CRANKS NORMALLY BUT WILL NOT START [SKYACTIV-D]

Troubleshooting item	CRANKS NORMALLY BUT WILL NOT START
Description	• Cranking occurs but no ignition.
Possible cause	• PCM DTC is stored. • A/C relay malfunction • ECT sensor malfunction • Fuel injection system malfunction ― Fuel leakage from fuel system ― Air suction in fuel system ― Common rail malfunction ― Supply pump malfunction ― Suction control valve malfunction ― Fuel injector malfunction ― Fuel pressure relief valve malfunction • Glow plug malfunction • Glow control module malfunction • Poor fuel quality • Mis-fueling/gasoline added to fuel tank • Mechanical (engine) malfunction ― Large mechanical resistance (such as A/C compressor) ― Improper engine compression ― Improper valve timing ― Engine oil malfunction (oil working up or down) ― Jet pump fuel transfer malfunction (AWD) Warning • The following troubleshooting flow chart contains the fuel system diagnosis and repair procedures. Read the following warnings before performing the fuel system services: ― Always keep sparks and flames away from fuel. Fuel can be easily ignited which could cause serious injury or death, and damage to equipment. ― Fuel line spills and leakage from the pressurized fuel system are dangerous. Fuel can ignite and cause serious injury or death, and damage to property and facilities. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure", while referring to the "BEFORE SERVICE PRECAUTION". (See BEFORE SERVICE PRECAUTION [SKYACTIV-D 1.8].) ― Fuel is highly flammable and dangerous. Fuel line spills and leakage can cause serious injury or death, and damage to equipment. When installing the fuel hose, always refer to the "AFTER SERVICE PRECAUTION" and perform the "Fuel Hose Installation Procedure". (See AFTER SERVICE PRECAUTION [SKYACTIV-D 1.8].)
System wiring diagram	• Not applicable
Connector diagram	• Not applicable

Troubleshooting item

CRANKS NORMALLY BUT WILL NOT START

Description

• Cranking occurs but no ignition.

Possible cause

• PCM DTC is stored.

• A/C relay malfunction

• ECT sensor malfunction

• Fuel injection system malfunction

― Fuel leakage from fuel system

― Air suction in fuel system

― Common rail malfunction

― Supply pump malfunction

― Suction control valve malfunction

― Fuel injector malfunction

― Fuel pressure relief valve malfunction

• Glow plug malfunction

• Glow control module malfunction

• Poor fuel quality

• Mis-fueling/gasoline added to fuel tank

• Mechanical (engine) malfunction

― Large mechanical resistance (such as A/C compressor)

― Improper engine compression

― Improper valve timing

― Engine oil malfunction (oil working up or down)

― Jet pump fuel transfer malfunction (AWD)

Warning

• The following troubleshooting flow chart contains the fuel system diagnosis and repair procedures. Read the following warnings before performing the fuel system services:

― Always keep sparks and flames away from fuel. Fuel can be easily ignited which could cause serious injury or death, and damage to equipment.

― Fuel line spills and leakage from the pressurized fuel system are dangerous. Fuel can ignite and cause serious injury or death, and damage to property and facilities. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure", while referring to the "BEFORE SERVICE PRECAUTION". (See BEFORE SERVICE PRECAUTION [SKYACTIV-D 1.8].)

― Fuel is highly flammable and dangerous. Fuel line spills and leakage can cause serious injury or death, and damage to equipment. When installing the fuel hose, always refer to the "AFTER SERVICE PRECAUTION" and perform the "Fuel Hose Installation Procedure". (See AFTER SERVICE PRECAUTION [SKYACTIV-D 1.8].)

System wiring diagram

• Not applicable

Connector diagram

• Not applicable

Step	Inspection	Results	Action
1	VERIFY PCM DTC • Retrieve PCM DTCs using the M-MDS. (See DTC INSPECTION.) • Are any DTCs present?	Yes	Go to the applicable DTC inspection. (See DTC TABLE [PCM (SKYACTIV-D)].)
No	Go to the next step.
2	VERIFY IF MALFUNCTION IS CAUSED BY POOR FUEL QUALITY OR INCORRECT FUEL ADDED TO FUEL TANK • Verify with the customer what type of fuel was last added to the fuel tank. ― Incorrect fuel (i.e. gasoline) was mistakenly added to the fuel tank. ― Poor fuel quality (such as old diesel fuel). • Is there a problem with the fuel currently in the fuel tank?	Yes	Go to the next step.
No	Go to Step 4.
3	MALFUNCTION DUE TO POOR FUEL QUALITY OR INCORRECT FUEL USED • Drain all fuel from fuel tank. (See FUEL DRAINING PROCEDURE [SKYACTIV-D 1.8].) • Allow fuel tank to dry out. • Add diesel to fuel tank, then start the engine. • Do the symptoms disappear?	Yes	If incorrect fuel was mistakenly added to the fuel tank: • Advise the customer to use only the recommended diesel fuel, otherwise, engine damage could occur. If poor quality fuel is being used: • Advise the customer to use only the recommended diesel fuel.
No	• If it has been confirmed that the customer mistakenly added gasoline to the fuel tank, replace the fuel filter (mounted on passenger side bulkhead), fuel filter drain plug o-rings, then bleed the fuel system. • Verify the engine starts and runs properly. • If the engine does not start, replace all of the following parts which may have been damaged during the mis-fueling. ― Supply pump ― Suction control valve ― Fuel pressure relief valve ― Fuel injectors ― Common rail ― Fuel check valve ― Fuel feed valve ― Injection pipe (supply pump side) ― Injection pipe (fuel injector side) • Flush and reuse all fuel system hoses and pipes with diesel fuel. • Verify the engine starts and runs properly.
4	INSPECT A/C RELAY • Switch the ignition off. • Remove the A/C relay. • Inspect the A/C relay. (See RELAY INSPECTION.) • Is the A/C relay normal?	Yes	Go to the next step.
No	Replace the A/C relay, then go to repair completion verification.
5	INSPECT ECT SENSOR FOR MALFUNCTION • Inspect the applicable part. (See ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION [SKYACTIV-D 1.8].) • Is the part normal?	Yes	Go to the next step.
No	Repair or replace the malfunctioning location and perform the repair completion verification. (See ENGINE COOLANT TEMPERATURE (ECT) SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)
6	INSPECT FOR FUEL LEAKAGE OR AIR SUCTION IN FUEL SYSTEM • Visually inspect the following: ― Fuel leakage from the fuel tank, fuel pump, hose, pipe, fuel injector, supply pump, common rail ― Cracking and damage in fuel hose and pipe ― Clamp installation condition for each hose and pipe ― Fuel pipe securing condition due to deterioration such as rubber of clamp • Are all items normal?	Yes	Go to the next step.
No	Repair or replace the malfunctioning part according to the inspection results, then go to repair completion verification.
7	INSPECT FUEL INJECTION RELATED PARTS • Inspect the following parts: ― Common rail (See COMMON RAIL INSPECTION [SKYACTIV-D 1.8].) ― Supply pump (See SUPPLY PUMP INSPECTION [SKYACTIV-D 1.8].) ― Suction control valve (See SUCTION CONTROL VALVE INSPECTION [SKYACTIV-D 1.8].) ― Fuel injector (See FUEL INJECTOR INSPECTION [SKYACTIV-D 1.8].) ― Fuel pressure relief valve (See FUEL PRESSURE RELIEF VALVE INSPECTION [SKYACTIV-D 1.8].) ― Jet pump (AWD) (See JET PUMP INSPECTION [SKYACTIV-D 1.8].) • Are all items normal?	Yes	Go to the next step.
No	Repair or replace the malfunctioning part according to the inspection results, then go to repair completion verification.
8	INSPECT GLOW PLUG CONNECTOR FOR MALFUNCTION • Inspect the applicable connector and terminal. (See CONNECTOR INSPECTION.) • Are the connector and terminal normal?	Yes	Go to the next step.
No	Repair or replace the malfunctioning location and perform the repair completion verification.
9	INSPECT GLOW CONTROL MODULE CONNECTOR FOR MALFUNCTION • Inspect the applicable connector and terminal. (See CONNECTOR INSPECTION.) • Are the connector and terminal normal?	Yes	Go to the next step.
No	Repair or replace the malfunctioning location and perform the repair completion verification.
10	INSPECT FOR MALFUNCTION DUE TO POOR FUEL • Replace the fuel. (See FUEL DRAINING PROCEDURE [SKYACTIV-D 1.8].) • Does the symptom disappear?	Yes	Advise the customer as to the change in the fuel used.
No	Remove the accumulated matter in the cylinder head using the following procedure, then go to the next step. • Carbon remover • Overhauling
11	DETERMINE IF MALFUNCTION IS DUE TO EXCESSIVE ENGINE SPEED RESISTANCE • Rotate the crankshaft pulley lock bolt clockwise using a wrench. (See FRONT OIL SEAL REPLACEMENT [SKYACTIV-D 1.8].) • Can bolts be rotated?	Yes	Go to Step 13.
No	Go to the next step.
12	INSPECT FOR MALFUNCTION DUE TO EXCESSIVE MECHANICAL RESISTANCE OF ENGINE ACCESSORIES • Remove all drive belts from engine accessories. (See DRIVE BELT REMOVAL/INSTALLATION [SKYACTIV-D 1.8].) Caution • Do not run the engine for long periods with the drive belts of engine accessories removed. Otherwise the engine could be damaged from overheating. • Start the engine. • Is cranking possible? (Does the engine start?)	Yes	Repair or replace the malfunctioning part according to the inspection results, then go to repair completion verification. (Large mechanical resistance in engine accessories such as the A/C compressor.)
No	Go to the next step.
13	INSPECT ENGINE COMPRESSION • Inspect the engine compression. (See COMPRESSION INSPECTION [SKYACTIV-D 1.8].) • Are compression pressures within specification?	Yes	Go to repair completion verification.
No	Go to the next step.
14	INSPECT FOR MALFUNCTION DUE TO DEVIATED VALVE TIMING • Inspect the valve timing (timing chain installation condition). (See TIMING CHAIN REMOVAL/INSTALLATION [SKYACTIV-D 1.8].) • Is the valve timing normal?	Yes	Inspect for the following engine internal parts: • Cylinder • Piston ring • Intake valve • Exhaust valve • Such as cylinder head gasket Repair or replace the malfunctioning part according to the inspection results, then go to the next step.
No	Adjust the valve timing to the correct timing, then go to the next step.
Repair completion verification 1	VERIFY THAT VEHICLE IS REPAIRED • Install/connect the part removed/disconnected during the troubleshooting procedure. • Has the malfunction symptom been eliminated?	Yes	Complete the symptom troubleshooting. (Explain contents of repair to customer)
No	Refer to the controller area network (CAN) malfunction diagnosis flow to inspect for a CAN communication error. (See CONTROLLER AREA NETWORK (CAN) MALFUNCTION DIAGNOSIS FLOW [(E)].) • If the CAN communication is normal, perform the diagnosis from Step 1. ― If the malfunction recurs, go to the next step.
Repair completion verification 2	VERIFY IF MALFUNCTION IS CAUSED BY NOT PERFORMING PCM REPROGRAMMING • Verify repair information and verify that there is a new calibration in the PCM. • Is there a new calibration in the PCM?	Yes	Perform the PCM reprogramming and verify if the malfunction symptom was corrected. • If the malfunction recurs, replace the PCM. (See PCM REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)
No	Replace the PCM. (See PCM REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

Step

Inspection

Results

Action

VERIFY PCM DTC

• Retrieve PCM DTCs using the M-MDS.

(See DTC INSPECTION.)

• Are any DTCs present?

Yes

Go to the applicable DTC inspection.

(See DTC TABLE [PCM (SKYACTIV-D)].)

Go to the next step.

VERIFY IF MALFUNCTION IS CAUSED BY POOR FUEL QUALITY OR INCORRECT FUEL ADDED TO FUEL TANK

• Verify with the customer what type of fuel was last added to the fuel tank.

― Incorrect fuel (i.e. gasoline) was mistakenly added to the fuel tank.

― Poor fuel quality (such as old diesel fuel).

• Is there a problem with the fuel currently in the fuel tank?

Yes

Go to the next step.

Go to Step 4.

MALFUNCTION DUE TO POOR FUEL QUALITY OR INCORRECT FUEL USED

• Drain all fuel from fuel tank.

(See FUEL DRAINING PROCEDURE [SKYACTIV-D 1.8].)

• Allow fuel tank to dry out.

• Add diesel to fuel tank, then start the engine.

• Do the symptoms disappear?

Yes

If incorrect fuel was mistakenly added to the fuel tank:

• Advise the customer to use only the recommended diesel fuel, otherwise, engine damage could occur.

If poor quality fuel is being used:

• Advise the customer to use only the recommended diesel fuel.

• If it has been confirmed that the customer mistakenly added gasoline to the fuel tank, replace the fuel filter (mounted on passenger side bulkhead), fuel filter drain plug o-rings, then bleed the fuel system.

• Verify the engine starts and runs properly.

• If the engine does not start, replace all of the following parts which may have been damaged during the mis-fueling.

― Supply pump

― Suction control valve

― Fuel pressure relief valve

― Fuel injectors

― Common rail

― Fuel check valve

― Fuel feed valve

― Injection pipe (supply pump side)

― Injection pipe (fuel injector side)

• Flush and reuse all fuel system hoses and pipes with diesel fuel.

• Verify the engine starts and runs properly.

INSPECT A/C RELAY

• Switch the ignition off.

• Remove the A/C relay.

• Inspect the A/C relay.

(See RELAY INSPECTION.)

• Is the A/C relay normal?

Yes

Go to the next step.

Replace the A/C relay, then go to repair completion verification.

INSPECT ECT SENSOR FOR MALFUNCTION

• Inspect the applicable part.

(See ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION [SKYACTIV-D 1.8].)

• Is the part normal?

Yes

Go to the next step.

Repair or replace the malfunctioning location and perform the repair completion verification.

(See ENGINE COOLANT TEMPERATURE (ECT) SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

INSPECT FOR FUEL LEAKAGE OR AIR SUCTION IN FUEL SYSTEM

• Visually inspect the following:

― Fuel leakage from the fuel tank, fuel pump, hose, pipe, fuel injector, supply pump, common rail

― Cracking and damage in fuel hose and pipe

― Clamp installation condition for each hose and pipe

― Fuel pipe securing condition due to deterioration such as rubber of clamp

• Are all items normal?

Yes

Go to the next step.

Repair or replace the malfunctioning part according to the inspection results, then go to repair completion verification.

INSPECT FUEL INJECTION RELATED PARTS

• Inspect the following parts:

― Common rail

(See COMMON RAIL INSPECTION [SKYACTIV-D 1.8].)

― Supply pump

(See SUPPLY PUMP INSPECTION [SKYACTIV-D 1.8].)

― Suction control valve

(See SUCTION CONTROL VALVE INSPECTION [SKYACTIV-D 1.8].)

― Fuel injector

(See FUEL INJECTOR INSPECTION [SKYACTIV-D 1.8].)

― Fuel pressure relief valve

(See FUEL PRESSURE RELIEF VALVE INSPECTION [SKYACTIV-D 1.8].)

― Jet pump (AWD)

(See JET PUMP INSPECTION [SKYACTIV-D 1.8].)

• Are all items normal?

Yes

Go to the next step.

Repair or replace the malfunctioning part according to the inspection results, then go to repair completion verification.

INSPECT GLOW PLUG CONNECTOR FOR MALFUNCTION

• Inspect the applicable connector and terminal.

(See CONNECTOR INSPECTION.)

• Are the connector and terminal normal?

Yes

Go to the next step.

Repair or replace the malfunctioning location and perform the repair completion verification.

INSPECT GLOW CONTROL MODULE CONNECTOR FOR MALFUNCTION

• Inspect the applicable connector and terminal.

(See CONNECTOR INSPECTION.)

• Are the connector and terminal normal?

Yes

Go to the next step.

Repair or replace the malfunctioning location and perform the repair completion verification.

INSPECT FOR MALFUNCTION DUE TO POOR FUEL

• Replace the fuel.

(See FUEL DRAINING PROCEDURE [SKYACTIV-D 1.8].)

• Does the symptom disappear?

Yes

Advise the customer as to the change in the fuel used.

Remove the accumulated matter in the cylinder head using the following procedure, then go to the next step.

• Carbon remover

• Overhauling

DETERMINE IF MALFUNCTION IS DUE TO EXCESSIVE ENGINE SPEED RESISTANCE

• Rotate the crankshaft pulley lock bolt clockwise using a wrench.

(See FRONT OIL SEAL REPLACEMENT [SKYACTIV-D 1.8].)

• Can bolts be rotated?

Yes

Go to Step 13.

Go to the next step.

INSPECT FOR MALFUNCTION DUE TO EXCESSIVE MECHANICAL RESISTANCE OF ENGINE ACCESSORIES

• Remove all drive belts from engine accessories.

(See DRIVE BELT REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

Caution

• Do not run the engine for long periods with the drive belts of engine accessories removed. Otherwise the engine could be damaged from overheating.

• Start the engine.

• Is cranking possible? (Does the engine start?)

Yes

Repair or replace the malfunctioning part according to the inspection results, then go to repair completion verification. (Large mechanical resistance in engine accessories such as the A/C compressor.)

Go to the next step.

INSPECT ENGINE COMPRESSION

• Inspect the engine compression.

(See COMPRESSION INSPECTION [SKYACTIV-D 1.8].)

• Are compression pressures within specification?

Yes

Go to repair completion verification.

Go to the next step.

INSPECT FOR MALFUNCTION DUE TO DEVIATED VALVE TIMING

• Inspect the valve timing (timing chain installation condition).

(See TIMING CHAIN REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

• Is the valve timing normal?

Yes

Inspect for the following engine internal parts:

• Cylinder

• Piston ring

• Intake valve

• Exhaust valve

• Such as cylinder head gasket

Repair or replace the malfunctioning part according to the inspection results, then go to the next step.

Adjust the valve timing to the correct timing, then go to the next step.

Repair completion verification 1

VERIFY THAT VEHICLE IS REPAIRED

• Install/connect the part removed/disconnected during the troubleshooting procedure.

• Has the malfunction symptom been eliminated?

Yes

Complete the symptom troubleshooting. (Explain contents of repair to customer)

Refer to the controller area network (CAN) malfunction diagnosis flow to inspect for a CAN communication error.

(See CONTROLLER AREA NETWORK (CAN) MALFUNCTION DIAGNOSIS FLOW [(E)].)

• If the CAN communication is normal, perform the diagnosis from Step 1.

― If the malfunction recurs, go to the next step.

Repair completion verification 2

VERIFY IF MALFUNCTION IS CAUSED BY NOT PERFORMING PCM REPROGRAMMING

• Verify repair information and verify that there is a new calibration in the PCM.

• Is there a new calibration in the PCM?

Yes

Perform the PCM reprogramming and verify if the malfunction symptom was corrected.

• If the malfunction recurs, replace the PCM.

(See PCM REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

Replace the PCM.

(See PCM REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

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