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ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZR-CD (RF Turbo)]

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Guide Blade Actuator Operation Inspection

1.  Connect WDS or equivalent to DLC-2.

2.  Start the engine and run it at idle.

3.  Access the VBCV PID.

4.  Verify that the guide blade actuator rod moves when the VBCV PID from 0 to 100 % using simulation function.

•  If the rod movement cannot be verified inspect the followings;

―  Guide blade actuator (See GUIDE BLADE ACTUATOR INSPECTION [MZR-CD (RF Turbo)].)

―  Vacuum hose connection between the vacuum chamber and the guide blade actuator through the VBC solenoid valve (See INTAKE-AIR SYSTEM VACUUM HOSE ROUTING DIAGRAM [MZR-CD (RF Turbo)].)

―  VBC solenoid valve (See VARIABLE BOOST CONTROL (VBC) SOLENOID VALVE INSPECTION [MZR-CD (RF Turbo)].)

Glow Plug Control Operation Inspection

1.  Verify that the battery is charged fully.

2.  If not, charge the battery.

3.  Connect the WDS or equivalent to the DLC.

4.  Turn the engine switch to the ON position.

5.  Access and monitor the B+ and GPC PIDs.

6.  Verify that the B+ PID drops 0.3 V or more while the GPC is turned on from off using the simulation function.

•  If it cannot be verified, inspect the followings;

―  Glow plug relay

―  Glow plug

―  Wiring harness for battery positive post—glow plug relay—glow plug

―  Wiring harness for PCM terminal 37—glow plug relay—ground

Intake Shutter Valve Operation Inspection

1.  Connect the WDS or equivalent to the DLC-2.

2.  Start the engine and run it at idle.

3.  Access and monitor the ETC_DSD, TP and MAP PIDs.

4.  Verify that the MAP PID increases and TP PID increases linearly, while increasing the opening angle of the intake shutter valve using the simulation function of ETC_DSD.

•  If both PIDs do not increase according to the intake shutter valve opening angle, inspect using the following steps.

1.  Remove the intake shutter valve with connector connected.

2.  Verify that the intake shutter valve opens and closes while it is operated using the simulation function of the ETC_DSD.

―  If not verified, retest after cleaning the intake shutter valve and inspecting related wiring harness and connectors.

3.  If the intake shutter valve does not operate, replace the intake shutter valve.

•  If the MAP PID increases but TP PID does not increase linearly according to the intake shutter valve opening angle inspect using the following steps.

1.  Inspect the intake shutter valve position sensor related wiring harness and connector.

2.  Remove the intake shutter valve with the connector connected.

3.  Verify that the TP PID increases and decreases linearly while the intake shutter valve is operated using the simulation function of ETC_DSD.

―  If the TP PID does not increase and decrease linearly, replace the intake shutter valve.

•  If the TP PID increases linearly but the MAP PID does not increase according to the intake shutter valve opening angle inspect using the following steps.

1.  Inspect air for leakage at the intake shutter valve and cylinder head.

2.  If normal, inspect and replace the MAP sensor.

EGR Valve Operation Inspection

1.  Crank the engine and verify that the EGR valve operation (initial operation) sound is heard.

•  If the operation sound is not heard, connect the WDS or equivalent to the DLC-2 and verify that the DTC P0403 is shown. Perform the DTC inspection. (See DTC TABLE [MZR-CD (RF Turbo)].)

2.  Start the engine run it at idle.

3.  Access and monitor SEGRP, EGRVP and MAP PIDs.

4.  Verify that the MAP PID increases and EGRVP PID increasing linearly while increase the opening value of the EGR valve from 0 % to 100 % using the SEGR PID of simulation function.

•  If both PIDs do not increase according to the EGR valve opening values, inspect using the following steps.

1.  Remove the EGR valve with the connector connected.

2.  Verify that the EGR valve opens and closes while it is operated using the simulation function of SEGRP.

―  If not verified, retest after cleaning the EGR valve and inspecting the related harness and connectors.

3.  If the EGR valve does not operate, replace the EGR valve.

•  If the MAP PID increases but the EGRVP PID does not increase linearly according to the EGR valve opening values, inspect using the following steps.

1.  Inspect the EGR valve position sensor related harness and connector.

2.  Remove the EGR valve with the connector connected.

3.  Verify that the EGRVP PID increases and decreases linearly while increasing the EGR valve steps using simulation function of the SGERP.

―  If the EGRVP PID does not increase and decrease linearly, replace the EGR valve.

•  If the EGRVP PID increases linearly but MAP PID does not increase according to the EGR valve opening values, inspect using the following steps.

1.  Inspect for leakage between the exhaust manifold and surge tank.

2.  If normal, inspect and replace MAP sensor.

Fuel Injector Operation Inspection

1.  Connect the WDS or equivalent to the DLC-2.

2.  Start the engine and warm it up to normal operating temperature.

3.  Perform the KOER self-test. (See KOEO/KOER SELF TEST [MZR-CD (RF Turbo)].)

4.  Verify that DTCs P0200, P0201, P0202, P0203 and/or P0204 are not shown using the KOER self-test.

•  If DTC P0200, P0201, P0202, P0203 and/or P0204 are shown, perform the DTC troubleshooting procedure. (See DTC TABLE [MZR-CD (RF Turbo)].)

5.  Verify that the engine speed drops or stalls when each cylinder fuel injector turns to off from on using the simulation function.

•  If it cannot be verified, inspect the following for the suspected cylinder;

―  Fuel injector (See FUEL INJECTOR INSPECTION [MZR-CD (RF Turbo)].)

―  Wiring harness for PCM—fuel injector

Cooling Fan Control System Inspection

Cooling fan system operation

Engine condition	Cooling fan relay No.1	Cooling fan relay No.2
ECT below 100 °C {212 °F}	OFF	OFF
ECT above 100 °C {212 °F} (Until below 97 °C {207 °F})	ON	OFF
ECT above 108 °C {226 °F} (Until below 105 °C {221 °F})	ON	ON
A/C and fan switches are ON	ON	ON
ECT sensor malfunction (PCM stores DTCs P0117 or P0118)	ON	ON

1.  Connect the WDS or equivalent to the DLC-2.

2.  Perform the KOEO or KOER self-test. (See KOEO/KOER SELF TEST [MZR-CD (RF Turbo)].)

3.  Verify that the DTC P0117, P0118 are not displayed.

4.  If the DTC P0117, P0118 is displayed, perform DTC inspection. (See DTC TABLE [MZR-CD (RF Turbo)].)

5.  Verify that the ECT PID is below 100 °C {212 °F}.

6.  Turn the A/C switch to off.

7.  Turn the engine switch to ON position.

8.  Verify that the cooling fan and additional fan are not operating.

•  If the cooling fan and additional fan operate, inspect the following:

―  Short to ground circuit between A/C refrigerant pressure switch and PCM terminal 32

•  If the cooling fan operates and the additional fan does not operate, inspect the following:

―  Short to power between cooling fan relay No.1 and cooling fan motor

―  Cooling fan relay (stuck close)

•  If the cooling fan does not operate and the additional fan operates, inspect the following:

―  Short to power between additional fan relay and additional fan motor

―  Cooling fan relay No.2 (stuck close)

9.  Turn the engine switch to off.

10.  Disconnect the ECT sensor connector.

11.  Turn the engine switch to ON position.

12.  Verify that the cooling fan and additional fan are operating.

•  If the cooling fan and additional fan do not operates, inspect the following:

―  Open circuit in wiring from battery positive post to cooling fan relay and additional fan relay (secondary power supply)

•  If the cooling fan does not operates, inspect the following:

―  Open circuit between cooling fan relay and cooling fan motor

―  Open circuit between cooling fan motor and ground

―  Cooling fan relay (stuck open)

•  If the additional fan does not operates, inspect the following:

―  Open circuit between additional fan relay and additional fan motor

―  Open circuit between additional fan motor and ground

―  Additional fan relay (stuck open)

13.  Clear the DTC P0118 from PCM memory using the WDS or equivalent. (See AFTER REPAIR PROCEDURE [MZR-CD (RF Turbo)].)