GR00001600 17 PDF

17-1
GROUP 17
ENGINE AND
EMISSION
CONTROL
CONTENTS
ENGINE CONTROL . . . . . . . . . . .
17-2
GENERAL INFORMATION . . . . . . .
17-2
SERVICE SPECIFICATIONS . . . . .
17-2
ON-VEHICLE SERVICE . . . . . . . . . .
17-2
ACCEL CABLE CHECK AND

ADJUSTMENT. . . . . . . . . . . . . . . . . . . .
ACCELERATOR CABLE AND

PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION . . . . .
17-2
17-3
17-3
EMISSION CONTROL <MPI> . .
17-4
GENERAL INFORMATION . . . . . . .
17-4
EMISSION CONTROL DEVICE

REFERENCE TABLE . . . . . . . . . . . . . .
17-5
SERVICE SPECIFICATIONS . . . . .
17-5
VACUUM HOSE . . . . . . . . . . . . . . . . .
17-5
17-5
17-6
17-7
17-7
VACUUM HOSE PIPING DIAGRAM . . .

VACUUM CIRCUIT DIAGRAM . . . . . . .
VACUUM HOSE CHECK. . . . . . . . . . . .
VACUUM HOSE INSTALLATION . . . . .
CRANKCASE EMISSION
CONTROL SYSTEM . . . . . . . . . . . . .
GENERAL INFORMATION (CRANKCASE
EMISSION CONTROL SYSTEM) . . . . .
COMPONENT LOCATION (CRANKCASE
17-8
17-8
17-9
POSITIVE CRANKCASE VENTILATION

SYSTEM CHECK . . . . . . . . . . . . . . . . . .
(PCV) VALVE CHECK . . . . . . . . . . . . . .
17-9
17-9
EVAPORATIVE EMISSION
CONTROL SYSTEM . . . . . . . . . . . . .
17-10
GENERAL INFORMATION (EVAPORATIVE
17-10
COMPONENT LOCATION (EVAPORATIVE
17-11
PURGE CONTROL SYSTEM CHECK. .
17-11
PURGE PORT VACUUM CHECK . . . . .
17-11
PURGE CONTROL SOLENOID VALVE
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . .
17-12
FUEL VAPOUR CANISTER REMOVAL
AND INSTALLATION . . . . . . . . . . . . . . .
17-13
EXHAUST GAS RECIRCULATION

(EGR) SYSTEM . . . . . . . . . . . . . . . . . .
GENERAL INFORMATION
(EGR SYSTEM) . . . . . . . . . . . . . . . . . . .
COMPONENT LOCATION
(EGR SYSTEM) . . . . . . . . . . . . . . . . . . .
EGR SYSTEM CHECK . . . . . . . . . . . . .
EGR VALVE CHECK . . . . . . . . . . . . . . .
EGR PORT VACUUM CHECK <4G1>. .
EGR PORT VACUUM CHECK <4G6>. .
EGR CONTROL SOLENOID VALVE
CHECK <4G1> . . . . . . . . . . . . . . . . . . . .
CHECK <4G6> . . . . . . . . . . . . . . . . . . . .
EXHAUST GAS RECIRCULATION (EGR)
VALVE REMOVAL AND INSTALLATION
CATALYTIC CONVERTER . . . . . . .
REMOVAL AND INSTALLATION. . . . . .
17-14
17-14
17-15
17-16
17-16
17-17
17-17
17-17
17-18
17-18
17-19
17-19
17-2
ENGINE AND EMISSION CONTROL

ENGINE CONTROL
ENGINE CONTROL
GENERAL INFORMATION
M1171000100277
A cable-type accelerator mechanical

suspended-type pedal has been adopted.
SERVICE SPECIFICATIONS
M1171000300088
Item
Standard value
Accel cable play mm
1.0 2.0
Engine idle speed r/min
ON-VEHICLE SERVICE
4G1
750 50
4G6
750 100
<4G1>
Adjusting bolts
ACCEL CABLE CHECK AND

ADJUSTMENT
Plate
M1171000900314
1. Turn A/C and lights OFF. Inspect and adjust at no

load.
2. Warm engine until stabilized at idle.
3. Confirm idle speed is at standard value.
Standard value:
750 50 r/min <4G1>
750 100 r/min <4G6>
4. Stop engine. [ignition switch: LOCK (OFF)
position].
5. Confirm there are no sharp bends in the
accelerator cable.
6. Check the inner cable for correct slack.
Standard value: 1.0 2.0 mm
7. If there is too much slack or no slack, adjust play
by the following procedures.
Accel cable
AC207966 AC
<4G6>
Adjusting bolts
Plate
Accel cable
AC301055 AC
(1) Loosen the adjusting bolts to release the

cable.
(2) Move the plate until the inner cable play is at
the standard value, and then tighten the
adjusting bolts.
(3) After adjusting, check that the throttle lever is
touching the stopper.
17-3
ENGINE CONTROL
ACCELERATOR CABLE AND PEDAL

REMOVAL AND INSTALLATION
M1171001200341
Post-installation Operation
Adjusting the Accelerator Cable (Refer to P.17-2).
<L.H. drive vehicles>
5.0 1.0 Nm
10
12 2 Nm
1
7
5N
4
8
13
12 N
6
<R.H. drive vehicles>

5.0 1.0 Nm
11
Y1060AU
12 2 Nm
9
7
11
10
N5
12 N
13
Accelerator cable assembly
removal steps
1. Inner cable connection (Accelerator
pedal side)
2. Inner cable connection (Throttle body
side)
3. Accelerator cable assembly
1.
4.
5.
6.
Y1059AU
AC304070AB
Accelerator pedal assembly

removal steps
Inner cable connection (Accelerator
pedal side)
Accelerator control equip nut
Accelerator pedal arm and
accelerator pedal pad assembly
17-4
EMISSION CONTROL <MPI>

removal steps (Continued)
7. Accelerator control equip bushing
8. Accelerator pedal arm return spring
9. Accelerator pedal arm stopper
10.
11.
>>A<< 12.
13.

removal steps (Continued)
Accelerator pedal arm bracket
Accelerator pedal arm
Accelerator pedal pad
Accelerator pedal arm stopper
INSTALLATION SERVICE POINT

>>A<< ACCEL PEDAL PAD INSTALLATION
!
CAUTION
To prevent damages to the accelerator pedal pad,

warm the thumb area of the accelerator pedal
pad with a dryer, etc. prior to assembling it.
NOTE: If it is difficult to assemble, apply soapy water
to the thumb area to enhance the assembling
process.

GENERAL INFORMATION
M1173000100370
The emission control system consists of the following

subsystems:
Items
Name
Crankcase emission control system

Evaporative emission control system
Exhaust emission control system
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

EGR valve
EGR control solenoid valve
Equipped
Single type
Duty cycle type solenoid valve
(Purpose: NOx reduction)
Catalytic converter
Monolith type
(Purpose: CO, HC, NOx reduction)
17-5
EMISSION CONTROL DEVICE

REFERENCE TABLE
M1173006600135
Related parts
Crankcase
emission
control
system
PCV valve
Evaporative
emission
control
system
Purge control solenoid valve
MPI system component
Air/fuel ratio Catalytic

control
converter
system
Exhaust gas
recirculation
system
Catalytic converter
EGR valve
EGR control solenoid valve
SERVICE SPECIFICATIONS
M1173000300288
Items
Standard value
Purge control solenoid valve coil resistance (at 20C)
30 34
EGR control solenoid valve coil resistance (at 20C)
29 35
VACUUM HOSE
VACUUM HOSE PIPING DIAGRAM
M1173000900417
<4G1>
Air cleaner
Air
To
fuel tank
Fuel pressure From

regulator
fuel pump
EGR valve
Canister
Oxygen sensor
(front)
EGR control
solenoid valve
Catalytic
converter
Purge control
solenoid valve
Oxygen sensor (rear)
Catalytic
converter
AK300964 AB
17-6
<4G6>
Air cleaner
Air
To
fuel tank
Fuel pressure
From
regulator
fuel pump
PCV valve
EGR valve
Canister
Oxygen sensor
(front)
EGR control
solenoid valve
Catalytic
converter
Purge control
solenoid valve
Oxygen sensor (rear)

Catalytic
converter
AK204364AC
VACUUM CIRCUIT DIAGRAM

M1173007100263
<4G1>
Intake manifold
Throttle body
To
combustion
chamber
From
air
cleaner
G
R
Fuel
pressure
regulator
Y
Vacuum hose colour
B: Black
G: Green
R: Red
Y: Yellow
EGR
L: Blue
valve
Canister
G
G
EGR
control
solenoid
valve
B
Purge
control
solenoid
valve
AK300765 AB
17-7

<4G6>
Throttle body
Intake manifold
To
combustion
chamber
From
air
cleaner
W
R
Fuel
pressure
regulator
G
Vacuum hose colour
B: Black
G: Green
R: Red
W: White
Y: Yellow
L: Blue
EGR
valve
EGR
control
solenoid
valve
VACUUM HOSE CHECK
Canister
B
B
Purge
control
solenoid
valve
AK300766 AB
VACUUM HOSE INSTALLATION

M1173007300159
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.
M1173007200107
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.
17-8
CRANKCASE EMISSION CONTROL

SYSTEM
GENERAL INFORMATION (CRANKCASE
EMISSION CONTROL SYSTEM)
M1173005000237
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
Air cleaner
Air
Ventilation hose
Breather hose
PCV valve
AK204365AB
17-9
COMPONENT LOCATION (CRANKCASE

PCV valve
M1173007400208
<4G1>
AKX00336 AD
PCV valve
AK300767AB
<4G6>
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
M1173001200187
PCV valve
AK204366AC

SYSTEM CHECK
PCV valve
M1173001100179
1.
2.
3.
4.
Remove the ventilation hose from the PCV valve.

Remove the PCV valve from the rocker cover.
Reinstall the PCV valve at the ventilation hose.
Start the engine and run at idle.
AK100010 AC
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 a clogging
in the PCV valve. In this case, clean or replace
the PCV valve.
17-10
EVAPORATIVE EMISSION CONTROL

SYSTEM
GENERAL INFORMATION (EVAPORATIVE
M1173005100405
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
Throttle body
Engine-ECU <4G1-M/T, 4G6>,
Engine-A/T-ECU <4G1-A/T>
From
fuel
tank
Canister
Manifold absolute pressure
(MAP) sensor <4G1>
OFF
Air flow sensor <4G6>
Purge
control
ON solenoid
valve
Battery
Engine coolant
temperature sensor
Control
relay
Intake air
temperature sensor
Barometric pressure
sensor <4G6>
AK204367AC
17-11
COMPONENT LOCATION (EVAPORATIVE

M1173007500216
<4G1>
1. Disconnect the vacuum hose (red stripe) from

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: 40C or less)
Engine condition
Normal condition
At idle
Purge control
solenoid valve
AK300769 AB
Vacuum is maintained.
3,000 r/min
When engine is hot
(Engine coolant temperature: 80C or higher)
Engine condition
Normal condition
<4G6>
Purge control
solenoid valve
AK300770 AB
PURGE CONTROL SYSTEM CHECK
At idle
Vacuum is maintained.
3,000 r/min (within 3

minutes after engine
starts)
Vacuum will leak.
PURGE PORT VACUUM CHECK

M1173001500177
<4G1>
Vacuum hose
M1173001400299
<4G1>
Vacuum hose
Plug
AK300773 AB
Plug
<4G6>
AK300771 AB
Vacuum hose
Plug
<4G6> Vacuum hose
Plug
AK300774 AB
AK300772AB
1. Disconnect the vacuum hose (red stripe) from the

throttle body and connect a hand vacuum pump to
the nipple.
2. Plug the vacuum hose (red stripe).
17-12
Vacuum
Engine speed (r/min)
Battery
AK100011AC
AK100012 AC
3. Start the engine.

4. Check that a fairly constant negative pressure is
generated regardless of the engine speed.
5. If no negative pressure is generated, the port is
probably blocked and should be cleaned.
PURGE CONTROL SOLENOID VALVE

CHECK
M1173001700193
NOTE: When disconnecting the vacuum hose,

always make a mark so that it can be reconnected at
original position.
AK100013
1. Disconnect the vacuum hose 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 (at 20C)

17-13
FUEL VAPOUR CANISTER REMOVAL

AND INSTALLATION
M1173004200153
Pre-removal and Post-installation Operation

Air Cleaner Assembly Removal and Installation (Refer to
GROUP 15 P.15-2).
3
2
6
4
AC208253 AD
1.
2.
3.
4.
Removal steps
Emission vacuum hose connection
Fuel vapour control line hose
Fuel vapour control check valve
Fuel vapour control line hose
5.
6.
7.
8.
Removal steps (Continued)

Fuel vapour control line clamp
Fuel vapour canister
Fuel high-pressure hose clamp
Fuel vapour canister bracket
17-14

EXHAUST GAS RECIRCULATION

(EGR) SYSTEM
The EGR flow rate is controlled by the EGR valve so

as not to decrease the driveability.
GENERAL INFORMATION (EGR SYSTEM)

M1173005200327
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.
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.
The engine coolant temperature is low.
The engine is at idle.
The throttle valve is widely opened.
SYSTEM DIAGRAM
<4G1>
EGR
control
solenoid
valve
OFF
Engine-ECU <M/T>,
Engine-A/T-ECU <A/T>
EGR valve
ON
Control
relay
Battery
Manifold absolute
pressure (MAP) sensor
Engine coolant
temperature sensor
Crank angle sensor
AK300775 AB
17-15
<4G6>
EGR
control
Solenoid
valve
OFF
Engine-ECU
EGR valve
Barometric pressure
sensor
ON
Air flow sensor
Control
relay
Engine coolant
temperature sensor
Crank angle sensor
Battery
AK302349 AB
COMPONENT LOCATION (EGR SYSTEM)

M1173007600224
<4G1>
<4G1>
EGR control
solenoid valve
EGR valve
AK300777AB
AK300776AB
<4G6>
EGR valve
<4G6>
EGR control
solenoid valve
AK300779AB
AK300778 AB
17-16
EGR SYSTEM CHECK

M1173002600348
<4G1>
<4G1>
Green stripe
Green stripe
Three-way
terminal
EGR valve
AK300782 AB
EGR valve
AK300780 AB
<4G6>
Green stripe
<4G6>
Three-way
terminal
Green stripe
EGR valve
EGR valve
AK300783AB
AK300781AB
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: 20C 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: 80C or higher)
Throttle valve
Normal vacuum condition
Open quickly
4. Connect the hand vacuum pump to the EGR

valve nipple.
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

M1173002800223
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.
It will momentarily rise over 13

kPa
3. Disconnect the three-way terminal.
AKX00348
4. Apply a vacuum and check the passage of air by

blowing through one side of the EGR passage.
Vacuum
Passage of air
5.3 kPa or less
Air is not blown out
27 kPa or more
Air is blown out
17-17
5. Replace the gasket, and tighten to the specified

torque.
Tightening torque:
<4G1> 21 4 Nm
<4G6> 20 2 Nm
1. Disconnect the vacuum hose (White stripe) from

the throttle body EGR vacuum nipple and connect
a hand vacuum pump to the nipple.
2. Plug the vacuum hose (White stripe).
EGR PORT VACUUM CHECK <4G1>

M1173002900167
Vacuum

AK100011AC
Green strip
AK300784AB
1. Disconnect the vacuum hose (Green stripe) from

the throttle body EGR vacuum nipple and connect
a hand vacuum pump to the nipple.
2. Plug the vacuum hose (Green stripe).
3. Start the engine.

4. Check that a fairly constant negative is generated
regardless of the engine speed.
5. If no negative pressure is generated, the port is
probably blocked and should be cleaned.

CHECK <4G1>
M1173003100238

original position.
Vacuum

AK201224AB
3. 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 change in
vacuum, the throttle body purge port may be
clogged and require cleaning.
EGR PORT VACUUM CHECK <4G6>

M1173002900156
White stripe
AK300786AB
Battery
AKX00351AE

valve.
4. Check air tightness by applying a vacuum with
EGR control solenoid valve and without applying
voltage.
Battery voltage
Normal condition
Applied
Vacuum leaks
Not applied
Vacuum maintained
17-18

4. Check air tightness by applying a vacuum with
EGR control solenoid valve and without applying
voltage.
AKX00352

the solenoid valve.
Battery
voltage
B nipple
condition
Normal condition
Not applied
Open
Vacuum
maintained
Applied
Open
Vacuum leaks
Closed
Vacuum
maintained

CHECK <4G6>
M1173003100249

original position.
A
AK100016

the solenoid valve.
C
Battery
AK201251AB

valve.
EXHAUST GAS RECIRCULATION (EGR)

VALVE REMOVAL AND INSTALLATION
M1173010500175
Pre-removal and Post-installation Operation

Air Cleaner Assembly Removal and Installation (Refer to
GROUP 15 P.15-2).
<4G1>
21 4 Nm
3N
1
AC208130 AC
17-19
<4G6>
1
2
19 3 Nm
3N
AC301219AC
1.
Removal steps
Emission vacuum hose connection
CATALYTIC CONVERTER
REMOVAL AND INSTALLATION
M1173003900386
Refer to GROUP 15 - Exhaust Pipe and Main Muffler P.15-11.
2.
3.
Removal steps (Continued)

EGR valve
EGR valve gasket
127(6

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17-1

ACCEL CABLE CHECK AND

ACCELERATOR CABLE AND

EMISSION CONTROL <MPI> . .

EMISSION CONTROL DEVICE

VACUUM HOSE PIPING DIAGRAM . . .

POSITIVE CRANKCASE VENTILATION

EXHAUST GAS RECIRCULATION

ENGINE AND EMISSION CONTROL

A cable-type accelerator mechanical

Accel cable play mm

Engine idle speed r/min

ACCEL CABLE CHECK AND

1. Turn A/C and lights OFF. Inspect and adjust at no

(1) Loosen the adjusting bolts to release the

ENGINE AND EMISSION CONTROL

ACCELERATOR CABLE AND PEDAL

<L.H. drive vehicles>

<R.H. drive vehicles>

Accelerator pedal assembly

ENGINE AND EMISSION CONTROL

EMISSION CONTROL <MPI>

Accelerator pedal assembly

INSTALLATION SERVICE POINT

To prevent damages to the accelerator pedal pad,

EMISSION CONTROL <MPI>

The emission control system consists of the following

Crankcase emission control system

Crankcase emission control

Positive crankcase ventilation

Variable flow type

Evaporative emission control

Exhaust emission control system

Air-fuel ratio control device - MPI

Oxygen sensor feedback type

Exhaust gas recirculation system

ENGINE AND EMISSION CONTROL

EMISSION CONTROL <MPI>

EMISSION CONTROL DEVICE

Purge control solenoid valve

MPI system component

Air/fuel ratio Catalytic

EGR control solenoid valve

Purge control solenoid valve coil resistance (at 20C)

EGR control solenoid valve coil resistance (at 20C)

Fuel pressure From

Oxygen sensor (rear)

ENGINE AND EMISSION CONTROL

EMISSION CONTROL <MPI>

Oxygen sensor (rear)

VACUUM CIRCUIT DIAGRAM

ENGINE AND EMISSION CONTROL

EMISSION CONTROL <MPI>

VACUUM HOSE CHECK

VACUUM HOSE INSTALLATION

1. Using the piping diagram as a guide, check to be

1. When connecting the vacuum hoses, they should

ENGINE AND EMISSION CONTROL

EMISSION CONTROL <MPI>