17-1 ENGINE AND EMISSION CONTROL CONTENTS ENGINE CONTROL SYSTEM <4G9-GDI> GENERAL . Outline of Change .. vite 2 ACCELERATOR PEDAL AUTO-CRUISE CONTROL SYSTEM <4G9-GDI> GENERAL Outline of Change : 3 GENERAL INFORMATION . SPECIAL TOOL .. TROUBLESHOOTING . ON-VEHICLE SERVICE ... AUTO-CRUISE CONTROL . EMISSION CONTROL SYSTEM <4G9> GENERAL : Outline of Changes ......... ce 19 SPECIAL TOOL . VACUUM HOSE . Vacuum Hose Piping Diagram 19 Vacuum Circuit Diagram a1 EVAPORATIVE EMISSION CONTROL SYSTEM System Diagram 22 Purge Control System Check 23, Purge Port Vacuum Check ........... 28 Purge Port Vacuum Check 23 CATALYTIC CONVERTER ..17-2 __ ENGINE AND EMISSION CONTROL - Engine Control System <4G9-GDI> ENGINE CONTROL SYSTEM <4G9-GDI> GENERAL OUTLINE OF CHANGE The service procedures have been revised due to the addition of the accelerator pedal position sensor. ACCELERATOR PEDAL REMOVAL AND INSTALLATION Post-installation Operation Chock and Adjustment ofthe Accelerator Pedal Position ‘Sensor (Refer to GROUP 13 - On-vehicle Service.) : © | leo ! , eI she a W Removal steps ra ee jsten soe o senge fect 8 pan ponte eer ‘Accelerator pedal assembly Snap ring ‘Accelerator pedal Retum spring ‘Accelerator pedal pad Bushing 10. Accelerator pedal bracket 11. Accelerator pedal stopper 12, Wide open throttle switch connector 1. Wide open throttle switch ENGINE AND EMISSION CONTROL - Auto-crutse Control System <4G9-GDI> AUTO-CRUISE CONTROL SYSTEM <4G9-GDI> GENERAL OUTLINE OF CHANGE The following service procedures have been added to correspond to the introduction of the electronically controlled throttle valve system and a built-in auto-cruise control switch, GENERAL INFORMATION By using the auto-cruise control, the driver can drive at the speed he/she likes (in a range of ‘Stop lamp switch % Throttle control Clutch switch approximately 40-200 km/h) without depressing the accelerator pedal. ‘Auto-cruise control switch NTA ean /—_ KeG/FES GG ERBEION/oF® ea oro0ss 17-3 fo | 4 L Actors cont Ss indicator lamp ponent itor sch Tree vate note Vice speed SPECIAL TOOL Teel [Rombor Name Use MUTiIadb [6 Reading diagnose codes assenbiy & Aito-eise onto system check17-4 ENGINE AND EMISSION CONTROL — Auto-cruise Controt System <4G9-aDI> TROUBLESHOOTING DIAGNOSIS FUNCTION METHOD OF READING THE DIAGNOSIS CODES WHEN USING THE MUT-II ‘Connect the MUT-II to the diagnosis connector and take a reading of the diagnosis codes. ’ Caution Turn the Ignition switch to LOCK (OFF) position before Axcess] connecting or disconnecting the MUT-II. WHEN USING THE AUTO-CRUISE CONTROL INDICATOR LAMP RESUME 1, Tum the ignition switch to ON, and then turn on the MAIN switch of the auto-cruise control switch ~ 2. Tum off the MAIN switch of the auto-cruise control switch 7 /eemagisnest gen MAIN ite: and the ignition switch, <—eonsrraerl 3. While the MAIN switch and the SET switch of the Aito-crutee contol auto-cruise control switch remain on, turn the ignition ‘witch t SET ewiteh: ON switch to ON. Then turn on the RESUME switch of the auto-cruise control switch within one second, conooss Indication of diagnosis code by the auto-crulse control indicator lamp ‘When the diagnosis code No.23 is output ‘When no diagnosis code is output T—— 05 sec. 0.5 sec - on Hy on on “UU Pause Tens Place — Units on aes Tae, gin Sa re geen tenors METHOD OF ERASING DIAGNOSIS CODES WHEN USING THE MUT-IT Connect the MUT-II to the diagnosis connector and erase the diagnosis code. Caution Turn off the Ignition switch before connecting or disconnecting the MUT- WHEN NOT USING THE MUT-IT 1. Turn the ignition switch to LOCK (OFF) position. 2. After disconnecting the battery cable from the battery (-) terminal for 10 seconds or more, reconnect the cable.ENGINE AND EMISSION CONTROL - auto-cruise Contro! System <4c9-ap> 17-5 INSPECTION CHART FOR DIAGNOSIS CODES. Code No. | Diagnosis item Reference page 18 ‘Auto-cruise control switch system 175 ~| 2 Cancel latch signal system 175 22 ‘Stop lamp switch system 176 23 Engine-ECU system [arr INSPECTION PROCEDURE FOR DIAGNOSIS CODES Code No. 15 Auto-crulse control switch system Probable cause ‘This diagnosis code is ouput the RESUME and SET ewitches of the auto-crlse | © Malfuncion of the aulo-cuisa control switch control swatch remain on ‘© Mailuncion of the connector (© Mattunction of the hares. No Texkia arieton heck the hamess belwean the eufo-cnise cont ewich and [heck wouble symptom, J throttle valve controller, and repair if necessary. Code No. 21 Cancel latch signal system Probable cause ‘The throtti valve controler and the engine-ECU send a cancel holding information |e Malfunction of the connector | {othe engine ECU va'a cancel ach signal ine andthe serial communication tne. | © Matuncton ofthe harness. ‘Tis dagosis code To output there ls afar ste cancel latch signal ine, or | © Mafunction ofthe tote vale controler a Gsaccord Inthe communieaton dela Matton of the euto-ese conva- cu No [heck the folowing connectors: 6.118, B16 = pair mG (Check vowbie ametom i? it ‘Gheckihe harness bawean he thatievalveconiralie and engine ECU, and repair f necessary. Ne engine ECU ] Fe17-6 ENGINE AND EMISSION CONTROL - Auto-cruise Control System <4G9-GDI> Code No. 22 Stop Iai mp switch system Probable cause the stop lamp switch output “This diagnosis code i output when the thtie valve contrllr detects a fale in | » Malfunction of the connector or harness wire ‘© Mallunetion of the slop lamp switch 1 Maitunetion of the theatte valve controter (Be he sop laps Marinate nomali? }No—+[ Gheck the stop lamp creu — Yoo "Disconnect the connector (1) Vottage between 25 and Pig No continually (Stop lamp ©. (Stop lamp switch: OFF) System voltage (Stop lamp switch: ON) @) Canty betnean 2s ard Boy ear Continuity (Stop lamp swith: ON) asus at the tattle valve contvller connector 6-118. ](1)NG__,[ Check the following connectors: ‘end measure a the hamess sie, body garth ‘suteh> OFF) (ane B43, 8-113, B18 OK Ne Repair Check trouble Symptons, NG Measure at engine-ECU connector 6116. foK NG "Disconnect the connector and measure at the hemes side, ‘© Voltage between 63 and body earth OK: 0.V (Stop lamp switch: OFF) ‘System voltage (Stop lam FI P witch: ON) “Check the trot valve cniralier and top lamp avch, and repel W nooessary. ‘Check the following B18, 8113, B43, B7EX Check trouble eympiom. i ‘Check the harness between the trate valva controler and stp lamp switch, and earth, and repair I necessary. OK Tote vave controler ‘ac th harass between te eage-EOU and he Sop ‘switch, and repair it sary. % sop lameENGINE AND EMISSION CONTROL - auto-cruise Control System <469-GDI> 17-7 Code No. 23 Engine-ECU system Probable cause This diagnosis code i ouput i the engie-EGU system i dolecive es folows ‘Communication error between the thie valve controle and the engine-ECU ‘ Maifunction of te thrttle postion sensor Maitunction of the accelerator pedal postion sensor Mattuncion of the thottie control servo 1 _Maitunetion of the vehicle speed sensor "© Malluncion of the connector © Mallunction of the hamese ‘© Mattunction of the engine ECU arty out the toubleshooting regarding the GDI syslom, UTI Sell-Diag code lear" Confirm diagnosis code regarding the GOI system, iagnosis. | (oter to GROUP. 12 iar egerding Syst Capris | foto G ) I "No Diagnosis code output Foplace the engine ECU INSPECTION CHART FOR TROUBLE SYMPTOMS Trouble symplom Inspection | Reference page procedure No. ‘Communication with MUTI is not possible. 1 178 ‘Auto-cruise control is | Even if brake pedal is depressed 2 178 not cancelled . Even if clutch pedal is depressed 3 179 Even if select lever is set to N range 4 179 Even if CANCEL switch is set to ON 5 1740 ‘Auto-ctuise control cannot be set. 6 17-10 Hunting (repeated acceleration and deceleration) oocurs atthe set vehicle speed. | 7 wit When the MAIN switch of the auto-cruise control ewitch is tured on, the | 8 wait auto-cruise control indicator lamp does not illuminate. (However, the auto-cruise Control is normal}17-8 ENGINE AND EMISSION CONTROL - Auto-cruise Contro! System <4G9-GDI> INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS Inspection Procedure 1 ‘Communication with MUT-I Is not possible. Probable cause Tithe MUTI can not loo communicate with the systems other than the GOI system, ‘the dlagnosis tne crcult may be defective If the MUTT can not communicate with ‘only the GOI system and the auto-cuise contol system, the harness wie between {the ongine-ECU and the diagnosis connecter, may be defective, Imadaiion, Ifthe the MUTI can not communicate with ony the autocruse control system, the auto-crulse control ewitoh erout may be defective Malfunction of the connector or harness ‘auto-crise contra switch ‘Gan the MUTI communicate with the other eystema (except the GDI system)? | No__ Refer o GROUP 18) — Trodbesnoaing {mapection procedure 1) he No ‘Check the auto-crlsa coro! switch Input signal (Refer to inspection Procedure 8, P.17-12) Inspection Procedure 2 | 8°___. Refer to GROUP 1a) ~ Troubleshooting Anapection procedure 2) ‘Auto-crulse control can not be cancel even If brake pedal Is depressed. Probable cause “The cause is probably a malfunction ofthe stop lamp switch, or the stop lamp cou. ‘aifunction of the connector or the harness Maifuncion of the siop lamp switch Matfunetion of the tote valve controller Matfunction of the engine-ECU. Follow the INSPECTION PROGEDURE FOR DIAGNOSIS CODE No. 22 ~ Stop lamp switch system (Refer to P.17-6)ENGINE AND EMISSION CONTROL - auto-cruise Control System <4c9-cp> 17-9 Inspection Procedure 3 Even if clutch pedal Is depressed, auto-crulse control is | Probable cause not cancelled. ‘The cause Ie probably a malfunction of cuich ewitch or etch ewtch ereul atfunation of the eutch switch Malfunction of the connector Matfunetion of the harness © Malunction of the tote valve controller No ([Ghaten swatch check a y* No — Waasire al clutch avtch connector 6-07 ee "Disconnect the connector and measure atthe harness side, © Continuity between terminal (1) and body eeh OK: ‘Continuity ‘Check (rouble eympiom Ne | Check the following connectors: [NS Repair Boot, B13, B18 _ OK { Check the hamess between the lich switch and body earth ‘and repair I necessary ‘Check trouble symptom NG _ i ‘Check the hamess betwoon the clutch ewitch andthe tvatiavalva |=» Replace tho trottie valve cont contrat ~ JN Ropalr Inspection Procedure 4 Even if select lever is set to N rangi Is not cancelled. The cause Is probably a defective inhibor switch okul. uuto-crulse control | Probable cause "© Malfuncion of the connector or harness Malfunction of the Init switch Mattuncion of the trate valve controller Check the following connector AS38118 OK 0K (Gheck toxtie sme jo rch [ Rovlace tie Grote veive conroler————]17-10 ENGINE AND EMISSION CONTROL ~ auto-cruise Control System <4G9-GOI> Inspection Procedure 5 Even if auto-cruise control CANCEL switch auto-cruise control Is not cancelled. ‘set to ON, Probable cause ‘The cause le probably en open-croult in the clout inside the CANCEL ewitch Maltuncion of ‘auto-erise control ewitch aplace the aulo crise contol wich. J Inspection Procedure 6 ‘Auto-crulse control cannot be set. Probable cause Yes —— (eter 10 178) ————— 111" —»[INSPECTIONCHART FOR DIAGNOSIS CODES (RefertoP.17-5) “The cause ls probably thatthe fal-sfefurcion i cancaling auto-cuise contol | » Mallunaton ofthe auo-culse consol evtch inthis cave, the MUTI can be used to check the ouble symptoms n each system | ® Mathncton ofthe herrasses or comectors By inapecing the dagnosla codes. The MUTI can alga ba used fo check ho | © Matunction of the conta sweh Chouts of ea Input Sule are normal or not by nepecing the Input switch codes. | © Maltin of the tte valve controler Maitnction of the engine COU. —_ NO [[Gar the ecio-cnise conic! communicate withthe MUTI? —}~°——e{ Follow inapecon procedure for wouble aympiom No.1 Replace the throtie valve controller (Grea woubio symptoms. ~ +8 (1) Is a diagnosis code regarding the auto-cuise contrat output fs n diagnosis code rearing the GDI system oupu? | 2s a cecaanctng rgung the GOT atom No (Rotor to GROUP 131) No ——_ MOTT Data Tet [NS check the contol switch Input syatar 02 SET swite {inspection procedure 8. P.17-12) OK WOT Data tt NG Follow inepediion procedures for Waibie sympiom Nos. 3 of 4] 7 Giutch switch or inhibitor switch eter 10 P179) Pe — _—» [Replace te engine ECU.ENGINE AND EMISSION CONTROL - auto-crui 17-11 Controt System <4G9-GDI> Inspection Procedure 7 at the set vehicle speed. Hunting (repeated acceleration and deceleration) occurs Probable cause “The cause Is probably a malfunction of vehicle speed sensar or thotle contol serv. In'elher case, a clagnosis code regarding the GDI system must be confirmed. Malluncion of the connector end hamess Maltunction of the venice speed sensor Maliunction of the throttle control evo Malfunction of the tattle valve controler Maifunetion of the engine-£0U Yeo ‘MUT-I Selt-Diag code: Is a diagnosis code regarding tho GDI systom output? yr [Feiace a Trot |= x. Fottow the troubleshooting regarding the GOI systom (Reter to GROUP 13), ([Ghecie one aympiome— Inspection Procedure 8 |So—+-[Repiace the engine EU, When the MAIN switch of the auto-cruise control switch Is turned on, the auto-crulse control Indicator lamp does not Illuminate. (However, the auto-crulse control is normal.) Probable cause lamp creat, “There may be a bumi-out bulb or @ malfunction ofthe auto-rulse canal indicator ‘© Burni-out bulb Mattuncion of the connector end harness Mattuneion of the engine-£0U [Faio-cze corral nicaor lamp bub ches ican Wensure at combination rater connector 6-05, Disconnect the connector and measure at the harness side, Ignition switch: ON © Vattage between ter ‘OK: “System votage inal (82) and body earth OK Check trouble symptom ‘Check the hamess between the J/B and the combination met and repar i necessary. Weasure a engine ECU connector 6-1 ct fe connecter and measure at the harness side, Ignition ‘stch: ON. Voltage between terminal (28) and body earth {Check th following connectors: BOS O18, atte fox NG Repair ( Check route aymton, — NG ‘Check te hamess beiwean he combinallon meler andthe engine17-12 ENGINE AND EMISSION CONTROL - auto-crui Controt System <4G9-GDI> Inspection Procedure 9 ‘Auto-cruise control switch input system check No ‘Ruto-crulse conivol éwitch check (Refer to P1718) - > —~ repiece fox Ne Glock spring check (Refer to GROUP 828) o> replace |NS__.[ Check the following connectors: 6-62, 655, 6-50, 653 | ‘Disconnect the connector end measure ai the hamess sie, Ignition switch: ON ok {No + Vatage between termina (1) and body oath Repair OK ‘Check trouble symptom. NG Check the harness between theignition itch and the auto-cruse contol switch, © Disconnect the connector and measure al the hamess sid, ® Ignition switch and euto-cruise control MAIN switch: ON Weasure al Uvatie valve controler connector BT. NS_.- Cheek the following connectors: B62, 659, 6118, B10 OK eo © Votage between terminal (12) and body earth Repair Ok: “System voltage [Greek touble symptom SSSS~*Y Ns ssa ao jo-orise contol ewlich and] fro vote vale tortor end fpar recess) # "Disconnect the connector and measure atthe hamess side Ignition switch and euto-cruise contol MAIN and CANCEL | ng switches: ON [NS __.Fcheck the following connectors: 662, B69, 6113, 6116 | + Vollage between terminal (10) and body earth 7 ne Ok: “System votsge 3 1 Repair oK iace the tote valve controle DATA LIST REFERENCE TABLE For the data, which is input to the throttle valve controller and the engine-ECU, the following be read out by using the MUT-II. HOW TO READ OUT DATA LIST 1, Connect the MUT-I to the 16. Caution ‘Turn the Ignition switch to LOCK (OFF) position before connecting and disconnecting the MUT-IT. Turn the ignition switch to ON, and then turn on the auto-cruise control MAIN switch. Select “auto-cruise control” on the MUT-II menu, and then read out the data list.ENGINE AND EMISSION CONTROL 17-13 Controt System <4G9-GDI> position sensor (2nd channel) Item No. | Check item ‘Check conditions Normal condition ot ‘Auto. [MAIN | MAIN switch: ON ‘ON cruise control MAIN switch: OFF OFF oo |W Ser SET switch: ON ‘ON SET switch: OFF OFF 03 RESUME | RESUME switch: ON ON 7 RESUME switch: OFF OFF om ‘CANCEL | CANCEL switch: ON ON ‘CANCEL switch: OFF OFF 05 Stop lamp switch | Brake pedal: Depressed ON - Brake pedal: Released OFF 06 Stop lamp switch | Brake pedal: Depressed OFF | Brake pedal: Released _ 07 Clutch switch | Clutch pedal: Depressed - Clutch pedal: Released OFF Inhibitor switch Selector lever: N position ON | Selector lever: Other than N position OFF 08 ‘Accelerator pedal | Accelerator pedal: Released ON position switeh — 7 ‘Accelerator pedal: Depressed OFF 09 ‘Auto-cruise control | Auto-cruise control Activated ON ‘Auto-cruise control: No activated OFF 10 | Vehicle speed Fooad test the vehicle The speedometer and sensor the MUT-II display the same value. 1 Throttle position ‘Accelerator pedal: Released 450 - 800 mV sensor (Ist channel) ‘Accelerator pedal: Depressed The more deeply the pedal is depressed, the higher value the MUT-IL displays ‘Accelerator pedal: Fully depressed 4,200 - 4,200 mV 2 ‘Accelerator pedal | Accelerator pedal: Released 995 - 1,135 mV ‘Accelerator pedal: Depressed Accelerator pedal: Fully depressed The more deeply the pedal is depressed, the higher value the MUT-IL displays 4,000 mV or more17-14 ENGINE AND EMISSION CONTROL - auto-cruise Controt System <4G9-GDi> CHECK AT THE THROTTLE VALVE CONTROLLER TERMINALS lralas|tel Terminal | Check item | Check conditions Normal condition No. 1 Throttle con | Ignition ewitch: ON Value changes tol servo | Accelerator peal Fully depested poston to related poston ) @ Throttle con- trol servo (B+) 14 Throttle con- ‘tol servo (A) 15 Throttle con- trol servo @) 2 Throttie con- | Ignition switch: ON ‘System voltage trol servo power supply 3,4, 16 | Earth = ov 5 Power supply | Ignition switch: ON ‘System voltage 6 Sensor power | Ignition switch: ON 45-55V supply 7 Throttle posi- | Ignition switch: ON Accelerator pedal: Released | 0.4-0.8V tion sensor (istehannel Accelerator pedal: Fully de- | 42-49V pressed 10 ‘Auto-cruise | Ignition switch: ON ‘SET switch: ON ‘Approximately 3 V control switch | MAIN switch: ON RESUME switch: ON ‘Approximately 6 V ‘CANCEL switch: ON System voltage ‘Al swishes: OFF ov 1 Clutch switch | Ignition switch: ON ~~T Clutch pedal: Depressed | 0V }— 7 _| ‘Clutch pedal: Released 8-14V Inhibitor lgnition switch: ON Selector lever. N or P [OV switch position Selector lever: Other than | 8-14V the above 2 ‘Auto-cruise | Ignition switch: ON MAIN switch: ON ‘System voltage control switch | een MAIN switch: OFF ov 17 | Sensorearth | - ovENGINE AND EMISSION CONTROL - auto-cruise Control System 17-15 Terminal | Check item | Check conditions: Normal condition No. 20 ‘Accelerator | Ignition switch: ON ‘Accelerator pedal: Released | 0.9-1.2V pedal position sensor ‘Accelerator pedal: Fully 4V or more (2nd channel) depressed 22 Ignition, Ignition switch: ON System voltage switch (1G) 23 ‘Auto-cruise | Auto-cruise control: Activated ov ccontrol cancel a latch signal | Auto-cruise control: Not activated System voltage 25 Stop lamp | Brake pedal: Depressed System voltage switch ~ Brake pedal: Released ov 26 ‘Stop lamp —_| Ignition switch: ON Brake pedal: Depressed | OV switch Brake pedal: Released ‘System voltage17-16 ENGINE AND EMISSION CONTROL - Auto-cruise Control System <4G9- ACC7RES ) LC CREB oWorr COAST SET Auto-cruise ‘control switch onooss Auto-cruise ‘xo indicator lamp Coxsrrser ON-VEHICLE SERVICE ‘The other items than the below are the same as the ones for 4G9-MPI. AUTO-CRUISE CONTROL SWITCH CHECK AUTO-CRUISE MAIN SWITCH CHECK 1. Tum the ignition key to ON. 2. Check to be sure that the indicator lamp within the combination meter illuminates when the MAIN switch is switched ON. AUTO-CRUISE CONTROL SETTING 1. Switch ON the MAIN switch. 2 Drive at the desired speed within the range of approximately 40 - 200 km/h. 3. Push the auto-cruise control switch in the direction of arrow (B). 4. Check to be sure that when the switch is released the speed is the desired constant speed. NOTE If the vehicles speed decreases to approximately 15 km/h below the set speed because of climbing a hill for example, 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 is hold, and that when it is released the constant speed at the 'time when it was released becomes the driving speed. NOTE Acceleration can be continued even if the vehicle speed has passed the high-speed limit (approx. 200 km/h). But the speed when the auto-cruise control switch is released will be recorded as the high-speed limi.ENGINE AND EMISSION CONTROL - auto-cruise Control system _ 17-17 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 ‘switch is pressed, and that when itis released the constant speed at the time when it was released becomes the driving speed. NOTE When the vehicle speed reaches the low limit (approximately 40 km/h) during deceleration, the auto-cruise control will be cancelled. RETURN TO THE SET SPEED BEFORE CANCELLATION AND AUTO-CRUISE CONTROL CANCELLATION 1. Set the auto-cruise speed control. 2. When any of the following operations are performed while at constant speed during auto-cruise control, check if normal 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 ¢. The clutch pedal is depressed. d._ The selector lever is moved to the "N* range. 3. When the auto-cruise control switch is pushed in the direction of arrow (A) at a vehicle speed of 40 km/h or higher, check if the vehicle speed retums to the speed before auto-cruise control driving was cancelled, and constant speed driving occurs. 4. When the MAIN switch is turned to OFF while driving at constant speed, check if normal driving is resumed and deceleration occurs.17-18 ENGINE AND EMISSION CONTROL - Auto-cruise Contro! System <4G9-GDI> INSPECTION AUTO-CRUISE CONTROL AUTO-CRUISE CONTROL SWITCH CHECK Measure the resistance between the terminals when each ofthe SET, RESUME, CANCEL and MAIN switches is pressed. If the values measured at this time correspond to those in the table below, then there is no problem. ‘Switch position __| Resistance between terminals ‘Switch OFF No continuity CANCEL ‘switch: | Terminals 1 and3 | Approx. 3.9 kQ Terminals 2and3 | Approx02 | PRESUME switch: | Terminals t and | Approx. 4.8 k@ oN Terminals 2 and3_| Approx. 910 2 ‘SET switch: ON | Terminals 1 and3 | Approx. 4.1 k& Terminals 2 and 3_| Approx. 2208 MAIN switch: ON Terminals 1 and 2 Approx. 39 KOENGINE AND EMISSION CONTROL - Emission Contro! System <4G9> 17-19 EMISSION CONTROL SYSTEM <4G9> GENERAL OUTLINE OF CHANGES The service procedures have been revised due to the following changes: The purge port vacuum characteristics has been changed . The purge port nipple has been relocated . © The catalytic converter has been changed. SPECIAL TOOL Too! ‘Number | Name Use MD998770 | Oxygen sensor | Removalinstallalion of oxygen sensor “oO wrench VACUUM HOSE VACUUM HOSE PIPING DIAGRAM Ax leone: trankease ‘etision a iPey —= : Fuel pressure regulator < D-pec. ‘vebices for Germanys, Fogen | sensor EGR valve Canister EGR control Purge contro! solenoid valve solencidvaive | |, Catalyie |= Catalytic converter aFu096117-20 ENGINE AND EMISSION CONTROL - Emission Control System <4G9> From fuel pump (low pressure) To fuel tank tt J High pressure fuel eguiatorassembly Positive ‘crankcase ventilation a) valve. = Fuel pump (high pressure) Throttle control servo Air cleaner i ae EGR vale (Stepper motor) Canister Purge control solenoid valve Oxygen sensor Catalytic convertor (Loan NOx + three-way) 9Fuog33ENGINE AND EMISSION CONTROL — Emission contro! System <4G9> VACUUM CIRCUIT DIAGRAM Intake manifold Throttlebody Purge control solenold valve (ON: OPEN) ‘Vacuum hose colour Br Black W604BAE17-22 EVAPORATIVE EMISSION CONTROL SYSTEM DIAGRAM ENGINE AND EMISSION CONTROL - emission Control System SYSTEM Engine-ECU ‘coolant smperature sensor Intake air temperature sensor Py Barometric pressure sensor Thott body Fromvltank Canister Purpeconwel fama vane Open) Cont aay - eatoy [= Tote body Canister From{ueltank pt Purge contro! solenoid valve (ON' Open) \ Ato snr a Fe ea Intake air temperature sensor Barometric pressure sensor gS prosoure some cexce78ENGINE AND EMISSION CONTROL - Emission Control System <4Go> 17-23 Vacuum hose (ed stripe) WoOL1AY, Purge por vacuum nipple Engine spaed (cmin) ‘vacuum nipple We012Ay. PURGE CONTROL SYSTEM CHECK 1. Disconnect the vacuum hose (red stripe) from the intake manifold, and connect it to a hand vacuum pump. 2. Plug the nipple from which the vacuum hose was removed. 3. When the engine is cold or hot, apply a vacuum of 53 kPa, and check the condition of the vacuum. When engine Is cold (Engine coolant temperature: 40°C or less) Engine condition Normal condition Atide ‘Vacuum is maintained 3,000 r/min When engine is hot (Engine coolant temperature: 80°C or higher) Engine condition Normal condition Atidle ‘Vacuum is maintained {3,000 r/min (fore Vacuum will leak, approximately 3 minutes after the engine is started.) PURGE PORT VACUUM CHECK 1, Disconnect the vacuum hose (red stripe) from the throttle body purge vacuum nipple and connect a hand vacuum pump to the nipple. 2. Start the engine and check that the vacuum remains fairly constant after racing the engine, NOTE If vacuum changes, it is possible thal the throttle body purge port may be clogged and require cleaning. PURGE PORT VACUUM CHECK 1. Disconnect the vacuum hose (red stripe) from the intake manifold purge vacuum nipple and connect a hand vacuum pump to the nipple.17-24 _ ENGINE AND EMISSION CONTROL - Emission contro! System <4G9> Vacuum 2. Start the engine and check that the vacuum remains fairly constant after racing the engine. NOTE if vacuum changes, it is possible that the intake manifold purge port may be clogged and require cleaning, Engine speed (cmin) agpENGINE AND EMISSION CONTROL - Emission Control system 17-25, CATALYTIC CONVERTER REMOVAL AND INSTALLATION Pro-removal and Post-installation Operation Under Cover Removal and Installation 13. Nm s0 wm 8> | ae | oe | 49. Nm 49-59Nm 4 ‘AXO040BN Removal steps Am PAK 1. Oxygen sensor 7. Front exhaust pipe 2. Selt-locking nut & Front exhaust pipe bracket 3. Gasket 9. Hunger 4, Front catalytic converter 10: SolMocking nut 11. Gasket 5. Bolt 12. Catalytic converter 6. Gasket17-26 ENGINE AND EMISSION CONTROL lon Control System <4G9> ‘AxOD41BN Removal steps A PA 1 Onygen sensor 7. Front exhaust pipe bracket 2. Selflocking nut 8. Hunger 3. Gasket 9. Sel-locking nut 4. Bolt 10. Gasket 5. Gasket 11, Catalytic converter 6. Front exhaust pipe REMOVAL SERVICE POINT <4Ap OXYGEN SENSOR REMOVAL INSTALLATION SERVICE POINT >A OXYGEN SENSOR INSTALLATION MD998770