17-1

ENGINE AND
EMISSION
CONTROL
CONTENTS
ENGINE CONTROL SYSTEM . . . . . . . . 2

CRANKCASE EMISSION CONTROL

SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

GENERAL INFORMATION . . . . . . . . . . . . . . . . 2

General Information . . . . . . . . . . . . . . . . . . . . . . 10

SERVICE SPECIFICATIONS . . . . . . . . . . . . . . 2
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . 2
Accelerator Cable Check and Adjustment . . . . 2

System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 10
Component Location . . . . . . . . . . . . . . . . . . . . . . 10
Positive Crankcase Ventilation System
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Accelerator Pedal Position Sensor Check . . . . 3

PCV Valve Check . . . . . . . . . . . . . . . . . . . . . . . . 11

ACCELERATOR CABLE AND PEDAL . . . . 4

EVAPORATIVE EMISSION CONTROL

SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

ACCELERATOR PEDAL POSITION

SENSOR <4G6> . . . . . . . . . . . . . . . . . . . . . . . . . 5

General Information . . . . . . . . . . . . . . . . . . . . . . 12

EMISSION CONTROL SYSTEM . . . . . . 6

System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 12
Component Location . . . . . . . . . . . . . . . . . . . . . . 12
Purge Control System Check . . . . . . . . . . . . . . 13

GENERAL INFORMATION . . . . . . . . . . . . . . . . 6

Purge Port Vacuum Check . . . . . . . . . . . . . . . . 13

Emission Control Device Reference

Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Purge Control Solenoid Valve Check . . . . . . . 14

SERVICE SPECIFICATION . . . . . . . . . . . . . . . 7
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . 7

EXHAUST GAS RECIRCULATION (EGR)

SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
General Information . . . . . . . . . . . . . . . . . . . . . . 15
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

VACUUM HOSE . . . . . . . . . . . . . . . . . . . . . . . . . 7

System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 15

Vacuum Hose Piping Diagram . . . . . . . . . . . . . . 7

Component Location . . . . . . . . . . . . . . . . . . . . . . 15

Vacuum Circuit Diagram . . . . . . . . . . . . . . . . . . . 9

Exhaust Gas Recirculation (EGR) Control

System Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Vacuum Hose Check . . . . . . . . . . . . . . . . . . . . . . 9

Vacuum Hose Installation . . . . . . . . . . . . . . . . . . 9

EGR Valve (Stepper Motor)

Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

CATALYTIC CONVERTER . . . . . . . . . . . . . . 17

17-2

ENGINE AND EMISSION CONTROL - Engine Control System

ENGINE CONTROL SYSTEM

17100010102

GENERAL INFORMATION
A cable-type accelerator mechanism and a
suspended-type pedal have been adopted.

Accelerator pedal position sensor is used for

vehicles with 4G6 engine which is equipped with
the electronically-controlled fuel injection system.

SERVICE SPECIFICATION

17100030139

Items

Standard value

Accelerator cable play mm

1- 2

ON-VEHICLE SERVICE

17100090243

ACCELERATOR CABLE CHECK AND

ADJUSTMENT
1. Turn A/C and lamps OFF.
Inspect and adjust at no load.
2. Warm engine until stabilized at idle.
3. Confirm idle speed is at prescribed value. (Refer to
GROUP 11 - On-vehicle Service.)
4. Stop engine (ignition switch OFF).
5. Confirm there are no sharp bends in accelerator cable.
6. Check inner cable for correct slack.
Standard value: 1 - 2 mm

<4G6>

Adjusting nut
Accelerator pedal
position sensor

Lock nut

Lever

<4G9>

Adjusting bolt or
adjusting nut

Plate

7. If there is too much slack or no slack, adjust play by the

following procedures.
<4G6>
(1) Loosen the adjusting nut, and then move the lever
to throttle fully-closed position.
(2) Tighten the adjusting nut until the lever start to move,
turn back one turn, and then tighten the lock nut
to the specified torque.
<4G9>
(1) Loosen the adjusting bolt or adjusting nut to release
the cable.
(2) Move the plate until the inner cable play is at the
standard value, and then tighten the adjusting bolt
or adjusting nut.
(3) After adjusting, check that the throttle lever is touching
the stopper.

ENGINE AND EMISSION CONTROL - Engine Control System

17-3

ACCELERATOR PEDAL POSITION SENSOR

17100190011
CHECK
Refer to GROUP 13A - On-vehicle Service.

17-4

ENGINE AND EMISSION CONTROL - Engine Control System

ACCELERATOR CABLE AND PEDAL

17100120256

REMOVAL AND INSTALLATION

Post-installation Operation
Adjusting
the
Accelerator
P.17-2plink=17100090052.)

Cable

(Refer

to

<4G6>
<4G9 - R.H. drive vehicles>

<4G9 - L.H. drive vehicles>

4

10 Nm
5 Nm

5 Nm

2
12 Nm

3
9

<4G6>

10

10
5

12 Nm

6
7

<4G9>

8
6

Removal steps
1. Adjusting bolt or adjusting nut
2. Inner cable connection (Engine
side)
3. Inner cable connection (Pedal side)
4. Accelerator cable
5. Snap ring

11

6.
7.
8.
9.
10.
11.

Accelerator arm assembly

Spring
Pedal pad
Accelerator pedal bracket
Bushing
Accelerator pedal stopper
sub=

ENGINE AND EMISSION CONTROL - Engine Control System

ACCELERATOR PEDAL POSITION SENSOR <4G6>

17-5
17100180018

REMOVAL AND INSTALLATION

Post-installation Operation
Adjusting the Accelerator Cable (Refer to P.17-2.)

10 - 13 Nm

2
10 Nm

10 - 13 Nm

10 - 13 Nm

Removal steps
1. Inner cable connection
2. Accelerator pedal position sensor
connector
3. Accelerator pedal position sensor
assembly

4. Accelerator pedal position sensor

bracket

17-6

ENGINE AND EMISSION CONTROL -

Emission Control System

EMISSION CONTROL SYSTEM

GENERAL INFORMATION
The emission control system consists of the following subsystems:
D Crankcase emission control system
D Evaporative emission control system
D Exhaust emission control system
Items

Name

Specification

Crankcase emission
control system

Positive crankcase ventilation (PCV) valve

Variable flow type

(Purpose: HC reduction)

Evaporative emission
control system

Canister
Purge control solenoid valve

Equipped
Duty cycle type solenoid valve
(Purpose: HC reduction)

Exhaust emission
control system

Air-fuel ratio control device- GDI system

Oxygen sensor feedback type

(Purpose: CO, HC, NOx reduction)

Exhaust gas recirculation system

D EGR valve

Equipped
Stepper motor type
(Purpose: NOx reduction)

Catalytic converter

Monolith type
(Purpose: CO, HC, NOx reduction)

EMISSION CONTROL DEVICE REFERENCE TABLE

Related parts

PCV valve

Crankcase
emission
control
system

Evaporative
emission
control
system

Exhaust
gas
recirculation
system

Reference
page

17-11

GDI system component

EGR valve

Catalytic
converter

Purge control solenoid valve

Catalytic converter

Air/fuel
ratio
control
system

17-14

GROUP
13A <4G6>
GROUP
13B <4G9>

17-17

17-16

ENGINE AND EMISSION CONTROL -

Emission Control System

SERVICE SPECIFICATIONS
Items

Standard value

Purge control solenoid valve coil resistance (at 20_C) W

36 - 44

EGR valve coil resistance (at 20_C) W

10 - 20

SPECIAL TOOL
Tool

Number

Name

Use

MB991658

Test harness set

Inspection of EGR valve

VACUUM HOSE
VACUUM HOSE PIPING DIAGRAM
<4G9>
From fuel pump (low-pressure)
To fuel tank

Fuel pressure
regulator (highpressure)

PCV
valve

EGR valve
(stepper
motor)
Canister
Injector

Fuel pump (highpressure)

Oxygen sensor

Catalytic converter

Purge control
solenoid valve

17-7

17-8

ENGINE AND EMISSION CONTROL -

Emission Control System

<4G6>
From fuel pump (low-pressure)
To fuel tank

Fuel pressure regulator

(high-pressure)

P
EGR valve
(stepper
motor)
Canister

PCV valve
Injector
Purge control
solenoid valve

Fuel pump
(high-pressure)
Oxygen sensor

Catalytic converter

ENGINE AND EMISSION CONTROL -

Emission Control System

17-9

VACUUM CIRCUIT DIAGRAM

Intake manifold

Throttle body

To
combustion
chamber

Vacuum hose colour

B: Black
R: Red

From air
cleaner

Purge control
solenoid valve
(ON: OPEN)

Canister

VACUUM HOSE CHECK

1. Using the piping diagram as a guide, check to be sure
that the vacuum hoses are correctly connected.
2. Check the connection condition of the vacuum hoses,
(removed, loose, etc.) and check to be sure that there
are no bends or damage.

VACUUM HOSE INSTALLATION

1. When connecting the vacuum hoses, they should be
securely inserted onto the nipples.
2. Connect the hoses correctly, using the vacuum hose piping
diagram as a guide.

17-10

ENGINE AND EMISSION CONTROL -

Emission Control System

CRANKCASE EMISSION CONTROL SYSTEM

GENERAL INFORMATION
The crankcase emission control system prevents
blow-by gases from escaping inside the crankcase
into the atmosphere.
Fresh air is sent from the air cleaner into the
crankcase through the breather hose. The air
becomes mixed with the blow-by gases inside the
crankcase.
The blow-by gas inside the crankcase is drawn
into the intake manifold through the positive
crankcase ventilation (PCV) valve.

The PCV valve lifts the plunger according to the

intake manifold vacuum so as to regulate the flow
of blow-by gas properly. In other words, the blow-by
gas flow is regulated during low load engine
operation to maintain engine stability, while the flow
is increased during high load operation to improve
the ventilation performance.

SYSTEM DIAGRAM

Ventilation hose

PCV
valve

Breather hose

COMPONENT LOCATION
PCV valve <4G9>

PCV valve <4G6>

ENGINE AND EMISSION CONTROL -

Emission Control System

17-11

POSITIVE CRANKCASE VENTILATION SYSTEM

CHECK
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. Place a finger at the opening of the PCV valve and check

that vacuum of the intake manifold is felt.
PCV valve

NOTE
At this moment, the plunger in the PCV valve moves
back and forth.
6. If vacuum is not felt, clean the PCV valve or replace
it.

PCV VALVE CHECK

1. Insert a thin rod into the PCV valve from the side shown
in the illustration (rocker cover installation side), and move
the rod back and forth to check that the plunger moves.
2. If the plunger does not move, there is clogging in the
PCV valve. In this case, clean or replace the PCV valve.

17-12

ENGINE AND EMISSION CONTROL -

Emission Control System

EVAPORATIVE EMISSION CONTROL SYSTEM

GENERAL INFORMATION
The evaporative emission control system prevents
fuel vapours generated in the fuel tank from
escaping into the atmosphere.
Fuel vapours from the fuel tank flow through the
fuel tank pressure control valve and vapour
pipe/hose to be stored temporarily in the canister.
When driving the vehicle, fuel vapours stored in
the canister flow through the purge solenoid and
purge port and go into the intake manifold to be

sent to the combustion chamber.

When the engine coolant temperature is low or
when the intake air quantity is small (when the
engine is at idle, for example), the engine control
unit turns the purge solenoid off to shut off the
fuel vapour flow to the intake manifold.
This does not only insure the driveability when the
engine is cold or running under low load but also
stabilize the emission level.

SYSTEM DIAGRAM
Throttle body

Engine-ECU
Canister

Air flow sensor

From fuel tank

Engine coolant
temperature sensor
Purge control
solenoid valve
(ON: Open)
Control
relay

Intake air
temperature sensor
Barometric pressure
sensor

COMPONENT LOCATION
Purge control solenoid valve <4G9>

Purge control solenoid valve<4G6>

ENGINE AND EMISSION CONTROL -

17-13

PURGE CONTROL SYSTEM CHECK

<4G9>
Vacuum hose (red stripe)

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

body <4G9>, intake manifold <4G6>, and connect it to
a hand vacuum pump.
2. Plug the nipple from which the vacuum hose was removed.
3. When the engine is cold or hot, apply a vacuum of 53
kPa, and check the condition of the vacuum.
When engine is cold
(Engine coolant temperature: 40_C or less)

Plug

<4G6>

Emission Control System

Plug

Vacuum hose (red stripe)

Engine condition

Normal condition

At idle

Vacuum is maintained

3,000 r/min

When engine is hot

(Engine coolant temperature: 80_C or higher)
Engine condition

Normal condition

At idle

Vacuum is maintained

3,000 r/min (fore

approximately 3 minutes
after the engine is started.)

Vacuum will leak.

PURGE PORT VACUUM CHECK

<4G9>

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

body <4G9>, intake manifold <4G6> purge vacuum nipple
and connect a hand vacuum pump to the nipple.

Vacuum hose
(red stripe)

<4G6>

Vacuum hose (red stripe)

17-14

ENGINE AND EMISSION CONTROL -

Emission Control System

2. Start the engine and check that the vacuum remains fairly
constant after racing the engine.

Vacuum

NOTE
If vacuum changes, it is possible that the throttle body
purge port may be clogged and require cleaning.

Engine speed (r/min)

PURGE CONTROL SOLENOID VALVE CHECK

Battery

NOTE
When disconnecting the vacuum hose, always make a mark
so that it can be reconnected at original position.
1. Disconnect the vacuum hose (black stripe, red stripe)
from the solenoid valve.
2. Disconnect the harness connector.
3. Connect a hand vacuum pump to nipple (A) of the solenoid
valve (refer to the illustration at left).
4. Check airtightness by applying a vacuum with voltage
applied directly from the battery to the purge control
solenoid valve and without applying voltage.
Battery voltage

Normal condition

Applied

Vacuum leaks

Not applied

Vacuum maintained

5. Measure the resistance between the terminals of the

solenoid valve.
Standard value: 36 - 44 W (at 20_C)

ENGINE AND EMISSION CONTROL -

17-15

Emission Control System

EXHAUST GAS RECIRCULATION (EGR) SYSTEM

GENERAL INFORMATION
The exhaust gas recirculation (EGR) system lowers
the nitrogen oxide (NOx) emission level. When the
air/fuel mixture combustion temperature is high,
a large quantity of nitrogen oxides (NOx) is
generated in the combustion chamber. Therefore,
this system recirculates part of emission gas from

the exhaust port of the cylinder head to the

combustion chamber through the intake manifold
to decrease the air/fuel mixture combustion
temperature, resulting in reduction of NOx.
The EGR flow rate is controlled by the EGR valve
so as not to decrease the driveability.

OPERATION
The EGR valve is being closed and dose not
recirculate exhaust gases under one of the following
conditions. Otherwise, the EGR valve is opened
and recirculate exhaust gases.

D
D
D

The engine coolant temperature is low.

The engine is at idle.
The throttle valve is widely opened.

SYSTEM DIAGRAM
Throttle body

EGR
valve

Engine-ECU

Air flow sensor

Engine
control
relay
Battery

Engine coolant
temperature sensor

Crank angle sensor

Throttle position sensor

COMPONENT LOCATION
EGR valve <4G6>

EGR valve <4G9>

Throttle
body

Intake manifold

17-16

ENGINE AND EMISSION CONTROL -

Emission Control System

EXHAUST GAS RECIRCULATION (EGR)

CONTROL SYSTEM CHECK
Refer to GROUP 13 - Troubleshooting.

EGR VALVE (STEPPER MOTOR) CHECK

<4G9>

Checking the Operation Sound

1. Check that the operation sound of the stepper motor
can be heard from the EGR valve when the ignition switch
is turned to ON (without starting the engine).
2. If the operation sound cannot be heard, check the stepper
motor drive circuit.
Intake manifold
EGR valve

NOTE
If the circuit is normal, the cause is probably a malfunction
of the stepper motor or of the engine-ECU.

<4G6>
Throttle
body

Checking the Coil Resistance

1. Disconnect the EGR valve connector.
2. Measure the resistance between the EGR valve-side
connector terminal No.2 and terminal No.1 or terminal
No.3.
Standard value: 10 - 20 W (at 20_C)
3. Measure the resistance between the EGR valve-side
connector terminal No.5 and terminal No.4 or terminal
No.6.
Standard value: 10 - 20 W (at 20_C)

ENGINE AND EMISSION CONTROL -

17-17

Operation Check
1. Remove the EGR valve.
2. Connect the special tool (test harness set) to the EGR
valve-side connector.
3. Connect terminal No.2 and terminal No.5 to the positive
(+) terminal of power supply of approximately 6 V.
4. Connect each clip to the negative ( - ) terminal of power
supply in the order given below to test if any vibration
occurs (as though the stepper motor is shaking slightly)
due to the operation of the stepper motor.

EGR valve

Battery

Emission Control System

MB991658

(1) Connect terminal No.1 and terminal No.4 to

negative ( - ) terminal of the power supply.
(2) Connect terminal No.3 and terminal No.4 to
negative ( - ) terminal of the power supply.
(3) Connect terminal No.3 and terminal No.6 to
negative ( - ) terminal of the power supply.
(4) Connect terminal No.1 and terminal No.6 to
negative ( - ) terminal of the power supply.
(5) Connect terminal No.1 and terminal No.4 to
negative ( - ) terminal of the power supply.
(6) Repeat the test in the order from (5) to (1).

the
the
the
the
the

5. If the results of testing show that the vibration could be

felt, the stepper motor is normal.

CATALYTIC CONVERTER

17500270021

REMOVAL AND INSTALLATION

Catalytic converter

49 Nm
49 Nm

NOTES