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

BME010300103290

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)].)

Diagnostic Procedure

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
No | No DTC is displayed: Go to the next step.
2 | Does any other symptom exist? | Yes | Go to appropriate flowchart.
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.
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.
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.
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.
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.
No | Replace the malfunctioning parts.
8 | Perform the EGR system inspection. Is the EGR system normal? | Yes | Go to the next step.
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.
No | Service if necessary.
10 | Inspect the VSC system operation. Does the VSC system operate properly? | Yes | Go to the next step.
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.
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.
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.
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)].)