P1604, P1621, P1622, P1624

Yes
Go to the applicable DTC inspection.
No
Go to the next step.
9
Disconnect the accelerator pedal position sensor connector.
Inspect for continuity between GND terminal at the accelerator pedal position sensor vehicle wiring harness connector and body GND.
Is there continuity?
Yes
Go to the next step.
No
Access PCM connector.
Inspect for continuity between PCM connector 65 and 85 terminals and body GND.
Repair or replace if necessary.
10
Turn the engine switch to the ON position.
Access VPWR PID.
Is VPWR PID normal?

VPWR PID

Battery positive voltage

Yes
Go to the next step.
No
Repair or replace the wiring harness.
11
Disconnect the immobilizer control module connector.
Turn the engine switch to the ON position.
Is there battery voltage at immobilizer control module wiring harness-side connector terminal J?
Yes
Inspect for following:
• Open or short circuit between immobilizer control module terminal A and PCM terminal 54
No
Go to the next step.
12
Inspect for the 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 normal?
Yes
Go to the next step.
No
Service if necessary.
Repeat Step 12.
13
Is the engine overheating?
Yes
Go to symptom troubleshooting "NO.17 COOLING SYSTEM CONCERNS-OVERHEATING".
No
Go to the next step.
14
Note
• Ignore DTC P0122, P0123, P0222 or P0223 while performing this test.
Disconnect the accelerator pedal position sensor connector.
Measure the voltage at accelerator pedal position sensor connector VREF terminal (terminal D) with the engine switch at the ON position.

Specification

4.5-5.5 V

Is voltage normal?
Yes
Go to the next step.
No
Go to symptom troubleshooting "NO.26 CONSTANT VOLTAGE".
15
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.

Communication error message is displayed:

Inspect for the 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
No

No DTC is displayed:

Go to the next step.
16
Does the engine start normally after warm up?
Yes
Inspect the glow system operation.
Replace the malfunctioning part if necessary.
If the glow system is normal, go to the next step.
No
Go to the next step.
17
Is there any restriction in the exhaust system or the catalyst converter?
Yes
Repair or replace if necessary.
No
Go to the next step.
18
Access RPM PID.
Is RPM PID indicating the engine speed during cranking the engine?
Yes
Go to the next step.
No
Go to Step 20.
19
Note
• The following test should be performed on the vehicles with the A/C system. If the following test cannot be performed due to the engine stalling, go to the next step.
• Go to the next step for the vehicle without the A/C system.
Connect a pressure gauge to A/C line.
Turn the blower and A/C switches on.
Is pressure within the specification?
Yes
Go to the next step.
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 the following:
• Refrigerant charging amount
• Main fan and/or additional fan operation
20
Depress the accelerator pedal slightly.
Crank the engine.
Does the engine start now?
Yes
Inspect idle speed.
No
Go to the next step.
21
Inspect for fuel leakage from the fuel pipe.
Is any fuel leakage found on the fuel pipe?
Yes
Repair or replace the malfunctioning part if necessary.
No
Go to the next step.
22
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.
No
Replace the malfunctioning part.
23
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.
No
Adjust the CKP sensor position.
24
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:
• 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.
No
Replace the malfunctioning part.
25
Inspect the fuel pressure sensor.
Is fuel pressure normal?
Yes
Go to the next step.
No
Replace the common rail.
26
Inspect the suction control valve.
Is the suction control valve normal?
Yes
Go to the next step.
No
Repair the supply pump.
27
Is the engine compression correct?
Yes
Go to the next step.
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.
28
Inspect the fuel injector.
Is the fuel injector normal?
Yes
Go to the next step.
No
Repair or replace if necessary.
29
Inspect the EGR system operation.
Is the EGR system operation normal?
Yes
Remove and inspect the supply pump and the common rail.
No
Repair or replace the malfunctioning part according to the EGR system operation results.
30
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)].)