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Symptom Troubleshooting - Engine Control System [Mzr 2.0, Mzr 2.5]: Other Mazda 3 BL рестайлинг

Testing & Diagnostics 10 illustrations ~2354 words

FOREWORD [MZR 2.0, MZR 2.5]

  1. If there is any vehicle malfunction complaint lodged by a customer, perform malfunction diagnosis according to the troubleshooting procedure.

Troubleshooting Procedure Chart. Scheme 80

Scheme 80: Troubleshooting Procedure Chart
Scheme 80: Troubleshooting Procedure Chart

Scheme 81

Scheme 81: Action for Non-repeatable Malfunction
Scheme 81: Action for Non-repeatable Malfunction

Scheme 82

Scheme 82
Scheme 82
  1. If the malfunction does not recur, verify the malfunction cause by performing the following actions: Based on the repair order form, attempt to drive the vehicle or perform tests to replicate the malfunction, record the data (such as PCM circuit voltage) at that time, and detect the malfunction cause. Shake the wiring harness or connector of the electrical component which is suspected to be the cause of the malfunction, and inspect for malfunction or occurrence of any DTCs. (Scheme 81): Shaking Wiring Harness Or Connector Of Electrical Component Inspect the female terminals on the connector of the electric component which is suspected to be the cause of the malfunction for poor connection. (Scheme 82): Inspecting Female Terminals On Connector Of Electric Component

ENGINE CONTROL SYSTEM DEVICE AND CONTROL RELATIONSHIP CHART [MZR 2.0, MZR 2.5]

x: Applicable

Engine Control System Device And Control Relationship Chart [MZR 2.0, MZR 2.5] (1 Of 2). Scheme 83

Scheme 83: Engine Control System Device And Control Relationship Chart [MZR 2.0, MZR 2.5] (1 Of 2)
Scheme 83: Engine Control System Device And Control Relationship Chart [MZR 2.0, MZR 2.5] (1 Of 2)

Engine Control System Device And Control Relationship Chart [MZR 2.0, MZR 2.5] (2 Of 2). Scheme 84

Scheme 84: Engine Control System Device And Control Relationship Chart [MZR 2.0, MZR 2.5] (2 Of 2)
Scheme 84: Engine Control System Device And Control Relationship Chart [MZR 2.0, MZR 2.5] (2 Of 2)

NO.1 MELTING OF MAIN OR OTHER FUSES [MZR 2.0, MZR 2.5]

1 MELTING OF MAIN OR OTHER FUSES [TROUBLESHOOTING HINTS] Inspect condition of fuse. Damaged Fuse Related Wiring Harness FAN1 Fan control module IG KEY1 Ignition switch (vehicles without advanced keyless entry and push button start system) ACC relay (vehicles with advanced keyless entry and push button start system) IG1 relay (vehicles with advanced keyless entry and push button start system) Power window relay (vehicles with advanced keyless entry and push button start system) IG KEY2 Starter relay Ignition switch (vehicles without advanced keyless entry and push button start system) IG2 relay (vehicles with advanced keyless entry and push button start system) Windshield wiper relay (vehicles with advanced keyless entry and push button start system) FUEL PUMP Fuel pump relay ST SIG Starter relay STARTER Starter Generator ENG+B PCM Main relay ENG Fuel pump relay PCM HO2S Ignition coil No.1 Ignition coil No.2 Ignition coil No.3 Ignition coil No.4 ENG MAIN Main relay ENG INJ Fuel injector No.1 Fuel injector No.2 Fuel injector No.3 Fuel injector No.4 CV solenoid valve (except for Mexico) APP sensor ENG BAR EGR valve Purge solenoid valve Variable tumble solenoid valve Variable intake air solenoid valve MAF/IAT sensor A/F sensor ENG BAR2 PCM ETV PCM STOP Starter cut relay (vehicles with advanced keyless entry and push button start system (MTX))

Scheme 85

Scheme 85: NO.1 MELTING OF MAIN OR OTHER FUSES [MZR 2.0, MZR 2.5]
Scheme 85: NO.1 MELTING OF MAIN OR OTHER FUSES [MZR 2.0, MZR 2.5]

NO.2 MIL ILLUMINATES [MZR 2.0, MZR 2.5]

2MIL ILLUMINATES
DESCRIPTIONMIL is illuminated incorrectly.
POSSIBLE CAUSEMIL illuminates for emission-related concern (PCM DTC is stored) Instrument cluster malfunction NOTE: If the MIL blinks at steady rate, misfire condition could possibly exist.
NOTE
If the MIL blinks at steady rate, misfire condition could possibly exist.

NO.3 WILL NOT CRANK [MZR 2.0, MZR 2.5]

3 WILL NOT CRANK DESCRIPTION Starter does not work. POSSIBLE CAUSE Vehicles without advanced keyless entry and push button start system: Coil antenna connector or terminals malfunction Instrument cluster and related wiring harness malfunction Immobilizer system malfunction Coil antenna circuit and related connectors malfunction Charging system malfunction Open circuit in wiring harness between PCM terminal 1BB and starter relay TR switch misadjustment (ATX) Open or short circuit in wiring harness between TR switch and TCM (ATX) Starter interlock switch and related wiring harness malfunction (MTX) Open or short circuit in wiring harness between starter relay and PCM Open or short circuit in wiring harness between starter relay and ignition switch Ignition switch and related wiring harness malfunction Open or short circuit in wiring harness between starter relay and battery positive terminal Open or short circuit in wiring harness between starter relay and starter Starter malfunction Seized/hydro locked engine, drive plate (ATX), flywheel (MTX) PCM continuous memory DTC is stored Starter circuit in ignition switch Vehicles with advanced keyless entry and push button start system: Advanced keyless entry and push button start system malfunction Coil antenna connector or terminals malfunction Instrument cluster and related wiring harness malfunction Immobilizer system malfunction Coil antenna circuit and related connectors malfunction Charging system malfunction Starter relay malfunction Open circuit in wiring harness between keyless control module terminal 3B and starter relay terminal E Short to ground in wiring harness between keyless control module terminal 3B and starter relay terminal E Keyless control module malfunction TR switch malfunction (ATX) Open or short circuit in wiring harness between battery positive terminal and starter cut relay (MTX) Starter cut relay malfunction (MTX) Open or short circuit in wiring harness between starter cut relay and clutch cut switch (MTX) Open or short circuit in wiring harness between clutch cut switch and body ground (MTX) Clutch cut switch malfunction (MTX) Open or short circuit in wiring harness between starter relay terminal A and keyless control module terminal 2F Open circuit in wiring harness between keyless control module terminal 3T and TR switch terminal A (ATX) Open circuit in wiring harness between keyless control module terminal 3T and starter cut relay terminal D (MTX) Starter and related wiring harness malfunction Open circuit in wiring harness between TR switch terminal A and PCM terminal 1BB (ATX) Open circuit in wiring harness between starter cut relay terminal D and PCM terminal 1BB (MTX) Open circuit in wiring harness between PCM terminal 1BB and starter relay TR switch misadjustment (ATX) Open or short circuit in wiring harness between TR switch and TCM (ATX) Starter interlock switch and related wiring harness malfunction (MTX) Open or short circuit in wiring harness between starter relay and PCM Open or short circuit in wiring harness between starter relay and ignition switch Ignition switch and related wiring harness malfunction Open or short circuit in wiring harness between starter relay and battery positive terminal Open or short circuit in wiring harness between starter relay and starter Starter malfunction Seized/hydro locked engine, drive plate (ATX), flywheel (MTX) PCM continuous memory DTC is stored Starter circuit in ignition switch

Scheme 86

Scheme 86: NO.3 WILL NOT CRANK [MZR 2.0, MZR 2.5]
Scheme 86: NO.3 WILL NOT CRANK [MZR 2.0, MZR 2.5]

Scheme 87

Scheme 87
Scheme 87

NO.4 HARD TO START/LONG CRANK/ERRATIC START/ERRATIC CRANK [MZR 2.0, MZR 2.5]

4HARD TO START/LONG CRANK/ERRATIC START/ERRATIC CRANK
DESCRIPTIONStarter cranks engine at normal speed but engine requires excessive cranking time before starting.
POSSIBLE CAUSENOTE: If the ignition is not switched off (to LOCK or ACC) after the engine stalls, and then an engine restart is attempted, the PCM corrects the difference between CKP sensor and CMP sensor signals caused by engine stalling, which may result in more time needed to restart the engine. Vacuum leakage Poor fuel quality Air leakage or restriction in intake-air system Low or dead battery Charging system malfunction PCM DTC is stored Cooling system malfunction Ignition coil related wiring harness malfunction Spark plug malfunction CKP sensor and teeth of crankshaft pulley malfunction Improper operation of drive-by-wire control system Excessive fuel pressure Fuel leakage from fuel system Purge solenoid valve malfunction MAF sensor malfunction Restriction in exhaust system EGR valve malfunction Starting system 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 2.0, MZR 2.5] .) (See AFTER SERVICE PRECAUTION [MZR 2.0, MZR 2.5] .) CAUTION: Disconnecting/connecting the quick release connector without cleaning it may possibly cause damage to the fuel pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting, and make sure that it is free of foreign material.
NOTE
If the ignition is not switched off (to LOCK or ACC) after the engine stalls, and then an engine restart is attempted, the PCM corrects the difference between CKP sensor and CMP sensor signals caused by engine stalling, which may result in more time needed to restart the engine. Vacuum leakage Poor fuel quality Air leakage or restriction in intake-air system Low or dead battery Charging system malfunction PCM DTC is stored Cooling system malfunction Ignition coil related wiring harness malfunction Spark plug malfunction CKP sensor and teeth of crankshaft pulley malfunction Improper operation of drive-by-wire control system Excessive fuel pressure Fuel leakage from fuel system Purge solenoid valve malfunction MAF sensor malfunction Restriction in exhaust system EGR valve malfunction Starting system 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 2.0, MZR 2.5] .) (See AFTER SERVICE PRECAUTION [MZR 2.0, MZR 2.5] .)
CAUTION
Disconnecting/connecting the quick release connector without cleaning it may possibly cause damage to the fuel pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting, and make sure that it is free of foreign material.

NO.5 ENGINE STALLS-AFTER START/AT IDLE [MZR 2.0, MZR 2.5]

5ENGINE STALLS-AFTER START/AT IDLE
DESCRIPTIONEngine stops unexpectedly at idle and/or after start.
POSSIBLE CAUSEAir cleaner restriction EGR valve malfunction Electrical connector disconnected Poor fuel quality Ignition wiring malfunction Air leakage from intake air system Intake air system restriction Vacuum leakage APP sensor and related wiring harness malfunction TP sensor and related wiring harness malfunction PCM continuous memory DTC is stored Improper operation of drive-by-wire control system CKP sensor and related wiring harness malfunction CKP sensor and teeth of crankshaft pulley malfunction Ignition coil and related wiring harness malfunction Spark plug malfunction Exhaust system part malfunction Excessive or insufficient fuel pressure Fuel pump relay or fuel pump circuit malfunction Restriction in fuel line Pressure regulator malfunction Fuel pump unit malfunction Fuel leakage from fuel system Fuel injector malfunction Improper operation of A/C system Purge solenoid valve malfunction Evaporative emission control system malfunction Air leakage from intake air system EGR valve malfunction Improper operation of variable valve timing control system Improper valve timing Low engine compression PCV 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 PRECAUTION" and "AFTER SERVICE PRECAUTION" described in this manual. (See BEFORE SERVICE PRECAUTION [MZR 2.0, MZR 2.5] .) (See AFTER SERVICE PRECAUTION [MZR 2.0, MZR 2.5] .) CAUTION: Disconnecting/connecting the quick release connector without cleaning it may possibly cause damage to the fuel pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting, and make sure that it is free of foreign material.
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 2.0, MZR 2.5] .) (See AFTER SERVICE PRECAUTION [MZR 2.0, MZR 2.5] .)
CAUTION
Disconnecting/connecting the quick release connector without cleaning it may possibly cause damage to the fuel pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting, and make sure that it is free of foreign material.

NO.6 CRANKS NORMALLY BUT WILL NOT START [MZR 2.0, MZR 2.5]

6CRANKS NORMALLY BUT WILL NOT START
DESCRIPTIONThe starter cranks engine at normal speed but engine will not run. Refer to symptom troubleshooting "No.5 ENGINE STALLS" if this symptom appears after engine stall. Fuel is in tank. Battery is in normal condition.
POSSIBLE CAUSEVacuum leakage External fuel shut off or accessory Poor fuel quality Air leakage from intake air system Intake air system restriction Proper sealing of intake manifold and components attached to intake manifold: EGR valve Ignition wiring malfunction Electrical connector disconnected Fuse malfunction APP sensor and related wiring harness malfunction TP sensor and related wiring harness malfunction PCM continuous memory DTC is stored Improper operation of drive-by-wire control system CKP sensor and related wiring harness malfunction CKP sensor and teeth of crankshaft pulley malfunction Ignition coil and related wiring harness malfunction Spark plug malfunction Exhaust system part malfunction Excessive or insufficient fuel pressure Fuel pump relay or fuel pump circuit malfunction Restriction in fuel line Pressure regulator malfunction Fuel pump unit malfunction Fuel leakage from fuel system Fuel injector malfunction Purge solenoid valve malfunction Evaporative emission control system malfunction Air leakage from intake air system EGR valve malfunction Improper operation of variable valve timing control system Low engine compression Improper valve timing 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 2.0, MZR 2.5] .) (See AFTER SERVICE PRECAUTION [MZR 2.0, MZR 2.5] .) CAUTION: Disconnecting/connecting the quick release connector without cleaning it may possibly cause damage to the fuel pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting, and make sure that it is free of foreign material.
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 2.0, MZR 2.5] .) (See AFTER SERVICE PRECAUTION [MZR 2.0, MZR 2.5] .)
CAUTION
Disconnecting/connecting the quick release connector without cleaning it may possibly cause damage to the fuel pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting, and make sure that it is free of foreign material.

NO.7 SLOW RETURN TO IDLE [MZR 2.0, MZR 2.5]

7SLOW RETURN TO IDLE
DESCRIPTIONEngine takes more time than normal to return to idle speed.
POSSIBLE CAUSEPCM DTC is stored ECT sensor No.1 malfunction Thermostat is stuck open Throttle body malfunction Air leakage from intake air system

NO.8 ENGINE RUNS ROUGH/ROLLING IDLE [MZR 2.0, MZR 2.5]

8ENGINE RUNS ROUGH/ROLLING IDLE
DESCRIPTIONEngine speed fluctuates between specified idle speed and lower speed, and engine shakes excessively. Idle speed is too slow and engine shakes excessively.
POSSIBLE CAUSEIdle learning of drive-by-wire control system is not completed Electrical connector disconnected External fuel shut off or accessory Poor fuel quality Fuse malfunction Ignition wiring malfunction Air leakage from intake air system Vacuum leakage PCM ground circuit (1E, 1F, 1G or 1BE) malfunction Improper installation of EGR valve PCM DTC is stored Engine overheating MAF sensor and related wiring harness malfunction Improper operation of A/C system CKP sensor and teeth of crankshaft pulley malfunction Ignition system malfunction Ignition coil and related wiring harness malfunction Spark plug malfunction Improper operation of drive-by-wire control system Excessive or insufficient fuel pressure Fuel pump relay or fuel pump circuit malfunction Restriction in fuel line Pressure regulator malfunction Fuel pump unit malfunction Fuel leakage from fuel system Fuel injector malfunction Purge solenoid valve malfunction Evaporative emission control system malfunction Exhaust system part malfunction CMP sensor and teeth of camshaft malfunction EGR valve malfunction Improper operation of variable valve timing control system Low engine compression PCV 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 PRECAUTION" and "AFTER SERVICE PRECAUTION" described in this manual. (See BEFORE SERVICE PRECAUTION [MZR 2.0, MZR 2.5] .) (See AFTER SERVICE PRECAUTION [MZR 2.0, MZR 2.5] .) CAUTION: Disconnecting/connecting the quick release connector without cleaning it may possibly cause damage to the fuel pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting, and make sure that it is free of foreign material.
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 2.0, MZR 2.5] .) (See AFTER SERVICE PRECAUTION [MZR 2.0, MZR 2.5] .)
CAUTION
Disconnecting/connecting the quick release connector without cleaning it may possibly cause damage to the fuel pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting, and make sure that it is free of foreign material.

NO.9 FAST IDLE/RUNS ON [MZR 2.0, MZR 2.5]

9FAST IDLE/RUNS ON
DESCRIPTIONEngine speed continues at fast idle after warm-up. Engine runs after the ignition is off.
POSSIBLE CAUSECooling fan system malfunction ECT sensor No.1 malfunction Improper load signal input Refrigerant pressure sensor malfunction Evaporator temperature sensor malfunction Climate control unit malfunction Communication between climate control unit and instrument cluster Communication between instrument cluster and PCM CPP switch malfunction (MTX) Neutral switch malfunction (MTX) TR switch malfunction (ATX) Communication between TCM and PCM (ATX) Improper operation of drive-by-wire control system APP sensor malfunction

NO.10 LOW IDLE/STALLS DURING DECELERATION [MZR 2.0, MZR 2.5]

10LOW IDLE/STALLS DURING DECELERATION
DESCRIPTIONEngine stops unexpectedly at the beginning of deceleration or recovery from deceleration.
POSSIBLE CAUSEECT sensor No.1 malfunction Improper operation of A/C magnetic clutch Vacuum leakage Air leakage from intake air system Engine mount installation loose PCM DTC is stored Improper operation of drive-by-wire control system Improper operation of evaporative emission control system Erratic signal to PCM APP sensor or related wiring harness malfunction TP sensor or related wiring harness malfunction MAF sensor or related wiring harness malfunction A/F sensor or related wiring harness malfunction VSS or related wiring harness malfunction Erratic load signal input Refrigerant pressure sensor malfunction Evaporator temperature sensor malfunction Climate control unit malfunction Communication between climate control unit and instrument cluster Communication between instrument cluster and PCM CPP switch malfunction (MTX) Neutral switch malfunction (MTX) TR switch malfunction (ATX) Communication between TCM and PCM (ATX)

NO.11 ENGINE STALLS/QUITS, ENGINE RUNS ROUGH, MISSES, BUCK/JERK, HESITATION/STUMBLE, SURGES [MZR 2.0, MZR 2.5]

11ENGINE STALLS/QUITS-ACCELERATION/CRUISE ENGINE RUNS ROUGH-ACCELERATION/CRUISE MISSES-ACCELERATION/CRUISE BUCK/JERK-ACCELERATION/CRUISE/DECELERATION HESITATION/STUMBLE-ACCELERATION SURGES-ACCELERATION/CRUISE
DESCRIPTIONEngine stops unexpectedly at the beginning of acceleration or during acceleration. Engine stops unexpectedly while cruising. Engine speed fluctuates during acceleration or cruising. Engine misses during acceleration or cruising. Vehicle bucks/jerks during acceleration, cruising, or deceleration. Momentary pause at beginning of acceleration or during acceleration. Momentary minor irregularity in engine output.
POSSIBLE CAUSEDrive-by-wire control system operates with brake override system Air cleaner restriction Clutch slippage (MTX) Electrical connector disconnected Poor fuel quality Ignition wiring malfunction Air leakage from intake air system Intake air system restriction Improper installation of EGR valve Vacuum leakage Engine mount loose PCM DTC is stored Engine overheating Ignition system malfunction Throttle valve restriction or clogged Erratic signal to PCM APP sensor or related wiring harness malfunction TP sensor or related wiring harness malfunction CKP sensor or related wiring harness malfunction MAF sensor or related wiring harness malfunction Battery power supply circuit malfunction VSS or related wiring harness malfunction CKP sensor and teeth of crankshaft pulley malfunction Spark plug malfunction Improper operation of drive-by-wire control system Exhaust system part malfunction Excessive or insufficient fuel pressure Fuel pump relay or fuel pump circuit malfunction Restriction in fuel line Pressure regulator malfunction Fuel pump unit malfunction Fuel leakage from fuel system Fuel injector malfunction Improper operation of A/C control system Improper operation of cruise control system A/F sensor malfunction Fuel shut-off valve malfunction Purge solenoid valve malfunction Evaporative emission control system malfunction CMP sensor and teeth of camshaft malfunction Improper operation of variable valve timing control system Improper operation of EGR valve Low engine compression PCV valve malfunction Improper valve timing ATX internal malfunction (ATX) EGR valve mechanical stuck Check valve (two-way) 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 2.0, MZR 2.5] .) (See AFTER SERVICE PRECAUTION [MZR 2.0, MZR 2.5] .) CAUTION: Disconnecting/connecting the quick release connector without cleaning it may possibly cause damage to the fuel pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting, and make sure that it is free of foreign material.
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 2.0, MZR 2.5] .) (See AFTER SERVICE PRECAUTION [MZR 2.0, MZR 2.5] .)
CAUTION
Disconnecting/connecting the quick release connector without cleaning it may possibly cause damage to the fuel pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting, and make sure that it is free of foreign material.

NO.12 LACK/LOSS OF POWER-ACCELERATION/CRUISE [MZR 2.0, MZR 2.5]

12LACK/LOSS OF POWER-ACCELERATION/CRUISE
DESCRIPTIONPerformance is poor under load (such as power down when climbing hills).
POSSIBLE CAUSEDrive-by-wire control system operates with brake override system Poor fuel quality Air leakage from intake air system Intake air system restriction Intake air temperature is too hot EGR valve malfunction Vacuum leakage Clutch slippage (MTX) PCM DTC is stored Engine overheating Erratic signal to PCM APP sensor malfunction TP sensor malfunction CKP sensor or related wiring harness malfunction IAT sensor or related wiring harness malfunction MAF sensor or related wiring harness malfunction Battery power supply circuit malfunction VSS or related wiring harness malfunction CKP sensor and teeth of crankshaft pulley malfunction Spark plug malfunction Ignition coil malfunction Fuel injector malfunction Fuel leakage from fuel injector Fuel injector is clogging Throttle valve restriction or clogged Improper operation of drive-by-wire control system Exhaust system part malfunction Excessive or insufficient fuel pressure Fuel pump relay or fuel pump circuit malfunction Restriction in fuel line Pressure regulator malfunction Fuel pump unit malfunction Improper operation of variable tumble control Improper operation of variable intake air control Improper operation of A/C system Purge solenoid valve malfunction Evaporative emission control system malfunction CMP sensor and teeth of camshaft malfunction Improper operation of EGR valve Improper operation of variable valve timing control system Low engine compression Improper valve timing PCV valve malfunction ATX internal malfunction (ATX) Brake dragging 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 2.0, MZR 2.5] .) (See AFTER SERVICE PRECAUTION [MZR 2.0, MZR 2.5] .) CAUTION: Disconnecting/connecting the quick release connector without cleaning it may possibly cause damage to the fuel pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting, and make sure that it is free of foreign material.
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 2.0, MZR 2.5] .) (See AFTER SERVICE PRECAUTION [MZR 2.0, MZR 2.5] .)
CAUTION
Disconnecting/connecting the quick release connector without cleaning it may possibly cause damage to the fuel pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting, and make sure that it is free of foreign material.

NO.13 KNOCKING/PINGING-ACCELERATION/CRUISE [MZR 2.0, MZR 2.5]

13KNOCKING/PINGING-ACCELERATION/CRUISE
DESCRIPTIONSound is produced when air/fuel mixture is ignited by something other than spark plug (such as hot spot in combustion chamber).
POSSIBLE CAUSEEngine overheating due to cooling system malfunction Erratic signal to PCM ECT sensor No.1 or related wiring harness malfunction IAT sensor or related wiring harness malfunction MAF sensor or related wiring harness malfunction CMP signal malfunction Loose installation CMP sensor and/or damaged pulse wheel CKP signal malfunction Loose installation CKP sensor and/or pulse wheel PCM DTC is stored Low engine compression Excessive or insufficient fuel pressure Fuel pump relay or fuel pump circuit malfunction Restriction in fuel line Pressure regulator malfunction Fuel pump unit malfunction KS malfunction Improper ignition timing Poor fuel quality (i.e. Fuel RON is not specified, excessive cleaning agents added in fuel) 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 2.0, MZR 2.5] .) (See AFTER SERVICE PRECAUTION [MZR 2.0, MZR 2.5] .) CAUTION: Disconnecting/connecting the quick release connector without cleaning it may possibly cause damage to the fuel pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting, and make sure that it is free of foreign material.
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 2.0, MZR 2.5] .) (See AFTER SERVICE PRECAUTION [MZR 2.0, MZR 2.5] .)
CAUTION
Disconnecting/connecting the quick release connector without cleaning it may possibly cause damage to the fuel pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting, and make sure that it is free of foreign material.

NO.14 POOR FUEL ECONOMY [MZR 2.0, MZR 2.5]

14POOR FUEL ECONOMY
DESCRIPTIONFuel economy is unsatisfactory.
POSSIBLE CAUSEContaminated air cleaner element Improper ATF level (ATX) Brake dragging Clutch slippage (MTX) Low tire pressure Improper coolant level Poor fuel quality PCM DTC is stored Engine cooling system malfunction Improper operation of cooling fan control system Ignition system malfunction Excessive or insufficient fuel pressure Fuel pump relay or fuel pump circuit malfunction Restriction in fuel line Pressure regulator malfunction Fuel pump unit malfunction Improper operation of variable tumble control Improper operation of variable valve timing control system Improper operation of variable valve intake air control Exhaust system restricted Contaminated MAF sensor Low engine compression PCV valve malfunction Improper valve timing 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 2.0, MZR 2.5] .) (See AFTER SERVICE PRECAUTION [MZR 2.0, MZR 2.5] .) CAUTION: Disconnecting/connecting the quick release connector without cleaning it may possibly cause damage to the fuel pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting, and make sure that it is free of foreign material.
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 2.0, MZR 2.5] .) (See AFTER SERVICE PRECAUTION [MZR 2.0, MZR 2.5] .)
CAUTION
Disconnecting/connecting the quick release connector without cleaning it may possibly cause damage to the fuel pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting, and make sure that it is free of foreign material.

NO.15 EMISSION COMPLIANCE [MZR 2.0, MZR 2.5]

15EMISSION COMPLIANCE
DESCRIPTIONFails emissions test.
POSSIBLE CAUSEElectrical connector disconnected Intake air system and air cleaner element malfunction Vacuum lines leakage or blockage PCM DTC is stored Cooling system malfunction Fuel-filler cap malfunction A/F sensor malfunction Spark plug malfunction Erratic or no signal from CMP sensor Excessive or insufficient fuel pressure Fuel pump relay or fuel pump circuit malfunction Restriction in fuel line Pressure regulator malfunction Fuel pump unit malfunction Charcoal canister malfunction Exhaust system restricted TWC malfunction EGR system malfunction PCV valve malfunction Improper engine compression Improper valve timing 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 2.0, MZR 2.5] .) (See AFTER SERVICE PRECAUTION [MZR 2.0, MZR 2.5] .) CAUTION: Disconnecting/connecting the quick release connector without cleaning it may possibly cause damage to the fuel pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting, and make sure that it is free of foreign material.
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 2.0, MZR 2.5] .) (See AFTER SERVICE PRECAUTION [MZR 2.0, MZR 2.5] .)
CAUTION
Disconnecting/connecting the quick release connector without cleaning it may possibly cause damage to the fuel pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting, and make sure that it is free of foreign material.

NO.16 HIGH OIL CONSUMPTION/LEAKAGE [MZR 2.0, MZR 2.5]

16HIGH OIL CONSUMPTION/LEAKAGE
DESCRIPTIONOil consumption is excessive.
POSSIBLE CAUSEImproper dipstick Improper engine oil viscosity PCV valve malfunction Engine internal parts malfunction

NO.17 COOLING SYSTEM CONCERNS-OVERHEATING [MZR 2.0, MZR 2.5]

17COOLING SYSTEM CONCERNS-OVERHEATING
DESCRIPTIONEngine runs at higher than normal temperature/overheats.
POSSIBLE CAUSERadiator hoses damage Coolant leakage Improper coolant level Fans reverse rotation Fuse malfunction Coolant overflow system malfunction Poor radiator condition Improper or damaged radiator cap Improper water/anti-freeze mixture PCM, climate control unit, instrument cluster or multi information display DTC is stored Improper operation of A/C system (always on) Improper operation of cooling fan control system Improper tension of drive belt Leakage around heater unit Leakage at coolant hoses and/or radiator Thermostat malfunction Improper indication of high engine coolant warning light ECT sensor No.1 malfunction Instrument cluster malfunction

NO.18 COOLING SYSTEM CONCERNS-RUNS COLD [MZR 2.0, MZR 2.5]

18COOLING SYSTEM CONCERNS-RUNS COLD
DESCRIPTIONEngine takes excessive time to reach normal operating temperature.
POSSIBLE CAUSEA/C and heater system malfunction Thermostat malfunction Improper operation of cooling fan control system ECT sensor No.1 malfunction

NO.19 EXHAUST SMOKE [MZR 2.0, MZR 2.5]

19EXHAUST SMOKE
DESCRIPTIONBlue, black, or white smoke from exhaust system.
POSSIBLE CAUSEBlue smoke (Burning oil): PCV valve malfunction Engine internal oil leakage White smoke (Water in combustion): Cooling system malfunction (coolant loss) Engine internal coolant leakage Black smoke (Rich fuel mixture): Air cleaner restriction Intake air system is collapsed or restricted Fuel return line is restricted PCM DTC is stored Erratic signal to PCM APP sensor or related wiring harness malfunction ECT sensor No.1 or related wiring harness malfunction IAT sensor or related wiring harness malfunction MAF sensor or related wiring harness malfunction MAP sensor or related wiring harness malfunction A/F sensor or related wiring harness malfunction HO2S or related wiring harness malfunction TP sensor or related wiring harness malfunction Excessive or insufficient fuel pressure Fuel pump relay or fuel pump circuit malfunction Restriction in fuel line Pressure regulator malfunction Fuel pump unit malfunction CMP sensor malfunction Ignition system malfunction Improper engine compression Improper fuel injection timing and amount 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 2.0, MZR 2.5] .) (See AFTER SERVICE PRECAUTION [MZR 2.0, MZR 2.5] .) CAUTION: Disconnecting/connecting the quick release connector without cleaning it may possibly cause damage to the fuel pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting, and make sure that it is free of foreign material.
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 2.0, MZR 2.5] .) (See AFTER SERVICE PRECAUTION [MZR 2.0, MZR 2.5] .)
CAUTION
Disconnecting/connecting the quick release connector without cleaning it may possibly cause damage to the fuel pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting, and make sure that it is free of foreign material.

NO.20 FUEL ODOR (IN ENGINE COMPARTMENT) [MZR 2.0, MZR 2.5]

20FUEL ODOR (IN ENGINE COMPARTMENT)
DESCRIPTIONGasoline fuel smell or visible leakage.
POSSIBLE CAUSEExcessive or insufficient fuel pressure Fuel pump relay or fuel pump circuit malfunction Restriction in fuel line Pressure regulator malfunction Fuel pump unit malfunction Fuel leakage from fuel system Fuel injector malfunction Fuel tank vent system blockage Purge solenoid valve malfunction PCM DTC is stored Charcoal canister 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 2.0, MZR 2.5] .) (See AFTER SERVICE PRECAUTION [MZR 2.0, MZR 2.5] .) CAUTION: Disconnecting/connecting the quick release connector without cleaning it may possibly cause damage to the fuel pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting, and make sure that it is free of foreign material.
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 2.0, MZR 2.5] .) (See AFTER SERVICE PRECAUTION [MZR 2.0, MZR 2.5] .)
CAUTION
Disconnecting/connecting the quick release connector without cleaning it may possibly cause damage to the fuel pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting, and make sure that it is free of foreign material.

NO.23 A/C DOES NOT WORK SUFFICIENTLY [MZR 2.0, MZR 2.5]

23A/C DOES NOT WORK SUFFICIENTLY
DESCRIPTIONA/C compressor magnetic clutch does not engage when A/C is turned on.
POSSIBLE CAUSEPCM, climate control unit, instrument cluster or multi information display DTC is stored Refrigerant pressure sensor malfunction Improper refrigerant charging amount Seized A/C compressor Evaporator temperature sensor malfunction Open or short circuit in wiring harness between evaporator temperature sensor and climate control unit (Full-auto air conditioner) Instrument cluster malfunction (Does not receive A/C request signal from climate control unit or transmit it to PCM) Multi information display malfunction Climate control unit malfunction (A/C switch malfunction or climate control unit does not determine A/C request or transmit the A/C request signal) Open or short circuit in wiring harness between climate control unit terminal 2P and instrument cluster terminal 2I (Manual air conditioner) A/C compressor malfunction Open circuit in wiring harness between A/C compressor terminal A and body ground A/C relay malfunction Open circuit in wiring harness between A/C relay and PCM terminal 1I Open circuit in wiring harness between ignition switch (IG2) and A/C relay (vehicles without advanced keyless entry and push button start system) Open circuit in wiring harness between IG2 relay and A/C relay (vehicles with advanced keyless entry and push button start system) Open circuit in wiring harness between battery positive terminal and A/C relay Open circuit in wiring harness between A/C relay and A/C magnetic clutch

NO.24 A/C IS ALWAYS ON OR A/C COMPRESSOR RUNS CONTINUOUSLY [MZR 2.0, MZR 2.5]

24A/C IS ALWAYS ON OR A/C COMPRESSOR RUNS CONTINUOUSLY
DESCRIPTIONA/C compressor magnetic clutch does not disengage.
POSSIBLE CAUSEPCM, instrument cluster or climate control unit DTC is stored Short to power supply in wiring harness between A/C relay and magnetic clutch A/C compressor magnetic clutch engagement is stuck A/C relay malfunction Short to ground in wiring harness between A/C relay and PCM Short to ground in wiring harness between climate control unit terminal 2P and instrument cluster (Manual air conditioner) Climate control unit malfunction Instrument cluster malfunction (Manual air conditioner)

NO.25 A/C IS NOT CUT OFF UNDER WIDE OPEN THROTTLE CONDITIONS [MZR 2.0, MZR 2.5]

25A/C IS NOT CUT OFF UNDER WIDE OPEN THROTTLE CONDITIONS
DESCRIPTIONA/C compressor magnetic clutch does not disengage under wide open throttle.
POSSIBLE CAUSEPCM DTC is stored APP sensor malfunction

NO.26 EXHAUST SULPHUR SMELL [MZR 2.0, MZR 2.5]

26EXHAUST SULPHUR SMELL
DESCRIPTIONRotten egg smell (sulphur) from exhaust.
POSSIBLE CAUSEElectrical connector disconnected Poor fuel quality Vacuum leakage PCM DTC is stored Excessive or insufficient fuel pressure Fuel pump relay or fuel pump circuit malfunction Restriction in fuel line Pressure regulator malfunction Fuel pump unit malfunction Charcoal canister 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 2.0, MZR 2.5] .) (See AFTER SERVICE PRECAUTION [MZR 2.0, MZR 2.5] .) CAUTION: Disconnecting/connecting the quick release connector without cleaning it may possibly cause damage to the fuel pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting, and make sure that it is free of foreign material.
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 2.0, MZR 2.5] .) (See AFTER SERVICE PRECAUTION [MZR 2.0, MZR 2.5] .)
CAUTION
Disconnecting/connecting the quick release connector without cleaning it may possibly cause damage to the fuel pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting, and make sure that it is free of foreign material.

NO.28 FUEL FILLING SHUT OFF CONCERNS [MZR 2.0, MZR 2.5]

28FUEL FILLING SHUT OFF CONCERNS
DESCRIPTIONFuel does not shut off properly.
POSSIBLE CAUSEPCM DTC is stored Nonreturn valve malfunction Fuel nozzle is not inserted correctly Fuel nozzle malfunction Fuel shut-off 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 PRECAUTION" and "AFTER SERVICE PRECAUTION" described in this manual. (See BEFORE SERVICE PRECAUTION [MZR 2.0, MZR 2.5] .) (See AFTER SERVICE PRECAUTION [MZR 2.0, MZR 2.5] .) CAUTION: Disconnecting/connecting the quick release connector without cleaning it may possibly cause damage to the fuel pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting, and make sure that it is free of foreign material.
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 2.0, MZR 2.5] .) (See AFTER SERVICE PRECAUTION [MZR 2.0, MZR 2.5] .)
CAUTION
Disconnecting/connecting the quick release connector without cleaning it may possibly cause damage to the fuel pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting, and make sure that it is free of foreign material.

NO.29 SPARK PLUG CONDITION [MZR 2.0, MZR 2.5]

29SPARK PLUG CONDITION
DESCRIPTIONIncorrect spark plug condition.
POSSIBLE CAUSENOTE: Inspecting the spark plug conditions can determine whether a problem is related to a specific cylinder or possibly all cylinders. Wet/carbon stuck on specific plug: Spark-Weak, not visible Air/fuel mixture-Excessive fuel injection volume Compression-No compression, low compression Malfunction spark plug Grayish white with specific plug: Air/fuel mixture-Insufficient fuel injection volume Malfunction spark plug Wet/carbon is stuck on all plugs: Spark-Spark weak Air/fuel mixture-Too rich, excessive fuel line pressure Erratic signal to PCM ECT sensor No.1 or related wiring harness malfunction MAF sensor or related wiring harness malfunction A/F sensor or related wiring harness malfunction HO2S or related wiring harness malfunction Compression-Low compression Restriction in intake/exhaust system Grayish white with all plugs: Air/fuel mixture-Too lean, insufficient fuel line pressure Erratic signal to PCM ECT sensor No.1 or related wiring harness malfunction MAF sensor or related wiring harness malfunction A/F sensor or related wiring harness malfunction HO2S or related wiring harness 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 2.0, MZR 2.5] .) (See AFTER SERVICE PRECAUTION [MZR 2.0, MZR 2.5] .) CAUTION: Disconnecting/connecting the quick release connector without cleaning it may possibly cause damage to the fuel pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting, and make sure that it is free of foreign material.
NOTE
Inspecting the spark plug conditions can determine whether a problem is related to a specific cylinder or possibly all cylinders. Wet/carbon stuck on specific plug: Spark-Weak, not visible Air/fuel mixture-Excessive fuel injection volume Compression-No compression, low compression Malfunction spark plug Grayish white with specific plug: Air/fuel mixture-Insufficient fuel injection volume Malfunction spark plug Wet/carbon is stuck on all plugs: Spark-Spark weak Air/fuel mixture-Too rich, excessive fuel line pressure Erratic signal to PCM ECT sensor No.1 or related wiring harness malfunction MAF sensor or related wiring harness malfunction A/F sensor or related wiring harness malfunction HO2S or related wiring harness malfunction Compression-Low compression Restriction in intake/exhaust system Grayish white with all plugs: Air/fuel mixture-Too lean, insufficient fuel line pressure Erratic signal to PCM ECT sensor No.1 or related wiring harness malfunction MAF sensor or related wiring harness malfunction A/F sensor or related wiring harness malfunction HO2S or related wiring harness 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 2.0, MZR 2.5] .) (See AFTER SERVICE PRECAUTION [MZR 2.0, MZR 2.5] .)
CAUTION
Disconnecting/connecting the quick release connector without cleaning it may possibly cause damage to the fuel pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting, and make sure that it is free of foreign material.

Water Sprinkling Method

If malfunction occurs only under high humidity or rainy/snowy weather, perform the following steps

CAUTIONIndirectly change the temperature and humidity by spraying water onto the front of the radiator. If a vehicle is subject to water leakage, the leakage may damage the control module. When testing a vehicle with a water leakage problem, special caution must be used.
  1. Connect the M-MDS to the DLC-2 if you are inspecting sensors or switches.
  2. Switch the ignition to ON (engine off). NOTE: If the engine starts and runs, perform the following steps at idle.
  3. Access PIDs for sensor or switch if you are inspecting sensors or switches.
  4. If you are inspecting the switch, turn it on manually.
  5. Spray water onto the vehicle or run it through a car wash. If PID value is unstable or malfunction occurs, repair or replace part if necessary.

Scheme 88

Fig. 23: Identifying Water Sprinkling Method
Scheme 23: Identifying Water Sprinkling Method

Finding irregular signals

While referring to ON-BOARD DIAGNOSTIC TEST [MZR 2.0, MZR 2.5] , use the PID/DATA monitor and record function to inspect the input signal system relating to the problem.

  1. Start the engine and idle the vehicle. You can assume that any signals that are out of specification by a wide margin are irregular.
  2. When recreating the problem, any sudden change in monitor input signals that is not intentionally created by the driver can be determined as irregular.

Locating the source of unusual signals

CAUTIONCompare the M-MDS monitor voltage with the measurement voltage using the digital measurement system function. If you use another tester, misreading may occur. When measuring voltage, attach the tester ground to the ground of the PCM that is being tested, or to the engine itself. If this is not performed, the measured voltage and actual voltage may differ. After connecting the pin to a waterproof coupler, confirming continuity and measuring the voltage, inspect the waterproof connector for cracks. If there are any, use sealant to fix them. Failure to do this may result in deterioration of the wiring harness or terminal from water damage, leading to problems with the vehicle.

Scheme 89

Fig. 24: Thermistor Type Circuit Diagram (IAT Sensor And ECT Sensor No.1, No.2)
Scheme 24: Thermistor Type Circuit Diagram (IAT Sensor And ECT Sensor No.1, No.2)

If simulation function of M-MDS is used

  1. Start the engine.
  2. Disconnect the vacuum hose between the purge solenoid valve and the charcoal canister.
  3. Put a finger to the purge solenoid valve and verify that there is no vacuum applied when the engine is cold. If there is a vacuum, inspect the following: Wiring harness and connectors (Purge solenoid valve-PCM terminal 1BA) Purge solenoid valve (stuck open) (See «PURGE SOLENOID VALVE INSPECTION [MZR 2.0, MZR 2.5]»(ref-520382-S25863973002013010300000) .)
  4. Verify that the DTC P0443:00 is displayed. (See «ON-BOARD DIAGNOSTIC TEST [MZR 2.0, MZR 2.5]»(ref-520374-S36338215812013010300000) .) If the DTC P0443:00 is shown, perform the DTC inspection. (See «DTC P0443:00 [MZR 2.0, MZR 2.5]»(ref-520374-S18150118442013010300000) .)
  5. Access the EVAPCP PID using the M-MDS. (See «ON-BOARD DIAGNOSTIC TEST [MZR 2.0, MZR 2.5]»(ref-520374-S36338215812013010300000) .)
  6. Put a finger to the purge solenoid valve with Step 2 condition and verify that there is vacuum applied when set the present to 100% duty value of the purge solenoid valve using the EVAPCP PID simulation function. If there is no vacuum, inspect the following: Increase the duty value of the purge solenoid valve to 50% and inspect if the operation sound of the valve is heard. If the operation sound is heard, inspect for loose or damaged vacuum hoses. (Intake manifold-Purge solenoid valve-Charcoal canister) If the operation sound is not heard, inspect the purge solenoid valve. (See «PURGE SOLENOID VALVE INSPECTION [MZR 2.0, MZR 2.5]»(ref-520382-S25863973002013010300000) .)
  7. Warm up the engine to normal operating temperature.
  8. Monitor the EVAPCP PID using the M-MDS, and drive the vehicle approx. 2000 rpm for 30 s or more . If the EVAPCP PID is 0% , inspect the following. MAF, APP1, APP2, TP REL and LOAD PIDs (See «PCM INSPECTION [MZR 2.0, MZR 2.5]»(ref-520375-S24065888622013010300000) .)

If simulation function of M-MDS is not used

  1. Start the engine.
  2. Disconnect the vacuum hose between the purge solenoid valve and the charcoal canister.
  3. Put a finger to the purge solenoid valve and verify that there is no vacuum applied when the engine is cold. If there is a vacuum, inspect the following: Wiring harness and connectors (Purge solenoid valve terminal A-PCM terminal 1BA) Purge solenoid valve (See «PURGE SOLENOID VALVE INSPECTION [MZR 2.0, MZR 2.5]»(ref-520382-S25863973002013010300000) .)
  4. Warm up the engine to the normal operating temperature.
  5. Stop the engine.
  6. Connect the M-MDS to the DLC-2 and verify that the DTC P0443:00 is shown. Perform DTC inspection. (See «DTC P0443:00 [MZR 2.0, MZR 2.5]»(ref-520374-S18150118442013010300000) .)
  7. Switch the ignition to ON.
  8. Access the ECT PID.
  9. Verify that the engine coolant temperature is more than 60 °C {140 °F} . If the M-MDS indicates less than 60 °C {140 °F} , perform the ECT sensor No.1 inspection. (See «ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION [MZR 2.0, MZR 2.5]»(ref-520375-S03750691572013010300000) .)
  10. Set the vehicle on the dynamometer or chassis roller. WARNING: When the dynamometer or chassis roller is operating, there is a possibility that the operator may come into contact with or be caught up in the rotating parts, leading to serious injuries or death. When performing work while the dynamometer or chassis roller is operating, be careful not to come into contact with or be caught up in any of the rotating parts.
  11. Drive vehicle at engine speed approx. 2,000 rpm for 30 s or more.
  12. Put a finger to the purge solenoid valve and verify that there is no vacuum applied while step 2. If there is no vacuum, inspect the following: Wiring harness and connector (Main relay-Purge solenoid valve-PCM terminal 1BA) Purge solenoid valve (See «PURGE SOLENOID VALVE INSPECTION [MZR 2.0, MZR 2.5]»(ref-520382-S25863973002013010300000) .) MAF, APP1, APP2, TP_REL and LOAD PIDs (See «PCM INSPECTION [MZR 2.0, MZR 2.5]»(ref-520375-S24065888622013010300000) .) If there is vacuum, inspect the following: Vacuum hose (Purge solenoid valve-Charcoal canister)

Cooling fans do not operate

  1. Inspect the following: Open circuit between the fan control module and battery post Open circuit between fan control module and ground Poor connection of the fan control module connector If there is no malfunction, replace the cooling fan component. (See «COOLING FAN COMPONENT REMOVAL/INSTALLATION [MZR 2.0, MZR 2.5]»(ref-520381-S29256486192013010300000) .)

Cooling fan motor does not operate

  1. Inspect the following: Open or short to ground circuit between the fan control module and cooling fan motor Poor connection of the fan control module connector or cooling fan motor connector If there is no malfunction, replace the cooling fan component. (See «COOLING FAN COMPONENT REMOVAL/INSTALLATION [MZR 2.0, MZR 2.5]»(ref-520381-S29256486192013010300000) .)

When idling cannot be continued

  1. Remove the OCV and verify that the spool valve is at maximum retard position. (See «OIL CONTROL VALVE (OCV) REMOVAL/INSTALLATION [MZR 2.0, MZR 2.5]»(ref-520378-S26950759572013010300000) .)
  2. Connect the OCV.
  3. Switch the ignition to ON.
  4. Verify that the spool valve is at maximum retard position. If the spool valve is stuck in the advance direction, inspect for the following: Short circuit in wiring harnesses or connectors between OCV and PCM
  5. Inspect the variable valve timing actuator. (See «VARIABLE VALVE TIMING ACTUATOR INSPECTION [MZR 2.0, MZR 2.5]»(ref-520378-S13566408022013010300000) .)

When idling can be continued

  1. Disconnect OCV connector.
  2. Warm up the engine and idle it.
  3. Apply battery voltage to the OCV and verify that the engine idles roughly or stalls. If the engine idles roughly or stalls, inspect the timing chain component (valve timing deviation). If the engine does not idle roughly or stalls, go to the next step.
  4. Remove the OCV and perform spool valve operation inspection. (See «OIL CONTROL VALVE (OCV) REMOVAL/INSTALLATION [MZR 2.0, MZR 2.5]»(ref-520378-S26950759572013010300000) .) If not as specified, inspect the following: OCV (See «OIL CONTROL VALVE (OCV) INSPECTION [MZR 2.0, MZR 2.5]»(ref-520378-S35273220922013010300000) .) Harnesses and connectors between OCV and PCM open or short If as specified, inspect the following hydraulic passages for restriction or leakage or both: Oil pressure switch-OCV OCV-Camshaft Camshaft internal passage
  5. If they are normal, replace the camshaft pulley (with built-into variable valve timing actuator). (See «VARIABLE VALVE TIMING ACTUATOR REMOVAL/INSTALLATION [MZR 2.0, MZR 2.5]»(ref-520378-S03117126292013010300000) .)

More articles — Symptom Troubleshooting - Engine Control System [Mzr 2.0, Mzr 2.5]