EMISSION CONTROL SYSTEM >

PARTS LOCATION

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EMISSION CONTROL SYSTEM >

SYSTEM DIAGRAM

EMISSION CONTROL SYSTEM >

ON-VEHICLE INSPECTION

1. INSPECT FUEL CUT-OFF RPM

1. Increase the engine speed to approximately 3,000 rpm.

2. Using a sound scope, check the operation sound of the injector.

3. Release the throttle lever. Check that the operation noise stops momentarily and
then resumes.

2. VISUALLY INSPECT HOSES, CONNECTIONS AND GASKETS

1. Check that there are no cracks, leakage or scratches on the hoses, connections and
gaskets.
HINT:

Removing the oil level gauge, oil filter cap or PCV hose may cause the
engine to malfunction or stall.
Disconnections, looseness or cracks in the parts of the air induction system
between the intake system and cylinder head will allow air suction and
cause the engine to run improperly.

CANISTER > COMPONENTS

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CANISTER > ON-VEHICLE

INSPECTION

1. INSPECT CANISTER

1. Separate the purge hose.

2. Separate canister outlet hose sub-assembly No. 1.

3. Inspect the ventilation of the canister.

1. Open the fuel tank cap, apply compressed air into the purge hose and
check that the air flows out from canister outlet hose sub-assembly No. 1.

2. Open the fuel tank cap, apply compressed air into canister outlet hose subassembly No. 1 and check that the air flows out from the purge hose.

4. Inspect the check valve.

1. Open the fuel tank cap, close canister outlet hose sub-assembly No. 1 (C)
and apply compressed air into the purge hose (B).
Standard:
Air does not flow at first. By gradually increasing the pressure, air flows when the
pressure in the port reaches the specified level.

2. Open the fuel tank cap and close canister outlet hose sub-assembly No. 1
(C). Using a hand-held vacuum pump, apply a vacuum to the purge hose
(B).
Standard:
The vacuum is maintained at first. By gradually increasing the vacuum, air flows
and the vacuum decreases after the vacuum reaches the specified level.

CANISTER > REMOVAL

NOTICE:
Always use "Torx" socket wrench E10 when installing the rear seat.

1. REMOVE PACKAGE TRAY TRIM PANEL ASSEMBLY

1. Remove the 2 package tray trim suspenders.

2. Remove the 5 pieces of hook tape.
3. Disengage the 2 claws and remove the package tray trim.

2. REMOVE DECK BOARD SUB-ASSEMBLY (w/ Deck Board)

1. Release the 2 knobs and remove the deck board.

3. REMOVE SPARE WHEEL COVER ASSEMBLY (w/ Deck Board)

1. Remove the spare wheel cover.

4. REMOVE DECK FLOOR BOX (w/ Deck Board)

1. Release the 2 knobs and remove the deck floor box.

5. REMOVE REAR SEAT LEG COVER NO. 1

1. Disengage the 4 claws in the sequence shown in the illustration and remove the
No. 1 rear seat leg cover.

6. REMOVE REAR SEAT LEG COVER NO. 2

1. Disengage the 3 claws in the sequence shown in the illustration and remove the
No. 1 rear seat leg cover.

7. REMOVE REAR SEAT ASSEMBLY

1. Using "Torx" socket wrench E10, remove the 3 bolts and pull up the rear seat
cushion.

2. Using "Torx" socket wrench E10, remove the 4 bolts and the rear seat.

8. REMOVE REAR FLOOR SERVICE HOLE COVER

1. Remove the clip from the floor carpet.

2. Remove the rear floor service hole cover.

3. Disconnect the fuel pump connector.

9. DISCHARGE FUEL SYSTEM PRESSURE

()

10. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

11. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

1. Widen the tip of the tube joint clip and pull out the clip.
2. Pull the fuel tank main tube to disconnect it.
NOTICE:

Keep the O-ring free of any foreign matter, as it become contaminated

easily.
Do not use any tools in this procedure.
Do not forcefully bend or twist the tube.
Put the tube in a plastic bag to prevent damage and contamination.
If the fuel suction plate and tube are stuck together, pinch the tube and
turn it carefully to disconnect it.
Do not damage any clip. If a clip is damaged, replace it.

12. DISCONNECT FUEL EMISSION TUBE NO. 2

1. Loosen the clamp and disconnect fuel emission tube No. 2.

13. DISCONNECT CANISTER OUTLET HOSE SUB-ASSEMBLY NO. 1

1. Disconnect the canister outlet hose.

14. REMOVE FUEL PUMP GAUGE RETAINER

1. Using SST, remove the fuel pump gauge retainer.

SST
09808-14020 (09808-01410, 09808-01420, 09808-01430)
HINT:
Align the claws of the fuel pump gauge retainer and the tips of SST.

15. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY

1. Remove the fuel suction with pump and gauge tube assembly.
NOTICE:
Do not bend the arm of the sender gauge.

2. Remove the fuel suction tube gasket from the fuel tank.

CANISTER > DISASSEMBLY

1. REMOVE FUEL SENDER GAUGE ASSEMBLY

1. Disconnect the connector of the fuel sender gauge.

2. Release the lock as shown in the illustration and slide the fuel sender gauge to
remove it.

2. REMOVE FUEL PUMP

1. Disconnect the connector of the fuel pump harness.

2. Disconnect the fuel pump filter hose.

3. Using a screwdriver with its tip wrapped in protective tape, disengage the 2 claws,
remove the fuel filter and the fuel pump from the fuel sub-tank.

4. Disengage the 2 claws and remove the fuel suction support.

5. Using a screwdriver with its tip wrapped in protective tape, disengage the 5 claws,
and remove the fuel pump filter and fuel pump from the fuel filter.
NOTICE:

Do not damage the fuel pump filter.

Do not remove the suction filter.
Do not use either the fuel pump or the suction filter if the suction filter is
removed from the fuel pump.

6. Disconnect the fuel pump harness.

7. Remove the O-ring.

3. REMOVE FUEL PRESSURE REGULATOR ASSEMBLY

1. Using a screwdriver with its tip wrapped in protective tape, remove the pressure
regulator.

2. Remove the 2 O-rings.

4. REMOVE FUEL SUCTION PLATE SUB-ASSEMBLY

1. Remove the retainer ring.

2. Remove the fuel sub-tank.

3. Remove the spring.

CANISTER > REASSEMBLY

1. INSTALL FUEL SUCTION PLATE SUB-ASSEMBLY

1. Install the spring.

2. Install the fuel sub-tank.

3. Install a new retainer ring.

2. INSTALL FUEL PRESSURE REGULATOR ASSEMBLY

1. Apply gasoline to 2 new O-rings.

2. Install the pressure regulator.

3. INSTALL FUEL PUMP

1. Apply gasoline to a new O-ring, and then install it onto the fuel filter.
NOTICE:
Do not disassemble the fuel pump and the suction filter because they are
nonreusable parts.

2. Connect the fuel pump harness.

3. Engage the 5 claws of the fuel pump.

NOTICE:

Do not remove the suction filter.

Do not use either the fuel pump or the suction filter if the suction filter is
removed from the fuel pump.

4. Engage the 2 claws of the fuel suction support.

5. Engage the 2 claws of the fuel suction support and install the fuel filter and the
fuel pump onto the fuel sub-tank.

6. Connect the fuel pump filter hose.

7. Connect the connector of the fuel pump harness.

4. INSTALL FUEL SENDER GAUGE ASSEMBLY

1. Install the fuel sender gauge by sliding it downward.

2. Connect the connector of the fuel sender gauge.

CANISTER > INSTALLATION

NOTICE:
Always use "Torx" socket wrench E10 when installing the rear seat.

1. INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY

1. Install a new fuel suction tube gasket onto the fuel tank.

2. Align the protrusion of the fuel pump with the cutout of the fuel tank and install
the fuel suction with pump and gauge tube assembly.
NOTICE:
The arm of the sender gauge should not be bent.

2. INSTALL FUEL PUMP GAUGE RETAINER

1. Using SST, turn the retainer 540 clockwise from the screw starting point and
align the claw of the retainer with the matchmark on the fuel tank.
SST
09808-14020 (09808-01410, 09808-01420, 09808-01430)
NOTICE:
Replace the fuel pump gauge retainer with a new one if not installed properly.
Part No. 77144-52040
HINT:

Align the claws of the fuel pump gauge retainer and the tips of SST.
At the point where the retainer is turned 90 from the start of the thread,
push the retainer in from the opposite side to the start of the thread. Check
that the thread of the retainer is properly engaged with that on the fuel
tank.

3. CONNECT CANISTER OUTLET HOSE SUB-ASSEMBLY NO. 1

1. Connect the canister outlet hose.

4. CONNECT FUEL EMISSION TUBE NO. 2

1. Connect the fuel emission tube.

5. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

1. Insert the fuel tank main tube.

2. Install the tube joint clip.
NOTICE:

Check that there are no scratches or foreign objects on the connecting

parts.

Check that the fuel tube joint is inserted securely.

Check that the fuel tube joint clip is on the collar of the fuel tube joint.
After installing the tube joint clip, check that the fuel tube joint have not
been pulled off.
Do not damage any clip. If a clip is damaged, replace it.

6. INSTALL REAR FLOOR SERVICE HOLE COVER

1. Connect the fuel pump connector.

2. Install the rear floor service hole cover with new butyl tape.

7. INSTALL REAR SEAT ASSEMBLY

1. Insert the 2 location pins through the 2 body holes and install the rear seat.
2. Using "Torx" socket wrench E10, install the 4 bolts in the sequence shown in the
illustration.
Torque:
37 N*m{ 375 kgf*cm , 27 ft.*lbf }

3. Install the rear seat cushion.

4. Using "Torx" socket wrench E10, install the 3 bolts in the sequence shown in the
illustration.
Torque:
37 N*m{ 375 kgf*cm , 27 ft.*lbf }

8. INSTALL REAR SEAT LEG COVER NO. 2

1. Engage the 3 claws and install the No. 2 rear seat leg cover.

9. INSTALL REAR SEAT LEG COVER NO. 1

1. Engage the 4 claws and install the No. 1 rear seat leg cover.

10. INSTALL DECK FLOOR BOX (w/ Deck Board)

1. Install the deck floor box and lock the 2 knobs.

11. INSTALL SPARE WHEEL COVER ASSEMBLY (w/ Deck Board)

1. Install the spare wheel cover.

12. INSTALL DECK BOARD SUB-ASSEMBLY (w/ Deck Board)

1. Set the deck board and lock the 2 knobs.

13. INSTALL PACKAGE TRAY TRIM PANEL ASSEMBLY

1. Engage the 2 claws and install the package tray trim panel.
2. Install the 5 pieces of hook tape.
3. Install the 2 package tray trim suspenders.

14. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Torque:
5.4 N*m{ 55 kgf*cm , 48 in.*lbf }

15. CHECK FOR FUEL LEAKAGE

1. When using the intelligent tester.
1. Connect the intelligent tester to the DLC3.
2. Turn the ignition switch on (IG) and intelligent tester main switch on.
NOTICE:
Do not start the engine.
3. Select the Active Test mode on the intelligent tester.
HINT:
Refer to the intelligent tester operator's manual for further details.
2. Check that there is no fuel leakage anywhere on the fuel system after doing
maintenance.

FUEL TANK CAP > ON-VEHICLE

INSPECTION

1. INSPECT FUEL TANK CAP ASSEMBLY

1. Check that there is no deformation or damage to the fuel tank cap or gasket. If
necessary, replace the fuel tank cap.

HEATED OXYGEN SENSOR (for

Sensor 1) > COMPONENTS

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HEATED OXYGEN SENSOR (for

Sensor 1) > REMOVAL

1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

2. REMOVE HEATED OXYGEN SENSOR

1. Disconnect the heated oxygen sensor connector and clamp.

2. Using SST, remove the heated oxygen sensor.

SST
09224-00010

HEATED OXYGEN SENSOR (for

Sensor 1) > INSPECTION

1. INSPECT HEATED OXYGEN SENSOR

1. Check the resistance.

1. Using an ohmmeter, measure the resistance between the terminals.
Standard resistance:
Tester
Specified
Connection
Condition
1 (HT1A) - 2
(+B)

6 to 14 at 20C
(68F)

1 (HT1A) - 4
(E1)

10 k or higher

If the resistance is not as specified, replace the sensor.

HEATED OXYGEN SENSOR (for

Sensor 1) > INSTALLATION

1. INSTALL HEATED OXYGEN SENSOR

1. Using SST, install the heated oxygen sensor.

SST

09224-00010
Torque:
44 N*m{ 449 kgf*cm , 32 ft.*lbf }

2. Connect the heated oxygen sensor connector and clamp.

2. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Torque:
5.4 N*m{ 55 kgf*cm , 48 in.*lbf }

3. CHECK FOR EXHAUST GAS LEAKAGE

HEATED OXYGEN SENSOR (for

Sensor 2) > COMPONENTS

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HEATED OXYGEN SENSOR (for

Sensor 2) > REMOVAL

1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

2. REMOVE HEATED OXYGEN SENSOR

1. Disconnect the sensor connector and disengage the 3 clamps.

2. Using SST, remove heated oxygen sensor No. 2.

SST
09224-00010

HEATED OXYGEN SENSOR (for

Sensor 2) > INSPECTION

1. INSPECT HEATED OXYGEN SENSOR

1. Check the resistance.

1. Using an ohmmeter, measure the resistance between the terminals.
Standard resistance:
Tester
Specified
Connection
Condition
1 (HT1B) - 2
(+B)

6 to 14 at 20C
(68F)

1 (HT1B) - 4
(E1)

10 k or higher

If the resistance is not as specified, replace the sensor.

HEATED OXYGEN SENSOR (for

Sensor 2) > INSTALLATION

1. INSTALL HEATED OXYGEN SENSOR

1. Using SST, install the sensor onto the front exhaust pipe.
SST

09224-00010
Torque:
44 N*m{ 449 kgf*cm , 32 ft.*lbf }

2. Connect the sensor connector and engage the 3 clamps.

2. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Torque:
5.4 N*m{ 55 kgf*cm , 48 in.*lbf }

3. CHECK FOR EXHAUST GAS LEAKAGE

VENTILATION VALVE >

COMPONENTS

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VENTILATION VALVE > REMOVAL

1. REMOVE CYLINDER HEAD COVER NO. 2

2. DISCONNECT VENTILATION HOSE

1. Disconnect the ventilation hose.

3. REMOVE POSITIVE CRANKCASE VENTILATION VALVE (PCV VALVE)

1. Remove the positive crankcase ventilation valve (PCV valve).

VENTILATION VALVE >

INSPECTION

1. INSPECT POSITIVE CRANKCASE VENTILATION VALVE (PCV VALVE)

1. Install the hose onto the positive crankcase ventilation valve (PCV valve).

2. Check the ventilation.

1. Check the ventilation when air is applied from the cylinder head side.
Standard:
Air flows.
CAUTION:
Do not inhale the air from the ventilation valve because it is harmful.

2. Check the ventilation when air is applied from the intake manifold side.
Standard:
Air does not flow.
If the ventilation is not as specified, replace the positive crankcase
ventilation valve (PCV valve).
3. Remove the hose from the positive crankcase ventilation valve (PCV valve).

VENTILATION VALVE >

INSTALLATION

1. INSTALL POSITIVE CRANKCASE VENTILATION VALVE (PCV VALVE)

1. Install the positive crankcase ventilation valve (PCV valve).

2. CONNECT VENTILATION HOSE

1. Connect the ventilation hose.

3. INSTALL CYLINDER HEAD COVER NO. 2

DUTY VACUUM SWITCHING

VALVE > COMPONENTS

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DUTY VACUUM SWITCHING

VALVE > REMOVAL

1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

2. REMOVE PURGE VSV

1. Disconnect the purge VSV connector (a).

2. Remove the clip and disconnect fuel vapor feed hose No. 1 (b).
3. Remove the clip and disconnect fuel vapor feed hose No. 2 (c).

4. Remove the bolt and the purge VSV.

DUTY VACUUM SWITCHING

VALVE > INSPECTION

1. INSPECT PURGE VSV

1. Check the resistance.

1. Using an ohmmeter, measure the resistance between the terminals.
Standard resistance:
Tester
Specified
Connection
Condition
1-2

26 to 30 at 20C
(68F)
If the resistance is not as specified, replace the purge VSV.

2. Check the operation.

1. Check that air does not flow from port E to F.

2. Apply battery voltage across the terminals.

3. Check that air flows from port E to F.
If the operation is not as specified, replace the purge VSV.

DUTY VACUUM SWITCHING

VALVE > INSTALLATION

1. INSTALL PURGE VSV

1. Install the purge VSV with the bolt.

Torque:
8.8 N*m{ 90 kgf*cm , 78 in.*lbf }

2. Connect fuel vapor feed hose No. 1 (b) with the clip.
3. Connect fuel vapor feed hose No. 2 (c) with the clip.
4. Connect the purge VSV connector (b).

2. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Torque:
5.4 N*m{ 55 kgf*cm , 48 in.*lbf }