manual pajero 4x4 engine and emision control.docx

8/11/2019 manual pajero 4x4 engine and emision control.docx

1/48

17-1

ENGINEANDEMISSIONCONTROL

CONTENTS 17109000308

ENGINE CONTROL SYSTEM . . . . . . . . 3 AUTO-CRUISE CONTROL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

GENERAL INFORMATION . . . . . . . . . . . . . . . .3

GENERAL INFORMATION . . . . . . . . . . . . . . . .6SERVICE SPECIFICATIONS . . . . . . . . . . . . . .3

SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . .6SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

CONTINUED

ON

NEXT

PAGEON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . .3

Accelerator Cable Check andAdjustment. . . . 3

ACCELERATOR CABLE AND PEDAL . . . .4

WARNINGS REGARDING SERVICING OFSUPPLEMENTALRESTRAINT SYSTEM (SRS)EQUIPPED VEHICLES

WARNING!

(1) Improperserviceor maintenance

of any componentof the SRS,or any SRS-related

component,

can lead

to personalinjuryordeath toservicepersonnel(frominadvertentfiringoftheairbag)ortothedriverandpassenger(fromrenderingthe SRS inoperative).

(2) Service

or

maintenance

of

any

SRS

component

or

SRS-related

component

must

be

performed

only

at

an

authorizedMITSUBISHI dealer.

(3) MITSUBISHI dealer personnel must thoroughly review this manual,and especiallyits GROUP 52B SupplementalRestraintSystem(SRS)beforebeginningany serviceormaintenanceofany componentof theSRSoranySRS-relatedcomponent.

NOTETheSRS includes the following components: Front impact sensors. SRS-ECU, SRS warning lamp, airbag module, clock spring,and interconnecting wiring.OtherSRS-related components (thatmayhave toberemoved/installed inconnection withSRSserviceormaintenance) are indicated in the tableofcontents byanasterisk (*).


2/48

17-2

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . .7 EXHAUST GAS RECIRCULATION (EGR)SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

General Information . . . . . . . . . . . . . . . . . . . . . . 36

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

System

Diagram

. . . . . . . . . . . . . . . . . . . . . . . . .

36

Component

Location

. . . . . . . . . . . . . . . . . . . . . .

36

Exhaust Gas Recirculation (EGR) ControlSystem Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

EGR Valve Check . . . . . . . . . . . . . . . . . . . . . . . . 37

EGR Port Vacuum Check . . . . . . . . . . . . . . . . 38

EGR Control Solenoid Valve Check . . . . . . . . 38

ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . 23

Auto-cruise

Control

Main

Switch

Check

. . . .

23

Auto-cruise Control Switch Check. . . . . . . . . . 23

Auto-cruise

Control

Component

Check

. . . . .

24

AUTO-CRUISE CONTROL* . . . . . . . . . . . . . 26

EMISSION CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

GENERAL INFORMATION . . . . . . . . . . . . . . 28

Emission Control Device Reference Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

CATALYTIC CONVERTER . . . . . . . . . . . . . . 39


SERVICE SPECIFICATIONS . . . . . . . . . . . . 29 CANISTERAND TWO-WAY VALVE . . . . . 40

VACUUM HOSE . . . . . . . . . . . . . . . . . . . . . . . 29

Vacuum Hose Piping Diagram . . . . . . . . . . . . . 29

Vacuum Circuit Diagram . . . . . . . . . . . . . . . . . . 30

Vacuum Hose Check . . . . . . . . . . . . . . . . . . . . . 31

Vacuum Hose Installation . . . . . . . . . . . . . . . . . 31

EMISSION CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

GENERAL INFORMATION . . . . . . . . . . . . . . 41

SERVICE SPECIFICATIONS . . . . . . . . . . . . 41

CRANKCASE EMISSION CONTROLSYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31


System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 31

Component

Location

. . . . . . . . . . . . . . . . . . . . . .

32

Positive Crankcase Ventilation SystemCheck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

PCV Valve Check . . . . . . . . . . . . . . . . . . . . . . . . 32

SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . 41

EXHAUST

GAS

RECIRCULATION

(EGR)SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42


System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 42

Component Location . . . . . . . . . . . . . . . . . . . . . . 42

Function Check . . . . . . . . . . . . . . . . . . . . . . . . . . 43

EGR Solenoid Valve Operation Check . . . . . 43

EGR Solenoid Valve Resistance Check . . . . 44

Lever Position Sensor (LPS)Adjustment . . . 44

Engine Speed Sensor Check . . . . . . . . . . . . . . 45

Engine

Coolant

Temperature

SensorCheck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Check at the Glow & EGR Control Unit. . . . 46

Two-way Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

EVAPORATIVE EMISSION CONTROLSYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33


System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 33

Component Location . . . . . . . . . . . . . . . . . . . . . . 33

Purge

Control

System

Check

. . . . . . . . . . . . . .

34Purge Port Vacuum Check . . . . . . . . . . . . . . . . 34

Purge Control Solenoid Valve Check . . . . . . . 35


3/48


4/48

17-4 ENGINEAND EMISSION CONTROL Engine ControlSystem

ACCELERATOR CABLE AND PEDAL

REMOVALAND INSTALLATION

17100120348

1

3

13

9.3 Nm

2

9 914

71413

12

1312

82

111110

10 65

3.4 Nm

4

Accelerator cable removal steps

1. Inner cable connection (Injectionpump side or throttle body side)

2. Inner cable connection(Accelerator pedal side)

3. Accelerator

cable

Throttle control cable removalsteps

4. Knob5. Nut6. Throttle cable7. Cable bracket

Accelerator pedal removal steps

2. Inner cable connection(Accelerator pedal side)

4. Knob5. Nut6. Throttle

cable8. Split pin9. Spring

10. Accelerator arm11. Pedal pad12. Stopper13. Washer14. Bracket

10

9 14

3

10

Post-installation Operation Adjusting theAccelerator Cable (Refer to P.17-3.)


5/48

17-5ENGINE AND EMISSION CONTROL Engine ControlSystem

1

21116

1514

103

12

13

21 4

35

6

161115149.3 Nm

10

98

133.4 Nm7 12

Accelerator

cable

removal

steps1. Inner cable connection

(Injection pump side)2. Inner cable connection

(Accelerator pedal side)3. Accelerator cable4. Spring

Throttle control cable removalsteps

5. Wire stopper6. Bush7. Knob8. Nut9. Throttle control cable

Accelerator

pedal

removal

steps2. Inner cable connection

(Accelerator pedal side)5.Wire stopper

10. Split pin11. Spring12. Accelerator

arm13. Pedal pad14. Stopper15. Washer16. Bracket

11 16

12 Toeboard

Sealant:3M Nut LockingPart No. 4171orequivalent

3

12


6/48

17-6 ENGINEAND EMISSION CONTROLAuto-cruise Control System

AUTO-CRUISECONTROL

GENERAL INFORMATION

By using the auto-cruise control, the driver can

SYSTEM 17200010211

approximately 40200 km/h) without depressingdrive at the speed he/she likes (in a range of the accelerator pedal.

Stop lamp switch Clutch pedal position switch

Vacuumactuator

Vehicle speedThrottle sensorbody

Auto-cruiseassemblyvacuum pump

Auto-cruisecontrol-ECU assembly

SPECIAL TOOL 17200060209

Tool Number Name Use

MB991502 MUT-II

sub

assembly Reading diagnosis codes Auto-cruise control system check

Diagnosisconnector

Auto-cruise control indicator lamp

Auto-cruise

controlmain switch

Auto-cruise control switch


7/48

17-7ENGINEAND EMISSION CONTROLAuto-cruise Control System

TROUBLESHOOTING

STANDARD FLOW OF DIAGNOSIS TROUBLESHOOTING

Refer to GROUP 00 How to Use Troubleshooting/Inspection Service Points.

NOTECheckthatthevacuumhoseisconnectedcorrectlyandisnotdamaged,andthencarryoutthediagnosis.

17200200410

DIAGNOSIS FUNCTION 17200210277

METHOD OF READING THE DIAGNOSIS CODES

Using the MUT-II

1. Connect the MUT-II to the diagnosis connector (16-pin)under the instrument under cover.

2. WiththeignitionswitchintheONposition,takeareadingof the diagnosis codes.

Using aAuto-cruise Control Indicator Lamp

1. TurntheignitionswitchONwiththeSETswitchon.Then,turn the RESUME switch ON within 1 second.

2. Read a diagnosis code by observing the flash displaypattern of the auto-cruise control indicatorcombination meter.

lamp in the

Auto-cruise switch: ON

Indication of diagnosis code by auto-cruisecontrol indicator lamp

signals atintervals of0.5s

NOTEOther on-board diagnostic items arealso outputas voltagewaveformscorresponding to diagnosiscodenumbers.

WhenthediagnosiscodeNo.24isoutput Whennodiagnosiscodeisoutput

0.5s0.5s

12V1s

0V

Pause Tens

signal Place Units

signal

time:3s division:2s

0.5s

12V

0

V

Continuous ONandOFF

RESUMEswitch: ON

SET

control switch

MB991502

Diagnosisconnector


8/48

17-8 ENGINE AND EMISSION CONTROLAuto-cruise Control System

METHOD OF ERASING THE DIAGNOSISCODES

The diagnosis codes can be erased by the followingprocedure.

NOTEThe diagnosis code will not be erased even if the battery() terminal is diconnected.

Using

the

MUT-II


2. WiththeignitionswitchintheONposition,takeaerasingof the diagnosis codes.

Without using the MUT-II

control switch

1.2.

Turn the ignition switch ON.Pushtheauto-cruisecontrolswithinthedirectionofarrow(B) in the illustration.Thenpress theauto-cruisecontrolmainswitchtotheONposition,andwithin1secondpushthe auto-cruise control switch back in the direction o

arrow

(A).Pushtheauto-cruiseconteolswitchagain inthedirectionof arrow (B) in the illustration. While holding the switchin this position, press the stoplamp switch to the ONposition, for 5 seconds or more.

3.

INPUT SWITCH CODE CHECK METHOD


2. WiththeignitionswitchintheONposition,takeaerasingof the input switch codes.

(A)

Auto-cruise (B)

Stoplamp switch

Onposition

Brake

pedal


9/48


10/48

17-10 ENGINEAND EMISSION CONTROL Auto-cruise Control System

INSPECTION PROCEDURE FOR DIAGNOSIS CODES

NG

Replacepump.

(Refer

to

P.17-25.)

NG

auto-cruise

control-ECU.

NoIs

the

speedometer

operating

normally? Vehicle speed sensor circuit inspection(Refer

to

GROUP

54 Combination Meter.)Yes

Disconnect

the

vehicle

speed

sensor

connector

B-03.

OK

Measure

at

auto-cruise

control-ECU

connector

C-64. Disconnect the connector and measure at the harness Ignition switch: ON Voltage between terminal (10) and earth

OK:

4.5

V

or

more

Check

the

following

connector:

C-64side.

OK NG

Repair

NG Check

trouble

symptom.

Check

the

harness

between

the

vehicle

speed

sensor

and

auto-cruise

control-ECU,

and

repair

if

necessary.

NG

Replace

the

auto-cruise

control-ECU.

CodeNo.12Vehicle speed signal system Probable cause

This

diagnosis

code

is

output

if

the

vehicle

speed

signals

from

the

vehicle

speed

sensor

are

not

input

to

the

auto-cruise

control-ECU

when

the

vehicle

speed

is

40

km/h

or

more.

Malfunction of the vehicle speed sensor

Malfunction of the connector Malfunction of the harness Malfunction of the auto-cruisecontrol-ECU

Check

the

following

connectors:A-04,

C-38,

C-64Repair

OK

Check

trouble

symptom. Check the harness between the auto-cruise vacuum pump and

OK NG

Repair

Replace

the

auto-cruise

control-ECU.

Check

the

auto-cruise

vacuum

OK

CodeNo.11Auto-cruisevacuum pump drive system Probable cause

This

diagnosis

code

is

output

if

the

release

valve,

control

valve

or

motor

drive

signals

from the auto-cruise vacuum pump are not input to the auto-cruise control-ECU. Malfunction of the auto-cruise vacuum pump Malfunction of the connector Malfunction of the harness Malfunction of the auto-cruisecontrol-ECU


11/48

17-11ENGINE AND EMISSION CONTROL Auto-cruise Control System

NG

rs:

auto-cruise

control-ECU.

Replace

the

auto-cruise

control-ECU.

CodeNo.16Auto-cruisecontrol-ECU Probable cause

This

diagnosis

code

is

output

if

there

is

an

abnormality

in

the

CANCEL

hold

circuit

or

the

microprocessor

monitor

circuit

in

the

auto-cruise

control-ECU. Malfunction of the auto-cruisecontrol-ECU

Replace the auto-cruisecontrol switch.

CodeNo.15Auto-cruise controlswitch Probable cause

This

diagnosis

code

is

output

if

the

cruise

control

RESUME

switch

or

SET

switch

remains

ON.

Malfunction

of

the

auto-cruise

control

switch

Measure

at

the

auto-cruise

vacuum

pump

connector

A-04. Disconnect the connector and measure at the harness Ignition switch and main switch: ON Stop lampswitch:OFF(Whenbrakepedalisnotdepre Voltage between terminal (1) and earth

OK:

System

voltage

Check

the

auto-cruise

vacuum

pump.

(Refer

to

P.17-25.)side.

sed.)

OK NG

Replace

Check

the

following

connectors:A-04,

C-38,

C-64NG

OKCheck

the

stop

lamp

switch

(Refer

to

P.17-24.)

OK NG Repair

ep ace Check trouble symptom.

Check

the

following

connectoA-04,

C-38,

C-60,

C-64NG

Replace

the

auto-cruise

control-ECU.OK

Check

trouble

symptom.

NG

Check

the

harness

between

the

auto-cruise

vacuum

pump

and

OK NG

Repair

Replace

the

auto-cruise

control-ECU.

Code No. 14Auto-cruise vacuum pump power supplysystem

Probable cause

This

diagnosis

code

is

output

when

none

of

the

drive

signals

from

the

release

valve,

control

valve

and

motor

of

the

auto-cruise

vacuum

pump

are

input

to

the

auto-cruise

control-ECU.

Malfunction of the stop lamp switch

Malfunction of the connector Malfunction of the harness Malfunction of the auto-cruisecontrol-ECU Malfunction of the auto-cruise vacuum pump


12/48


Yes

Repair

INSPECTION

CHART

FOR

TROUBLE

SYMPTOMS 17200230440

Troublesymptom InspectionprocedureNo.

Referencepage

CommunicationwithMUT-II isnotpossible.

Communication

with

all

systems

is

not

possible. 1 17-13

Communicationwithauto-cruisecontrol-ECUonlyisnotpossible.

2 17-14

Inputswitch inspectionusing theMUT-II isnotpossible. (However,diagnosisinspectionispossible.)

3 17-15

Auto-cruise

control

is

notcancelled. Even

if

brake

pedal

is

depressed 4 17-16Evenifclutchpedalisdepressed 5 17-17

EvenifCANCELswitchissettoON 6 17-18

Auto-cruisecontrolcannotbeset. 7 17-18

Hunting(repeatedaccelerationanddeceleration)occursatthesetvehiclespeed. 8 17-19

Auto-cruisecontrolindicatorlampinsidecombinationmeterdoesnotilluminate.(However,auto-cruisecontrolisnormal.)

9 17-19

Check

trouble

symptom. Check the harness between the throttle position sensor and

-

-

OK NG

Repair

Replace

the

auto-cruise

control-ECU.

Check

the

following

connectors:

- ,

- ,

- ,

- ,

-

OK

-

Throttle position sensor check (Refer to GROUP 13ATroubleshooting.).

-

No

CodeNo.17Throttlepositionsensor system Probable cause

This

diagnosis

code

is

output

if

a

voltage

of

2.5

V

or

more

when

the

idle

switch

is

ON

or

0.2

V

or

less

when

the

idle

switch

is

OFF

is

output

for

a

continuous

period

of

4

seconds

or

more.

Malfunction of the throttle position sensor Malfunction of the connector Malfunction of the harness Malfunction of the auto-cruisecontrol-ECU


13/48


INSPECTION PROCEDURE

Inspection Procedure 1

FOR TROUBLE SYMPTOMS

NGNGonnectors:

Check

trouble

symptom. Check

the

harness

wire

between

th

power

supply

and

diagnosis

connector,

and

repair

if

necessary.

tor onnector:C-63

NG

Measure at the diagnosis conC-63. Voltage between 16 and ea

OK:

Battery

voltage

Check

the

following

cA-25X,

C-63,

D-19,

D-21Repair

thOK

NGOK

RepairMeasure

at

the

diagnosis

connec

C-63.Check

the

following

c

OK

Check

trouble

symptom. Check

the

harness

wire

between

the

diagnosis

connector

and

earth,

and

re-pair

if

necessary.Replace

the

MUT-II.

Communicationwith MUT-IIisnotpossible.(Communica-tion with all system is not possible.)

Probable cause

The reason is probably a defect in the power supply system (including earth) forthe

diagnosis

line. Malfunction of the connector Malfunction of the harness


14/48


Inspection

Procedure 2

NG

OK

Measure

at

auto-cruise

control-ECU

connector

C-64. Disconnect the connector and measure at the harness Ignition switch: ON Voltage between the terminal (6) and earth

OK:

System

voltage

Check

the

following

connectors:

C-64,

D-19,

D-28

side. OK NG

Repair

OK Check trouble symptom.

NG

Check

the

harness

between

the

auto-cruise

control-ECU

and

power

supply,

and

repair

if

necessary.

Measure

at

auto-cruise

control-ECU

connector

C-64. Disconnect the connector and measure at the harness Continuity between terminal (14) and earth.

OK:

Continuity

Check

the

following

connector:

C-64

side.OK

NG

RepairNG

Check trouble symptom.

Checktheharnessbetweentheauto-cruisecontrol-ECUandearth,and

repair

if

necessary.NG

Check

the

harness

between

the

auto-cruise

control-ECU

and

diag-nosis

connector

OK NG

Repair

Replace

the

auto-cruise

control-ECU.

Communicationwith MUT-IIisnotpossible.(Communica-tion with auto-cruisecontrol-ECUonly is not possible.)

Probable cause

The

cause

is

probably

a

malfunction

of

auto-cruise

control-ECU

earth

circuit. Malfunction of the connector Malfunction of the harness Malfunction of the auto-cruisecontrol-ECU


15/48


Inspection

Procedure 3

NGReplace

Replace

NGMeasure

at

the

clock

spring

connector

D-10. Disconnect the connector and measure at the harness Ignition switch: ON Voltage between terminal (1) and earth

OK: System voltage

Check

the following connectors:

A-25X,

C-37,

D-08,

D-19,

D-28side.

OK NG

RepairOK

Check

trouble

symptom.

NG

RepairCheck the following connectors:C-64,

C-08

OK

Check

the

harness

between

the

clock

spring

and

power

supply,and

repair

if

necessary.Check trouble symptom.

NG

Check the harnessbetween theclockspring andauto-cruisecontrol-ECU,

and

repair

if

necessary.

Auto-cruise

control

switch

check

(Refer

to

P.17-23.)

OKNG

Clock spring check (Refer to GROUP 52B Air Bag.

OK

Input switchinspectionusing the MUT-II is not possible.(However, diagnosisinspectionis possible.)

Probable cause

The

cause

is

probably

a

malfunction

of

auto-cruise

control

switch

circuit

system. Malfunction of the auto-cruisecontrol switch Malfunction of the clock spring Malfunction of the connector Malfunction of the harness


16/48



Yes

air

NG

NG

Measure

at

stop

lamp

switch

connector

C-60. Disconnect the connector and measure at the harness Voltage between terminal (2) and earth

OK:

System

voltage

Check

the

following

connectors:

C-60,

D-22,

D-29

side.OK NG

Repair

OK

RepairCheck the following connectors:

C-12,

C-60,

C-64OK

Check

trouble

symptom. Checktheharnessbetweenthestoplampswitchandauto-cruisecontrol-ECU,

and

repair

if

necessary.

Check

trouble

symptom.

NG

Check

the

harness

between

thestoplampswitchandpowersupply,

and

repair

if

necessary.

Does

stop

lamp

illuminate? Check

the

following

connectors:

C-60,

C-64

No OK NG

Re Stop

lamp

switch

check

(Refer

to

P.17-24.)

OK NG Check

trouble

symptom.

NGReplace

Check

the

harness

between

the

stop

lamp

switch

and

auto-cruise

control-ECU.

OK NG

Repair

Replace

the

auto-cruise

control-ECU.

Even if brake pedal is depressed,auto-cruise control isnot cancelled.

Probable cause

The

cause

is

probably

a

malfunction

of

stop

lamp

switch

or

a

malfunction

of

stop

lamp

circuit. Malfunction of the stop lamp switch Malfunction of the connector Malfunction of the harness Malfunction of the auto-cruisecontrol-ECU


17/48

17-17ENGINEAND EMISSION CONTROL Auto-cruise Control System


NG

and

Repair

Clutch

pedal

position

switch

check

(Refer

to

P.17-24.) Replace

OK

Measure

at

clutch

pedal

position

switch

connector

C-61. Disconnect the connector and measure at the harness Ignition switch: ON Voltage between terminal (1) and earth

OK:

5

V

Check

the

following connectors: C-61,

C-64

side.OK NG

Repair

OK Check trouble symptom.

NG

RepairCheck the following connector:C-61

OKCheck

the

harness

between

the

clutch

pedal

position

switch

and

auto-cruise

control-ECU,

and

repair

if

necessary.Check

trouble

symptom.

NG

Check

the

harness

between

the

clutch

pedal

position

switc

earth.

Replace

the

auto-cruise

control-ECU.

NG

Even if clutchpedal is depressed,auto-cruisecontrol isnot cancelled.

Probable cause

The

cause

is

probably

a

malfunction

of

clutch

pedal

position

switch

or

clutch

circuit. Malfunction of the clutch pedal position switch Malfunction of the connector Malfunction of the harness Malfunction of the auto-cruisecontrol-ECU


18/48


Inspection

Procedure 6

IInspection Procedure 7

No

or

17

(CODE

No.12:

Refer

to

P.17-10.)

No

Yes

Can

the

auto-cruise

control

communicate

with

theMUT-II? Check

for

each

trouble

symptom.

(Refer

to

inspection

procedure

No.

2

on

P.17-14.)Yes

Yes

Are

any

of

MUT-II

diagnosis

code

Nos.

11,

12,

14,

15,

16output?

Check

for

each

diagnosis

code.(CODE

No.11:

Refer

to

P.17-10.)

(CODE No.14: Refer to P.17-11.)(CODE

No.15:

Refer

to

P.17-11.)(CODE

No.16:

Refer

to

P.17-11.)(CODE

No.17:

Refer

to

P.17-12.)

No

Is

input

switch

inspection

possible

with

theMUT-II? Check foreach troublesymptom.(Refer to inspectionprocedure

No.

3

on

P.17-15.)Yes

Is

either

of

MUT-II

input

check

code

Nos.

05

or

13

output? Stoplampswitchinputcircuitsystem[codeNo.05]inspection(Refer to inspection procedure No. 10 on P.17-20.)

Clutch pedal position switchinputcircuitsystem[codeNo.13]

inspection

(Refer

to

inspection

procedure

No.

11

on

P.17-20.)

No

Replace

the

auto-cruise

control-ECU.

Auto-cruise controlcannot beset. Probable cause

The

cause

is

probably

that

the

fail-safe

function

is

cancelling

auto-cruise

control.

In

this

case,

the

MUT-II

can

be

used

to

check

the

trouble

symptoms

in

each

system

by

inspecting

the

diagnosis

codes.

The

MUT-II

can

also

be

used

to

check

if

the

circuits

of

each

input

switch

are

normal

or

not

by

inspecting

the

input

switch

codes.

Malfunction of the auto-cruisecontrol main switch Malfunction of the auto-cruisecontrol switch Malfunction of the clock spring Malfunction of the harnesses or connectors Malfunction of the clutch pedal position switch Malfunction of the auto-cruisecontrol-ECU

Replace

the

auto-cruise

control

switch.

Even if auto-cruisecontrol CANCEL switch is set to ON,auto-cruisecontrol is not cancelled.

Probable cause

The

cause

is

probably

an

open-circuit

in

the

circuit

inside

the

CANCEL

switch. Malfunction of the auto-cruisecontrol-ECU


19/48

17-19ENGINEAND EMISSION CONTROL Auto-cruise Control System


NGReplace

NGReplace

NGReplace


NG

NG

Auto-cruisecontrol indicator lamp bulb check Replace

Repair

OK

Combination

meter

check

OK

Measure

at

the

combination

meter

connector

C-04. Disconnect the connector and measure at the harness Ignition switch and main switch: ON Voltage between terminal (24) and earth

OK:

System

voltage

Check

the

following

connectors:C-04,

D-19,

D-28side.

OK NG

Repair

OKCheck

trouble

symptom.

Check

the

following connectors:C-05,

C-64NG

OK Check the harness between the combination meter and powersupply,

and

repair

if

necessary.Repair

Check

trouble

symptom.

NG

Checktheharnessbetweenthecombination meterandauto-cruisecontrol-ECU,

and

repair

if

necessary.

Auto-cruise

control

indicator

lamp

inside

combination

meter does not illuminate. (However, auto-cruise controlis normal.)

Probable

cause

The

cause

is

probably

a

malfunction

of

bulb

or

a

malfunction

of

connector

or

harness. Malfunction of the bulb

Malfunction of the harness Malfunction of the connector Malfunction of the auto-cruisecontrol-ECU

Vehicle

speed

sensor

checke er

o om na on e er.

OK

Auto-cruise

vacuum

pump

check

(Refer

to

P.17-25.)

OK

Vacuum

actuator

check

(Refer

to

P.17-25.)

OK

Replace

the

auto-cruise

control-ECU.

Hunting(repeated accelerationand deceleration)occursatthe setvehicle speed.

Probable cause

The

cause

is

probably

a

malfunction

of

vehicle

speed

sensor

or

incorrect

vacuum

in

the

auto-cruise

vacuum

pump

or

vacuum

actuator. Malfunction of the vehicle speed sensor Malfunction of the auto-cruise vacuum pump Malfunction of the vacuum actuator Malfunction of the auto-cruisecontrol-ECU


20/48


21/48


CHECKAT ECU TERMINALS 17200270213

TerminalNo.

Checkitem Checkconditions Normalcondition

1 Throttleposi-tionsensorinput

Whenacceleratorpedalisfullydepressed 4.55.5V

Whenacceleratorpedalisreleased 0.31.0V

2 Engine-ECUoutput

Whenacceleratorpedalisdepressed 4.55.5V

Whenacceleratorpedalisnotreleased 0V

4 Stoplamp

switchinput When

brake

pedal

is

depressed When

stop

lamp

switch

is

ON System

voltage

Whenbrakepedalisnotdepressed When stop lamp switch isOFF

0V

5 Pumppowersupply

Ignitionswitch:ON

Stoplamp

switch:

OFF

Systemvoltage

6 ECUpowersupply

Ignitionswitch:ON Systemvoltage

7 Auto-cruisevacuumpumprelease

valve

andcontrolvalveinput

When decelerating with the SETswitch while driving at constantspeed

Releasevalveclosed Systemvoltage

8 Controlvalveopen/closed Systemvoltage

7 When cancelling constant speeddrivingwiththeCANCELswitch

Releasevalveopen Systemvoltage

8 Controlvalveopen Systemvoltage

9 Auto-cruisecontrolswitchinput

WhenmainswitchisON Approx.9.0V

When input switch has not beenoperated

WhenallswitchesareOFF Approx.4.5V

Wheninputswitchispusheddown WhenSETswitchisON Approx.1.5V

Wheninputswitchispushedup WhenRESUMREswitch isON

Approx.3.0V

When

input

switch

is

pulled

forward When

CANCEL

switch

isON

Approx.

0

V

10 Vehiclespeedsensorinput

When vehicle is moved forwardsand backwards, sensor turns ONandOFFrepeatedly

WhensensorisON 0V

WhensensorisOFF 4.5Vormore

11 Diagnosiscontrolinput

WhenignitionswitchisON 4Vormore

12 ACC powersupply

WhenignitionswitchisinACCposition

Mainswitch:ON

Systemvoltage


22/48


TerminalNo.

Checkitem Checkconditions Normalcondition

13 Clutch

pedal

positionswitchinput

Whenpedalisnotdepressed When clutch pedal positionswitch

is

OFFSystemvoltage

Whenpedalisdepressed When clutch pedal positionswitchisON

0V

14 Earth At

any

time Continuity

15 Indicatorlampinput (insidecombinationmeter)

Whenindicatorlampisilluminated 0V

Whenindicatorlampisswitchoff Systemvoltage

16 Auto-cruisevacuumpumpmotor

input

When driving at constant speedusingtheSETswitch

Motorstopped/running Systemvoltage/0V

When

accelerating

with

the

RE-

SUME switch while driving atconstantspeed

Motor

stopped/running System

voltage/0

V

When decelerating with the SET

switch

while

driving

at

constant

speed

Motorstopped Systemvoltage

When cancelling constant speeddriving

with

the

CANCEL

switchMotorstopped Systemvoltage


23/48

17-23ENGINE AND EMISSION CONTROLAuto-cruise Control System

ON-VEHICLE SERVICE 17200120198

AUTO-CRUISECONTROLMAINSWITCHCHECK

1. Turn the ignition key to ON.2. Check to be sure that the indicator lamp within the

combination meter illuminates when the main switch isswitched ON.

AUTO-CRUISE CONTROL SWITCHAUTO-CRUISE CONTROL SETTING

CHECK

1. Switch ON the main switch.2. Drive at the desired speed within

approximately 40200 km/h.3. Push the auto-cruise control switch in

the range of

the direction ofarrow (B).

4. Check to be sure that when the switch is released thespeed is the desired constant speed.

NOTEIfthevehiclesspeeddecreasestoapproximately15km/hbelowthesetspeedbecauseofclimbingahillforexample,the auto-cruise control will be cancelled.

SPEED-INCREASE SETTING

1. Set to the desired speed.2. Push the auto-cruise control switch in the direction of

arrow (A).3. Check to be sure that acceleration continues while the

switch ishold,and thatwhen it is released theconstantspeed at the time when it was released becomes thedriving speed.

NOTEAcceleration

can

be

continued

even

if

the

vehicle

speedhaspassed thehigh-speed limit(approx.200km/h).Butthespeedwhentheauto-cruisecontrolswitchisreleasedwill be recorded as the high-speed limit.

(A)

(C)

(B)

Auto-cruise indicator lamp


24/48


SPEED-REDUCTION SETTING

1. Set to the desired speed.2. Push the auto-cruise control switch in the direction of

arrow (B).3. Check to be sure that deceleration continues while the

switchispressed,andthatwhenitisreleasedtheconstantspeed at the time when it was released becomes thedriving speed.

NOTEWhen the vehicle speed reaches the low limit(approximately 40 km/h) during deceleration, theauto-cruise control will be cancelled.

RETURNTOTHE SETSPEED BEFORE CANCELLATIONANDAUTO-CRUISE CONTROL CANCELLATION

1. Set the auto-cruise speed control.2. Whenanyofthefollowingoperationsareperformedwhile

at constant speed during auto-cruise control, check ifnormal driving is resumed and deceleration occurs.a. The auto-cruise control switch is pushed in the

direction of arrow (C).

b. The

brake

pedal

is

depressed.c. The

clutch

pedal

is

depressed.3. When the auto-cruise control switch is pushed in the

direction of arrow (A) at a vehicle speed of 40 km/h orhigher, check if the vehicle speed returns to the speedbefore auto-cruise control driving was cancelled, andconstant speed driving occurs.

4. When the main switch is turned to OFF while drivingat constant speed, check if normal driving is resumedand deceleration occurs.

AUTOCRUISE CONTROL COMPONENTCHECK

STOP LAMP SWITCH

1. Disconnect the connector.2. Checkforcontinuitybetweenthe terminalsof theswitch.

CLUTCH PEDAL POSITION SWITCH

Refer to GROUP 21 On-vehicle Service.

THROTTLE POSITION SENSOR

Refer to GROUP 13A On-vehicle Service.

Measurementconditions TerminalNo.

1 3 4 5

When

brake

pedal

is

depressed.(forstoplampcircuit)

Whenbrakepedalisdepressed.(forauto-cruisecontrolcircuit)


25/48


AUTO-CRUISE VACUUM PUMP

1. Disconnectthevacuumhosefromtheauto-cruisevacuumpumpandconnectavacuumgaugetothevacuumpump.Disconnect the vacuum pump connector.Check that the reading on the vacuum gauge matchesthevaluesinthetablebelowwhenthebatteryisconnectedto each connector terminal.

2.3.

valve valve

VACUUMACTUATOR

1. Disconnect thevacuumhose fromthevacuumactuator,and connect a hand vacuum pump to the actuator.

2. Check that the throttle lever operates when applyingvacuum, and the vacuum is kept.

AUTO-CRUISE CONTROL SWITCH CHECK

Measure the resistance between the terminals when eachoftheSET,RESUME,CANCELandMAINswitchesispressed If the values measured at this time correspond to those inthe table below, then there is no problem.

OFFON ON ON

VEHICLE SPEED SENSOR CHECK

Refer to GROUP54 Combination meters.

Switchposition Resistancebetweenterminals

SwitchOFF Nocontinuity

CANSELswitchON Terminals1and3 Approx.3.9kfi

Terminals2and3 Approx.0fi

RESUMEswitchON Terminals1and3 Approx.4.8kfi


SETswitchON Terminals1and3 Approx.4.1kfi


MAINswitchON Terminals1and2 Approx.3.9kfi

1

Main

OFF

OFF OFF

ON

CAN

SET RES

3 2

Vacuum actuator

Terminal

No. Valve

condition VacuumgaugekPa1 2 3 4

Releasevalveclosed

Controlvalveclosed53ormore

Releasevalveopen20orless

Controlvalveopen

Vacuum

gauge

Release Control


26/48


AUTO-CRUISE CONTROL 17200140477

REMOVALAND INSTALLATION

78

2

1

4

5

3 6

Removal steps

1. Vacuum hose2. Wiring connector3. Actuator bracket4. Auto-cruisevacuumpumpandpump

bracket assembly

5. Auto-cruise vacuum pump6. Pump bracket7. Distance piece8. Rubber mount


27/48

17-27ENGINE AND EMISSION CONTROL Auto-cruise Control System

10

1312

9

14

Auto-cruise

control

switch

removal

steps

Airbagmodule(RefertoGROUP52BAir Bag Module and ClockSpring.)

9.Auto-cruise control switch

Sensor remov

al

11. Throttle position sensor12. Stop lamp switch13. Clutch pedal position switch14. Vehicle speed sensor

Auto-cruise control-ECU removalsteps

Cowlsidetrim(RefertoGROUP52A Trims.)

10.Auto-cruise control-ECU

11

CAUTION: SRSBefore removal of air bag module, refer toGROUP 52B SRS Service Precautions and AirBag Modules and Clock Spring.


28/48

17-28 ENGINEAND EMISSION CONTROL Emission Control System

EMISSIONCONTROL

GENERAL INFORMATION

The emission control system consists of

SYSTEM 17300010283

the following subsystems:

Crankcase emission control systemEvaporative emission control system

Exhaust

emission

control

system

EMISSION CONTROL DEVICE REFERENCE TABLE

Relatedparts Crankcaseemission

controlsystem

Evaporativeemission

controlsystem

Air/fuelratio

controlsystem

Catalyticconverter

Exhaustgas

recircula-tionsystem

Referencepage

PCVvalve 17-32

Purgecontrolsolenoidvalve 17-35

MPIsystemcomponent GROUP13A

Catalyticconverter 17-39

EGRvalve 17-37

EGR

control

solenoid

valve 17-38

Items Name Specification

Crankcase emissioncontrol

systemPositivecrankcaseventilation(PCV)valve Variableflowtype

(Purpose:HCreduction)

Evaporative

emission

controlsystemCanister

Purgecontrolsolenoidvalve

Equipped

ON/OFFtypesolenoidvalve

(Purpose:HCreduction)

Exhaust emissioncontrolsystem

Air-fuelratiocontroldeviceMPIsystem Oxygensensorfeedbacktype

(Purpose:

CO,

HC,

NOx

reduction)

Exhaust

gas

recirculation

system

EGR valve EGR control solenoid valve

Equipped

Singletype

Dutycycletypesolenoidvalve

(Purpose:NOxreduction)

Catalyticconverter Monolithtype

(Purpose:CO,HC,NOxreduction)


29/48

17-29ENGINEAND EMISSION CONTROL Emission Control System

SERVICE SPECIFICATIONS 17300030371

VACUUM

HOSEVACUUM HOSE PIPING DIAGRAM 17300090508

AircleanerAir inlet

PCVvalve P E AEGRvalve

Fuel pres-sure regu-lator

EGRcontrolsolenoidvalve

FromTo

fueltank

fuel

pump

From fueltank

CanisterPurge controlsolenoid valveOxygen

sensor

Three-way catalytic converter

Items Standardvalue

Purgecontrolsolenoidvalvecoilresistance(at20C) fi 2836

EGRcontrolsolenoidvalvecoilresistance(at20C) fi 2836


30/48


VACUUM CIRCUIT DIAGRAM

Intake manifold Throttle body

To combustionchamber

From aircleaner

EGRvalve

Fuel pressure regulatorEGRcontrolsolenoid valve

Canister

Vacuum

hose colourPurge controlsolenoid valveB: Black

L: LightblueR: RedY: YellowG: Green


31/48


VACUUM HOSE CHECK

1. Using the piping diagram as a guide, check to be sur 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 ther are no bends or damage.

VACUUM

HOSE

INSTALLATION

1. When

connecting

the

vacuum

hoses,

they

should

b

securely inserted onto the nipples.2. Connectthehosescorrectly,usingthevacuumhosepipin

diagram as a guide.

CRANKCASE EMISSION CONTROL SYSTEM

GENERAL

INFORMATION

17300500308

The crankcase emission control system prevent blow-bygases fromescaping inside thecrankcas into the atmosphere.

crankcase ventilation (PCV) valve.The PCV valve lifts the plunger according to theintakemanifoldvacuumsoas toregulate theflowofblow-bygasproperly.Inotherwords,theblow-bygas flow is regulated during low load engineoperation

to

maintain

engine

stability,

while

the

flo

is increasedduringhigh loadoperationto improvethe ventilation performance.

Fresh air is sent fromcrankcase through the

the air cleaner into thebreather hose. The air

becomes

mixed

with

the

blow-by

gases

inside

the

crankcase.The blow-by gas inside the crankcase is drawninto the intake manifold through the positive

SYSTEM DIAGRAM

Aircleaner

Air inletVentilation hose

PCVvalve

Fuelpressureregulator

Breather hose


32/48


COMPONENT LOCATION

POSITIVE

CRANKCASE

VENTILATION

SYSTEMCHECK 17300110266

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.

5. PlaceafingerattheopeningofthePCVvalveandcheckthat vacuum of the intake manifold is felt.

NOTEAt this moment, the plunger in the PCV valve movesback and forth.

If vacuum is not felt, clean the PCV valve or replaceit.

6.

PCV VALVE CHECK 17300120238

1. Inserta thin rod into thePCVvalve from thesideshownintheillustration(rockercoverinstallationside),andmov the rodbackand forth tocheck that theplungermoves.

2. If the plunger does not move, there is a clogging in th PCVvalve.In thiscase,cleanorreplacethePCVvalve.

PCVvalve

PCVvalve

Rocker cover


33/48


EVAPORATIVE EMISSION CONTROL SYSTEM

GENERAL INFORMATION

17300510561

The evaporative emission control system prevent fuel vapours generated in the fuel tank fromescaping into the atmosphere.Fuel vapours from the fuel tank flow through th fuel tank pressure control valve and vapou pipe/hose

to

be

stored

temporarily

in

the

canister

When driving the vehicle, fuel vapours stored inthe canister flow through the purge solenoid an purge port and go into the intake manifold to be

sent to the combustion chamber.When the engine coolant temperature is low o when the intake air quantity is small (when theengine is at idle, for example), the engine controlunit turns the purge solenoid off to shut off thefuel

vapour

flow

to

the

intake

manifold.Thisdoesnotonly insure thedriveabilitywhen theengine iscoldor runningunder low load butalsostabilize the emission level.

SYSTEM DIAGRAM

Engine-ECUThrottle body

From fuel tank Airflowsensor

Engine coolanttemperature sensor

Intake airtemperature sensor

Barometric pressuresensor

OFF

Canister

ON

Purge controlsolenoid valve Control

relay

COMPONENT LOCATION


34/48

17-34 ENGINE AND EMISSION CONTROL Emission Control System

PURGE CONTROL SYSTEM CHECK 17300140531

1. Disconnectthevacuumhose(redstripe)fromthethrottlebody and connect it to a hand vacuum pump.Plugthenipplefromwhichthevacuumhosewasremoved.When the engine is cold or hot, apply a vacuum whiletheengineisidling,andchecktheconditionoftheengineand the vacuum.

When

engine

is

cold

2.3.

(Engine coolant temperature: 40C or less)

When engine is hot(Engine coolant temperature: 80C or higher)

NOTE

*: The

vacuum

will

leak

continuously if

the

atmosphericpressureisapproximately77kPaorless,orthetemperatureoftheintakeairisapproximately50Corhigher.

PURGE PORT VACUUM CHECK 17300150411

1. Disconnectthevacuumhose(redstripe)fromthethrottl body purge vacuum nipple and connect a hand vacuumpump to the nipple.

Purge portvacuum nipple

Vacuum Enginecondition Normalcondition

53kPa Atidle Vacuumismaintained

3,000

r/min Vacuum

will

leak

forapproximately3minutesaftertheengineisstarted.After3minuteshavepassed,thevacuumwillbemaintainedmomentarily, afterwhich it will againleak.*

Vacuum Enginecondition Normalcondition

53kPa 3,000r/min Vacuumismaintained

Plug

Redstripe


35/48

17-35ENGINE AND EMISSION CONTROL Emission Control System

2. Start the engine and check that, after raising the enginespeed by racing the engine, purge vacuum raisesaccording to engine speed.

NOTEIf there is a problem with the change in vacuum, thethrottle body purge port may be clogged and requirecleaning.

PURGE CONTROL SOLENOID VALVE CHECK17300170370

NOTEWhendisconnectingthevacuumhose,alwaysmakeamarkso1.

that it can be reconnected at original position.Disconnect the vacuum hose (black stripe, red stripe)from the solenoid valve.Disconnect the harness connector.

Connect

a

hand

vacuum

pump

to

nipple

(A)

of

the

solenoidvalve (refer to the illustration at left).Check airtightness by applying a vacuum with voltageapplied directly from the battery to the purge controlsolenoid valve and without applying voltage.

2.

3.

4.

5. Measure the resistance between the terminals of thesolenoid valve.

Standard

value:

28

36

fi

(at

20C)

Batteryvoltage Normalcondition

Applied Vacuumleaks

Notapplied Vacuummaintained

A

Battery

Vacuum

Engine speed (r/min)


36/48


EXHAUST GAS RECIRCULATION

GENERAL INFORMATION

Theexhaustgasrecirculation(EGR)systemlowersthenitrogenoxide (NOx)emission level.When theair/fuel mixture combustion temperature is high,a large quantity of nitrogen oxides (NOx) isgenerated in the combustion chamber. Therefore,this

system

recirculates

part

of

emission

gas

from

(EGR) SYSTEM 17300520434

the exhaust port of the cylinder head to thecombustion chamber through the intake manifoldto decrease the air/fuel mixture combustiontemperature, resulting in reduction of NOx.TheEGRflowrate iscontrolledbytheEGRvalveso as

not

to

decrease

the

driveability.

OPERATION

The EGR valve is being closed and does no recirculateexhaustgasesunderoneofthefollowin conditions. Otherwise, the EGR valve is opened

TheTheThe

engine coolant temperature is low.engine is at idle.throttle valve is widely opened.

and recirculates exhaust gases.

SYSTEM DIAGRAM

EGRvalve

OFF ON

Airflowsensor


EGRcontrolsolenoidvalve

Crank angle sensor

Control

relayEngine-ECU

Battery

COMPONENT LOCATION


37/48


EXHAUST GAS RECIRCULATION (EGR)CONTROL SYSTEM CHECK 17300260398

1. Disconnectthevacuumhose(black)fromtheEGRvalve,andthenconnectahandvacuumpumpviathethree-wayterminal.When the engine is hot or cold, check the condition ofvacuum by racing the engine.

When

engine

is

cold

2.

(Engine coolant temperature: 20C or less)

When engine is hot(Engine coolant temperature: 80C or higher)

3.4.

Disconnect the three-way terminal.Connectthehandvacuumpumptothe(Black).

EGRvalvenipple

5. Checkwhether theenginestallsor the idling isunstabl when a vacuum of 30 kPa or higher is applied durin idling.

EGR VALVE CHECK 17300280257

1. Remove the EGR valve and inspect for sticking, carbondeposits, etc. If found, clean with a suitable solvent sothat the valve seats correctly.Connect a hand vacuum pump to the EGR valve.

Apply 67 kPa of vacuum, and check that the vacuumis maintained.

2.3.

4. Applyavacuumandcheckthepassageofairbyblowingthrough one side of the EGR passage.

5. Replace thegasket,and tighten to thespecified torque.

Tightening torque: 22 Nm

Vacuum Passageofair

2.7kPaorless Airisnotblownout

29kPaormore Airisblownout

Throttlevalve Normalvacuumcondition

Openquickly Itwillmomentarilyriseover13

kPa

Plug

Black

Throttlevalve Normalvacuumcondition

Openquickly No vacuum will generate(the same as barometricpressure.)

Black

Three-wayterminal


38/48

acuum

Engine

speed

rmin

17-38 ENGINE AND EMISSION CONTROL Emission Control System

EGR PORT VACUUM CHECK 17300290304

1. Disconnect the vacuum hose (green stripe) from thethrottle body EGR vacuum nipple and connect a handvacuum pump to the nipple.

2. Starttheengineandcheckvacuumremainsfairlyconstantafter racing the engine.

NOTEIfthevacuumfluctuates,thethrottlebodyEGRportmaybe clogged and need cleaning.

EGR CONTROL SOLENOID VALVE CHECK17300310352

NOTEWhendisconnectingthevacuumhose,alwaysmakeamarkso1.

that it can be reconnected at original position.Disconnectthevacuumhose(yellowstripe,greenstripe)from the solenoid valve.Disconnect the harness connector.

Connect

a

hand

vacuum

pump

to

the

nipple

to

which

the

green-striped

vacuum

hose

was

connected.Check airtightness by applying a vacuum with voltageapplied directly from the battery to the EGR controlsolenoid valve and without applying voltage.

2.

3.

4.

5. Measure the resistance between the terminals of thesolenoid valve.

Standard

value:

28

36fi

(at

20C)


Notapplied Vacuumleaks

Applied Vacuummaintained

Battery

V

(

/ )

EGRport

vacuum

nipple


39/48


CATALYTIC CONVERTER

GENERAL INFORMATION

The three-way catalytic converter, together withthe closed loop air-fuel ration control based onthe oxygen sensor signal, oxidizes carbon

17300530154

When the mixture is controlled at stoichiometri air-fuel ratio, the three-way catalytic converte provides thehighestpurificationagainst the three

monoxides (CO) and hydrocarbons (HC)reduces nitrogen oxides (NOx).

and constituents, namely, CO, HC and Nox.

REMOVALAND INSTALLATION 17300390325

2

3

1

49 Nm

49 Nm

Removal steps

1. Front exhaust pipe2. Center exhaust pipe3. Catalytic converter


40/48


CANISTERAND TWO-WAY VALVE 17300480329

REMOVAL AND INSTALLATION

56

12

3

5

4

Canister removal steps

1. Breather hose connection2. Vapour hose connection3. Canister4. Canister holder

Two-way valve removal steps

5. Vapour hose connection}A] 6.Two-way valve

INSTALLATION SERVICE POINT

}A]TWO-WAY VALVE INSTALLATION

Becarefulabouttheinstallationdirectionofthetwo-wayvalve.

INSPECTION

TWO-WAY VALVE SIMPLE CHECK

Attachacleanhoseandchecktheoperationof thetwo-wayvalve.

17300490094

Lightlyblowfrominletside(fueltankside)

Airpassesthroughwithaslightfeelingofresistance.

Lightly

blow

from

outlet

side. Air

passes

through.

Two-way valve

InletsideOutletside

Rubber side

Canister side Tankside


41/48


EMISSION CONTROL SYSTEM

GENERAL INFORMATION

Theelectronically-controlledEGRsystem and the

17500010043

fuel injection timing control system (loadreduce the level of exhaust gases (NOx).

timer)

ON-OFFsolenoidvalve

SERVICE SPECIFICATIONS 17500030049

SEALANT 17500050021

SPECIAL

TOOL 17500060024

Tool Number Name Use

MD998464 Testharness(4P,

square)Inspectionofleverpositionsensor

Item Specifed

sealant Remark

Enginecoolanttemperaturesensorthreadedportion 3MNutLockingPartNo.4171orequivalent Dryingsealant

Item Standardvalue

EGR

solenoid

valve

No.1/No.2

resistance

(at

20

C)fi

36

44

LeverpositionsensoroutputvoltageV Idleposition 0.81.0

Fullyopen 3.75.0

Enginespeedsensorresistancekfi 1.31.9

Enginecoolanttemperaturesensorresistancekfi At20C 2.93.6

At80C 0.260.35

Item Name Specification

Exhaustemissioncontrolsystem Exhaustgasrecirculationsystem

EGR valve EGR solenoid valve No.1 EGR solenoid valve No.2

Electronically-controlledEGRsystem

Singletype

Dutycyclesolenoidvalve


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EXHAUST GAS RECIRCULATION

GENERAL INFORMATION

Theelectronically-controlledEGRsystemconsistsof an EGR valve, vacuum pump, EGR solenoid

(EGR) SYSTEM 17500090023

The EGR solenoid valvesoptimally controlled by the

No.1 and No.2 areglow & EGR control

valves No.1 and No.2, glow &and various sensors.The EGR valve is controlled

EGR control unit unitinresponsetotheengineoperationconditions,based on data input from each of the sensors.In thisway, the EGR iscontrolled to reduce NOxby the negative

pressure

inside

the

valve,

which

is

controlled

by emissions while

maintaining good engineEGR solenoid valves No.1 and No.2. performance.

SYSTEM DIAGRAM

OFF ON

Orifice

EGR

solenoid

valve

No.2

(ONOFFcontrol)

EGRsolenoidvalve

No.1

(duty

control)Alternator

Vacuum pumpOFF ON

EGRvalve Glow&EGRcontrol unit

Engine coolanttemperature switch

Rotation sensor

Leverposition sensor

Engine coolanttemperature

sensor

COMPONENT LACATION

EGR

solenoid

valve

No.2EGR

solenoid

valve

No.1


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GR solenoid valve No.1


FUNCTION CHECK 17500100047

1. Starttheengineandletitwarmupuntiltheenginecoolanttemperature is 65C or above.

2. When the engine is raced by suddenly depressing theaccelerator pedal, check to be sure that the diaphragmof the EGR valve lifts.

EGR SOLENOID VALVE OPERATION CHECK17500290034

1. Remove the EGR solenoid valve No.1/No.2 connectorsand vacuum hoses.

2. AttachavacuumpumptoeachnippleoftheEGRsolenoidvalveNo.1/No.2andapplynegativepressure.Checktha the valves are airtight both when voltage is applied toeach terminal of the EGR solenoid valves and when itis not applied.

EGR solenoid valve No.1


Whencurrentisflowing

Vacuumleaks(VacuumismaintainedwhennippleBiscovered)

Whencurrentisnotflowing

Vacuumismaintained

E

A

B

Diaphragm

Lever position sensor (LPS)

Fuel injection pump

ng ne

spee

Engine

coolant

temperature sensor

Rocker cover

vave


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ENGINE SPEED SENSOR CHECK 17500140025

1. Disconnect the engine speed sensor connector.2. Measuretheresistancebetweentheenginespeedsensor

terminals.

Standard value: 1.3 1.9 kfi

ENGINE COOLANT TEMPERATURE SENSORCHECK 17500150035

1. Remove the engine coolant temperature sensor.

2. Measure rhe resistance between terminal (B) and thebody earth when the temperature sensing portion of theengine coolant temperature sensor is immeresd in ho water.

3. Iftheresistancedeviatesfromthestandardvaluegreatly,replace the sensor.

Apply sealant threaded portion.

Specified

sealant:3M NUT Locking Part No. 4171 or equivalent

Install engine coolant temperature sensor and tightenit to specified torque.

Sensor

tightening

torque:

35

NmFasten harness connectors securely.

4.

5.

6.

Temperature(C) Resistance(kfi)

0 7.79.5

20 2.93.6

40 1.31.7

80 0.260.35

A

B



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CHECKAT THE GLOW & EGR CONTROL

TERMINAL VOLTAGE CHECK CHART

UNIT 17500180041

Glow & EGR Control Unit Connector TerminalArrangement

HARNESS-SIDE CONNECTOR TERMINAL RESISTANCECHART

AND CONTINUITY CHECK

Glow

&

EGR

Control

Unit

Harness

Side

Connector

Terminal

Arrangement

TerminalNo. Checkitem Normalcondition(Checkcondition)

31 EGRsolenoidvalveNo.1 3644fi(At20C)

5Bodyearth Enginecoolanttemperaturesensor 7.79.5kfi(Whencoolanttemperatureis0C)

2.93.6kfi(Whencoolanttemperatureis20C)



1124 Enginespeedsensor 1.31.9kfi

161 EGRsolenoidvalveNo.2 3644fi(At20C)

TerminalNo.

Checkitem Checkcondition(Enginecondition) Normalcondition

3 EGRsolenoidvalveNo.1


Whileengineisidleaftrerhavingwarmedup,suddenlydepresstheacceleratorpedal.

Momentarilyincreases

6 Leverpositionsensor

Ignitionswitch:ON Setthrottlelevertoidleposition 0.81.0V

Fullyopenthrottlelever 3.75.0V

7 Sensorimpressedvoltage

Ignition

switch:

ON 4.55.5V

16 EGRsolenoidvalveNo.2


Whileengineisidleafterhavingwarmedup,suddenlydepresstheacceleratorpedal.

Momentarilydecreases


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TWO-WAY VALVE 17500240022

REMOVAL AND INSTALLATION

2

3

1

Removal steps

1. Vapour hose connection

2. Breather case3. Two-way valve}A]

INSTALLATION SERVICE POINT

}A]TWO-WAY VALVE INSTALLATION

Becarefulabouttheinstallationdirectionofthetwo-wayvalve.

INSPECTION

TWO-WAY VALVE SIMPLE CHECK

Attachacleanhoseandchecktheoperationof thetwo-wayvalve.

17500250025

Lightlyblowfrominletside(fueltankside)

Airpassesthroughwithaslightfeelingofresistance.

Lightlyblowfromoutletside. Airpassesthrough.

Two-way valve

Inletside

Outletside

Rubber side

Canister side Tankside


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NOTES

Documents

manual pajero 4x4 engine and emision control.docx