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

BME010300000W54

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.

Diagnostic Procedure

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
No | No DTC is displayed: Go to next step.
2 | Does any other symptom exist? | Yes | Go to appropriate flowchart.
No | Go to next step.
3 | Inspect for air cleaner element for clogging. Is air cleaner element okay? | Yes | Go to next step.
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.
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.
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.
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.
No | Replace malfunctioning parts.
8 | Perform EGR system inspection. Is EGR system okay? | Yes | Go to next step.
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.
No | Service as necessary.
10 | Inspect VSC system operation. Does VSC system operate properly? | Yes | Go to next step.
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.
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.
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.
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)].)