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 pedal position sensor and/or idle switch • Accelerator pedal 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 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	Is engine overheating?	Yes	Go to symptom troubleshooting "NO.17 COOLING SYSTEM CONCERNS-OVERHEATING". (See NO.17 COOLING SYSTEM CONCERNS-OVERHEATING [MZR-CD (RF Turbo)].)
1	Is engine overheating?	No	Go to the next step.
2	Does engine run cold?	Yes	Go to symptom troubleshooting "NO.18 COOLING SYSTEM CONCERNS-RUNS COLD". (See NO.17 COOLING SYSTEM CONCERNS-OVERHEATING [MZR-CD (RF Turbo)].)
2	Does engine run cold?	No	Go to the next step.
3	Connect the WDS or equivalent to the DLC-2. Perform self-test function using the WDS or equivalent. Turn the 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 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
3		No	No DTC is displayed: Go to the next step.
4	Inspect for the 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 normal?	Yes	Go to the next step.
4		No	Service if necessary. Repeat Step 4.
5	Inspect adjustment of the accelerator pedal position sensor and the idle switch. (See ACCELERATOR PEDAL POSITION (APP) SENSOR INSPECTION [MZR-CD (RF Turbo)].) (See IDLE SWITCH INSPECTION [MZR-CD (RF Turbo)].) Are the accelerator pedal position sensor and the idle switch adjusted correctly?	Yes	Go to the next step.
5		No	Adjust the accelerator pedal position sensor and idle switch correctly. (See ACCELERATOR PEDAL POSITION (APP) SENSOR INSPECTION [MZR-CD (RF Turbo)].) (See IDLE SWITCH ADJUSTMENT [MZR-CD (RF Turbo)].)
6	Inspect adjustment of the neutral switch. (See NEUTRAL SWITCH INSPECTION [MZR-CD (RF Turbo) MTX].) Is the neutral switch adjusted correctly?	Yes	Go to the next step.
6		No	Adjust the neutral switch correctly.
7	Inspect the intake shutter valve and the VSC valve operations. (See ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZR-CD (RF Turbo)].) Is there any problem?	Yes	Repair or replace if necessary.
7		No	Go to the next step.
8	Inspect the guide blade valve operation. (See ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZR-CD (RF Turbo)].) Is there any problem?	Yes	Repair or replace if necessary.
8		No	Go to the next step.
9	Inspect hose bands between the 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 the inspection. If concern still exists, go to the next step.
9		No	Go to the next step.
10	Inspect for improper operation, kinks, clogging or disconnection on the guide blade actuator. (See ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZR-CD (RF Turbo)].) Is the actuator normal?	Yes	Go to the next step.
10		No	Repair or replace if necessary. If concern is resolved, complete the inspection. If concern still exists, the turbocharger is normal. Go to the next step.
11	Note • Do not remove the turbocharger. Remove the parts for easier access to inspect the turbocharger. Inspect if the turbocharger compressor wheel is bent, damaged, or interfering with housing on the vehicle. (See TURBOCHARGER INSPECTION [MZR-CD (RF Turbo)].) Is there any problem?	Yes	Replace the turbocharger.
11		No	Go to the next step.
12	Inspect if the turbocharger compressor wheel locknut is loose or has fallen down inside the turbocharger. Is there any problem?	Yes	Replace the turbocharger.
12		No	Go to the next step.
13	Inspect the turbocharger compressor wheel by hand. Does the wheel turn easily and smoothly?	Yes	Go to the next step.
13		No	Replace the turbocharger.
14	Inspect if the turbocharger turbine wheel is damaged, cracked or interfering with housing on the vehicle. Note • Inspect all fins on each turbine wheel. Is there any problem?	Yes	Replace the turbocharger.
14		No	Go to the next step.
15	Is any engine oil found inside the turbocharger turbine housing?	Yes	Excessive amount of oil is found: Replace the turbocharger. Small amount of oil is found: Wipe off oil of the vehicle, then go to the next step.
15		No	Go to the next step.
16	Is any engine oil found inside the turbocharger compressor hosing?	Yes	Wipe off oil of the vehicle and install all removed parts in Step 10. Then, go to the next step.
16		No	The turbocharger is normal. Install all parts removed in Step10. Then, go to the next step.
17	Perform the EGR system inspection. Is the EGR system normal?	Yes	Go to the next step.
17		No	Repair or replace malfunctioning part according to the EGR system operation results.
18	Inspect the EGR water cooler for the following: • Coolant passage clogging/restriction • Exhaust gas clogging/restriction Is the EGR water cooler normal?	Yes	Go to the next step.
18		No	Service if necessary.
19	Inspect the glow system operation. (See RELAY INSPECTION.) Is the glow system operation normal?	Yes	Go to the next step.
19		No	Repair or replace the malfunctioning part according to glow system operation results.
20	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.
20		No	Replace the malfunctioning part.
21	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.
21		No	Adjust the CKP sensor position.
22	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 • MAP • RPM • VSS If PID value is not as specified, repair or replace the malfunctioning part. If PID value is normal, go to the next step.
22		No	Replace the malfunctioning parts.
23	Inspect the fuel pressure sensor. (See FUEL PRESSURE SENSOR INSPECTION [MZR-CD (RF Turbo)].) Is fuel pressure normal?	Yes	Go to the next step.
23		No	Replace the common rail.
24	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.
24		No	Repair the supply pump. (See SUPPLY PUMP INSPECTION [MZR-CD (RF Turbo)].)
25	Is the engine compression correct? (See COMPRESSION INSPECTION [MZR-CD (RF Turbo)].)	Yes	Go to the next step.
25		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.
26	Inspect the fuel injector. (See FUEL INJECTOR INSPECTION [MZR-CD (RF Turbo)].) Is the fuel injector normal?	Yes	Go to the next step.
26		No	Repair or replace if necessary.
27	Inspect the timing belt for the following: • Chipping of gear teeth • Low tension • Breakage damage or cracks Is the timing belt normal?	Yes	Inspect the following: • ECT sensor • Boost sensor • MAF/IAT sensor • Catalyst converter If normal, remove and inspect the supply pump and the common rail.
27		No	If timing is incorrect, adjust valve timing. If the timing belt is not normal, replace the timing belt.
28	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)].)