ENGINE

EMISSION CONTROL SYSTEMS

EG121

EXHAUST GAS RECIRCULATION (EGR) SYSTEM (4AFE)

EGR SYSTEM INSPECTION

1. INSPECT AND CLEAN FILTER IN EGR VACUUM MODULATOR (a) Remove the cap and filter. (b) Check the filter for contamination or damage. (c) Using compressed air, clean the filter. (d) Reinstall the filter and cap. HINT: Install the filter with the coarser surface facing the atmospheric side (outward).

2. INSTALL VACUUM GAUGE Using a 3way connector, connect a vacuum gauge to the hose between the EGR valve and EGR vacuum modulator. 3. INSPECT SEATING OF EGR VALVE Start the engine and check that the engine starts and runs at idle.

4. CONNECT TERMINALS TE1 AND E1 OF DATA LINK CONNECTOR 1 Using SST, connect terminals TE1 and E1 of the data link connector 1. SST 0984318020 5. INSPECT VSV OPERATION WITH COLD ENGINE (a) The engine coolant temperature should be below 47C (117F). (b) Check that the vacuum gauge indicates zero at 2,500 rpm. 6. INSPECT OPERATION OF VSV AND EGR VACUUM MODULATOR WITH HOT ENGINE (a) Warm up the engine to above 53C (127F). (b) Check that the vacuum gauge indicates low vacuum at 2,500 rpm.

EG122

ENGINE

EMISSION CONTROL SYSTEMS

(c) Disconnect the vacuum hose from port R of the EGR vacuum modulator and connect port R directly to the intake manifold with another hose. (d) Check that the vacuum gauge indicates high vacuum at 2,500 rpm. HINT: As a large amount of exhaust gas enters, the engine will misfire slightly. 7. REMOVE VACUUM GAUGE Remove the vacuum gauge, and reconnect the vacuum hoses to the proper locations. 8. INSPECT EGR VALVE (a) Apply vacuum directly to the EGR valve with the engine idling. (b) Check that the engine runs rough or dies. (c) Reconnect the vacuum hoses to the proper locations. 9. REMOVE SST FROM DATA LINK CONNECTOR 1 SST 0984318020 IF NO PROBLEM IS FOUND WITH THIS INSPECTION, SYSTEM IS NORMAL; OTHERWISE INSPECT EACH PART

VSV INSPECTION
1. REMOVE VSV

2. INSPECT VSV A. Inspect VSV for open circuit Using an ohmmeter, check that there is continuity between the terminals. Resistance: At 205 C (885 F): 37 44 W If there is no continuity, replace the VSV.

B. Inspect VSV for ground Using an ohmmeter, check that there is no continuity between each terminal and the body. If there is continuity, replace the VSV.

ENGINE

EMISSION CONTROL SYSTEMS

EG123

C. Inspect VSV operation (a) Check that air flows from port E to the filter.

(b) Apply battery voltage across the terminals. (c) Check that air does not flow from port E to the filter. If operation is not as specified, replace the VSV. 3. REINSTALL VSV

EGR VACUUM MODULATOR INSPECTION

INSPECT EGR VACUUM MODULATOR OPERATION (a) Disconnect the vacuum hoses from ports P, Q and R of the EGR vacuum modulator. (b) Block ports P and R with your finger. (c) Blow air into port Q, and check that the air passes through to the air filter side freely. (d) Start the engine, and maintain speed at 2,500 rpm. (e) Repeat the above test. Check that there is a strong resistance to air flow. (f) Reconnect the vacuum hoses to the proper locations.

EG124

ENGINE

EMISSION CONTROL SYSTEMS

COMPONENTS FOR EGR VALVE REMOVAL AND INSTALLATION

EGR VALVE REMOVAL

1. REMOVE AIR CLEANER HOSE AND CAP (a) Disconnect the IAT sensor connector. (b) Loosen the air cleaner hose clamp bolt. (c) Disconnect the 4 air cleaner cap clips. (d) Disconnect the air cleaner hose from the throttle body, and remove the air cleaner cap together with the air cleaner hose.

ENGINE

EMISSION CONTROL SYSTEMS

EG125

2. DISCONNECT ACCELERATOR CABLE BRACKET FROM THROTTLE BODY 3. DISCONNECT THROTTLE BODY FROM AIR INTAKE CHAMBER (See throttle body removal in MFI/SFI System) 4. REMOVE ENGINE HANGER, AIR INTAKE CHAMBER STAY AND EGR VACUUM MODULATOR (a) Disconnect the EGR hose and vacuum hose from the EGR valve. (b) Remove the 2 bolts, and disconnect the air pipe and fuel inlet hose. (c) Remove the nut, engine hanger, air intake chamber stay, EGR vacuum modulator and gasket.

6. REMOVE EGR VALVE AND PIPE (a) Loosen the union nut of the EGR pipe.

(b) Disconnect the vacuum hose from the EGR valve. (c) Disconnect the EGR gas temperature sensor connector.

(d) Remove the 4 nuts, EGR valve and pipe. (e) Remove the 2 gaskets.

EG126

ENGINE

EMISSION CONTROL SYSTEMS

EGR VALVE INSPECTION

INSPECT EGR VALVE Check for sticking and heavy carbon deposits. If a problem is found, replace the valve.

EGR VALVE INSTALLATION

1. INSTALL EGR VALVE AND PIPE (a) Install a new gasket to the cylinder head, facing the protrusion downward. (b) Install a new gasket to the EGR valve and pipe with the 4 nuts.
Torque: 13 Nm (130 kgfcm, 9 ftlbf)

(c) Connect the EGR gas temperature sensor connector. (d) Connect the vacuum hose to the EGR valve. (e) Tight the union nut of the EGR valve.
Torque: 59 Nm (600 kgfcm. 43 ftlbf)

2. INSTALL AIR INTAKE CHAMBER STAY, EGR VACUUM MODULATOR AND ENGINE HANGER (a) Place a new gasket to the intake manifold, facing the protrusion downward.

(b) Install the air intake chamber stay, EGR vacuum modulator and engine hanger with the nut.
Torque: 28 Nm (290 kgfcm, 21 ftlbf)

(c) Connect the air pipe and fuel inlet hose with the 2 bolts. (d) Connect the EGR hose and vacuum hose to the EGR valve. 3. CONNECT THROTTLE BODY (See throttle body Installation In MFI/SFI System) 4. CONNECT ACCELERATOR CABLE BRACKET TO THROTTLE BODY
Torque: 11 Nm (115 kgfcm, 8 ftlbf)

6. INSTALL AIR CLEANER HOSE AND CAP (a) Connect the air cleaner hose to the throttle body. (b) Install the air cleaner cap together with the air cleaner hose. (c) Connect the IAT sensor connector.