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17 engine and emission control

This document provides information about engine and emission control systems, including specifications, diagrams, component locations, and inspection procedures. It covers the crankcase emission control system, evaporative emission control system, exhaust gas recirculation system, and catalytic converter. Check procedures are described for the accelerator cable, positive crankcase ventilation system, purge control system, and exhaust gas recirculation valve. Specifications and diagrams are provided for reference.

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ENGINE AND EMISSION CONTROL Click on the applicable bookmark to selected the required model year
17-1 ENGINE AND EMISSION CONTROL CONTENTS ENGINE CONTROL SYSTEM 3. . . . . . . . SERVICE SPECIFICATION 3. . . . . . . . . . . . . . . ON-VEHICLE SERVICE 3. . . . . . . . . . . . . . . . . . Accelerator Cable Check and Adjustment 3. . . ACCELERATOR CABLE AND PEDAL 4. . . . EMISSION CONTROL SYSTEM 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION 5. . . . . . . . . . . . . . . . Emission Control Device Reference Table 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SERVICE SPECIFICATIONS 6. . . . . . . . . . . . . . SPECIAL TOOL 6. . . . . . . . . . . . . . . . . . . . . . . . . VACUUM HOSE 6. . . . . . . . . . . . . . . . . . . . . . . . . Vacuum Hose Piping Diagram 6. . . . . . . . . . . . . . Vacuum Circuit Diagram 7. . . . . . . . . . . . . . . . . . . . Vacuum Hose Check 7. . . . . . . . . . . . . . . . . . . . . . . Vacuum Hose Installation 7. . . . . . . . . . . . . . . . . . . CRANKCASE EMISSION CONTROL SYSTEM 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Information 8. . . . . . . . . . . . . . . . . . . . . . . . System Diagram 8. . . . . . . . . . . . . . . . . . . . . . . . . . . Component Location 8. . . . . . . . . . . . . . . . . . . . . . . Positive Crankcase Ventilation System Check 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PCV Valve Check 9. . . . . . . . . . . . . . . . . . . . . . . . . . EVAPORATIVE EMISSION CONTROL SYSTEM 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Information 10. . . . . . . . . . . . . . . . . . . . . . System Diagram 10. . . . . . . . . . . . . . . . . . . . . . . . . Component Location 10. . . . . . . . . . . . . . . . . . . . . Purge Control System Check 11. . . . . . . . . . . . . . Purge Port Vacuum Check 11. . . . . . . . . . . . . . . . . Purge Control Solenoid Valve Check 12. . . . . . CONTINUED ON NEXT PAGE
17-2 EXHAUST GAS RECIRCULATION (EGR) SYSTEM 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Information 13. . . . . . . . . . . . . . . . . . . . . . Operation 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System Diagram 13. . . . . . . . . . . . . . . . . . . . . . . . . Component Location 13. . . . . . . . . . . . . . . . . . . . . Exhaust Gas Recirculation (EGR) ControL System Check 14. . . . . . . . . . . . . . . . . . . . . . . . . . . EGR Valve (Stepper Motor) Check 14. . . . . . . . EGR VALVE 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . CATALYTIC CONVERTER 17. . . . . . . . . . . . . . .
ENGINE AND EMISSION CONTROL – Engine Control System 17-3 ENGINE CONTROL SYSTEM SERVICE SPECIFICATION Items Standard value Accelerator cable play mm 1 – 2 ON-VEHICLE SERVICE ACCELERATOR CABLE CHECK AND ADJUSTMENT 1. Check the accelerator cable play when the accelerator pedal is released. Standard value: 1 – 2 mm 2. If the play is not within the standard value, turn the adjusting nut to adjust the play to the standard value. Adjusting nut
ENGINE AND EMISSION CONTROL – Engine Control System17-4 ACCELERATOR CABLE AND PEDAL REMOVAL AND INSTALLATION Post-installation Operation D Accelerator Pedal Position Sensor Check and Adjustment (Refer to GROUP 13A – On-vehicle Service.) D Kickdown Cable Adjustment (Refer to GROUP 23 – On-vehicle Service.) 12 Nm 2 9 5 1 6 8 3 7 10 Nm 4 Removal steps 1. Kickdown cable connection 2. Spring nut 3. Bushing 4. Return spring 5. Accelerator pedal 6. Accelerator pedal pad 7. Accelerator pedal position sensor 8. Accelerator pedal bracket 9. Accelerator pedal stopper
ENGINE AND EMISSION CONTROL – Emission Control System 17-5 EMISSION CONTROL SYSTEM GENERAL INFORMATION The emission control system consists of the following subsystems: D Crankcase emission control system D Evaporative emission control system D Exhaust emission control system Items Name Specification Crankcase emission control system Positive crankcase ventilation (PCV) valve Variable flow type (Purpose: HC reduction) Evaporative emission control system Canister Purge control solenoid valve Equipped Duty cycle type solenoid valve (Purpose: HC reduction) Exhaust emission control system Air-fuel ratio control device–GDI system Oxygen sensor feedback type (Purpose: CO, HC, NOx reduction) Exhaust gas recirculation system D EGR valve Equipped Stepper motor type (Purpose: NOx reduction) Catalytic converter Monolith type (Purpose: CO, HC, NOx reduction) EMISSION CONTROL DEVICE REFERENCE TABLE Related parts Crankcase emission control system Evaporative emission control system Air/fuel ratio control system Catalytic converter Exhaust gas recircula- tion system Reference page PCV valve × 17-9 Purge control solenoid valve × 17-12 GDI system component × × GROUP 13A Catalytic converter × 17-17 EGR valve × 17-14
ENGINE AND EMISSION CONTROL – Emission Control System17-6 SERVICE SPECIFICATIONS Items Standard value Purge control solenoid valve coil resistance (at 20_C) Ω 36 – 44 EGR valve (stepper motor) coil resistance (at 20_C) Ω 10 – 20 SPECIAL TOOL Tool Number Name Use MB991658 Test harness set Inspection of EGR valve VACUUM HOSE VACUUM HOSE PIPING DIAGRAM PCV valve From fuel pump (low-pressure) Canister Purge control solenoid valve Oxygen sensor Fuel pressure regulator (high- pressure) To fuel tank EGR valve (stepper motor) P Catalytic converter Fuel pump (high- pressure) Injector Air cleaner Air
ENGINE AND EMISSION CONTROL – Emission Control System 17-7 VACUUM CIRCUIT DIAGRAM To combustion chamber Intake manifold Throttle body From air cleaner Vacuum hose colour B: Black R: Red Purge control solenoid valve (ON: OPEN) Canister VACUUM HOSE CHECK 1. Using the piping diagram as a guide, check to be sure that the vacuum hoses are correctly connected. 2. Check the connection condition of the vacuum hoses, (removed, loose, etc.) and check to be sure that there are no bends or damage. VACUUM HOSE INSTALLATION 1. When connecting the vacuum hoses, they should be securely inserted onto the nipples. 2. Connect the hoses correctly, using the vacuum hose piping diagram as a guide.
ENGINE AND EMISSION CONTROL – Emission Control System PCV valve PCV valve 17-8 CRANKCASE EMISSION CONTROL SYSTEM GENERAL INFORMATION The crankcase emission control system prevents blow-by gases from escaping inside the crankcase into the atmosphere. Fresh air is sent from the air cleaner into the crankcase through the breather hose. The air becomes mixed with the blow-by gases inside the crankcase. The blow-by gas inside the crankcase is drawn into the intake manifold through the positive crankcase ventilation (PCV) valve. The PCV valve lifts the plunger according to the intake manifold vacuum so as to regulate the flow of blow-by gas properly. In other words, the blow-by gas flow is regulated during low load engine operation to maintain engine stability, while the flow is increased during high load operation to improve the ventilation performance. SYSTEM DIAGRAM PCV valve Ventilation hose Breather hose COMPONENT LOCATION
ENGINE AND EMISSION CONTROL – Emission Control System 17-9 POSITIVE CRANKCASE VENTILATION SYSTEM CHECK 1. Remove the ventilation hose from the PCV valve. 2. Remove the PCV valve from the rocker cover. 3. Reinstall the PCV valve at the ventilation hose. 4. Start the engine and run at idle. 5. Place a finger at the opening of the PCV valve and check that vacuum of the intake manifold is felt. NOTE At this moment, the plunger in the PCV valve moves back and forth. 6. If vacuum is not felt, clean the PCV valve or replace it. PCV VALVE CHECK 1. Insert a thin rod into the PCV valve from the side shown in the illustration (rocker cover installation side), and move the rod back and forth to check that the plunger moves. 2. If the plunger does not move, there is clogging in the PCV valve. In this case, clean or replace the PCV valve. PCV valve
ENGINE AND EMISSION CONTROL – Emission Control System Purge control solenoid valve Purge control solenoid valve 17-10 EVAPORATIVE EMISSION CONTROL SYSTEM GENERAL INFORMATION The evaporative emission control system prevents fuel vapours generated in the fuel tank from escaping into the atmosphere. Fuel vapours from the fuel tank flow through the fuel tank pressure control valve and vapour pipe/hose to be stored temporarily in the canister. When driving the vehicle, fuel vapours stored in the canister flow through the purge solenoid and purge port and go into the intake manifold to be sent to the combustion chamber. When the engine coolant temperature is low or when the intake air quantity is small (when the engine is at idle, for example), the engine control unit turns the purge solenoid off to shut off the fuel vapour flow to the intake manifold. This does not only insure the driveability when the engine is cold or running under low load but also stabilize the emission level. SYSTEM DIAGRAM From fuel tank Canister Purge control solenoid valve (ON: Open) Air flow sensor Barometric pressure sensor Control relay Throttle body Engine-ECU Engine coolant temperature sensor Intake air temperature sensor Battery COMPONENT LOCATION
ENGINE AND EMISSION CONTROL – Emission Control System 17-11 PURGE CONTROL SYSTEM CHECK 1. Disconnect the vacuum hose (red stripe) from the throttle body and connect it to a hand vacuum pump. 2. Plug the nipple from which the vacuum hose was removed. 3. When the engine is cold or hot, apply a vacuum of 53 kPa, and check the condition of the vacuum. When engine is cold (Engine coolant temperature: 40_C or less) Engine condition Normal condition At idle Vacuum is maintained 3,000 r/min When engine is hot (Engine coolant temperature: 80_C or higher) Engine condition Normal condition At idle Vacuum is maintained 3,000 r/min (fore approximately 3 minutes after the engine is started.) Vacuum will leak. PURGE PORT VACUUM CHECK 1. Disconnect the vacuum hose (red stripe) from the throttle body purge vacuum nipple and connect a hand vacuum pump to the nipple. 2. Start the engine. 3. Check that vacuum is produced almost constantly regardless of engine revolution. 4. When the vacuum is not produced, clean the hose as it may be clogged. Plug Vacuum hose (red stripe) Vacuum hose (red stripe) Vacuum Engine speed (r/min)
ENGINE AND EMISSION CONTROL – Emission Control System17-12 PURGE CONTROL SOLENOID VALVE CHECK NOTE When disconnecting the vacuum hose, always make a mark so that it can be reconnected at original position. 1. Disconnect the vacuum hose (black stripe, red stripe) from the solenoid valve. 2. Disconnect the harness connector. 3. Connect a hand vacuum pump to nipple (A) of the solenoid valve (refer to the illustration at left). 4. Check airtightness by applying a vacuum with voltage applied directly from the battery to the purge control solenoid valve and without applying voltage. Jumper wire Nipple B Normal condition Connected Open Vacuum leaks Closed Vacuum maintained Disconnected Open Vacuum maintained 5. Measure the resistance between the terminals of the solenoid valve. Standard value: 36 – 44 Ω (at 20_C) Battery B A
ENGINE AND EMISSION CONTROL – Emission Control System EGR valve Throttle body EGR valve 17-13 EXHAUST GAS RECIRCULATION (EGR) SYSTEM GENERAL INFORMATION The exhaust gas recirculation (EGR) system lowers the nitrogen oxide (NOx) emission level. When the air/fuel mixture combustion temperature is high, a large quantity of nitrogen oxides (NOx) is generated in the combustion chamber. Therefore, this system recirculates part of emission gas from the exhaust port of the cylinder head to the combustion chamber through the intake manifold to decrease the air/fuel mixture combustion temperature, resulting in reduction of NOx. The EGR flow rate is controlled by the EGR valve so as not to decrease the driveability. OPERATION The EGR valve is being closed and dose not recirculate exhaust gases under one of the following conditions. Otherwise, the EGR valve is opened and recirculate exhaust gases. D The engine coolant temperature is low. D The engine is at idle. D The throttle valve is widely opened. SYSTEM DIAGRAM Air flow sensor Engine coolant tem- perature sensor Crank angle sensor Control relay Engine-ECU Battery Throttle body EGR valve (Stepper motor) Throttle position sensor COMPONENT LOCATION
ENGINE AND EMISSION CONTROL – Emission Control System17-14 EXHAUST GAS RECIRCULATION (EGR) CONTROL SYSTEM CHECK Refer to GROUP 13A – Troubleshooting. EGR VALVE (STEPPER MOTOR) CHECK Checking the Operation Sound 1. Check that the operation sound of the stepper motor can be heard from the EGR valve when the ignition switch is turned to ON (without starting the engine). 2. If the operation sound cannot be heard, check the stepper motor drive circuit. NOTE If the circuit is normal, the cause is probably a malfunction of the stepper motor or of the engine-ECU. Checking the Coil Resistance 1. Disconnect the EGR valve connector. 2. Measure the resistance between the EGR valve-side connector terminal No.2 and terminal No.1 or terminal No.3. Standard value: 10 – 20 Ω (at 20_C) 3. Measure the resistance between the EGR valve-side connector terminal No.5 and terminal No.4 or terminal No.6. Standard value: 10 – 20 Ω (at 20_C) Throttle body EGR valve
ENGINE AND EMISSION CONTROL – Emission Control System 17-15 Operation Check 1. Remove the EGR valve. 2. Connect the special tool (test harness set) to the EGR valve-side connector. 3. Connect terminal No.2 and terminal No.5 to the positive (+) terminal of power supply of approximately 6 V. 4. Connect each clip to the negative (–) terminal of power supply in the order given below to test if any vibration occurs (as though the stepper motor is shaking slightly) due to the operation of the stepper motor. (1) Connect terminal No.1 and terminal No.4 to the negative (–) terminal of the power supply. (2) Connect terminal No.3 and terminal No.4 to the negative (–) terminal of the power supply. (3) Connect terminal No.3 and terminal No.6 to the negative (–) terminal of the power supply. (4) Connect terminal No.1 and terminal No.6 to the negative (–) terminal of the power supply. (5) Connect terminal No.1 and terminal No.4 to the negative (–) terminal of the power supply. (6) Repeat the test in the order from (5) to (1). 5. If the results of testing show that the vibration could be felt, the stepper motor is normal. Cleaning the EGR Valve Remove the EGR valve, and then check if the EGR valve is stuck and carbon is accumulated in it. If so, use a wire brush to clean the EGR valve. Caution Do not use a cleaning solvent. Solvent will penetrate to the motor and malfunction of EGR valve will result. EGR valve Battery MB991658
ENGINE AND EMISSION CONTROL – Emission Control System17-16 EGR VALVE REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation D Engine Coolant Draining and Supplying (Refer to GROUP 14 – On-vehicle Service.) D Engine Cover Removal and Installation 1 9 24 Nm 24 Nm 19 Nm 10 19 Nm 8 7 5 2 3 10 – 12 Nm 4 7 6 Removal steps AA" 1. Fuel pump protector 2. EGR valve harness connector connection 3. Water hose 4. Water pipe 5. Water hose 6. EGR valve and support assembly 7. EGR pipe gasket 8. EGR valve 9. EGR valve gasket 10. Water hose REMOVAL SERVICE POINT AA" FUEL PUMP PROTECTOR REMOVAL Lift up the transmission with a jack to create clearance between the engine and front deck, and then remove the fuel pump protector.
ENGINE AND EMISSION CONTROL – Emission Control System 17-17 CATALYTIC CONVERTER GENERAL INFORMATION The three-way catalytic converter, together with the closed loop air-fuel ratio control based on the oxygen sensor signal, oxidizes carbon monoxides (CO) and hydrocarbons (HC) and reduces nitrogen oxides (NOx). When the mixture is controlled at stoichiometric air-fuel ratio, the three-way catalytic converter provides the highest purification against the three constituents, namely, CO, HC and NOx. REMOVAL AND INSTALLATION 49 Nm 49 Nm 34 Nm 49 Nm 1 2 3 Removal steps 1. Oxygen sensor harness connector connection 2. Front exhaust pipe 3. Catalytic converter
NOTES
17-1 ENGINE AND EMISSION CONTROL CONTENTS EMISSION CONTROL SYSTEM GENERAL 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Outline of Change 2. . . . . . . . . . . . . . . . . . . . . . . . . SERVICE SPECIFICATIONS 2. . . . . . . . . . . . . . VACUUM HOSE 2. . . . . . . . . . . . . . . . . . . . . . . . . Vacuum Hose Piping Diagram 2. . . . . . . . . . . . . . Vacuum Circuit Diagram 3. . . . . . . . . . . . . . . . . . . . EVAPORATIVE EMISSION CONTROL SYSTEM 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Purge Control System Check 3. . . . . . . . . . . . . . . Purge Port Vacuum Check 4. . . . . . . . . . . . . . . . . . Purge Control Solenoid Valve Check 4. . . . . . . .
ENGINE AND EMISSION CONTROL – Emission Control System17-2 EMISSION CONTROL SYSTEM GENERAL OUTLINE OF CHANGE The flow rate of the purge control solenoid valve has been increased and the vacuum line routing has been changed. Due to these changes, the following service procedures have been established. Other items are the same as before. SERVICE SPECIFICATION Items Standard value EGR control solenoid valve coil resistance (at 20 _C) Ω 30 – 34 VACUUM HOSE VACUUM HOSE PIPING DIAGRAM Air cleaner Fuel pump (high pressure) Throttle control servo Canister Purge control solenoid valve (ON: Open) EGR valve (Stepper motor) Oxygen sensor (front) Oxygen sensor (rear) Catalytic converter Air From fuel pump (low pressure) To fuel tank Positive crankcase ventilation (PCV) valve M
ENGINE AND EMISSION CONTROL – Emission Control System 17-3 VACUUM CIRCUIT DIAGRAM To combustion chamber Intake manifold Throttle body From air cleaner EGR control solenoid valve (ON: OPEN)Vacuum hose colour B: Black R: Red Canister M EVAPORATIVE EMISSION CONTROL SYSTEM PURGE CONTROL SYSTEM CHECK 1. Disconnect the vacuum hose (black) from the intake manifold and connect it to a hand vacuum pump. 2. Plug the nipple from which the vacuum hose was removed. 3. When the engine is cold or hot, apply a vacuum of 53 kPa, and check the condition of the vacuum. When engine is cold (Engine coolant temperature: 40_C or less) Engine condition Normal condition At idle Vacuum is maintained 3,000 r/min When engine is hot (Engine coolant temperature: 80_C or higher) Engine condition Normal condition D At idle D Within 4 minutes after the engine has been started Vacuum is maintained D 3,000 r/min D Within 3 minutes after the engine has been started Vacuum will leak. Plug Vacuum hose (black)
ENGINE AND EMISSION CONTROL – Emission Control System17-4 PURGE PORT VACUUM CHECK 1. Disconnect the vacuum hose (black) from the intake manifold purge vacuum nipple and connect a hand vacuum pump to the nipple. 2. Start the engine and check that the vacuum remains fairly constant after racing the engine. NOTE If vacuum changes, it is possible that the intake manifold purge port may be clogged and require cleaning. PURGE CONTROL SOLENOID VALVE CHECK NOTE When disconnecting the vacuum hose, always make a mark so that it can be reconnected at original position. 1. Disconnect the vacuum hose (black stripe, red stripe) from the solenoid valve. 2. Disconnect the harness connector. 3. Connect a hand vacuum pump to nipple (A) of the solenoid valve (refer to the illustration at left). 4. Check airtightness by applying a vacuum with voltage applied directly from the battery to the purge control solenoid valve and without applying voltage. Battery voltage Normal condition Applied Vacuum leaks Not applied Vacuum maintained 5. Measure the resistance between the terminals of the solenoid valve. Standard value: 30 – 34 Ω (at 20_C) Purge port vacuum nipple Engine r/min Vacuum A B B Battery
17-1 ENGINE AND EMISSION CONTROL CONTENTS ENGINE CONTROL SYSTEM 2. . . . . . . . . . . . GENERAL 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Outline of Changes 2. . . . . . . . . . . . . . . . . . . . . . . . . SERVICE SPECIFICATION 2. . . . . . . . . . . . . . . . ON-VEHICLE SERVICE 2. . . . . . . . . . . . . . . . . . . Accelerator Cable Check and Adjustment <4G9-MPI> 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ACCELERATOR CABLE AND PEDAL 3. . . . . . EMISSION CONTROL SYSTEM <MPI> 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Outline of Changes 4. . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION 4. . . . . . . . . . . . . . . . SERVICE SPECIFICATIONS 5. . . . . . . . . . . . . . VACUUM HOSE 5. . . . . . . . . . . . . . . . . . . . . . . . . . Vacuum Hose Piping Diagram 5. . . . . . . . . . . . . . . . Vacuum Circuit Diagram 6. . . . . . . . . . . . . . . . . . . . . Vacuum Hose Check 6. . . . . . . . . . . . . . . . . . . . . . . . Vacuum Hose Installation 6. . . . . . . . . . . . . . . . . . . . CRANKCASE EMISSION CONTROL SYSTEM 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System Diagram 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . Component Location 7. . . . . . . . . . . . . . . . . . . . . . . . EVAPORATIVE EMISSION CONTROL SYSTEM 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Information 8. . . . . . . . . . . . . . . . . . . . . . . . . System Diagram 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . Component Location 8. . . . . . . . . . . . . . . . . . . . . . . . Purge Control System Check 9. . . . . . . . . . . . . . . . Purge Port Vacuum Check 9. . . . . . . . . . . . . . . . . . . Purge Control Solenoid Valve Check 10. . . . . . . . EXHAUST GAS RECIRCULATION (EGR) SYSTEM 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Information 11. . . . . . . . . . . . . . . . . . . . . . . . Operation 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System Diagram 11. . . . . . . . . . . . . . . . . . . . . . . . . . . Component Location 11. . . . . . . . . . . . . . . . . . . . . . . Exhaust Gas Recirculation (EGR) Control System Check 12. . . . . . . . . . . . . . . . . . . . . . . . . . . EGR Valve Check 12. . . . . . . . . . . . . . . . . . . . . . . . EGR Port Vacuum Check 13. . . . . . . . . . . . . . . . . . EGR Control Solenoid Valve Check 13. . . . . . . . . CATALYTIC CONVERTER 14. . . . . . . . . . . . . . .
ENGINE AND EMISSION CONTROL – Engine Control System17-2 ENGINE CONTROL SYSTEM GENERAL OUTLINE OF CHANGES The following service procedures have been established due to the addition of vehicles with 4G9-MPI engine. The other contents are the same as the 4G9-GDI engine. SERVICE SPECIFICATION Items Standard value Accelerator cable play mm 1 – 2 ON-VEHICLE SERVICE ACCELERATOR CABLE CHECK AND ADJUSTMENT <4G9-MPI> 1. Check the accelerator cable play when the accelerator pedal is released. Standard value: 1 – 2 mm 2. If the play is not within the standard value, turn the adjusting nut to adjust the play to the standard value. Adjusting nut
ENGINE AND EMISSION CONTROL – Engine Control SystemENGINE AND EMISSION CONTROL – Engine Control System 17-3 ACCELERATOR CABLE AND PEDAL REMOVAL AND INSTALLATION <4G9-MPI> Post-installation Operation Accelerator Cable Adjustment (Refer to P.17-2.) 1 2 3 2 4 <L.H. drive vehicles> <R.H. drive vehicles> 8 6 5 7 5 3 4 6 7 8 1 5.0 ± 1.0 N·m 6 6 45.0 ± 1.0 N·m 5.0 ± 1.0 N·m 12 ± 2 N·m 12 ± 2 N·m Removal steps 1. Accelerator cable 2. Push-on spring nut 3. Accelerator arm assembly 4. Spring 5. Accelerator pedal bracket 6. Bushing 7. Pedal pad "AA 8. Accelerator pedal stopper INSTALLATION SERVICE POINT AA" ACCELERATOR PEDAL STOPPER INSTALLATION Heat up the claw of the accelerator pedal pad with a drier and etc. before installation. NOTE Apply some soapsuds to the claw to facilitate installation if there is any difficulty.
ENGINE AND EMISSION CONTROL – Emission Control System <MPI>17-4 EMISSION CONTROL SYSTEM <MPI> GENERAL OUTLINE OF CHANGES The following contents have been established to correspond to the addition of vehicles with 4G9-MPI engine. The other contents are the same as before. GENERAL INFORMATION The emission control system consists of the following subsystems: D Crankcase emission control system D Evaporative emission control system D Exhaust emission control system Items Name Specification Crankcase emission control system Positive crankcase ventilation (PCV) valve Variable flow type (Purpose: HC reduction) Evaporative emission control system Canister Purge control solenoid valve Equipped Duty cycle type solenoid valve (Purpose: HC reduction) Exhaust emission control system Air-fuel ratio control device – MPI system Oxygen sensor feedback type (Purpose: CO, HC, NOx reduction) Exhaust gas recirculation system D EGR valve D EGR control solenoid valve Equipped Single type Duty cycle type solenoid valve (Purpose: NOx reduction) Catalytic converter Monolith type (Purpose: CO, HC, NOx reduction) EMISSION CONTROL DEVICE REFERENCE TABLE Related parts Crankcase emission control system Evaporative emission control system Air/fuel ratio control system Catalytic converter Exhaust gas recircula- tion system Reference page PCV valve × 17-9* Purge control solenoid valve × 17-9 MPI system component × × GROUP 13B Catalytic converter × 17-14 EGR valve × 17-12 EGR control solenoid valve × 17-13 NOTE *: Refer to the ’00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1)
ENGINE AND EMISSION CONTROL – Emission Control System <MPI> 17-5 SERVICE SPECIFICATIONS Items Standard value Purge control solenoid valve coil resistance (at 20_C) Ω 36 – 44 EGR control solenoid valve coil resistance (at 20_C) Ω 36 – 44 VACUUM HOSE VACUUM HOSE PIPING DIAGRAM PCV valve OFF EGR valve Air cleaner ON Canister Purge control solenoid valve EGR control solenoid valve Oxygen sensor <rear> Air OFF ON Oxygen sensor <front> M E A
ENGINE AND EMISSION CONTROL – Emission Control System <MPI>17-6 VACUUM CIRCUIT DIAGRAM From air cleaner Intake manifold Throttle body To combustion chamber Fuel pressure regulator EGR control solenoid valve (ON: OPEN) Canister Purge control solenoid valve (ON: OPEN) EGR valve Vacuum hose colour B: Black G: Green L: Light blue R: Red Y: Yellow M P A L G Y G G R B VACUUM HOSE CHECK 1. Using the piping diagram as a guide, check to be sure that the vacuum hoses are correctly connected. 2. Check the connection condition of the vacuum hoses, (removed, loose, etc.) and check to be sure that there are no bends or damage. VACUUM HOSE INSTALLATION 1. When connecting the vacuum hoses, they should be securely inserted onto the nipples. 2. Connect the hoses correctly, using the vacuum hose piping diagram as a guide.
ENGINE AND EMISSION CONTROL – Emission Control System <MPI> PCV valve 17-7 CRANKCASE EMISSION CONTROL SYSTEM SYSTEM DIAGRAM Ventilation hose Breather hose PCV valve COMPONENT LOCATION
ENGINE AND EMISSION CONTROL – Emission Control System <MPI> Purge control solenoid valve 17-8 EVAPORATIVE EMISSION CONTROL SYSTEM GENERAL INFORMATION The evaporative emission control system prevents fuel vapours generated in the fuel tank from escaping into the atmosphere. Fuel vapours from the fuel tank flow through the fuel tank pressure control valve and vapour pipe/hose to be stored temporarily in the canister. When driving the vehicle, fuel vapours stored in the canister flow through the purge solenoid and purge port and go into the intake manifold to be sent to the combustion chamber. When the engine coolant temperature is low or when the intake air quantity is small (when the engine is at idle, for example), the engine control unit turns the purge solenoid off to shut off the fuel vapour flow to the intake manifold. This does not only insure the driveability when the engine is cold or running under low load but also stabilize the emission level. SYSTEM DIAGRAM From fuel tank Canister Purge control solenoid valve OFF ON Air flow sensor Barometric pressure sensor Control relay Throttle body Engine-ECU Engine coolant temperature sensor Intake air temperature sensor COMPONENT LOCATION
ENGINE AND EMISSION CONTROL – Emission Control System <MPI> 17-9 PURGE CONTROL SYSTEM CHECK 1. Disconnect the vacuum hose (red stripe) from the throttle body and connect it to a hand vacuum pump. 2. Plug the nipple from which the vacuum hose was removed. 3. When the engine is cold or hot, apply a vacuum of 53 kPa, and check the condition of the vacuum. When engine is cold (Engine coolant temperature: 40_C or less) Engine condition Normal condition At idle Vacuum is maintained 3,000 r/min When engine is hot (Engine coolant temperature: 80_C or higher) Engine condition Normal condition At idle Vacuum is maintained 3,000 r/min (fore approximately 3 minutes after the engine is started.) Vacuum will leak. PURGE PORT VACUUM CHECK 1. Disconnect the vacuum hose (red stripe) from the throttle body purge vacuum nipple and connect a hand vacuum pump to the nipple. 2. Start the engine and check that the vacuum remains fairly constant after racing the engine. NOTE If vacuum changes, it is possible that the throttle body purge port may be clogged and require cleaning. Plug Purge port vacuum nipple Vacuum Engine speed (r/min)
ENGINE AND EMISSION CONTROL – Emission Control System <MPI>17-10 PURGE CONTROL SOLENOID VALVE CHECK NOTE When disconnecting the vacuum hose, always make a mark so that it can be reconnected at original position. 1. Disconnect the vacuum hose (black, red stripe) from the solenoid valve. 2. Disconnect the harness connector. 3. Connect a hand vacuum pump to nipple (A) of the solenoid valve (refer to the illustration at left). 4. Check airtightness by applying a vacuum with voltage applied directly from the battery to the purge control solenoid valve and without applying voltage. Battery voltage Normal condition Applied Vacuum leaks Not applied Vacuum maintained 5. Measure the resistance between the terminals of the solenoid valve. Standard value: 36 – 44 Ω (at 20_C) Battery B A
ENGINE AND EMISSION CONTROL – Emission Control System <MPI> EGR control solenoid valve EGR valve 17-11 EXHAUST GAS RECIRCULATION (EGR) SYSTEM GENERAL INFORMATION The exhaust gas recirculation (EGR) system lowers the nitrogen oxide (NOx) emission level. When the air/fuel mixture combustion temperature is high, a large quantity of nitrogen oxides (NOx) is generated in the combustion chamber. Therefore, this system recirculates part of emission gas from the exhaust port of the cylinder head to the combustion chamber through the intake manifold to decrease the air/fuel mixture combustion temperature, resulting in reduction of NOx. The EGR flow rate is controlled by the EGR valve so as not to decrease the driveability. OPERATION The EGR valve is being closed and does not recirculate exhaust gases under one of the following conditions. Otherwise, the EGR valve is opened and recirculates exhaust gases. D The engine coolant temperature is low. D The engine is at idle. D The throttle valve is widely opened. SYSTEM DIAGRAM ONOFF EGR control solenoid valve Air flow sensor Engine coolant temperature sensor Crank angle sensorControl relay Engine-ECU Battery EGR valve COMPONENT LOCATION
ENGINE AND EMISSION CONTROL – Emission Control System <MPI>17-12 EXHAUST GAS RECIRCULATION (EGR) CONTROL SYSTEM CHECK 1. Disconnect the vacuum hose (green stripe) from the EGR valve, and then connect a hand vacuum pump via the three-way terminal. 2. When the engine is hot or cold, check the condition of vacuum by racing the engine. When engine is cold (Engine coolant temperature: 20_C or less) Throttle valve Normal vacuum condition Open quickly No vacuum will generate (the same as barometric pressure.) When engine is hot (Engine coolant temperature: 80_C or higher) Throttle valve Normal vacuum condition Open quickly It will momentarily rise over 13 kPa 3. Disconnect the three-way terminal. 4. Connect the hand vacuum pump to the EGR valve. 5. Check whether the engine stalls or the idling is unstable when a vacuum of 30 kPa or higher is applied during idling. EGR VALVE CHECK 1. Remove the EGR valve and inspect for sticking, carbon deposits, etc. If found, clean with a suitable solvent so that the valve seats correctly. 2. Connect a hand vacuum pump to the EGR valve. 3. Apply 67 kPa of vacuum, and check that the vacuum is maintained. 4. Apply a vacuum and check the passage of air by blowing through one side of the EGR passage. Vacuum Passage of air 5.0 kPa or less Air is not blown out 27 kPa or more Air is blown out 5. Replace the gasket, and tighten to the specified torque. Tightening torque: 22 ± 5 N·m Three-way terminal Vacuum hose (Green stripe) EGR valve EGR valve Plug Vacuum hose (Green stripe)
ENGINE AND EMISSION CONTROL – Emission Control System <MPI> 17-13 EGR PORT VACUUM CHECK 1. Disconnect the vacuum hose (Green) from the throttle body EGR vacuum nipple and connect a hand vacuum pump to the nipple. 2. Start the engine and check that, after raising the engine speed by racing the engine, purge vacuum raises according to engine speed. NOTE If there is a problem with the change in vacuum, the throttle body EGR port may be clogged and require cleaning. EGR CONTROL SOLENOID VALVE CHECK NOTE When disconnecting the vacuum hose, always make a mark so that it can be reconnected at original position. 1. Disconnect the vacuum hose (yellow stripe, green stripe) from the solenoid valve. 2. Disconnect the harness connector. 3. Connect a hand vacuum pump to the nipple (A) of the solenoid valve (refer to the illustration at left). 4. Check airtightness by applying a vacuum with voltage applied directly from the battery to the EGR control solenoid valve and without applying voltage. Battery voltage Normal condition Not applied Vacuum maintained Applied Vacuum leaks 5. Measure the resistance between the terminals of the solenoid valve. Standard value: 36 – 44 Ω (at 20_C) Vacuum Engine speed (r/min) A B Battery
ENGINE AND EMISSION CONTROL – Emission Control System <MPI>17-14 CATALYTIC CONVERTER REMOVAL AND INSTALLATION 1 2 4 3 5 50 ± 10 N·m 50 ± 10 N·m 50 ± 10 N·m 50 ± 10 N·m 50 ± 10 N·m 50 ± 10 N·m 13 ± 2 N·m Front catalytic converter removal steps 1. Front pipe 2. Oxygen sensor (front) 3. Front catalytic converter Catalytic converter removal steps 1. Front pipe 4. Oxygen sensor (rear) 5. Catalytic converter

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17 engine and emission control

  • 1.
    ENGINE AND EMISSION CONTROL Click onthe applicable bookmark to selected the required model year
  • 2.
    17-1 ENGINE AND EMISSION CONTROL CONTENTS ENGINE CONTROLSYSTEM 3. . . . . . . . SERVICE SPECIFICATION 3. . . . . . . . . . . . . . . ON-VEHICLE SERVICE 3. . . . . . . . . . . . . . . . . . Accelerator Cable Check and Adjustment 3. . . ACCELERATOR CABLE AND PEDAL 4. . . . EMISSION CONTROL SYSTEM 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION 5. . . . . . . . . . . . . . . . Emission Control Device Reference Table 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SERVICE SPECIFICATIONS 6. . . . . . . . . . . . . . SPECIAL TOOL 6. . . . . . . . . . . . . . . . . . . . . . . . . VACUUM HOSE 6. . . . . . . . . . . . . . . . . . . . . . . . . Vacuum Hose Piping Diagram 6. . . . . . . . . . . . . . Vacuum Circuit Diagram 7. . . . . . . . . . . . . . . . . . . . Vacuum Hose Check 7. . . . . . . . . . . . . . . . . . . . . . . Vacuum Hose Installation 7. . . . . . . . . . . . . . . . . . . CRANKCASE EMISSION CONTROL SYSTEM 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Information 8. . . . . . . . . . . . . . . . . . . . . . . . System Diagram 8. . . . . . . . . . . . . . . . . . . . . . . . . . . Component Location 8. . . . . . . . . . . . . . . . . . . . . . . Positive Crankcase Ventilation System Check 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PCV Valve Check 9. . . . . . . . . . . . . . . . . . . . . . . . . . EVAPORATIVE EMISSION CONTROL SYSTEM 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Information 10. . . . . . . . . . . . . . . . . . . . . . System Diagram 10. . . . . . . . . . . . . . . . . . . . . . . . . Component Location 10. . . . . . . . . . . . . . . . . . . . . Purge Control System Check 11. . . . . . . . . . . . . . Purge Port Vacuum Check 11. . . . . . . . . . . . . . . . . Purge Control Solenoid Valve Check 12. . . . . . CONTINUED ON NEXT PAGE
  • 3.
    17-2 EXHAUST GAS RECIRCULATION(EGR) SYSTEM 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Information 13. . . . . . . . . . . . . . . . . . . . . . Operation 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System Diagram 13. . . . . . . . . . . . . . . . . . . . . . . . . Component Location 13. . . . . . . . . . . . . . . . . . . . . Exhaust Gas Recirculation (EGR) ControL System Check 14. . . . . . . . . . . . . . . . . . . . . . . . . . . EGR Valve (Stepper Motor) Check 14. . . . . . . . EGR VALVE 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . CATALYTIC CONVERTER 17. . . . . . . . . . . . . . .
  • 4.
    ENGINE AND EMISSIONCONTROL – Engine Control System 17-3 ENGINE CONTROL SYSTEM SERVICE SPECIFICATION Items Standard value Accelerator cable play mm 1 – 2 ON-VEHICLE SERVICE ACCELERATOR CABLE CHECK AND ADJUSTMENT 1. Check the accelerator cable play when the accelerator pedal is released. Standard value: 1 – 2 mm 2. If the play is not within the standard value, turn the adjusting nut to adjust the play to the standard value. Adjusting nut
  • 5.
    ENGINE AND EMISSIONCONTROL – Engine Control System17-4 ACCELERATOR CABLE AND PEDAL REMOVAL AND INSTALLATION Post-installation Operation D Accelerator Pedal Position Sensor Check and Adjustment (Refer to GROUP 13A – On-vehicle Service.) D Kickdown Cable Adjustment (Refer to GROUP 23 – On-vehicle Service.) 12 Nm 2 9 5 1 6 8 3 7 10 Nm 4 Removal steps 1. Kickdown cable connection 2. Spring nut 3. Bushing 4. Return spring 5. Accelerator pedal 6. Accelerator pedal pad 7. Accelerator pedal position sensor 8. Accelerator pedal bracket 9. Accelerator pedal stopper
  • 6.
    ENGINE AND EMISSIONCONTROL – Emission Control System 17-5 EMISSION CONTROL SYSTEM GENERAL INFORMATION The emission control system consists of the following subsystems: D Crankcase emission control system D Evaporative emission control system D Exhaust emission control system Items Name Specification Crankcase emission control system Positive crankcase ventilation (PCV) valve Variable flow type (Purpose: HC reduction) Evaporative emission control system Canister Purge control solenoid valve Equipped Duty cycle type solenoid valve (Purpose: HC reduction) Exhaust emission control system Air-fuel ratio control device–GDI system Oxygen sensor feedback type (Purpose: CO, HC, NOx reduction) Exhaust gas recirculation system D EGR valve Equipped Stepper motor type (Purpose: NOx reduction) Catalytic converter Monolith type (Purpose: CO, HC, NOx reduction) EMISSION CONTROL DEVICE REFERENCE TABLE Related parts Crankcase emission control system Evaporative emission control system Air/fuel ratio control system Catalytic converter Exhaust gas recircula- tion system Reference page PCV valve × 17-9 Purge control solenoid valve × 17-12 GDI system component × × GROUP 13A Catalytic converter × 17-17 EGR valve × 17-14
  • 7.
    ENGINE AND EMISSIONCONTROL – Emission Control System17-6 SERVICE SPECIFICATIONS Items Standard value Purge control solenoid valve coil resistance (at 20_C) Ω 36 – 44 EGR valve (stepper motor) coil resistance (at 20_C) Ω 10 – 20 SPECIAL TOOL Tool Number Name Use MB991658 Test harness set Inspection of EGR valve VACUUM HOSE VACUUM HOSE PIPING DIAGRAM PCV valve From fuel pump (low-pressure) Canister Purge control solenoid valve Oxygen sensor Fuel pressure regulator (high- pressure) To fuel tank EGR valve (stepper motor) P Catalytic converter Fuel pump (high- pressure) Injector Air cleaner Air
  • 8.
    ENGINE AND EMISSIONCONTROL – Emission Control System 17-7 VACUUM CIRCUIT DIAGRAM To combustion chamber Intake manifold Throttle body From air cleaner Vacuum hose colour B: Black R: Red Purge control solenoid valve (ON: OPEN) Canister VACUUM HOSE CHECK 1. Using the piping diagram as a guide, check to be sure that the vacuum hoses are correctly connected. 2. Check the connection condition of the vacuum hoses, (removed, loose, etc.) and check to be sure that there are no bends or damage. VACUUM HOSE INSTALLATION 1. When connecting the vacuum hoses, they should be securely inserted onto the nipples. 2. Connect the hoses correctly, using the vacuum hose piping diagram as a guide.
  • 9.
    ENGINE AND EMISSIONCONTROL – Emission Control System PCV valve PCV valve 17-8 CRANKCASE EMISSION CONTROL SYSTEM GENERAL INFORMATION The crankcase emission control system prevents blow-by gases from escaping inside the crankcase into the atmosphere. Fresh air is sent from the air cleaner into the crankcase through the breather hose. The air becomes mixed with the blow-by gases inside the crankcase. The blow-by gas inside the crankcase is drawn into the intake manifold through the positive crankcase ventilation (PCV) valve. The PCV valve lifts the plunger according to the intake manifold vacuum so as to regulate the flow of blow-by gas properly. In other words, the blow-by gas flow is regulated during low load engine operation to maintain engine stability, while the flow is increased during high load operation to improve the ventilation performance. SYSTEM DIAGRAM PCV valve Ventilation hose Breather hose COMPONENT LOCATION
  • 10.
    ENGINE AND EMISSIONCONTROL – Emission Control System 17-9 POSITIVE CRANKCASE VENTILATION SYSTEM CHECK 1. Remove the ventilation hose from the PCV valve. 2. Remove the PCV valve from the rocker cover. 3. Reinstall the PCV valve at the ventilation hose. 4. Start the engine and run at idle. 5. Place a finger at the opening of the PCV valve and check that vacuum of the intake manifold is felt. NOTE At this moment, the plunger in the PCV valve moves back and forth. 6. If vacuum is not felt, clean the PCV valve or replace it. PCV VALVE CHECK 1. Insert a thin rod into the PCV valve from the side shown in the illustration (rocker cover installation side), and move the rod back and forth to check that the plunger moves. 2. If the plunger does not move, there is clogging in the PCV valve. In this case, clean or replace the PCV valve. PCV valve
  • 11.
    ENGINE AND EMISSIONCONTROL – Emission Control System Purge control solenoid valve Purge control solenoid valve 17-10 EVAPORATIVE EMISSION CONTROL SYSTEM GENERAL INFORMATION The evaporative emission control system prevents fuel vapours generated in the fuel tank from escaping into the atmosphere. Fuel vapours from the fuel tank flow through the fuel tank pressure control valve and vapour pipe/hose to be stored temporarily in the canister. When driving the vehicle, fuel vapours stored in the canister flow through the purge solenoid and purge port and go into the intake manifold to be sent to the combustion chamber. When the engine coolant temperature is low or when the intake air quantity is small (when the engine is at idle, for example), the engine control unit turns the purge solenoid off to shut off the fuel vapour flow to the intake manifold. This does not only insure the driveability when the engine is cold or running under low load but also stabilize the emission level. SYSTEM DIAGRAM From fuel tank Canister Purge control solenoid valve (ON: Open) Air flow sensor Barometric pressure sensor Control relay Throttle body Engine-ECU Engine coolant temperature sensor Intake air temperature sensor Battery COMPONENT LOCATION
  • 12.
    ENGINE AND EMISSIONCONTROL – Emission Control System 17-11 PURGE CONTROL SYSTEM CHECK 1. Disconnect the vacuum hose (red stripe) from the throttle body and connect it to a hand vacuum pump. 2. Plug the nipple from which the vacuum hose was removed. 3. When the engine is cold or hot, apply a vacuum of 53 kPa, and check the condition of the vacuum. When engine is cold (Engine coolant temperature: 40_C or less) Engine condition Normal condition At idle Vacuum is maintained 3,000 r/min When engine is hot (Engine coolant temperature: 80_C or higher) Engine condition Normal condition At idle Vacuum is maintained 3,000 r/min (fore approximately 3 minutes after the engine is started.) Vacuum will leak. PURGE PORT VACUUM CHECK 1. Disconnect the vacuum hose (red stripe) from the throttle body purge vacuum nipple and connect a hand vacuum pump to the nipple. 2. Start the engine. 3. Check that vacuum is produced almost constantly regardless of engine revolution. 4. When the vacuum is not produced, clean the hose as it may be clogged. Plug Vacuum hose (red stripe) Vacuum hose (red stripe) Vacuum Engine speed (r/min)
  • 13.
    ENGINE AND EMISSIONCONTROL – Emission Control System17-12 PURGE CONTROL SOLENOID VALVE CHECK NOTE When disconnecting the vacuum hose, always make a mark so that it can be reconnected at original position. 1. Disconnect the vacuum hose (black stripe, red stripe) from the solenoid valve. 2. Disconnect the harness connector. 3. Connect a hand vacuum pump to nipple (A) of the solenoid valve (refer to the illustration at left). 4. Check airtightness by applying a vacuum with voltage applied directly from the battery to the purge control solenoid valve and without applying voltage. Jumper wire Nipple B Normal condition Connected Open Vacuum leaks Closed Vacuum maintained Disconnected Open Vacuum maintained 5. Measure the resistance between the terminals of the solenoid valve. Standard value: 36 – 44 Ω (at 20_C) Battery B A
  • 14.
    ENGINE AND EMISSIONCONTROL – Emission Control System EGR valve Throttle body EGR valve 17-13 EXHAUST GAS RECIRCULATION (EGR) SYSTEM GENERAL INFORMATION The exhaust gas recirculation (EGR) system lowers the nitrogen oxide (NOx) emission level. When the air/fuel mixture combustion temperature is high, a large quantity of nitrogen oxides (NOx) is generated in the combustion chamber. Therefore, this system recirculates part of emission gas from the exhaust port of the cylinder head to the combustion chamber through the intake manifold to decrease the air/fuel mixture combustion temperature, resulting in reduction of NOx. The EGR flow rate is controlled by the EGR valve so as not to decrease the driveability. OPERATION The EGR valve is being closed and dose not recirculate exhaust gases under one of the following conditions. Otherwise, the EGR valve is opened and recirculate exhaust gases. D The engine coolant temperature is low. D The engine is at idle. D The throttle valve is widely opened. SYSTEM DIAGRAM Air flow sensor Engine coolant tem- perature sensor Crank angle sensor Control relay Engine-ECU Battery Throttle body EGR valve (Stepper motor) Throttle position sensor COMPONENT LOCATION
  • 15.
    ENGINE AND EMISSIONCONTROL – Emission Control System17-14 EXHAUST GAS RECIRCULATION (EGR) CONTROL SYSTEM CHECK Refer to GROUP 13A – Troubleshooting. EGR VALVE (STEPPER MOTOR) CHECK Checking the Operation Sound 1. Check that the operation sound of the stepper motor can be heard from the EGR valve when the ignition switch is turned to ON (without starting the engine). 2. If the operation sound cannot be heard, check the stepper motor drive circuit. NOTE If the circuit is normal, the cause is probably a malfunction of the stepper motor or of the engine-ECU. Checking the Coil Resistance 1. Disconnect the EGR valve connector. 2. Measure the resistance between the EGR valve-side connector terminal No.2 and terminal No.1 or terminal No.3. Standard value: 10 – 20 Ω (at 20_C) 3. Measure the resistance between the EGR valve-side connector terminal No.5 and terminal No.4 or terminal No.6. Standard value: 10 – 20 Ω (at 20_C) Throttle body EGR valve
  • 16.
    ENGINE AND EMISSIONCONTROL – Emission Control System 17-15 Operation Check 1. Remove the EGR valve. 2. Connect the special tool (test harness set) to the EGR valve-side connector. 3. Connect terminal No.2 and terminal No.5 to the positive (+) terminal of power supply of approximately 6 V. 4. Connect each clip to the negative (–) terminal of power supply in the order given below to test if any vibration occurs (as though the stepper motor is shaking slightly) due to the operation of the stepper motor. (1) Connect terminal No.1 and terminal No.4 to the negative (–) terminal of the power supply. (2) Connect terminal No.3 and terminal No.4 to the negative (–) terminal of the power supply. (3) Connect terminal No.3 and terminal No.6 to the negative (–) terminal of the power supply. (4) Connect terminal No.1 and terminal No.6 to the negative (–) terminal of the power supply. (5) Connect terminal No.1 and terminal No.4 to the negative (–) terminal of the power supply. (6) Repeat the test in the order from (5) to (1). 5. If the results of testing show that the vibration could be felt, the stepper motor is normal. Cleaning the EGR Valve Remove the EGR valve, and then check if the EGR valve is stuck and carbon is accumulated in it. If so, use a wire brush to clean the EGR valve. Caution Do not use a cleaning solvent. Solvent will penetrate to the motor and malfunction of EGR valve will result. EGR valve Battery MB991658
  • 17.
    ENGINE AND EMISSIONCONTROL – Emission Control System17-16 EGR VALVE REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation D Engine Coolant Draining and Supplying (Refer to GROUP 14 – On-vehicle Service.) D Engine Cover Removal and Installation 1 9 24 Nm 24 Nm 19 Nm 10 19 Nm 8 7 5 2 3 10 – 12 Nm 4 7 6 Removal steps AA" 1. Fuel pump protector 2. EGR valve harness connector connection 3. Water hose 4. Water pipe 5. Water hose 6. EGR valve and support assembly 7. EGR pipe gasket 8. EGR valve 9. EGR valve gasket 10. Water hose REMOVAL SERVICE POINT AA" FUEL PUMP PROTECTOR REMOVAL Lift up the transmission with a jack to create clearance between the engine and front deck, and then remove the fuel pump protector.
  • 18.
    ENGINE AND EMISSIONCONTROL – Emission Control System 17-17 CATALYTIC CONVERTER GENERAL INFORMATION The three-way catalytic converter, together with the closed loop air-fuel ratio control based on the oxygen sensor signal, oxidizes carbon monoxides (CO) and hydrocarbons (HC) and reduces nitrogen oxides (NOx). When the mixture is controlled at stoichiometric air-fuel ratio, the three-way catalytic converter provides the highest purification against the three constituents, namely, CO, HC and NOx. REMOVAL AND INSTALLATION 49 Nm 49 Nm 34 Nm 49 Nm 1 2 3 Removal steps 1. Oxygen sensor harness connector connection 2. Front exhaust pipe 3. Catalytic converter
  • 19.
  • 20.
    17-1 ENGINE AND EMISSION CONTROL CONTENTS EMISSION CONTROLSYSTEM GENERAL 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Outline of Change 2. . . . . . . . . . . . . . . . . . . . . . . . . SERVICE SPECIFICATIONS 2. . . . . . . . . . . . . . VACUUM HOSE 2. . . . . . . . . . . . . . . . . . . . . . . . . Vacuum Hose Piping Diagram 2. . . . . . . . . . . . . . Vacuum Circuit Diagram 3. . . . . . . . . . . . . . . . . . . . EVAPORATIVE EMISSION CONTROL SYSTEM 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Purge Control System Check 3. . . . . . . . . . . . . . . Purge Port Vacuum Check 4. . . . . . . . . . . . . . . . . . Purge Control Solenoid Valve Check 4. . . . . . . .
  • 21.
    ENGINE AND EMISSIONCONTROL – Emission Control System17-2 EMISSION CONTROL SYSTEM GENERAL OUTLINE OF CHANGE The flow rate of the purge control solenoid valve has been increased and the vacuum line routing has been changed. Due to these changes, the following service procedures have been established. Other items are the same as before. SERVICE SPECIFICATION Items Standard value EGR control solenoid valve coil resistance (at 20 _C) Ω 30 – 34 VACUUM HOSE VACUUM HOSE PIPING DIAGRAM Air cleaner Fuel pump (high pressure) Throttle control servo Canister Purge control solenoid valve (ON: Open) EGR valve (Stepper motor) Oxygen sensor (front) Oxygen sensor (rear) Catalytic converter Air From fuel pump (low pressure) To fuel tank Positive crankcase ventilation (PCV) valve M
  • 22.
    ENGINE AND EMISSIONCONTROL – Emission Control System 17-3 VACUUM CIRCUIT DIAGRAM To combustion chamber Intake manifold Throttle body From air cleaner EGR control solenoid valve (ON: OPEN)Vacuum hose colour B: Black R: Red Canister M EVAPORATIVE EMISSION CONTROL SYSTEM PURGE CONTROL SYSTEM CHECK 1. Disconnect the vacuum hose (black) from the intake manifold and connect it to a hand vacuum pump. 2. Plug the nipple from which the vacuum hose was removed. 3. When the engine is cold or hot, apply a vacuum of 53 kPa, and check the condition of the vacuum. When engine is cold (Engine coolant temperature: 40_C or less) Engine condition Normal condition At idle Vacuum is maintained 3,000 r/min When engine is hot (Engine coolant temperature: 80_C or higher) Engine condition Normal condition D At idle D Within 4 minutes after the engine has been started Vacuum is maintained D 3,000 r/min D Within 3 minutes after the engine has been started Vacuum will leak. Plug Vacuum hose (black)
  • 23.
    ENGINE AND EMISSIONCONTROL – Emission Control System17-4 PURGE PORT VACUUM CHECK 1. Disconnect the vacuum hose (black) from the intake manifold purge vacuum nipple and connect a hand vacuum pump to the nipple. 2. Start the engine and check that the vacuum remains fairly constant after racing the engine. NOTE If vacuum changes, it is possible that the intake manifold purge port may be clogged and require cleaning. PURGE CONTROL SOLENOID VALVE CHECK NOTE When disconnecting the vacuum hose, always make a mark so that it can be reconnected at original position. 1. Disconnect the vacuum hose (black stripe, red stripe) from the solenoid valve. 2. Disconnect the harness connector. 3. Connect a hand vacuum pump to nipple (A) of the solenoid valve (refer to the illustration at left). 4. Check airtightness by applying a vacuum with voltage applied directly from the battery to the purge control solenoid valve and without applying voltage. Battery voltage Normal condition Applied Vacuum leaks Not applied Vacuum maintained 5. Measure the resistance between the terminals of the solenoid valve. Standard value: 30 – 34 Ω (at 20_C) Purge port vacuum nipple Engine r/min Vacuum A B B Battery
  • 24.
    17-1 ENGINE AND EMISSION CONTROL CONTENTS ENGINE CONTROLSYSTEM 2. . . . . . . . . . . . GENERAL 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Outline of Changes 2. . . . . . . . . . . . . . . . . . . . . . . . . SERVICE SPECIFICATION 2. . . . . . . . . . . . . . . . ON-VEHICLE SERVICE 2. . . . . . . . . . . . . . . . . . . Accelerator Cable Check and Adjustment <4G9-MPI> 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ACCELERATOR CABLE AND PEDAL 3. . . . . . EMISSION CONTROL SYSTEM <MPI> 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Outline of Changes 4. . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION 4. . . . . . . . . . . . . . . . SERVICE SPECIFICATIONS 5. . . . . . . . . . . . . . VACUUM HOSE 5. . . . . . . . . . . . . . . . . . . . . . . . . . Vacuum Hose Piping Diagram 5. . . . . . . . . . . . . . . . Vacuum Circuit Diagram 6. . . . . . . . . . . . . . . . . . . . . Vacuum Hose Check 6. . . . . . . . . . . . . . . . . . . . . . . . Vacuum Hose Installation 6. . . . . . . . . . . . . . . . . . . . CRANKCASE EMISSION CONTROL SYSTEM 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System Diagram 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . Component Location 7. . . . . . . . . . . . . . . . . . . . . . . . EVAPORATIVE EMISSION CONTROL SYSTEM 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Information 8. . . . . . . . . . . . . . . . . . . . . . . . . System Diagram 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . Component Location 8. . . . . . . . . . . . . . . . . . . . . . . . Purge Control System Check 9. . . . . . . . . . . . . . . . Purge Port Vacuum Check 9. . . . . . . . . . . . . . . . . . . Purge Control Solenoid Valve Check 10. . . . . . . . EXHAUST GAS RECIRCULATION (EGR) SYSTEM 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Information 11. . . . . . . . . . . . . . . . . . . . . . . . Operation 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System Diagram 11. . . . . . . . . . . . . . . . . . . . . . . . . . . Component Location 11. . . . . . . . . . . . . . . . . . . . . . . Exhaust Gas Recirculation (EGR) Control System Check 12. . . . . . . . . . . . . . . . . . . . . . . . . . . EGR Valve Check 12. . . . . . . . . . . . . . . . . . . . . . . . EGR Port Vacuum Check 13. . . . . . . . . . . . . . . . . . EGR Control Solenoid Valve Check 13. . . . . . . . . CATALYTIC CONVERTER 14. . . . . . . . . . . . . . .
  • 25.
    ENGINE AND EMISSIONCONTROL – Engine Control System17-2 ENGINE CONTROL SYSTEM GENERAL OUTLINE OF CHANGES The following service procedures have been established due to the addition of vehicles with 4G9-MPI engine. The other contents are the same as the 4G9-GDI engine. SERVICE SPECIFICATION Items Standard value Accelerator cable play mm 1 – 2 ON-VEHICLE SERVICE ACCELERATOR CABLE CHECK AND ADJUSTMENT <4G9-MPI> 1. Check the accelerator cable play when the accelerator pedal is released. Standard value: 1 – 2 mm 2. If the play is not within the standard value, turn the adjusting nut to adjust the play to the standard value. Adjusting nut
  • 26.
    ENGINE AND EMISSIONCONTROL – Engine Control SystemENGINE AND EMISSION CONTROL – Engine Control System 17-3 ACCELERATOR CABLE AND PEDAL REMOVAL AND INSTALLATION <4G9-MPI> Post-installation Operation Accelerator Cable Adjustment (Refer to P.17-2.) 1 2 3 2 4 <L.H. drive vehicles> <R.H. drive vehicles> 8 6 5 7 5 3 4 6 7 8 1 5.0 ± 1.0 N·m 6 6 45.0 ± 1.0 N·m 5.0 ± 1.0 N·m 12 ± 2 N·m 12 ± 2 N·m Removal steps 1. Accelerator cable 2. Push-on spring nut 3. Accelerator arm assembly 4. Spring 5. Accelerator pedal bracket 6. Bushing 7. Pedal pad "AA 8. Accelerator pedal stopper INSTALLATION SERVICE POINT AA" ACCELERATOR PEDAL STOPPER INSTALLATION Heat up the claw of the accelerator pedal pad with a drier and etc. before installation. NOTE Apply some soapsuds to the claw to facilitate installation if there is any difficulty.
  • 27.
    ENGINE AND EMISSIONCONTROL – Emission Control System <MPI>17-4 EMISSION CONTROL SYSTEM <MPI> GENERAL OUTLINE OF CHANGES The following contents have been established to correspond to the addition of vehicles with 4G9-MPI engine. The other contents are the same as before. GENERAL INFORMATION The emission control system consists of the following subsystems: D Crankcase emission control system D Evaporative emission control system D Exhaust emission control system Items Name Specification Crankcase emission control system Positive crankcase ventilation (PCV) valve Variable flow type (Purpose: HC reduction) Evaporative emission control system Canister Purge control solenoid valve Equipped Duty cycle type solenoid valve (Purpose: HC reduction) Exhaust emission control system Air-fuel ratio control device – MPI system Oxygen sensor feedback type (Purpose: CO, HC, NOx reduction) Exhaust gas recirculation system D EGR valve D EGR control solenoid valve Equipped Single type Duty cycle type solenoid valve (Purpose: NOx reduction) Catalytic converter Monolith type (Purpose: CO, HC, NOx reduction) EMISSION CONTROL DEVICE REFERENCE TABLE Related parts Crankcase emission control system Evaporative emission control system Air/fuel ratio control system Catalytic converter Exhaust gas recircula- tion system Reference page PCV valve × 17-9* Purge control solenoid valve × 17-9 MPI system component × × GROUP 13B Catalytic converter × 17-14 EGR valve × 17-12 EGR control solenoid valve × 17-13 NOTE *: Refer to the ’00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1)
  • 28.
    ENGINE AND EMISSIONCONTROL – Emission Control System <MPI> 17-5 SERVICE SPECIFICATIONS Items Standard value Purge control solenoid valve coil resistance (at 20_C) Ω 36 – 44 EGR control solenoid valve coil resistance (at 20_C) Ω 36 – 44 VACUUM HOSE VACUUM HOSE PIPING DIAGRAM PCV valve OFF EGR valve Air cleaner ON Canister Purge control solenoid valve EGR control solenoid valve Oxygen sensor <rear> Air OFF ON Oxygen sensor <front> M E A
  • 29.
    ENGINE AND EMISSIONCONTROL – Emission Control System <MPI>17-6 VACUUM CIRCUIT DIAGRAM From air cleaner Intake manifold Throttle body To combustion chamber Fuel pressure regulator EGR control solenoid valve (ON: OPEN) Canister Purge control solenoid valve (ON: OPEN) EGR valve Vacuum hose colour B: Black G: Green L: Light blue R: Red Y: Yellow M P A L G Y G G R B VACUUM HOSE CHECK 1. Using the piping diagram as a guide, check to be sure that the vacuum hoses are correctly connected. 2. Check the connection condition of the vacuum hoses, (removed, loose, etc.) and check to be sure that there are no bends or damage. VACUUM HOSE INSTALLATION 1. When connecting the vacuum hoses, they should be securely inserted onto the nipples. 2. Connect the hoses correctly, using the vacuum hose piping diagram as a guide.
  • 30.
    ENGINE AND EMISSIONCONTROL – Emission Control System <MPI> PCV valve 17-7 CRANKCASE EMISSION CONTROL SYSTEM SYSTEM DIAGRAM Ventilation hose Breather hose PCV valve COMPONENT LOCATION
  • 31.
    ENGINE AND EMISSIONCONTROL – Emission Control System <MPI> Purge control solenoid valve 17-8 EVAPORATIVE EMISSION CONTROL SYSTEM GENERAL INFORMATION The evaporative emission control system prevents fuel vapours generated in the fuel tank from escaping into the atmosphere. Fuel vapours from the fuel tank flow through the fuel tank pressure control valve and vapour pipe/hose to be stored temporarily in the canister. When driving the vehicle, fuel vapours stored in the canister flow through the purge solenoid and purge port and go into the intake manifold to be sent to the combustion chamber. When the engine coolant temperature is low or when the intake air quantity is small (when the engine is at idle, for example), the engine control unit turns the purge solenoid off to shut off the fuel vapour flow to the intake manifold. This does not only insure the driveability when the engine is cold or running under low load but also stabilize the emission level. SYSTEM DIAGRAM From fuel tank Canister Purge control solenoid valve OFF ON Air flow sensor Barometric pressure sensor Control relay Throttle body Engine-ECU Engine coolant temperature sensor Intake air temperature sensor COMPONENT LOCATION
  • 32.
    ENGINE AND EMISSIONCONTROL – Emission Control System <MPI> 17-9 PURGE CONTROL SYSTEM CHECK 1. Disconnect the vacuum hose (red stripe) from the throttle body and connect it to a hand vacuum pump. 2. Plug the nipple from which the vacuum hose was removed. 3. When the engine is cold or hot, apply a vacuum of 53 kPa, and check the condition of the vacuum. When engine is cold (Engine coolant temperature: 40_C or less) Engine condition Normal condition At idle Vacuum is maintained 3,000 r/min When engine is hot (Engine coolant temperature: 80_C or higher) Engine condition Normal condition At idle Vacuum is maintained 3,000 r/min (fore approximately 3 minutes after the engine is started.) Vacuum will leak. PURGE PORT VACUUM CHECK 1. Disconnect the vacuum hose (red stripe) from the throttle body purge vacuum nipple and connect a hand vacuum pump to the nipple. 2. Start the engine and check that the vacuum remains fairly constant after racing the engine. NOTE If vacuum changes, it is possible that the throttle body purge port may be clogged and require cleaning. Plug Purge port vacuum nipple Vacuum Engine speed (r/min)
  • 33.
    ENGINE AND EMISSIONCONTROL – Emission Control System <MPI>17-10 PURGE CONTROL SOLENOID VALVE CHECK NOTE When disconnecting the vacuum hose, always make a mark so that it can be reconnected at original position. 1. Disconnect the vacuum hose (black, red stripe) from the solenoid valve. 2. Disconnect the harness connector. 3. Connect a hand vacuum pump to nipple (A) of the solenoid valve (refer to the illustration at left). 4. Check airtightness by applying a vacuum with voltage applied directly from the battery to the purge control solenoid valve and without applying voltage. Battery voltage Normal condition Applied Vacuum leaks Not applied Vacuum maintained 5. Measure the resistance between the terminals of the solenoid valve. Standard value: 36 – 44 Ω (at 20_C) Battery B A
  • 34.
    ENGINE AND EMISSIONCONTROL – Emission Control System <MPI> EGR control solenoid valve EGR valve 17-11 EXHAUST GAS RECIRCULATION (EGR) SYSTEM GENERAL INFORMATION The exhaust gas recirculation (EGR) system lowers the nitrogen oxide (NOx) emission level. When the air/fuel mixture combustion temperature is high, a large quantity of nitrogen oxides (NOx) is generated in the combustion chamber. Therefore, this system recirculates part of emission gas from the exhaust port of the cylinder head to the combustion chamber through the intake manifold to decrease the air/fuel mixture combustion temperature, resulting in reduction of NOx. The EGR flow rate is controlled by the EGR valve so as not to decrease the driveability. OPERATION The EGR valve is being closed and does not recirculate exhaust gases under one of the following conditions. Otherwise, the EGR valve is opened and recirculates exhaust gases. D The engine coolant temperature is low. D The engine is at idle. D The throttle valve is widely opened. SYSTEM DIAGRAM ONOFF EGR control solenoid valve Air flow sensor Engine coolant temperature sensor Crank angle sensorControl relay Engine-ECU Battery EGR valve COMPONENT LOCATION
  • 35.
    ENGINE AND EMISSIONCONTROL – Emission Control System <MPI>17-12 EXHAUST GAS RECIRCULATION (EGR) CONTROL SYSTEM CHECK 1. Disconnect the vacuum hose (green stripe) from the EGR valve, and then connect a hand vacuum pump via the three-way terminal. 2. When the engine is hot or cold, check the condition of vacuum by racing the engine. When engine is cold (Engine coolant temperature: 20_C or less) Throttle valve Normal vacuum condition Open quickly No vacuum will generate (the same as barometric pressure.) When engine is hot (Engine coolant temperature: 80_C or higher) Throttle valve Normal vacuum condition Open quickly It will momentarily rise over 13 kPa 3. Disconnect the three-way terminal. 4. Connect the hand vacuum pump to the EGR valve. 5. Check whether the engine stalls or the idling is unstable when a vacuum of 30 kPa or higher is applied during idling. EGR VALVE CHECK 1. Remove the EGR valve and inspect for sticking, carbon deposits, etc. If found, clean with a suitable solvent so that the valve seats correctly. 2. Connect a hand vacuum pump to the EGR valve. 3. Apply 67 kPa of vacuum, and check that the vacuum is maintained. 4. Apply a vacuum and check the passage of air by blowing through one side of the EGR passage. Vacuum Passage of air 5.0 kPa or less Air is not blown out 27 kPa or more Air is blown out 5. Replace the gasket, and tighten to the specified torque. Tightening torque: 22 ± 5 N·m Three-way terminal Vacuum hose (Green stripe) EGR valve EGR valve Plug Vacuum hose (Green stripe)
  • 36.
    ENGINE AND EMISSIONCONTROL – Emission Control System <MPI> 17-13 EGR PORT VACUUM CHECK 1. Disconnect the vacuum hose (Green) from the throttle body EGR vacuum nipple and connect a hand vacuum pump to the nipple. 2. Start the engine and check that, after raising the engine speed by racing the engine, purge vacuum raises according to engine speed. NOTE If there is a problem with the change in vacuum, the throttle body EGR port may be clogged and require cleaning. EGR CONTROL SOLENOID VALVE CHECK NOTE When disconnecting the vacuum hose, always make a mark so that it can be reconnected at original position. 1. Disconnect the vacuum hose (yellow stripe, green stripe) from the solenoid valve. 2. Disconnect the harness connector. 3. Connect a hand vacuum pump to the nipple (A) of the solenoid valve (refer to the illustration at left). 4. Check airtightness by applying a vacuum with voltage applied directly from the battery to the EGR control solenoid valve and without applying voltage. Battery voltage Normal condition Not applied Vacuum maintained Applied Vacuum leaks 5. Measure the resistance between the terminals of the solenoid valve. Standard value: 36 – 44 Ω (at 20_C) Vacuum Engine speed (r/min) A B Battery
  • 37.
    ENGINE AND EMISSIONCONTROL – Emission Control System <MPI>17-14 CATALYTIC CONVERTER REMOVAL AND INSTALLATION 1 2 4 3 5 50 ± 10 N·m 50 ± 10 N·m 50 ± 10 N·m 50 ± 10 N·m 50 ± 10 N·m 50 ± 10 N·m 13 ± 2 N·m Front catalytic converter removal steps 1. Front pipe 2. Oxygen sensor (front) 3. Front catalytic converter Catalytic converter removal steps 1. Front pipe 4. Oxygen sensor (rear) 5. Catalytic converter