17-1

GROUP 17

ENGINE AND
EMISSION
CONTROL
CONTENTS

ENGINE CONTROL . . . . . . . . . . 17-3 ADJUSTMENT <4G63> . . . . . . . . . . . . . 17-5

ACCELERATOR CABLE CHECK AND
ADJUSTMENT <4G69> . . . . . . . . . . . . . 17-5
GENERAL INFORMATION . . . . . . 17-3
ACCELERATOR CABLE AND PEDAL
SERVICE SPECIFICATIONS. . . . . 17-3 <4G63> . . . . . . . . . . . . . . . . . . . . . . 17-6
REMOVAL AND INSTALLATION. . . . . . 17-6
TROUBLESHOOTING . . . . . . . . . . 17-3
INTRODUCTION TO ENGINE CONTROL ACCELERATOR CABLE AND PEDAL
SYSTEM DIAGNOSIS . . . . . . . . . . . . . . 17-3
<4G69> . . . . . . . . . . . . . . . . . . . . . . 17-7
ENGINE CONTROL SYSTEM DIAGNOSTIC REMOVAL AND INSTALLATION. . . . . . 17-7
TROUBLESHOOTING STRATEGY . . . 17-3
SYMPTOM CHART . . . . . . . . . . . . . . . . 17-3
SYMPTOM PROCEDURES . . . . . . . . . 17-3 ACCELERATOR PEDAL POSITION
SENSOR <4G69> . . . . . . . . . . . . . . 17-9
ON-VEHICLE SERVICE. . . . . . . . . 17-5 REMOVAL AND INSTALLATION. . . . . . 17-9
ACCELERATOR CABLE CHECK AND Continued on next page
17-2

EMISSION CONTROL <MPI> . . 17-10 GENERAL INFORMATION (EVAPORATIVE

EMISSION CONTROL SYSTEM) . . . . . 17-17
COMPONENT LOCATION (EVAPORATIVE
GENERAL INFORMATION . . . . . . 17-10 EMISSION CONTROL SYSTEM) . . . . . 17-18
PURGE CONTROL SYSTEM CHECK. . 17-18
EMISSION CONTROL DEVICE PURGE PORT VACUUM CHECK . . . . . 17-19
REFERENCE PURGE CONTROL SOLENOID VALVE
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . 17-20
TABLE . . . . . . . . . . . . . . . . . . . . . . 17-10
CANISTER REMOVAL AND
INSTALLATION . . . . . . . . . . . . . . . . . . . 17-21
SERVICE SPECIFICATIONS. . . . . 17-11
EXHAUST GAS RECIRCULATION (EGR)
SPECIAL TOOL . . . . . . . . . . . . . . . 17-11 SYSTEM . . . . . . . . . . . . . . . . . . . . . 17-22
GENERAL INFORMATION
VACUUM HOSE. . . . . . . . . . . . . . . 17-12 (EGR SYSTEM) . . . . . . . . . . . . . . . . . . . 17-22
VACUUM HOSE PIPING DIAGRAM . . . 17-12 COMPONENT LOCATION
VACUUM CIRCUIT DIAGRAM . . . . . . . 17-13 (EGR SYSTEM) . . . . . . . . . . . . . . . . . . . 17-23
VACUUM HOSE CHECK. . . . . . . . . . . . 17-14 EGR SYSTEM CHECK <4G63> . . . . . . 17-24
VACUUM HOSE INSTALLATION . . . . . 17-14 EGR PORT VACUUM CHECK<4G63> . 17-24
EGR VALVE CHECK <4G63> . . . . . . . . 17-24
EGR CONTROL SOLENOID VALVE
CRANKCASE EMISSION CONTROL CHECK <4G63> . . . . . . . . . . . . . . . . . . . 17-25
SYSTEM. . . . . . . . . . . . . . . . . . . . . 17-15 EGR VALVE (STEPPER MOTOR)
GENERAL INFORMATION (CRANKCASE CHECK <4G69> . . . . . . . . . . . . . . . . . . . 17-25
EMISSION CONTROL SYSTEM) . . . . . 17-15 EXHAUST GAS RECIRCULATION (EGR)
COMPONENT LOCATION (CRANKCASE VALVE REMOVAL AND INSTALLATION
EMISSION CONTROL SYSTEM) . . . . . 17-15 <4G63>. . . . . . . . . . . . . . . . . . . . . . . . . . 17-27
POSITIVE CRANKCASE VENTILATION EXHAUST GAS RECIRCULATION (EGR)
SYSTEM CHECK. . . . . . . . . . . . . . . . . . 17-16 VALVE REMOVAL AND INSTALLATION
POSITIVE CRANKCASE VENTILATION <4G69>. . . . . . . . . . . . . . . . . . . . . . . . . . 17-28
(PCV) VALVE CHECK . . . . . . . . . . . . . . 17-16
CATALYTIC CONVERTER . . . . . . 17-29
EVAPORATIVE EMISSION CONTROL REMOVAL AND INSTALLATION. . . . . . 17-29
SYSTEM. . . . . . . . . . . . . . . . . . . . . 17-17
 ENGINE AND EMISSION CONTROL
ENGINE CONTROL
17-3
ENGINE CONTROL
GENERAL INFORMATION SERVICE SPECIFICATIONS
M1171000100329 M1171000300099
A cable-type accelerator mechanical
suspended-type pedal has been adopted.
Items Standard value
Accelerator cable play mm 1.0 − 2.0
Engine idle speed r/min 4G63 750 ± 50
4G69 700 ± 100

TROUBLESHOOTING If you follow them carefully, you will be sure that you
have exhausted most of the possible ways to find an
INTRODUCTION TO ENGINE CONTROL engine control system fault.
1. Gather information from the customer.
SYSTEM DIAGNOSIS
M1171002000287 2. Verify that the condition described by the
If there is a malfunction in the engine control system, customer exists.
the accelerator cable, accelerator pedal or throttle
3. Find the malfunction by following the Symptom
lever may be faulty.
Chart.
ENGINE CONTROL SYSTEM 4. Verify that the malfunction is eliminated.
DIAGNOSTIC TROUBLESHOOTING SYMPTOM CHART
STRATEGY M1171002200322
M1171002100314
Use these steps to plan your diagnostic strategy.
SYMPTOM INSPECTION PROCEDURE REFERENCE PAGE
Throttle valve will not fully open or close <4G63> 1 P.17-3
Throttle valve will not fully open or close <4G69> 2 P.17-4
Accelerator pedal operation is not smooth (over 3 P.17-4
acceleration)

SYMPTOM PROCEDURES

INSPECTION PROCEDURE 1: Throttle Valve will not Fully Open or Close <4G63>

DIAGNOSIS YES : Go to Step 3 .

NO : Cleaning the throttle body (Refer to GROUP
13A, On-vehicle Service P.13A-324), or
STEP 1. Check the accelerator cable adjustment. replace the throttle body assembly (Refer to
Q: Is the accelerator cable properly adjusted? GROUP 13A, Throttle Body P.13A-340).
YES : Go to Step 2 . Then go to Step 3 .
NO : Adjust the accelerator cable (Refer to
P.17-5). Then go to Step 3 . STEP 3. Retest the system.
Q: Does the throttle valve fully open and close?
STEP 2. Check the throttle valve. YES : The procedure is complete.
Check that the throttle lever of the throttle body NO : Return to Step 1 .
assembly moves smoothly by moving it by hand.
Q: Does the throttle lever of the throttle body
assembly move smoothly?
17-4 ENGINE AND EMISSION CONTROL
ENGINE CONTROL

INSPECTION PROCEDURE 2: Throttle Valve will not Fully Open or Close <4G69>

DIAGNOSIS STEP 3. Check the accelerator pedal position

sensor assembly.
STEP 1. Check the accelerator cable adjustment. Refer to GROUP 13B, On-vehicle Service
P.13B-431.
Q: Is the accelerator cable properly adjusted?
YES : Go to Step 2 . Q: Is the accelerator pedal position sensor assembly
NO : Adjust the accelerator cable (Refer to normally?
P.17-5). Then go to Step 5 . YES : Go to Step 4 .
NO : Replace the accelerator pedal position
sensor assembly (Refer to P.17-9). Then go
STEP 2. Check the accelerator pedal position to Step 5 .
sensor assembly.
Check that the lever of the accelerator pedal position
sensor assembly moves smoothly by moving it by STEP 4. Check the Throttle valve (Throttle valve
hand. control servo).
Refer to GROUP 13B, On-vehicle Service P.13B-436
Q: Dose the lever of the accelerator pedal position
sensor assembly move smoothly? Q: Is the throttle valve control servo normally?
YES : Go to Step 3 . YES : Go to Step 5 .
NO : Replace the accelerator pedal position NO : Cleaning the throttle body (Refer to GROUP
sensor assembly (Refer to P.17-9). Then go 13B, On-vehicle Service P.13B-425), or
to Step 5 . replace the throttle body assembly (Refer to
GROUP 13B, Throttle Body P.13B-438).
Then go to Step 5 .

STEP 5. Retest the system.

Q: Does the throttle valve fully open and close?
YES : The procedure is complete.
NO : Return to Step 1 .

INSPECTION PROCEDURE 3: Accelerator Pedal Operation is not Smooth (Over Acceleration)

DIAGNOSIS STEP 3. Check the accelerator cable lubricant.

Q: Is the accelerator cable lubricated sufficiently?
STEP 1. Check the accelerator pedal. YES : Go to Step 4 .
NO : Refill or replace the lubricant. Then go to
Q: Is the accelerator pedal loose?
YES : Tighten the fasteners. Then go to Step 4 . Step 4 .
NO : Go to Step 2 .
STEP 4. Retest the system.
STEP 2. Check the accelerator cable wiring. Q: Does the accelerator pedal work normally?
YES : The procedure is complete.
Q: Is the accelerator cable routing bent sharply?
YES : Correct the cable routing Then go to Step 4 NO : Return to Step 1 .
.
NO : Go to Step 3 .
 ENGINE AND EMISSION CONTROL
ENGINE CONTROL
17-5
ON-VEHICLE SERVICE (3) After adjusting, check that the throttle lever is
touching the stopper.
ACCELERATOR CABLE CHECK AND
ADJUSTMENT <4G63> ACCELERATOR CABLE CHECK AND
M1171000900347 ADJUSTMENT <4G69>
1. Turn A/C and lights OFF. Inspect and adjust at no M1171000900358

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

2. Warm engine until stabilized at idle. load.
3. Confirm idle speed is at standard value. 2. Warm engine until stabilized at idle.
3. Confirm idle speed is at standard value.
Standard value: 750 ± 50 r/min
Standard value: 700 ± 100 r/min
4. Stop engine. [ignition switch: LOCK (OFF)
position]. 4. Stop engine. [ignition switch: LOCK (OFF)
5. Confirm there are no sharp bends in the position].
accelerator cable. 5. Confirm there are no sharp bends in the
6. Check the inner cable for correct slack. accelerator cable.
6. Check the inner cable for correct slack.
Standard value: 1.0 − 2.0 mm
Standard value: 1.0 − 2.0 mm

Accelerator pedal
Adjusting bolt position sensor
Plate Adjusting nut
Lock nut

Accelerator cable AC212490 AC Accelerator cable

AC304671 AE
7. If there is too much slack or no slack, adjust play
by the following procedures. 7. If there is too much slack or no slack, adjust play
(1) Loosen the adjusting bolts to release the by the following procedures.
cable. (1) Loosen the lock nut and adjusting nut to
(2) Move the plate until the inner cable play is at release the cable.
the standard value, and then tighten the (2) Tighten the adjusting nut until the inner cable
adjusting bolts. play is at the standard value, and then tighten
the lock nut.
17-6 ENGINE AND EMISSION CONTROL
ENGINE CONTROL

ACCELERATOR CABLE AND PEDAL

<4G63>
REMOVAL AND INSTALLATION
M1171001200404

Post-installation Operation
Adjusting the Accelerator Cable (Refer to P.17-5).

3
5.0 ± 1.0 N·m

12 ± 2 N·m
10
1 9 4
7
5N
7
11
6 N 12 8

13
AC309483AB

Accelerator cable assembly Accelerator pedal assembly

removal steps removal steps (Continued)
1. Inner cable connection (Accelerator 10. Accelerator pedal bracket
pedal side) 11. Accelerator arm
2. Inner cable connection (Throttle body >>A<< 12. Accelerator pedal pad
side) 13. Accelerator pedal stopper
3. Accelerator cable assembly
Accelerator pedal assembly INSTALLATION SERVICE POINT
removal steps >>A<< PEDAL PAD INSTALLATION
1. Inner cable connection (Accelerator
pedal side) CAUTION
4. Accelerator pedal assembly To prevent damages to the Pedal Pad, warm the
5. Push-on spring nut thumb area of the Pedal Pad with a dryer, etc.
6. Accelerator arm and accelerator prior to assembling it.
pedal pad assembly NOTE: If it is difficult to assemble, apply soapy water
7. Bushing to the thumb area to enhance the assembling
8. Spring
process.
9. Stopper
 ENGINE AND EMISSION CONTROL
ENGINE CONTROL
17-7
ACCELERATOR CABLE AND PEDAL
<4G69>
REMOVAL AND INSTALLATION
M1171001200415

<L.H. drive vehicles>

Post-installation Operation
Adjusting the Accelerator Cable (Refer to P.17-5).

4
2
3

12 ± 2 N·m
11
1
10 5
8
6N
8
12
7 N 13 9

14
AC309484AB

Accelerator cable assembly Accelerator pedal assembly

removal steps removal steps (Continued)
1. Inner cable connection (Accelerator 6. Push-on spring nut
pedal side) 7. Accelerator arm and accelerator
2. Inner cable connection (Accelerator pedal pad assembly
pedal position sensor side) 8. Bushing
3. Accelerator cable assembly 9. Spring
4. Accelerator cable bracket 10. Stopper
Accelerator pedal assembly 11. Accelerator pedal bracket
removal steps 12. Accelerator arm
1. Inner cable connection (Accelerator >>A<< 13. Accelerator pedal pad
pedal side) 14. Accelerator pedal stopper
5. Accelerator pedal assembly
17-8 ENGINE AND EMISSION CONTROL
ENGINE CONTROL

<R.H. drive vehicles>

Post-installation Operation
Adjusting the Accelerator Cable (Refer to P.17-5.)

4
2
3

5
12 ± 2 N·m
11
12 9
13
8
N7 14 N
6
10
9

15
AC309485 AB

Accelerator cable assembly Accelerator pedal assembly

removal steps removal steps (Continued)
1. Inner cable connection (Accelerator 11. Stopper
pedal side) 12. Accelerator pedal bracket
2. Inner cable connection (Accelerator 13. Accelerator arm
pedal position sensor side) >>A<< 14. Accelerator pedal pad
3. Accelerator cable assembly 15. Accelerator pedal stopper
4. Accelerator cable bracket
5. Accelerator cable clip INSTALLATION SERVICE POINT
Accelerator pedal assembly >>A<< PEDAL PAD INSTALLATION
removal steps
1. Inner cable connection (Accelerator CAUTION
pedal side) To prevent damages to the Pedal Pad, warm the
6. Accelerator pedal assembly thumb area of the Pedal Pad with a dryer, etc.
7. Push-on spring nut prior to assembling it.
8. Accelerator arm and accelerator NOTE: If it is difficult to assemble, apply soapy water
pedal pad assembly to the thumb area to enhance the assembling
9. Bushing
process.
10. Spring
 ENGINE AND EMISSION CONTROL
ENGINE CONTROL
17-9
ACCELERATOR PEDAL POSITION
SENSOR <4G69>
REMOVAL AND INSTALLATION
M1171001800053

Post-installation Operation
Adjusting the Accelerator Cable (Refer to P.17-5).

12 ± 1 N·m

3
2 1

5.0 ± 1.0 N·m

4

5.0 ± 1.0 N·m

5.0 ± 1.0 N·m

5 AC305408AC

Removal steps Removal steps (Continued)

1. Inner cable connection (Accelerator 4. Accelerator pedal position sensor
pedal position sensor side) bracket
2. Accelerator pedal position sensor 5. Accelerator pedal position sensor
connector bracket support
3. Accelerator pedal position sensor
assembly
17-10 ENGINE AND EMISSION CONTROL
EMISSION CONTROL <MPI>

EMISSION CONTROL <MPI>

GENERAL INFORMATION • Crankcase emission control system
M1173000100466 • Evaporative emission control system
The emission control system consists of the following • Exhaust emission control system
subsystems:
Items Name Specification
Crankcase emission control Positive crankcase ventilation Variable flow type
system (PCV) valve (Purpose: HC reduction)
Evaporative emission control Canister Equipped
system Purge control solenoid valve Duty cycle type solenoid valve
(Purpose: HC reduction)
Exhaust emission control system Air-fuel ratio control device - MPI Oxygen sensor feedback type
system (Purpose: CO, HC, NOx reduction)
Exhaust gas recirculation system Equipped
<4G63>
• EGR valve Single type
• EGR control solenoid valve Duty cycle type solenoid valve
(Purpose: NOx reduction)
Exhaust gas recirculation system Equipped
<4G69>
• EGR valve Steeper motor type
(Purpose: NOx reduction)
Catalytic converter Monolith type
(Purpose: CO, HC, NOx reduction)

EMISSION CONTROL DEVICE

REFERENCE TABLE
M1173006600157

Related parts Crankcase Evaporative Air/fuel ratio Catalytic Exhaust gas

emission emission control converter recirculation
control control system system
system system
PCV valve ×
Purge control solenoid valve ×
MPI system component × ×
Catalytic converter ×
EGR valve <4G63> ×
EGR control solenoid valve ×
<4G63>
EGR valve (Steeper moter) ×
<4G69>
 ENGINE AND EMISSION CONTROL
EMISSION CONTROL <MPI>
17-11
SERVICE SPECIFICATIONS
M1173000300363

Items Standard value

Purge control solenoid valve coil resistance (at 20°C) Ω 30 − 34
EGR control solenoid valve coil resistance (at 20°C) Ω 29 − 35
<4G63>
EGR valve coil resistance (at 20°C) Ω <4G69> 20 − 24

SPECIAL TOOL
M1173000600201

Tool Number Name Use

MD991658 Test harness EGR valve (Steeper moter)
CHECK

MB991658

MD998770 Oxygen sensor wrench Removal and installation of

oxygen sensor
17-12 ENGINE AND EMISSION CONTROL
EMISSION CONTROL <MPI>

VACUUM HOSE
VACUUM HOSE PIPING DIAGRAM
M1173000900439

<4G63>

Air cleaner

Air

Fuel pressure
To regulator From
fuel tank fuel pump

PCV valve
EGR valve
Oxygen sensor Canister
(front)

EGR control
solenoid valve Purge control
Catalytic solenoid valve
converter
Oxygen sensor (rear)

Catalytic
converter

AK204364AB

<4G69>

Air cleaner

Cylinder 2, 3 oxygen sensor (front)

Air
Cylinder 1, 4 oxygen sensor (front)

From
fuel pump

PCV valve

Canister

EGR valve
(Stepper motor) Purge control
Catalytic
converter solenoid valve

Catalytic
converter

Cylinder 1, 4 oxygen sensor (rear)

Cylinder 2, 3 oxygen sensor (rear)
AK302694 AB
 ENGINE AND EMISSION CONTROL
EMISSION CONTROL <MPI>
17-13
VACUUM CIRCUIT DIAGRAM
M1173007100285

<4G63>

Intake manifold Throttle body

To From
combustion air
chamber cleaner

B W
R
Fuel
pressure
regulator
G
Y B Canister
Vacuum hose colour EGR
B: Black control
G: Green solenoid B
R: Red valve Purge
W: White EGR
valve control
Y: Yellow solenoid
valve
AK201210 AC

<4G69>

Intake manifold Throttle body

To From
combustion air
chamber cleaner

B Canister

Purge B B
control
solenoid
Vacuum hose colour valve
B: Black
AK302823 AB
17-14 ENGINE AND EMISSION CONTROL
EMISSION CONTROL <MPI>

VACUUM HOSE CHECK VACUUM HOSE INSTALLATION

M1173007300160 M1173007200118
1. Using the piping diagram as a guide, check to be 1. When connecting the vacuum hoses, they should
sure that the vacuum hoses are correctly be securely inserted onto the nipples.
connected. 2. Connect the hoses correctly, using the vacuum
2. Check the connection condition of the vacuum hose piping diagram as a guide.
hoses, (removed, loose, etc.) and check to be
sure that there are no bends or damage.
 ENGINE AND EMISSION CONTROL
EMISSION CONTROL <MPI>
17-15
CRANKCASE EMISSION CONTROL The air becomes mixed with the blow-by gases
inside the crankcase.
SYSTEM The blow-by gas inside the crankcase is drawn into
the intake manifold through the positive crankcase
GENERAL INFORMATION (CRANKCASE ventilation (PCV) valve.
EMISSION CONTROL SYSTEM) The PCV valve lifts the plunger according to the
M1173005000334
intake manifold vacuum so as to regulate the flow of
The crankcase emission control system prevents
blow-by gas properly.
blow-by gases from escaping inside the crankcase
In other words, the blow-by gas flow is regulated
into the atmosphere.
during low load engine operation to maintain engine
Fresh air is sent from the air cleaner into the
stability, while the flow is increased during high load
crankcase through the breather hose.
operation to improve the ventilation performance.

SYSTEM DIAGRAM

Air cleaner

Air

Ventilation hose Breather hose

PCV valve

AK204365AB

COMPONENT LOCATION (CRANKCASE <4G69>

EMISSION CONTROL SYSTEM)
M1173007400242

<4G63>

PCV valve

AK302826 AB

PCV valve
AK204366AD
17-16 ENGINE AND EMISSION CONTROL
EMISSION CONTROL <MPI>

POSITIVE CRANKCASE VENTILATION 6. If vacuum is not felt, clean the PCV valve or
SYSTEM CHECK replace it.
M1173001100221
1. Remove the ventilation hose from the PCV valve. POSITIVE CRANKCASE VENTILATION
2. Remove the PCV valve from the rocker cover. (PCV) VALVE CHECK
M1173001200217
3. Reinstall the PCV valve at the ventilation hose.
4. Start the engine and run at idle.
PCV valve

PCV valve AK300022 AC

AK300021AC 1. Insert a thin rod into the PCV valve from the side
shown in the illustration (rocker cover installation
5. Place a finger at the opening of the PCV valve side), and move the rod back and forth to check
and check that vacuum of the intake manifold is that the plunger moves.
felt. 2. If the plunger does not move, there is a clogging
NOTE: At this moment, the plunger in the PCV in the PCV valve. In this case, clean or replace
valve moves back and forth. the PCV valve.
 ENGINE AND EMISSION CONTROL
EMISSION CONTROL <MPI>
17-17
EVAPORATIVE EMISSION CONTROL When driving the vehicle, fuel vapours stored in the
canister flow through the gurge control solenoid
SYSTEM valve and purge port and go into the intake manifold
to be sent to the combustion chamber.
GENERAL INFORMATION (EVAPORATIVE When the engine coolant temperature is low or when
EMISSION CONTROL SYSTEM) the intake air quantity is small (when the engine is at
M1173005100427
idle, for example), the engine control unit turns the
The evaporative emission control system prevents
purge solenoid off to shut off the fuel vapour flow to
fuel vapours generated in the fuel tank from escaping
the intake manifold.
into the atmosphere.
This does not only insure the driveability when the
Fuel vapours from the fuel tank flow through the fuel
engine is cold or running under low load but also
tank pressure control valve and vapour pipe/hose to
stabilize the emission level.
be stored temporarily in the canister.

SYSTEM DIAGRAM
<4G63>

Throttle body

Engine-ECU
Canister
From
fuel Air flow sensor
tank
OFF
Engine coolant
temperature sensor
Purge
control
ON Solenoid
Control Intake air
valve temperature sensor
relay

Barometric pressure
sensor
Battery

AK204367AB
17-18 ENGINE AND EMISSION CONTROL
EMISSION CONTROL <MPI>

<4G69>

Intake manifold

Engine-ECU <M/T> or
Engine-A/T-ECU <A/T>

Canister Air flow sensor

From
fuel
tank Engine coolant
OFF temperature sensor
Purge
control Intake air
ON Solenoid Control temperature sensor
valve relay
Barometric pressure sensor
(with engine-ECU <M/T>
or engine-A/T-ECU <A/T>)
Battery

AK302829AB

COMPONENT LOCATION (EVAPORATIVE PURGE CONTROL SYSTEM CHECK

M1173001400318
EMISSION CONTROL SYSTEM) <4G63>
M1173007500238

<4G63>
Vacuum hose

Plug

Purge control
solenoid valve
AK201217 AD AK201220AC

<4G69> 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.
Purge control
solenoid valve
AK302830 AB
 ENGINE AND EMISSION CONTROL
EMISSION CONTROL <MPI>
17-19
When engine is cold When engine is hot
(Engine coolant temperature: 40°C or less) (Engine coolant temperature: 80°C or higher)
Engine condition Normal condition Engine condition Normal condition
At idle Vacuum is maintained. At idle Vacuum is maintained.
3,000 r/min 3,000 r/min (within 3 Vacuum will leak.
minutes after engine
When engine is hot starts)
(Engine coolant temperature: 80°C or higher)
Engine condition Normal condition
PURGE PORT VACUUM CHECK
At idle Vacuum is maintained. M1173001500188

3,000 r/min (within 3 Vacuum will leak. <4G63>

minutes after engine Vacuum hose
starts)

<4G69>

Plug
Plug

AK201225 AD

1. Disconnect the vacuum hose (red stripe) from the

Vacuum hose throttle body and connect a hand vacuum pump to
the nipple.
AK302831AB 2. Plug the vacuum hose (red stripe).
1. Disconnect the vacuum hose (between purge
control solenoid valve and intake maniford) from
purge control solenoid valve and connect a hand
vacuum pump to the nipple.
2. Plug the vacuum hose. Vac-
uum
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 speed (r/min)
(Engine coolant temperature: 40°C or less) AK100011AC
Engine condition Normal condition
3. Start the engine.
At idle Vacuum is maintained.
4. Check that a fairly constant negative pressure is
3,000 r/min
generated regardless of the engine speed.
5. If no negative pressure is generated, the port is
probably blocked and should be cleaned.
17-20 ENGINE AND EMISSION CONTROL
EMISSION CONTROL <MPI>

<4G69>
A
Vacuum hose

Plug
Battery
AK100012 AC

AK302833 AB

1. Disconnect the vacuum hose (between purge

control solenoid valve and intake manifold) from
the purge control solenoid valve and connect it to
a hand vacuum pump.
2. Plug the nipple from which the vacuum hose was
removed.

AK100013

1. Disconnect the vacuum hose from the solenoid

Vac- valve.
uum 2. Disconnect the harness connector.
3. Connect a hand vacuum pump to nipple (A) of the
solenoid valve (refer to the illustration at left).
Engine speed (r/min)
4. Check airtightness by applying a vacuum with
AK100011AC
voltage applied directly from the battery to the
3. Start the engine. purge control solenoid valve and without applying
voltage.
4. Check that a fairly constant negative pressure is
generated regardless of the engine speed. Battery voltage Normal condition
5. If no negative pressure is generated, the port is Applied Vacuum leaks
probably blocked and should be cleaned. Not applied Vacuum maintained
PURGE CONTROL SOLENOID VALVE 5. Measure the resistance between the terminals of
the solenoid valve.
CHECK
M1173001700234 Standard value: 30 − 34 Ω (at 20°C)
NOTE: When disconnecting the vacuum hose,
always make a mark so that it can be reconnected at
original position.
 ENGINE AND EMISSION CONTROL
EMISSION CONTROL <MPI>
17-21
CANISTER REMOVAL AND INSTALLATION
M1173004200175

Pre-removal and Post-installation Operation

Air cleaner cover and air intake hose removal and installation
(4G63: Refer to GROUP 15 - Air cleaner P.15-3) (4G69:
Refer to GROUP 15 - Air cleaner P.15-4).

3
2

4 1
5 8

AC212494 AB

Removal steps Removal steps (Continued)

1. Purge hose connection 6. Canister
2. Vapour hose 7. Fuel high-pressure hose clamp
3. Vent connector <4G63>
4. Vapour hose 8. Canister bracket
5. Hose clamp
17-22 ENGINE AND EMISSION CONTROL
EMISSION CONTROL <MPI>

EXHAUST GAS RECIRCULATION The EGR flow rate is controlled by the EGR valve so
as not to decrease the driveability.
(EGR) SYSTEM
OPERATION
GENERAL INFORMATION (EGR SYSTEM)
M1173005200349 The EGR valve is being closed and does not
The exhaust gas recirculation (EGR) system lowers recirculate exhaust gases under one of the following
the nitrogen oxide (NOx) emission level. conditions.
When the air/fuel mixture combustion temperature is Otherwise, the EGR valve is opened and recirculates
high, a large quantity of nitrogen oxides (NOx) is exhaust gases.
generated in the combustion chamber. • The engine coolant temperature is low.
Therefore, this system recirculates part of emission • The engine is at idle.
gas from the exhaust port of the cylinder head to the • The throttle valve is widely opened.
combustion chamber through the intake manifold to
decrease the air/fuel mixture combustion
temperature, resulting in reduction of NOx.

SYSTEM DIAGRAM
<4G63>

EGR
control
Solenoid
valve

OFF
Engine-ECU
EGR valve
ON Barometric pressure
sensor

Air flow sensor

Control
relay
Engine coolant
temperature sensor

Battery Crank angle sensor

AK204368 AB
 ENGINE AND EMISSION CONTROL
EMISSION CONTROL <MPI>
17-23
<4G69>

Air flow sensor

Engine coolant
EGR valve temperature sensor
(stepper motor)

Control
relay
Crank angle sensor

Battery

Throttle position sensor

Engine-ECU <M/T> or
Engine-A/T-ECU <A/T> AK204431AC

COMPONENT LOCATION (EGR SYSTEM) <4G63>

M1173007600246
EGR valve
<4G63>

AK303696AB
EGR control
solenoid valve
AK201234AD <4G69>

EGR valve
(stepper motor)
AK302840AB
17-24 ENGINE AND EMISSION CONTROL
EMISSION CONTROL <MPI>

EGR SYSTEM CHECK <4G63> EGR PORT VACUUM CHECK<4G63>

M1173002600360 M1173002900178

Three-way terminal
white stripe
Green stripe

EGR valve AK200375AE AK201247 AC

1. Disconnect the vacuum hose (Green stripe) from 1. Disconnect the vacuum hose (White stripe) from
the EGR valve, and then connect a hand vacuum the throttle body EGR vacuum nipple and connect
pump via the three-way terminal. a hand vacuum pump to the nipple.
2. When the engine is hot or cold, check the 2. Plug the vacuum hose (White stripe).
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 Vac-
uum
same as barometric pressure.)
When engine is hot
(Engine coolant temperature: 80°C or higher) Engine speed (r/min)
Throttle valve Normal vacuum condition AK100011AC

Open quickly It will momentarily rise over 13 3. Start the engine.

kPa
4. Check that a fairly constant negative pressure is
3. Disconnect the three-way terminal. generated regardless of the engine speed.
Green stripe 5. If no negative pressure is generated, the port is
probably blocked and should be cleaned.

EGR VALVE CHECK <4G63>

M1173002800234
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.
EGR valve AK200376 AC 3. Apply 67 kPa of vacuum, and check that the
vacuum is maintained.
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.

AKX00348
 ENGINE AND EMISSION CONTROL
EMISSION CONTROL <MPI>
17-25
4. Apply a vacuum and check the passage of air by Battery B nipple Normal condition
blowing through one side of the EGR passage. voltage condition
Vacuum Passage of air Not applied Open Vacuum
5.3 kPa or less Air is not blown out maintained
27 kPa or more Air is blown out Applied Open Vacuum leaks
5. Replace the gasket, and tighten to the specified Closed Vacuum
torque. maintained
Tightening torque: 20 ± 2 N⋅m 5. Measure the resistance between the terminals of
the solenoid valve.
EGR CONTROL SOLENOID VALVE Standard value: 29 − 35 Ω (at 20°C)
CHECK <4G63>
M1173003100261
EGR VALVE (STEPPER MOTOR) CHECK
NOTE: When disconnecting the vacuum hose,
always make a mark so that it can be reconnected at
<4G69>
M1173050200134
original position. Checking the Operation Sound
A

Battery
EGR valve
AK201251AB (stepper motor)
AK302877AB

1. Check that the operation sound of the stepper

motor can be heard from the EGR valve when the
ignition switch is turned ON (without starting the
engine).
2. If the operation sound cannot be heard, inspect
the drive circuit of the stepper motor.
NOTE: If the circuit is normal, either the stepper
motor or the engine-ECU <M/T> or engine-A/T-ECU
AK304447
<A/T> may have failed.

1. Disconnect the vacuum hose from the solenoid Checking the Coil Resistance
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 air tightness by applying a vacuum with
voltage applied directly from the battery to the 1 2 3
4 5 6
EGR control solenoid valve and without applying
voltage. 1 2 3
4 5 6
AK200805 AC

1. Remove the EGR valve.

17-26 ENGINE AND EMISSION CONTROL
EMISSION CONTROL <MPI>

2. Measure the resistance between terminal No. 2 4. Connect terminals No. 1 and No. 3 to the negative
and either terminal No. 1 or terminal No. 3 of the (-) terminal of the battery, in order to test whether
connector at the EGR valve. the stepper motor vibrates (with a slight shudder),
Standard value: 20 − 24 Ω (at 20°C) indicating that the stepper motor is operating.
3. Measure the resistance between terminal No. 5 CAUTION
and either terminal No. 6 or terminal No. 4 of the Connecting battery voltage to the EGR valve for a
connector at the EGR valve. long term could damage the coil.
Standard value: 20 − 24 Ω (at 20°C)
4. Using a new gasket, install the EGR valve by
tightening its mounting bolts to the specified
torque.
Tightening Torque: 24 ± 4 N⋅m

Operation Check
MB991658 Battery

AK304039 AB

5. Connect the positive (+) terminal of the battery to

terminal No. 5.
6. Connect terminals No. 4 and No. 6 to the negative
1 2 3 (-) terminal of the battery, in order to test whether
4 5 6
the stepper motor vibrates (with a slight shudder),
indicating that the stepper motor is operating.
EGR valve
AK203698 AC
7. If a vibration can be felt during the test, the
stepper motor is normal.
1. Remove the EGR valve. 8. Using a new gasket, install the EGR valve by
2. Attach a test wiring harness (special tool tightening its mounting bolts to the specified
MB991658) to the connector at the EGR valve. torque.
Tightening torque: 24 ± 3 N⋅m

Cleaning the EGR Valve

CAUTION
Do not use a solvent or detergent, which could
enter the motor and cause it to malfunction.
MB991658 1. Remove the EGR valve and check that the EGR
Battery valve is not stuck or clogged with carbon deposits.
Use a wire brush to clean the valve if necessary.
AK302886 AB
2. Using a new gasket, install the EGR valve by
CAUTION tightening its mounting bolts to the specified
Connecting battery voltage to the EGR valve for a torque.
long term could damage the coil. Tightening torque: 24 ± 3 N⋅m
3. Connect the positive (+) terminal of the battery to
terminal No. 2.
 ENGINE AND EMISSION CONTROL
EMISSION CONTROL <MPI>
17-27
EXHAUST GAS RECIRCULATION (EGR) VALVE REMOVAL AND INSTALLATION
<4G63>
M1173010500249

Pre-removal and Post-installation Operation

Air cleaner cover and air intake hose removal and installation
(Refer to GROUP 15 - Air cleaner P.15-3).

1
2 20 ± 2 N·m

3N

AC301219 AB

Removal steps Removal steps (Continued)

1. Vacuum hose connection 2. EGR valve
3. EGR valve gasket
17-28 ENGINE AND EMISSION CONTROL
EMISSION CONTROL <MPI>

EXHAUST GAS RECIRCULATION (EGR) VALVE REMOVAL AND INSTALLATION

<4G69>
M1173010500250

Pre-removal and Post-installation Operation

Resonator removal and installation (Refer to GROUP 15 - Air
cleaner P.15-4).

1 24 ± 3 N·m

3N

AC302329AE

Removal steps INSTAIIATION SERVICE POINT

1. EGR valve connector >>A<< EGR PIPE B GASKET INSTALLATION
2. EGR valve
>>A<< 3. EGR valve gasket

Notched
part

Gasket
Notched
part AC302358AE

Install the EGR valve gasket as shown in the

illustration.
 ENGINE AND EMISSION CONTROL
EMISSION CONTROL <MPI>
17-29
CATALYTIC CONVERTER
REMOVAL AND INSTALLATION
M1173003900449

<4G63-2WD> 44 ± 5 N·m
49 ± 10 N·m 1 2

N5

3N 59 ± 10 N·m
6
AC212564 AC

<4G63-4WD>
44 ± 5 N·m
2
1
N 5

4
3N 59 ± 10 N·m
6
49 ± 10 N·m
AC212565 AD

<4G69>
2

N 5

4
3N 59 ± 10 N·m
6
49 ± 10 N·m
AC309495 AB

Removal steps Removal steps (Continued)

<<A>> >>A<< 1. Oxygen sensor <4G63> 4. Front exhaust pipe connection
2. Center exhaust pipe connection 5. Exhaust pipe gasket
3. Exhaust pipe gasket 6. Catalytic converter
17-30 ENGINE AND EMISSION CONTROL
EMISSION CONTROL <MPI>

REMOVAL SERVICE POINT INSTALLATION SERVICE POINT

<<A>> OXYGEN SENSOR REMOVAL >>A<< OXYGEN SENSOR INSTALLATION

MD998770 MD998770

Oxygen sensor Oxygen sensor

AC212566AB AC212566AB

Use special tool oxygen sensor wrench (MD998770) Use special tool oxygen sensor wrench (MD998770)
to remove the oxygen sensor. to install the oxygen sensor.