19

EXHAUST SMOKE

DESCRIPTION

• Blue, black, or white smoke from exhaust system.

POSSIBLE CAUSE

Blue 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):

• Erratic signal to PCM

• APP sensor or related circuit malfunction

• ECT sensor No.1 or related circuit malfunction

• IAT sensor No.1 (integrated in MAF sensor/IAT sensor No.1) or related circuit malfunction

• MAF sensor or related circuit malfunction

• MAP sensor or related circuit malfunction

• A/F sensor or related circuit malfunction

• HO2S or related circuit malfunction

• TP sensor or related circuit malfunction

• Improper fuel injection timing and amount

• Air cleaner restriction

• Intake-air system is collapsed or restricted

• Leakage at engine intake manifold and/or exhaust manifold

• Inadequate/Excessive fuel pressure

• Fuel pressure sensor malfunction

• High pressure fuel pump malfunction

• Spill valve control solenoid valve control circuit malfunction (damage to driver in PCM caused by short circuit to ground system)

• Spill valve control solenoid valve (built-into high pressure fuel pump) malfunction

• Relief valve (built-into high pressure fuel pump) malfunction

• Fuel line restricted or clogged

• Fuel pump unit malfunction

• Ignition system malfunction

• Improper engine compression

• Improper intake valve timing

• Improper exhaust valve timing

• Injector driver (built-into PCM) 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.

• Highly pressurized fuel may spray out if the fuel line is cut. Due to the following dangers occurring with a fuel spray, always complete the “Fuel Line Safety Procedure” to prevent the fuel from spraying. (See BEFORE SERVICE PRECAUTION [SKYACTIV-G 2.0].)

• Fuel may cause irritation if it comes in contact with skin and eyes.

• If fuel ignites and causes a fire, it may lead to serious injury or death, and damage to property and facilities.

• Fuel is highly flammable and dangerous. Fuel line spills and leakage can cause serious injury or death, and damage to equipment. Always refer to the “Quick Release Connector Removal/Installation (fuel system)” before performing the fuel hose installation, and execute the “Fuel Leakage Inspection” after installation. (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [SKYACTIV-G 2.0].) (See AFTER SERVICE PRECAUTION [SKYACTIV-G 2.0].)

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.

Item (definition)

Unit/Condition

Definition

Condition/Specification (Reference)

APP1

%

Accelerator pedal opening angle (absolute value) input from APP sensor No.1

• Accelerator pedal released: Approx. 15.29%

• Accelerator pedal fully depressed: Approx. 90.98%

V

APP sensor No.1 voltage

• Accelerator pedal released: Approx. 0.77 V

• Accelerator pedal fully depressed: Approx. 4.55 V

APP2

%

Accelerator pedal opening angle (absolute value) input from APP sensor No.2

• Accelerator pedal released: Approx. 7.84%

• Accelerator pedal fully depressed: Approx. 45.49%

V

APP sensor No.2 voltage

• Accelerator pedal released: Approx. 0.38 V

• Accelerator pedal fully depressed: Approx. 2.27 V

ECT

°C, °F

Engine coolant temperature input from ECT sensor No.1

• Displays ECT

V

ECT sensor No.1 voltage

Ignition switched ON (engine off)

• ECT is 92 °C {198 °F}: Approx. 0.65 V

Idle (after warm up)

• ECT is 93 °C {199 °F}: Approx. 0.64 V

Racing (Engine speed is 2,000 rpm)

• ECT is 92 °C {198 °F}: Approx. 0.66 V

Racing (Engine speed is 4,000 rpm)

• ECT is 93 °C {199 °F}: Approx. 0.64 V

FUEL_PRES

KPa , mBar , psi, in H20

Fuel pressure input from fuel pressure sensor

• Displays fuel pressure

V

Fuel pressure sensor voltage

Ignition switched ON (engine off)

• Fuel pressure is approx. 3.6 MPa {37 kgf/cm², 522 psi}: Approx. 1.01 V (ECT is 92 °C {198 °F})

Idle (after warm up)

• Fuel pressure is approx. 3.45 MPa {35.2 kgf/cm², 500 psi}: Approx. 1 V (ECT is 92 °C {198 °F})

Racing (Engine speed is 2,000 rpm)

• Fuel pressure is approx. 3.21 MPa {32.7 kgf/cm², 466 psi}: Approx. 0.96 V (ECT is 86 °C {187 °F})

Racing (Engine speed is 4,000 rpm)

• Fuel pressure is approx. 5.59 MPa {57.0 kgf/cm², 811 psi}: Approx. 1.29 V (ECT is 84 °C {183 °F})

IAT

°C, °F

Intake air temperature (No.1) input from IAT sensor No.1

• Displays IAT (No.1)

V

IAT sensor No.1 voltage

• IAT is 60 °C {140 °F}: Approx. 1.13 V

• IAT is 63 °C {145 °F}: Approx. 1.07 V

• IAT is 65 °C {149 °F}: Approx. 1.01 V

LOAD

%

Ratio of actual amount of intake air to the maximum air charging amount (mass volume) of cylinder

• Idle (after warm up): Approx. 27.05% (ECT is 91 °C {196 °F})

• Racing (engine speed is 2,000 rpm): Approx. 16.86% (ECT is 89 °C {192 °F})

• Racing (engine speed is 4,000 rpm): Approx. 17.64% (ECT is 87 °C {189 °F})

LONGFT1

%

Fuel learning correction amount estimated based on A/F sensor signal

• Idle (after warm up): Approx. −1.56% (ECT is 91 °C {196 °F})

• Racing (engine speed is 2,000 rpm): 2.34% (ECT is 89 °C {192 °F})

• Racing (engine speed is 4,000 rpm): 2.34% (ECT is 87 °C {189 °F})

MAF

g/Sec

Mass air flow input from MAF sensor

• Displays MAF

V

MAF sensor voltage

• Ignition switched ON (engine off) (MAF: 0.39 g/s {0.052 lb/min}): Approx. 0.72 V (ECT is 89 °C {192 °F})

• Idle (after warm up) (MAF: 4.29 g/s {0.567 lb/min}): Approx. 1.15 V (ECT is 88 °C {190 °F})

• Racing (engine speed is 2,000 rpm) (MAF: 4.32 g/s {0.571 lb/min}): Approx. 1.15 V (ECT is 89 °C {192 °F})

• Racing (engine speed is 4,000 rpm) (MAF: 12.71 g/s {1.681 lb/min}): Approx. 1.66 V (ECT is 89 °C {192 °F})

MAP

KPa , mBar , psi, in H20

Manifold absolute pressure input from MAP sensor

• Displays MAP

MAP_V

V

MAP sensor voltage

• Ignition switched ON (engine off) (MAP:101 kPa {1.03 kgf/cm², 14.6 psi}): Approx. 4.08 V (ECT is 89 °C {192 °F})

• Idle (after warm up) (MAP: 31 kPa {0.32 kgf/cm², 4.5 psi}): Approx. 1.25 V (ECT is 88 °C {190 °F})

• Racing (engine speed is 2,000 rpm) (MAP: 32 kPa {0.33 kgf/cm², 4.6 psi}): Approx. 1.31 V (ECT is 89 °C {192 °F})

• Racing (engine speed is 4,000 rpm) (MAP: 49 kPa {0.50 kgf/cm², 7.1 psi}): Approx. 2.03 V (ECT is 89 °C {192 °F})

O2S11

µA

A/F sensor current

• Idle (after warm up): −59 µA (ECT is 92 °C {198 °F})

• Deceleration fuel cut (accelerator pedal released from engine speed of 4,000 rpm or more): Approx. 3.48 mA (ECT is 92 °C {198 °F})

O2S12

V

HO2S voltage

• Idle (after warm up): 0—1.0 V (ECT is 91 °C {196 °F})

• Deceleration fuel cut (accelerator pedal released from engine speed of 4,000 rpm or more): Approx. 0 V (ECT is 92 °C {198 °F})

RPM

RPM

Engine speed

• Displays engine speed

SHRTFT1

%

Fuel feedback correction amount estimated based on A/F sensor signal

• Idle (after warm up): Approx. 0% (ECT is 91 °C {196 °F})

• Racing (engine speed is 2,000 rpm): Approx. 0.78% (ECT is 89 °C {192 °F})

• Racing (engine speed is 4,000 rpm): Approx. −21.87% (ECT is 87 °C {189 °F})

TP_REL

%

Throttle valve opening angle (relative value) with value at throttle valve fully close timing as the start point

• Accelerator pedal released: Approx. 12.15%

• Accelerator pedal fully depressed: Approx. 81.96%

VSS

KPH, MPH

Vehicle speed

• Displays vehicle speed

STEP

INSPECTION

RESULTS

ACTION

1

• What color is smoke coming from the exhaust system?

Blue

Burning oil is indicated.

• Go to the next step.

White

Water in combustion is indicated.

• Go to Step 4.

Black

Rich fuel mixture is indicated.

• Go to Step 5.

2

• Inspect the PCV valve.

  (See POSITIVE CRANKCASE VENTILATION (PCV) VALVE INSPECTION [SKYACTIV-G 2.0].)

• Is there any malfunction?

Yes

Replace the PCV valve.

(See POSITIVE CRANKCASE VENTILATION (PCV) VALVE REMOVAL/INSTALLATION [SKYACTIV-G 2.0].)

No

Go to the next step.

3

• Inspect for the following engine internal parts:

• Damaged valve guide, stems or valve seals

• Blocked oil drain passage in cylinder head

• Piston ring is not seated, seized or worn

• Damage cylinder bore

• Is there any malfunction?

Yes

Repair or replace the malfunctioning part according to the inspection results.

No

Engine internal parts are normal.

• If other driveability symptoms are present:

• Return to the diagnostic index to service additional symptoms.

  (See SYMPTOM DIAGNOSTIC INDEX [SKYACTIV-G 2.0].)

4

• Does the cooling system hold the coolant pressure?

  (See ENGINE COOLANT LEAKAGE INSPECTION [SKYACTIV-G 2.0].)

Yes

Inspect the following:

• Cylinder head gasket leakage

• Intake manifold gasket leakage

• Cracked or porous engine block

Repair or replace the malfunctioning part according to the inspection results.

• If other driveability symptoms are present:

• Return to the diagnostic index to service additional symptoms.

  (See SYMPTOM DIAGNOSTIC INDEX [SKYACTIV-G 2.0].)

No

Inspect for the cause.

Repair or replace the malfunctioning part according to the inspection results.

5

CAUTION:

• While performing this step, always operate the vehicle in a safe and lawful manner.

• When the M-MDS is used to observe monitor system status while driving, be sure to have another technician with you, or record the data in the M-MDS using the PID/DATA MONITOR AND RECORD capturing function and inspect later.

• Access the following PIDs using the M-MDS:

  (See ON-BOARD DIAGNOSTIC TEST [PCM (SKYACTIV-G 2.0)].)

• APP1

• APP2

• ECT

• IAT

• MAF

• MAP

• MAP_V

• TP_REL

• O2S11

• O2S12

• SHRTFT1

• LONGFT1

• Monitor the PIDs under the black smoke appeared engine condition.

• Do the PIDs indicate normal according to engine conditions?

  (See PCM INSPECTION [SKYACTIV-G 2.0].)

Yes

Go to the next step.

No

APP1, APP2 PIDs are not as specified:

• Inspect the APP sensor.

  (See ACCELERATOR PEDAL POSITION (APP) SENSOR INSPECTION [SKYACTIV-G 2.0].)

ECT PID is not as specified:

• Inspect the ECT sensor No.1.

  (See ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION [SKYACTIV-G 2.0].)

IAT PID is not as specified:

• Inspect the IAT sensor No.1.

  (See INTAKE AIR TEMPERATURE (IAT) SENSOR INSPECTION [SKYACTIV-G 2.0].)

MAF PID is not as specified:

• Inspect the MAF sensor.

  (See MASS AIR FLOW (MAF) SENSOR INSPECTION [SKYACTIV-G 2.0].)

MAP, MAP_V PIDs are not as specified:

• Inspect the MAP sensor.

  (See MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR INSPECTION [SKYACTIV-G 2.0].)

TP_REL PID is not as specified:

• Inspect the TP sensor.

  (See THROTTLE POSITION (TP) SENSOR INSPECTION [SKYACTIV-G 2.0].)

O2S11, SHRTFT1, LONGFT1 PIDs are not as specified:

• Inspect the A/F sensor.

  (See AIR FUEL RATIO (A/F) SENSOR INSPECTION [SKYACTIV-G 2.0].)

O2S12 PID is not as specified:

• Inspect the HO2S.

  (See HEATED OXYGEN SENSOR (HO2S) INSPECTION [SKYACTIV-G 2.0].)

Repair or replace the malfunctioning part according to the inspection results.

• If the malfunction remains:

• Perform the “INTERMITTENT CONCERN TROUBLESHOOTING” procedure.

  (See INTERMITTENT CONCERN TROUBLESHOOTING [SKYACTIV-G 2.0].)

6

• Perform the Fuel Injector Operation Inspection.

  (See ENGINE CONTROL SYSTEM OPERATION INSPECTION [SKYACTIV-G 2.0].)

• Do the fuel injectors operate properly?

Yes

Go to the next step.

No

Repair or replace the malfunctioning part according to the inspection results.

7

• Inspect the following for intake-air system:

• Air cleaner restriction

• Collapsed or restricted air hose

• Leakage at engine intake manifold

• Is there any malfunction?

Yes

Repair or replace the malfunctioning part according to the inspection results.

No

Go to the next step.

8

• Visually inspect for exhaust gas leakage from exhaust manifold.

• Is there any leakage?

Yes

Repair or replace the malfunctioning part according to the inspection results.

No

Go to the next step.

9

• Start the engine and warm it up completely.

• Access the FUEL_PRES PID using the M-MDS at idle.

  (See ON-BOARD DIAGNOSTIC TEST [PCM (SKYACTIV-G 2.0)].)

• Is the FUEL_PRES PID value approx. 3 MPa {31 kgf/cm², 435 psi}?

Yes

Go to Step 13.

No

Lower than 3 MPa {31 kgf/cm², 435 psi}:

• Inspect the following:

• Fuel leakage at the fuel line and fuel injector

• Fuel pump

• Perform the Fuel Pump (Low-pressure Side) Operation Inspection.

  (See ENGINE CONTROL SYSTEM OPERATION INSPECTION [SKYACTIV-G 2.0].)

• Fuel pressure sensor

  (See FUEL PRESSURE SENSOR INSPECTION [SKYACTIV-G 2.0].)

• High pressure fuel pump

  (See HIGH PRESSURE FUEL PUMP INSPECTION [SKYACTIV-G 2.0].)

• If there is any malfunction:

• Repair or replace the malfunctioning part according to the inspection results.

• If there is no malfunction:

• Go to Step 12.

Higher than 3 MPa {31 kgf/cm², 435 psi}:

• Go to the next step.

10

• Is the vehicle acceleration performance normal?

Yes

Go to the next step.

No

Go to Step 12.

11

• Inspect the fuel pressure sensor.

  (See FUEL PRESSURE SENSOR INSPECTION [SKYACTIV-G 2.0].)

• Is there any malfunction?

Yes

Replace the fuel distributor.

(See FUEL INJECTOR REMOVAL/INSTALLATION [SKYACTIV-G 2.0].)

No

Go to Step 13.

12

• Switch the ignition off.

• Disconnect the high pressure fuel pump and PCM connectors.

• Inspect for continuity between high pressure fuel pump terminal A (wiring harness-side) and body ground.

• Is there continuity?

Yes

Refer to the wiring diagram and verify whether or not there is a common connector between high pressure fuel pump terminal A and PCM terminal 1EE.

If there is a common connector:

• Determine the malfunctioning part by inspecting the common connector and the terminal for corrosion, damage, or pin disconnection, and the common wiring harness for a short to ground.

• Repair or replace the malfunctioning part.

If there is no common connector:

• Repair or replace the wiring harness which has a short to ground.

If the malfunction remains:

• Replace the PCM. (damage to driver in PCM)

  (See PCM REMOVAL/INSTALLATION [SKYACTIV-G 2.0].)

No

Replace the high pressure fuel pump.

(See HIGH PRESSURE FUEL PUMP REMOVAL/INSTALLATION [SKYACTIV-G 2.0].)

13

• Connect the fuel pressure gauge between fuel pump and high pressure fuel pump.

• Measure the low side fuel pressure.

  (See FUEL LINE PRESSURE INSPECTION [SKYACTIV-G 2.0].)

• Is the low side fuel pressure within specification?

Specification:

• 425—505 kPa {4.34—5.14 kgf/cm², 61.7—73.2 psi}

Yes

Go to the next step.

No

Inspect the following:

• Fuel line restriction

• Fuel filter clogged

• If there is any malfunction:

• Repair or replace the malfunctioning part according to the inspection results.

• If there is no malfunction:

• Replace the fuel pump unit.

  (See FUEL PUMP UNIT REMOVAL/INSTALLATION [SKYACTIV-G 2.0].)

14

NOTE:

• Because the malfunction may have been resolved by removing the carbon adhered to the spark plug during the spark inspection for the spark plug, verify that the repairs have been completed.

• Perform the Spark Test.

  (See ENGINE CONTROL SYSTEM OPERATION INSPECTION [SKYACTIV-G 2.0].)

• Is a strong blue spark visible at each cylinder?

Yes

Go to the next step.

No

Repair or replace the malfunctioning part according to the inspection results.

15

• Measure the compression pressure for each cylinder.

  (See COMPRESSION INSPECTION [SKYACTIV-G 2.0].)

• Are compression pressures within specification?

Yes

Injector driver malfunction.

• Replace the PCM.

  (See PCM REMOVAL/INSTALLATION [SKYACTIV-G 2.0].)

If the problem remains, overhaul the engine.

No

Inspect the following:

• Damaged valve seat

• Worn valve stem and valve guide

• Worn or stuck piston ring

• Worn piston, piston ring or cylinder

• Improper intake valve timing

• Improper exhaust valve timing

Service if necessary.

16

Verify the test results.

• If normal, return to the diagnostic index to service any additional symptoms.

  (See SYMPTOM DIAGNOSTIC INDEX [SKYACTIV-G 2.0].)

• If the malfunction remains, inspect the related Service Bulletins and/or On-line Repair Information and perform repair or diagnosis.

• If the vehicle is repaired, troubleshooting is completed.

• If the vehicle is not repaired or additional diagnostic information is not available, reprogram the PCM if a later calibration is available. Retest.