NO.19 EXHAUST SMOKE [SKYACTIV-G 2.5T]

id0103q4802500

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
•  Oil leakage at the compressor or turbine end of the turbocharger
White smoke (Water in combustion):
•  Cooling system malfunction (coolant loss)
•  Engine internal coolant leakage
•  Coolant leakage at the compressor or the turbine end of the turbocharger
Black smoke (Rich fuel mixture):
•  Erratic signal to PCM
?  APP sensor or related circuit malfunction
?  ECT sensor 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
?  Boost pressure sensor signal
?  Boost air temperature sensor signal
•  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 2.5T].)
•  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 2.5T].) (See AFTER SERVICE PRECAUTION [SKYACTIV-G 2.5T].)
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.

Diagnostic Procedure

STEP

INSPECTION

RESULTS

ACTION
1
VERIFY EXHAUST COLOR
•  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 5.
Black
Rich fuel mixture is indicated.
•  Go to Step 6.
2
INSPECT PCV VALVE
•  Inspect the PCV valve.
•  Is there any malfunction?
Yes
Replace the PCV valve.
(See POSITIVE CRANKCASE VENTILATION (PCV) VALVE REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)
No
Go to the next step.
3
VISUALLY INSPECT THE TURBOCHARGER
•  Remove the parts necessary to inspect the turbocharger without removing the turbocharger.
•  Visually inspect for the turbocharger compressor housing.
•  Is any engine oil found inside turbocharger compressor housing?
Yes
Install all removed parts in this step.
•  Excessive amount of oil is found:
?  Replace the turbocharger.
•  Small amount of oil is found:
?  Wipe the oil out of the vehicle, then go to the next step.
No
Turbocharger is normal.
•  Install all removed parts in this step, then go to the next step.
4
INSPECT ENGINE INTERNAL PARTS
•  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.
5
INSPECT ENGINE FOR ENGINE COOLANT LEAKAGE
•  Does the cooling system hold the coolant pressure?
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.
No
Inspect for the cause.
Repair or replace the malfunctioning part according to the inspection results.
6
VERIFY CURRENT INPUT SIGNAL STATUS
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:
?  APP1
?  APP2
?  ECT
?  IAT
?  MAF
?  MAP
?  MAP_V
?  TP_REL
?  INLET_PRES
?  O2S11
?  O2S12
?  SHRTFT1
?  LONGFT1
?  INT_CO_TEMP
•  Monitor the PIDs under the black smoke appeared engine condition.
•  Do the PIDs indicate normal according to engine conditions?
Yes
Go to the next step.
No
APP1, APP2 PIDs are not as specified:
•  Inspect the APP sensor.
ECT PID is not as specified:
•  Inspect the ECT sensor.
IAT PID is not as specified:
•  Inspect the IAT sensor No.1.
MAF PID is not as specified:
•  Inspect the MAF sensor.
MAP, MAP_V PIDs are not as specified:
•  Inspect the MAP sensor.
TP_REL PID is not as specified:
•  Inspect the TP sensor.
INLET_PRES PID is not as specified:
•  Inspect the boost pressure sensor inspection.
INT_CO_TEMP PID is not as specified:
•  Inspect the boost air temperature sensor inspection.
O2S11, SHRTFT1, LONGFT1 PIDs are not as specified:
•  Inspect the A/F sensor.
O2S12 PID is not as specified:
•  Inspect the HO2S.
Repair or replace the malfunctioning part according to the inspection results.
•  If the malfunction remains:
?  Perform the “INTERMITTENT CONCERN TROUBLESHOOTING” procedure.
7
INSPECT FUEL INJECTOR OPERATION
•  Perform the Fuel Injector Operation Inspection.
•  Do the fuel injectors operate properly?
Yes
Go to the next step.
No
Repair or replace the malfunctioning part according to the inspection results.
8
INSPECT INTAKE AIR SYSTEM
•  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.
9
INSPECT EXHAUST SYSTEM FOR LEAKAGE
•  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.
10
INSPECT FUEL PRESSURE (HIGH-SIDE)
•  Start the engine and warm it up completely.
•  Access the FUEL_PRES PID using the M-MDS at idle.
•  Is the FUEL_PRES PID value approx. 3 MPa {31 kgf/cm2, 435 psi}?
Yes
Go to Step 14.
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.
?  Fuel pressure sensor
?  High pressure fuel pump
•  If there is any malfunction:
?  Repair or replace the malfunctioning part according to the inspection results.
•  If there is no malfunction:
?  Go to Step 13.
Higher than 3 MPa {31 kgf/cm2, 435 psi}:
•  Go to the next step.
11
DETERMINE IF MALFUNCTION CAUSE IS FUEL PRESSURE SENSOR OR HIGH PRESSURE FUEL PUMP
•  Is the vehicle acceleration performance normal?
Yes
Go to the next step.
No
Go to Step 13.
12
INSPECT HIGH FUEL PRESSURE SENSOR
•  Inspect the high fuel pressure sensor.
•  Is there any malfunction?
Yes
Replace the fuel distributor.
(See FUEL INJECTOR REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)
No
Go to Step 14.
13
INSPECT SPILL VALVE CONTROL SOLENOID VALVE CONTROL CIRCUIT FOR SHORT TO GROUND
•  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)
No
Replace the high pressure fuel pump.
(See HIGH PRESSURE FUEL PUMP REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)
14
INSPECT FUEL PRESSURE (LOW-SIDE)
•  Connect the fuel pressure gauge between fuel pump and high pressure fuel pump.
•  Measure the low side fuel pressure.
•  Is the low side fuel pressure within specification?
Specification:
•  545—695 kPa {5.56—7.08 kgf/cm2, 79.1—100.0 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.
15
INSPECT IGNITION SYSTEM OPERATION
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.
•  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.
16
INSPECT IF MALFUNCTION CAUSE IS ENGINE COMPRESSION OR INJECTOR DRIVER (PCM INTEGRATED)
•  Measure the compression pressure for each cylinder.
•  Are compression pressures within specification?
Yes
Injector driver malfunction.
•  Replace the PCM.
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.
17
Verify the test results.
•  If normal, return to the diagnostic index to service any additional symptoms.
•  If a malfunction remains, inspect the related Service Information and perform the repair or diagnosis.
?  If the vehicle is repaired, troubleshooting is completed.
?  If the vehicle is not repaired or additional diagnostic information is not available, replace the PCM.