NS/GS EMISSION CONTROL SYSTEM 25 - 1

EMISSION CONTROL SYSTEM

CONTENTS

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EMISSION CONTROL SYSTEM ON-BOARD DIAGNOSTICS

2.0L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . 9 2.5L DIESEL ENGINE . . . . . . . . . . . . . . . . . . . 1
EXHAUST EMISSION CONTROLS
2.5L DIESEL ENGINE . . . . . . . . . . . . . . . . . . . 5

ON-BOARD DIAGNOSTICS2.5L DIESEL ENGINE

INDEX
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GENERAL INFORMATION DESCRIPTION AND OPERATION

SYSTEM DESCRIPTION DIAGNOSTIC TROUBLE CODES . . . . . . . . . . . . 2
2.5L DIESEL ENGINE . . . . . . . . . . . . . . . . . . . 1

GENERAL INFORMATION MONITORED CIRCUITS

The PCM can detect certain problems in the elec-
SYSTEM DESCRIPTION2.5L DIESEL ENGINE trical system.
The 2.5L diesel Powertrain Control Module (PCM) Open or Shorted Circuit The PCM can deter-
monitors and controls many different circuits in the mine if sensor output (which is the input to PCM) is
fuel injection pump and engine systems. If the PCM within proper range. It also determines if the circuit
senses a problem with a monitored circuit that indi- is open or shorted.
cates an actual problem, a Diagnostic Trouble Code Output Device Current Flow The PCM senses
(DTC) will be stored in the PCMs memory, and even- whether the output devices are electrically connected.
tually will illuminate the Diesel Glow Plug lamp con- If there is a problem with the circuit, the PCM
stantly while the key is on. If the problem is senses whether the circuit is open, shorted to ground
repaired, or is intermittent, the PCM will erase the (), or shorted to (+) voltage.
DTC after 40 warm-up cycles. A warm-up cycle con-
sists of starting the vehicle when the engine is cold, NONMONITORED CIRCUITS
then the engine to warms up to a certain tempera- The PCM does not monitor the following circuits,
ture, and finally, the engine temperature falls to a systems or conditions that could have malfunctions
normal operating temperature, then the key is that result in driveability problems. A DTC will not
turned off. be displayed for these conditions.
Certain criteria must be met for a DTC to be Fuel Pressure: Fuel pressure is controlled by the
entered into PCM memory. The criteria may be a fuel injection pump. The PCM cannot detect prob-
specific range of engine rpm, engine or fuel tempera- lems in this component.
ture and/or input voltage to the PCM. A DTC indi- Cylinder Compression: The PCM cannot detect
cates that the PCM has identified an abnormal uneven, low, or high engine cylinder compression.
signal in a circuit or the system. A DTC may indicate Exhaust System: The PCM cannot detect a
the result of a failure, but never identify the failed plugged, restricted or leaking exhaust system.
component directly. Fuel Injector Malfunctions: The PCM cannot
There are several operating conditions that the determine if the fuel injector is clogged, or the wrong
PCM does not monitor and set a DTC for. Refer to injector is installed. The fuel injectors on the diesel
the following Monitored Circuits and NonMonitored engine are not controlled by the PCM, although a
Circuits in this section.
25 - 2 EMISSION CONTROL SYSTEM NS/GS
GENERAL INFORMATION (Continued)
defective fuel injector sensor is monitored by the or the system. A DTC may indicate the result of a
PCM. failure, but most likely will not identify the failed
Vacuum Assist: Leaks or restrictions in the vac- component directly.
uum circuits of vacuum assisted engine control sys-
tem devices are not monitored by the PCM. ACCESSING DIAGNOSTIC TROUBLE CODES
PCM System Ground: The PCM cannot deter- A stored DTC can be displayed through the use of
mine a poor system ground. However, a DTC may be the DRB III scan tool. The DRB III connects to the
generated as a result of this condition. data link connector. The data link connector is
PCM Connector Engagement: The PCM cannot located under the instrument panel near bottom of
determine spread or damaged connector pins. How- the steering column (Fig. 1).
ever, a DTC may be generated as a result of this con-
dition.

HIGH AND LOW LIMITS

The PCM compares input signal voltages from each
input device. It will establish high and low limits
that are programmed into it for that device. If the
input voltage is not within specifications and other
DTC criteria are met, a DTC will be stored in mem-
ory. Other DTC criteria might include engine rpm
limits or input voltages from other sensors or
switches. The other inputs might have to be sensed
by the PCM when it senses a high or low input volt-
age from the control system device in question.

DESCRIPTION AND OPERATION

Fig. 1 Data Link Connector LocationTypical
DIAGNOSTIC TROUBLE CODES ERASING TROUBLE CODES
On the following pages, a list of DTCs is provided After the problem has been repaired, use the DRB
for the 2.5L diesel engine. A DTC indicates that the III scan tool to erase a DTC.
PCM has recognized an abnormal signal in a circuit

Generic Scan DRB III Scan Tool Display

Tool Code
P1112 Boost Pressure Sensor Signal High
Boost Pressure Sensor Signal Low
Boost Pressure Sensor Supply High
Boost Pressure Sensor Supply Low
Boost Pressure Sensor Plausibility
P0110 Intake Air Temperature Sensor Signal High
Intake Air Temperature Sensor Signal Low
P1685 Immobilizer Signal Lost
Invalid SKIM Message
P0115 Temperature of Engine Coolant SRC High Exceeded
Temperature of Engine Coolant SRC Low Exceeded
P0180 Fuel Temperature Sensor SRC High Exceeded
Fuel Temperature Sensor SRC Low Exceeded
P0400 EGR Open Circuit
EGR Short Circuit
P0500 Vehicle Speed Sensor PEC Frequency Too High
Vehicle Speed Sensor Signal SRC High Exceeded
NS/GS EMISSION CONTROL SYSTEM 25 - 3
DESCRIPTION AND OPERATION (Continued)

Generic Scan DRB III Scan Tool Display

Tool Code
P0725 Engine Speed Sensor Dynamic Plausibility
Engine Speed Sensor Over Speed Recognition
Engine Speed Sensor Static Plausibilty
P1105 Atmospheric Pressure Sensor SRC High Exceeded
Atmospheric Pressure Sensor SRC Low Exceeded
P1201 Needle Movement Sensor SRC High Exceeded
Needle Movement Sensor SRC Low Exceeded
P1220 Fuel Quantity Actuator Neg. Gov. Deviation Cold
Fuel Quantity Actuator Neg. Gov. Deviation Warm
Fuel Quantity Actuator Pos. Gov. Deviation Cold
Fuel Quantity Actuator Pos. Gov. Deviation Warm
P1225 Control Sleeve Sensor Signal High Exceeded
Control Sleeve Sensor Start End Pos. Not Attained
Control Sleeve Sensor Stop End Pos. Not Attained
P1230 Timing Governing Negative Governor Deviation
Timing Governing Positive Governor Deviation
P1515 Accelerator Pedal Sensor Signal High Exceeded
Accelerator Pedal Sensor Signal Low Exceeded
Accelerator Pedal Sensor Signal PWG Plaus With Low Idle Switch
Accelerator Pedal Sensor Signal PWG Plaus With Potentiometer
P1600 Battery Voltage SRC High Exceeded
P1605 Terminal #15 Plausibility After Startup
P1610 Regulator Lower Regulator Limit
Regulator Upper Regulator Limit
P1615 Microcontroller Gate-Array Monitoring
Microcontroller Gate-Array Watchdog
Microcontroller Prepare Fuel Quantity Stop
Microcontroller Recovery Was Occurred
Microcontrller Redundant Overrun Monitoring
P1630 Timing Solenoid Valve Controller Open Circuit
Timing Solenoid Valve Controller Short Circuit
P1635 Glow Relay Controller Open Circuit
Glow Relay Controller Short Circuit
P1650 Diagnostic Lamp Open Circuit
Diagnostic Lamp Short Circuit
P1655 A/C Control Short Circuit
A/C Control Open Circuit
P1660 Redundant Emer. Stop Plausibility In After-Run
Redundant Emer Stop Powerstage Defective
P1665 Cruise Status Indicator Lamp Short Circuit
P1680 EEPROM Plausibility Checksum Error for Adj.
EEPROM Plausibility Checksum Error in CC212
EEPROM Plausibility Communication With EEPROM
EEPROM Plausibility Func. Switch Wrong or Missing
25 - 4 EMISSION CONTROL SYSTEM NS/GS
DESCRIPTION AND OPERATION (Continued)

Generic Scan DRB III Scan Tool Display

Tool Code
EEPROM Plausibility Ver Number Not Corresponding
P1685 Vehicle Theft Alarm Code Line Breakdown
P1690 Fan Control Open Circuit Fan #1
Fan Control Open Circuit Fan #2
Fan Control Short Circuit Fan #1
Fan Control Short Circuit Fan #2
P1695 A/C System Pressure Sensor Signal High Exceeded
A/C System Pressure Sensor Signal Low Exceeded
A/C System Pressure Supply Signal High Exceeded
A/C System Pressure Supply Signal Low Exceeded
P1703 Brake Signal Plaus With Redundant Contact
P1740 Clutch Signal Plausibilty
P1725 Inductive Aux. Speed Sensor Dynamic Plausibilty
Inductive Aux. Speed Sensor Overspeed Recognition
Inductive Aux Speed Sensor Plausibilty
Inductive Aux. Speed Sensor Static Plausibilty
NS/GS EMISSION CONTROL SYSTEM 25 - 5

EXHAUST EMISSION CONTROLS2.5L DIESEL ENGINE

INDEX
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DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION

EXHAUST GAS RECIRCULATION (EGR) EGR TUBE . . . . . . . . . . . . . . . . . . . . . . . . ..... 7
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . ..... 5 EGR VALVE . . . . . . . . . . . . . . . . . . . . . . . ..... 7
VACUUM HOSE ROUTING SCHEMATIC . ..... 5 ELECTRIC VACUUM MODULATOR (EVM) ..... 7
DIAGNOSIS AND TESTING SPECIFICATIONS
EGR GAS FLOW TEST . . . . . . . . . . . . . . ..... 6 TORQUE CHART2.5L DIESEL . . . . . . . ..... 8
ELECTRIC VACUUM MODULATOR (EVM)
TEST . . . . . . . . . . . . . . . . . . . . . . . . . . ..... 7

DESCRIPTION AND OPERATION EXHAUST GAS RECIRCULATION (EGR) SYSTEM

VACUUM HOSE ROUTING SCHEMATIC GENERAL INFORMATION
Vacuum for the EGR system is supplied by the The EGR system reduces oxides of nitrogen (NOx)
internal engine mounted vacuum pump. Refer to in the engine exhaust. This is accomplished by allow-
EGR System Operation for vacuum pump informa- ing a predetermined amount of hot exhaust gas to
tion. Vacuum harness routing for emission related recirculate and dilute the incoming fuel/air mixture.
components is displayed in (Fig. 1). A malfunctioning EGR system can cause engine
stumble, sags or hesitation, rough idle, engine stall-
ing and poor driveability.

EGR SYSTEM OPERATION

The system consists of:
An EGR valve assembly. The valve is located
behind the intake manifold (Fig. 2).

Fig. 1 Typical Hose Routing

Fig. 2 EGR Valve and Tube Location

25 - 6 EMISSION CONTROL SYSTEM NS/GS
DESCRIPTION AND OPERATION (Continued)
An EGR Solenoid. The EGR solenoid is located
in the engine compartment next to the PDC (Fig. 3).
The EGR solenoid opens and closes the vaccum sup-
ply that opens and closes the EGR valve. The
amount of time the EGR solenoid is held open is con-
trolled by the PCM. This is referred to as the on
time of the EGR valve.

Fig. 4 Internal Vacuum Pump

The engine is running to operate the vacuum
pump.
A ground signal is supplied to the EVM.
Vacuum passes to the EGR valve.
The inlet seat (poppet valve) at the bottom of
the EGR valve opens to dilute and recirculate
Fig. 3 EGR Solenoid exhaust gas back into the intake manifold.
An EGR tube (Fig. 2) connecting a passage in The EGR system will be shut down by the PCM
the EGR valve to the rear of the exhaust manifold. after 60 seconds of continuous engine idling to
The vacuum pump, which supplies vacuum for improve idle quality.
the EGR Solenoid valve. This pump also supplies
vacuum for operation of the power brake booster. The DIAGNOSIS AND TESTING
pump is located internally in the front of the engine
block (Fig. 4) and is driven by the crankshaft gear. EGR GAS FLOW TEST
Vacuum lines and hoses to connect the various Use the following test procedure to determine if
components. exhaust gas is flowing through the EGR valve. It can
When the PCM supplies a on or off signal to the also be used to determine if the EGR tube is plugged,
EGR Solenoid by grounding the circuit, EGR system or the system passages in the intake or exhaust man-
operation starts to occur. The PCM will monitor var- ifolds are plugged.
ious engine conditions and determine when to supply This is not to be used as a complete test of the
and remove this ground signal. Some of the engine EGR system.
conditions that are monitored are the engine coolant The engine must be started, running and warmed
temperature, throttle position and engine speed sen- to operating temperature for this test.
sors. (1) All EGR valves are equipped with a vacuum
When the ground signal is supplied to the EGR supply fitting located on the EGR valve vacuum
Solenoid, vacuum from the vacuum pump will be motor (Fig. 2).
allowed to pass to the EGR valve via a connecting (2) Disconnect the rubber hose from the vacuum
hose. supply fitting (Fig. 2).
Exhaust gas recirculation will begin in this order (3) Connect a handheld vacuum pump to this fit-
when: ting.
The PCM determines that EGR system opera- (4) Start the engine.
tion is necessary.
NS/GS EMISSION CONTROL SYSTEM 25 - 7
DIAGNOSIS AND TESTING (Continued)
(5) Slowly apply 10 inches of vacuum to the fitting (5) Remove the two EGR valve mounting bolts
on the EGR valve motor. Vacuum should hold steady (Fig. 2) and remove EGR valve.
at 10 inches. If not, replace the EGR valve. If vac- (6) Discard both of the old EGR mounting gaskets.
uum holds steady at 10 inches, proceed to next step.
(6) While applying vacuum, and with the engine INSTALLATION
running at idle speed, the idle speed should drop, a (1) Clean the intake manifold of any old gasket
rough idle may occur, or the engine may even stall. material.
This is indicating that exhaust gas is flowing through (2) Clean the end of EGR tube of any old gasket
the EGR tube between the intake and exhaust man- material.
ifolds. (3) Position the EGR valve and new gasket to the
(7) If the engine speed did not change, the EGR intake manifold.
valve may be defective, the EGR tube may be (4) Install two EGR valve mounting bolts. Do not
plugged with carbon, or the passages in the intake tighten bolts at this time.
and exhaust manifolds may be plugged with carbon. (5) Position new gasket between EGR valve and
(a) Remove EGR valve from engine. Refer to EGR tube.
EGR Valve Removal in this group. (6) Install two EGR tube bolts. Tighten all four
(b) Apply vacuum to the vacuum motor fitting mounting bolts to 23 Nm (204 in. lbs.).
and observe the stem on the EGR valve. If the (7) Tighten EGR tube fitting at exhaust manifold.
stem is moving, it can be assumed that the EGR (8) Connect vacuum line to EGR valve.
valve is functioning correctly. The problem is in (9) Install the rubber hose from turbocharger to
either a plugged EGR tube or plugged passages at metal tube.
the intake or exhaust manifolds. Refer to step (c).
If the stem will not move, replace the EGR valve. EGR TUBE
(c) Remove the EGR tube between the intake The EGR tube connects the EGR valve to the rear
and exhaust manifolds. Check and clean the EGR of the exhaust manifold (Fig. 2).
tube and its related openings on the manifolds.
Refer to EGR Tube in this group for procedures. REMOVAL
Do not attempt to clean the EGR valve. If the (1) Remove rubber hose from turbocharger to
valve shows evidence of heavy carbon buildup near metal tube.
the base, replace it. (2) Remove two EGR tube mounting bolts at EGR
valve end of tube (Fig. 2).
ELECTRIC VACUUM MODULATOR (EVM) TEST (3) Loosen fitting at exhaust manifold end of tube
(Fig. 2).
VACUUM TEST (4) Remove EGR tube and discard old gasket.
With the engine running, disconnect the vacuum (5) Clean gasket mating surfaces and EGR tube
supply line at the fitting on the EVM. Minimum vac- flange gasket surfaces.
uum should be no less than 20 inches. If vacuum is (6) Check for signs of leakage or cracked surfaces
lower, check for leaks in vacuum supply line. If leaks at both ends of tube, exhaust manifold and EGR
cannot be found, check for low vacuum at vacuum valve.
pump. Refer to Group 5, Brake System for proce-
dures. INSTALLATION
(1) Install a new gasket to EGR valve end of EGR
tube.
REMOVAL AND INSTALLATION (2) Position EGR tube to engine.
(3) Loosely tighten fitting at exhaust manifold end
EGR VALVE of tube.
(4) Install 2 mounting bolts at EGR valve end of
REMOVAL tube. Tighten bolts to 23 Nm (204 in. lbs.) torque.
(1) Remove the rubber hose from turbocharger to (5) Tighten fitting at exhaust manifold end of tube.
metal tube. (6) Install hose from turbocharger to metal tube.
(2) Disconnect vacuum line at EGR valve vacuum
supply fitting (Fig. 2). ELECTRIC VACUUM MODULATOR (EVM)
(3) Loosen the tube fitting at exhaust manifold end The EVM (EGR Duty Cycle Purge Solenoid) is
of EGR tube (Fig. 2). mounted to the side of the PDC (Fig. 6).
(4) Remove the two bolts retaining the EGR tube
to the side of EGR valve (Fig. 2).
25 - 8 EMISSION CONTROL SYSTEM NS/GS
REMOVAL AND INSTALLATION (Continued)
REMOVAL INSTALLATION
(1) Disconnect both cables from battery, negative (1) Install electrical connector to EVM.
cable first. (2) Install EVM and tighten mounting screws.
(2) Remove 2 screws holding PDC to bracket, (3) Connect vacuum hoses.
swing out of way. (4) Install PDC to bracket and tighten mounting
(3) Remove nut and clamp holding battery to bat- screws.
tery tray (Fig. 5). (5) Install battery.
(6) Connect battery cables positive first.

Fig. 5 Battery Clamp

Fig. 6 EVM Location
(4) Remove battery from vehicle.
(5) Disconnect two vacuum hoses at EVM (Fig. 6). SPECIFICATIONS
(6) Remove mounting screws of EVM.
(7) Remove the EVM to gain access to the EVM TORQUE CHART2.5L DIESEL
electrical connector.
(8) Remove electrical connector at EVM. Description Torque
EGR Valve Mounting Bolts . . . . . . . . . . . . . . 23 Nm
(204 in. lbs.)
EGR Tube Mounting Bolts . . . . . . . . . . . . . . 23 Nm
(204 in. lbs.)
EVM (Electric Vacuum
Modulator) Mounting Bolt . . . . 2 Nm (20 in. lbs.)
NS/GS EMISSION CONTROL SYSTEM 25 - 9

EMISSION CONTROL SYSTEM2.0L ENGINE

INDEX
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GENERAL INFORMATION REMOVAL AND INSTALLATION

GENERAL INFORMATION . . . . . . . . . . . . . . . . . 9 EGR TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
POSITIVE CRANKCASE VENTILATION SYSTEM EGR VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
(PCV) SYSTEM2.0L ENGINE . . . . . . . . . . . . 9 TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

GENERAL INFORMATION The PCV System for 2.0L engines function the
same as PCV systems for 2.4/3.0/3.3/3.8L engines.
GENERAL INFORMATION Refer to group 25 for more information.
The emission control system for the 2.0L engine
functions the same as the systems for the 2.4/3.0/3.3/
REMOVAL AND INSTALLATION
3.8L engines. Refer to group 25 for more information
about Diagnostic Trouble Codes and other system
EGR VALVE
features.
If the EGR system operates incorrectly, replace the
entire EGR valve and transducer together. The EGR
POSITIVE CRANKCASE VENTILATION SYSTEM
valve and electrical transducer (EET) are calibrated
(PCV) SYSTEM2.0L ENGINE together.

REMOVAL
The EGR valve attaches to the rear of the cylinder
head (Fig. 2). EGR transducer is attached to the air
inlet duct.
(1) Remove EGR transducer from air inlet duct.
(2) Disconnect vacuum supply tube from EGR
transducer solenoid.
(3) Disconnect electrical connector from solenoid.
(4) Remove air inlet duct.
(5) Remove EGR tube to EGR valve screws.
(6) Remove EGR valve mounting screws. Remove
EGR valve and transducer.
(7) Clean gasket surfaces. Discard old gaskets. If
necessary, clean EGR passages.

Fig. 1 PCV System2.0L

25 - 10 EMISSION CONTROL SYSTEM NS/GS
REMOVAL AND INSTALLATION (Continued)
INSTALLATION (3) Remove EGR tube. Clean gasket surface on the
(1) Loosely install EGR valve with new gaskets. EGR valve. Wipe clean the grommet on the intake
(2) Finger tighten EGR tube fasteners. manifold.
(3) Tighten EGR tube fasteners to 11 Nm (95 in.
lbs.) torque.
(4) Tightening EGR valve mounting screws to 22
Nm (200 in. lbs.) torque.
(5) Install air inlet duct.
(6) Connect vacuum supply tube to solenoid.
(7) Attach electrical connector to solenoid.
(8) Install EGR transducer onto air inlet duct.

Fig. 3 EGR Tube Stud Bolts

INSTALLATION
The rubber grommet that seals the EGR tube to
intake manifold connection is reusable.
(1) Loosely install the EGR tube and fasteners.
(2) Tighten the EGR tube to intake manifold ple-
num screws to 11 Nm (95 in. lbs) torque.
Fig. 2 EGR System (3) Tighten the EGR tube to EGR valve screws to
11 Nm (95 in. lbs.) torque.
EGR TUBE
The EGR tube attaches to the intake manifold ple- TORQUE
num below the throttle body and EGR valve.
Description Torque
REMOVAL EGR valve to cyl. head . . . . . . . 22 Nm (200 in. lbs.)
(1) Remove screws attaching EGR tube to intake EGR tube to EGR valve . . . . . . . . . . . 11 (95 in. lbs.)
manifold (Fig. 3). EGR tube to intake manifold . . . 11 Nm (95 in. lbs.)
(2) Remove EGR tube to EGR valve screws.