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 pedal 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 SERVICE PRECAITION" 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	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
1		No	No DTC is displayed: Go to the next step.
2	Does any other symptom exist?	Yes	Go to appropriate flowchart.
2	Does any other symptom exist?	No	Go to the next step.
3	Inspect for the air cleaner element for clogging. Is the air cleaner element normal?	Yes	Go to the next step.
3		No	Repair or replace the air cleaner element.
4	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.
4		No	Go to the next step.
5	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.
5		No	Replace the malfunctioning parts.
6	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.
6		No	Adjust the CKP sensor position.
7	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 If PID value is not as specified, repair or replace the malfunctioning part. If PID value is normal, go to the next step.
7		No	Replace the malfunctioning parts.
8	Perform the EGR system inspection. Is the EGR system normal?	Yes	Go to the next step.
8		No	Repair or replace the malfunctioning part according to the EGR system operation results.
9	Inspect the EGR water cooler for following: • Coolant passage clogging/restriction • Exhaust gas clogging/restriction Is the EGR water cooler normal?	Yes	Go to the next step.
9		No	Service if necessary.
10	Inspect the VSC system operation. Does the VSC system operate properly?	Yes	Go to the next step.
10		No	Repair or replace the malfunctioning part according to the VSC system operation inspection results.
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	Inspect the following: • Boost sensor • Fuel pressure limiter (built-in common rail) • Fuel pressure sensor • Fuel return line restriction Service if necessary.
13		No	Repair or replace if necessary.
14	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)].)