25

EXHAUST SULPHUR SMELL

DESCRIPTION

• Rotten egg smell (sulphur) from exhaust.

POSSIBLE CAUSE

• Electrical connectors are disconnected or connected poorly

• Vacuum lines are disconnected or connected improperly.

• Poor fuel quality

• PCM DTC is stored

• Inadequate 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

• Charcoal canister malfunction

• Fuel tank vent 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.

• 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)

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})

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})

STEP

INSPECTION

RESULTS

ACTION

1

• Are any driveability or exhaust smoke concerns present?

Yes

Go to the applicable symptom troubleshooting.

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

No

Go to the next step.

2

• Inspect the following:

• Electrical connections

• Vacuum lines

• Fuel quality

• Is there any malfunction?

Yes

Service if necessary.

• Repeat this step.

No

Go to the next step.

3

• Retrieve any DTCs using the M-MDS.

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

• Are any DTCs present?

Yes

Go to the applicable DTC inspection.

(See DTC TABLE [PCM (SKYACTIV-G 2.0)].)

No

Go to the next step.

4

• 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 8.

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].)

• If there is any malfunction:

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

• If there is no malfunction:

• Go to Step 7.

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

• Go to the next step.

5

• Is the vehicle acceleration performance normal?

Yes

Go to the next step.

No

Go to Step 7.

6

• 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 8.

7

• 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].)

8

• 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].)

9

• Inspect the charcoal canister for fuel saturation.

  (See CHARCOAL CANISTER INSPECTION [SKYACTIV-G 2.0].)

• Is there excess amount of liquid fuel present in canister?

Yes

Replace the charcoal canister.

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

No

Inspect the fuel tank vent system.

• If the fuel tank vent system is normal:

• Suggest trying a different brand since sulfur content can vary in different fuels.

• If fuel tank vent system is not normal:

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

10

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.