FORESTER 20MY PubNo: G8270BE Version: 006

EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO) > General Description　

COMPONENT

1. CANISTER, PURGE CONTROL SOLENOID VALVE, DRAIN FILTER AND LEAK CHECK VALVE ASSEMBLY

For components of canister, purge control solenoid valve, drain filter and leak check valve assembly, refer to FU (H4DO). FUEL INJECTION (FUEL SYSTEMS)(H4DO)>General Description>COMPONENT

2. EXHAUST GAS RECIRCULATION CONTROL CIRCUIT RANGE/PERFORMANCE

(1)	EGR pipe adapter	(8)	EGR cooler	Tightening torque: N·m (kgf-m, ft-lb)
(2)	Gasket	(9)	Stud bolt	T1:	5 (0.5, 3.7)
(3)	Gasket	(10)	Clip	T2:	6.4 (0.7, 4.7)
(4)	O-ring	(11)	Water hose	T3:	19 (1.9, 14.0)
(5)	EGR pipe	(12)	Gasket	T4:	EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO)>EGR Cooler>INSTALLATION
(6)	EGR control valve	(13)	Stud bolt
(7)	Gasket

3. PCV SYSTEM 1

(1)	PCV connector	(3)	O-ring	Tightening torque: N·m (kgf-m, ft-lb)
(2)	O-ring			T:	6.4 (0.7, 4.7)

4. PCV SYSTEM 2

(1)	PCV hose No. 1	(3)	PCV hose No. 2	Tightening torque: N·m (kgf-m, ft-lb)
(2)	PCV valve	(4)	Clip	T:	23 (2.3, 17.0)

EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO) > General Description　

CAUTION

When performing service operation, refer to “Repair Contents” in “General Description”. REPAIR CONTENTS>Repair Contents
Prior to starting work, pay special attention to the following:
1. Always wear work clothes, a work cap, and protective shoes. Additionally, wear a helmet, protective goggles, etc. if necessary.
2. Protect the vehicle using a seat cover, fender cover, etc.
3. Prepare the service tools, clean cloth, containers to catch grease and oil, etc.
Prevent scattering of grease and oil. If it scatters, wipe it off immediately to prevent it from penetrating the floor or flowing out, to protect the environmental.
If the grease and oil is spilt over the engine, exhaust pipe or the under cover, completely wipe it off to avoid emission of smoke or causing a fire.
Vehicle components are extremely hot immediately after driving. Be wary of receiving burns from heated parts.
When performing a repair, identify the cause of trouble and avoid unnecessary work.
Before disconnecting connectors of sensors or units, be sure to disconnect the ground terminal from the battery sensor.
Always use the jack-up point when the lifting device, shop jacks or rigid racks are used to support the vehicle.
Before starting works, remove dirt and corrosion around the target area.
Keep the removed parts in order and protect them from dust and dirt.
All removed parts, if to be reused, should be reinstalled in the original positions with attention to the correct directions, etc.
For the parts except for the non-reusable parts, replace then with new parts if necessary.
Be sure to tighten bolts and nuts to the specified torque.

EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO) > General Description　

PREPARATION TOOL

1. SPECIAL TOOL

ILLUSTRATION	TOOL NUMBER	DESCRIPTION	REMARKS
	—	SUBARU SELECT MONITOR 4	Used for setting of each function and troubleshooting for electrical system. For detailed operation procedures, refer to “Help” of application.

2. GENERAL TOOL

TOOL NAME	REMARKS
TORX^® E8	Used for removing and installing EGR control valve stud bolts.
Circuit tester	Used for measuring resistance, voltage and current.

EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO) > Front Catalytic Converter　

REMOVAL

The front catalytic converter is integrated into the front exhaust pipe; therefore, refer to “Front Exhaust Pipe” for the removal procedure. EXHAUST(H4DO)>Front Exhaust Pipe>REMOVAL

EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO) > Front Catalytic Converter　

INSTALLATION

The front catalytic converter is integrated into the front exhaust pipe; therefore, refer to “Front Exhaust Pipe” for the installation procedure. EXHAUST(H4DO)>Front Exhaust Pipe>INSTALLATION

EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO) > Front Catalytic Converter　

INSPECTION

The front catalytic converter is integrated into the front exhaust pipe; therefore, refer to “Front Exhaust Pipe” for the inspection procedure. EXHAUST(H4DO)>Front Exhaust Pipe>INSPECTION

EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO) > Rear Catalytic Converter　

REMOVAL

The rear catalytic converter is integrated into the front exhaust pipe; therefore, refer to “Front Exhaust Pipe” for the removal procedure. EXHAUST(H4DO)>Front Exhaust Pipe>REMOVAL

EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO) > Rear Catalytic Converter　

INSTALLATION

The rear catalytic converter is integrated into the front exhaust pipe; therefore, refer to “Front Exhaust Pipe” for the installation procedure. EXHAUST(H4DO)>Front Exhaust Pipe>INSTALLATION

EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO) > Rear Catalytic Converter　

INSPECTION

The rear catalytic converter is integrated into the front exhaust pipe; therefore, refer to “Front Exhaust Pipe” for the inspection procedure. EXHAUST(H4DO)>Front Exhaust Pipe>INSPECTION

EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO) > Canister　

REMOVAL

1.

Remove the rear differential. DIFFERENTIALS>Rear Differential (VA-type)>REMOVAL

This operation procedure would be possible by simply lowering the rear differential to the position that the work is possible. In that case, it is not necessary to pull out the drive shaft from the rear differential.

2.

Disconnect the drain tube (A) and purge tube (B).

Drain tube:

FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Delivery and Evaporation Lines>REMOVAL > QUICK CONNECTOR DISCONNECTION (TYPE F)

Purge tube:

FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Delivery and Evaporation Lines>REMOVAL > QUICK CONNECTOR DISCONNECTION (TYPE E)

3.

Disconnect the vent tube (C). FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Delivery and Evaporation Lines>REMOVAL > QUICK CONNECTOR DISCONNECTION (TYPE G)

4.

Remove the canister.

5.

Disconnect the purge tube from the canister. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Delivery and Evaporation Lines>REMOVAL > QUICK CONNECTOR DISCONNECTION (TYPE D)

6.

Remove the canister bracket.

EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO) > Canister　

INSTALLATION

1.

Install the canister bracket.

Tightening torque:

8 N·m (0.8kgf-m, 5.9ft-lb)

2.

Connect the purge tube to the canister. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Delivery and Evaporation Lines>INSTALLATION > QUICK CONNECTOR CONNECTION (TYPE D)

3.

Install the canister.

Tightening torque:

8 N·m (0.8kgf-m, 5.9ft-lb)

4.

Connect the drain tube (A) and purge tube (B).

Drain tube:

FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Delivery and Evaporation Lines>INSTALLATION > QUICK CONNECTOR CONNECTION (TYPE F)

Purge tube:

FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Delivery and Evaporation Lines>INSTALLATION > QUICK CONNECTOR CONNECTION (TYPE E)

5.

Connect the vent tube (C). FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Delivery and Evaporation Lines>INSTALLATION > QUICK CONNECTOR CONNECTION (TYPE G)

6.

Install the rear differential. DIFFERENTIALS>Rear Differential (VA-type)>INSTALLATION

EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO) > Canister　

INSPECTION

1.

Check that the canister has no deformation, cracks or other damages.

2.

Check that the tube has no cracks, damage or loose part.

EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO) > Purge Control Solenoid Valve　

REMOVAL

1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Remove the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>REMOVAL

3.

Remove the clip from the air intake boot, and loosen the clamp.

4.

Remove the air intake boot, and place it aside so that it does not interfere with the work.

Be careful not to pull out the PCV hose.

5.

Disconnect the connector (A), and disconnect the purge hose (B).

6.

Disconnect the vacuum hose (C) from the intake manifold assembly, and remove the vacuum hose (C) from the clip (D).

7.

Remove the bolt securing the purge control solenoid valve, and remove the purge control solenoid valve.

8.

Remove the purge control solenoid valve bracket.

9.

Remove the vacuum hose from the purge control solenoid valve.

EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO) > Purge Control Solenoid Valve　

INSTALLATION

1.

Connect the vacuum hose to the purge control solenoid valve.

2.

Install the purge control solenoid valve bracket.

Tightening torque:

12 N·m (1.2kgf-m, 8.9ft-lb)

3.

Install the purge control solenoid valve.

Tightening torque:

6.4N·m (0.7kgf-m, 4.7ft-lb)

4.

Connect the vacuum hose (C) to the intake manifold assembly, and install the vacuum hose (C) to the clip (D).

5.

Connect the purge hose (B), and connect the connector (A).

6.

Install the air intake boot. INTAKE (INDUCTION)(H4DO)>Air Intake Boot>INSTALLATION

7.

Install the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>INSTALLATION

8.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO) > Purge Control Solenoid Valve　

INSPECTION

1. UNIT INSPECTION

1.

Check that the purge control solenoid valve has no deformation, cracks or other damages.

2.

Measure the resistance between the purge control solenoid valve terminals.

Terminal No.	Standard
1 and 2	24.5±1.5 Ω (when 20°C (68°F))

3.

Check that air does not come out from (B) when air is blown into (A).

4.

Connect the battery positive terminal to the terminal No. 1 and the battery negative terminal to the terminal No. 2. Check that air is discharged from (B), when supplying air to (A).

2. ON THE VEHICLE INSPECTION

1.

Disconnect purge hose (A) and vacuum hose (B).

2.

Check that air does not come out from (B) when air is blown into (A).

3.

Connect the Subaru Select Monitor to the vehicle.

4.

Turn the ignition switch to ON. (Engine OFF)

5.

Perform “CPC Solenoid” in “Active Test”. ENGINE (DIAGNOSTICS)(H4DO)>Active Test

Turn ON and OFF the purge control solenoid valve repeatedly during the active test.

6.

Check that air comes out from (B), then stops coming out, and this cycle repeats while air is being blown into (A).

3. OTHER INSPECTIONS

Check the purge hose and vacuum hose for cracks, clogging, damage or looseness.

EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO) > EGR Control Valve　

REMOVAL

1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Remove the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>REMOVAL

3.

Remove the clip from the air intake boot, and loosen the clamp.

4.

Remove the air intake boot, and place it aside so that it does not interfere with the work.

Be careful not to pull out the PCV hose.

5.

Loosen the bolts holding the EGR cooler to the cylinder head RH.

6.

Remove the EGR pipe. EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO)>EGR Pipe>REMOVAL

7.

Remove the PCV hose No. 1. EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO)>PCV Hose>REMOVAL > PCV HOSE NO. 1

8.

Remove the purge control solenoid valve. EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO)>Purge Control Solenoid Valve>REMOVAL

9.

Disconnect the connector.

10.

Remove the nuts securing the EGR cooler, and remove the stud bolts using TORX^® E8.

11.

Remove the EGR control valve from the intake manifold assembly.

12.

Remove the EGR control valve from the EGR pipe adapter.

EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO) > EGR Control Valve　

INSTALLATION

1.

Set a new gasket and install the EGR control valve to the EGR pipe adapter.

Tightening torque:

19 N·m (1.9kgf-m, 14.0ft-lb)

2.

Install the EGR control valve to the intake manifold assembly.

Tightening torque:

19 N·m (1.9kgf-m, 14.0ft-lb)

3.

Set a new gasket, and install the stud bolts using TORX^® E8.

Tightening torque:

5 N·m (0.5kgf-m, 3.7ft-lb)

4.

Install the nuts securing the EGR cooler.

Tightening torque:

19 N·m (1.9kgf-m, 14.0ft-lb)

5.

Connect the connector.

6.

Install the purge control valve. EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO)>Purge Control Solenoid Valve>INSTALLATION

7.

Attach the PCV hose No. 1. EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO)>PCV Hose>INSTALLATION > PCV HOSE NO. 1

8.

Install the EGR pipe. EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO)>EGR Pipe>INSTALLATION

9.

Tighten the bolts holding the EGR cooler to the cylinder head RH.

Tightening torque:

6.4N·m (0.7kgf-m, 4.7ft-lb)

10.

Install the air intake boot. INTAKE (INDUCTION)(H4DO)>Air Intake Boot>INSTALLATION

11.

Install the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>INSTALLATION

12.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO) > EGR Control Valve　

INSPECTION

1.

Check that the EGR control valve has no deformation, cracks or other damages.

2.

Measure the resistance between EGR control valve terminals.

Terminal No.	Standard
2 and 1	15±2 Ω
2 and 3	15±2 Ω
5 and 4	15±2 Ω
5 and 6	15±2 Ω

EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO) > EGR Pipe　

REMOVAL

1.

Remove the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>REMOVAL

2.

Remove the clip from the air intake boot, and loosen the clamp.

3.

Remove the air intake boot, and place it aside so that it does not interfere with the work.

Be careful not to pull out the PCV hose.

4.

Remove the bolts securing the throttle body to the intake manifold assembly, and tilt the throttle body to the rear side of vehicle.

5.

Remove the bolts securing the EGR pipe to the intake manifold assembly and EGR control valve, and remove the EGR pipe.

EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO) > EGR Pipe　

INSTALLATION

1.

Use a new gasket and install the EGR pipe to the intake manifold assembly and EGR control valve.

Tightening torque:

6.4N·m (0.7kgf-m, 4.7ft-lb)

2.

Install the throttle body. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Throttle Body>INSTALLATION

3.

Install the air intake boot. INTAKE (INDUCTION)(H4DO)>Air Intake Boot>INSTALLATION

4.

Install the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>INSTALLATION

EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO) > EGR Pipe　

INSPECTION

Check that the EGR pipe has no deformation, cracks or other damages.

EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO) > EGR Cooler　

REMOVAL

1.

Drain engine coolant. COOLING(H4DO)>Engine Coolant>REPLACEMENT > DRAINING OF ENGINE COOLANT

2.

Remove the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>REMOVAL

3.

Remove the clip from the air intake boot, and loosen the clamp.

4.

Remove the air intake boot, and place it aside so that it does not interfere with the work.

Be careful not to pull out the PCV hose.

5.

Disconnect the water hose (A), water hose (B) and the water hose (C).

6.

Remove the nuts and bolts which secure the EGR cooler to the EGR control valve and cylinder head RH, and remove the EGR cooler.

7.

Remove the gasket from the stud bolt.

8.

Disconnect the water hose (A).

Perform this procedure only when required.

9.

Remove the stud bolt.

Perform this procedure only when required.

EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO) > EGR Cooler　

INSTALLATION

1. WHEN THE WHOLE EGR SYSTEM IS NOT REMOVED

If the engine coolant is spilt over the engine or the exhaust pipe, completely wipe it off to avoid emission of smoke or causing a fire.

EGR system consists of EGR control valve, EGR pipe, EGR cooler.

1.

Install the stud bolt.

Tightening torque:

6.4N·m (0.7kgf-m, 4.7ft-lb)

2.

Connect the water hose (A).

3.

Set new gasket to the stud bolt.

4.

Set the EGR cooler, and temporarily tighten the nuts and bolts securing the EGR cooler to the EGR control valve and cylinder head RH.

5.

Tighten the nuts and bolts securing the EGR cooler in the numerical order shown in the figure.

Tightening torque:

T1: 9 N·m (0.9kgf-m, 6.6ft-lb)

T2: 19 N·m (1.9kgf-m, 14.0ft-lb)

T3: 6.4N·m (0.7kgf-m, 4.7ft-lb)

6.

Connect the water hose (A), water hose (B) and the water hose (C).

7.

Install the air intake boot. INTAKE (INDUCTION)(H4DO)>Air Intake Boot>INSTALLATION

8.

Install the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>INSTALLATION

9.

Fill engine coolant. COOLING(H4DO)>Engine Coolant>REPLACEMENT > FILLING OF ENGINE COOLANT

2. WHEN THE WHOLE EGR SYSTEM IS REMOVED

If the engine coolant is spilt over the engine or the exhaust pipe, completely wipe it off to avoid emission of smoke or causing a fire.

EGR system consists of EGR control valve, EGR pipe, EGR cooler.

1.

Install the stud bolts to the EGR control valve using TORX^® E8.

Tightening torque:

5 N·m (0.5kgf-m, 3.7ft-lb)

2.

Using a new gasket, install the EGR pipe adapter.

Tightening torque:

19 N·m (1.9kgf-m, 14.0ft-lb)

3.

Using a new gasket, install the EGR pipe.

Tightening torque:

6.4N·m (0.7kgf-m, 4.7ft-lb)

4.

Using a new O-ring, install to the intake manifold assembly.

Tightening torque:

T1: 6.4N·m (0.7kgf-m, 4.7ft-lb)

T2: 19 N·m (1.9kgf-m, 14.0ft-lb)

5.

Connect the connector.

6.

Install the purge control valve. EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO)>Purge Control Solenoid Valve>INSTALLATION

7.

Attach the PCV hose No. 1. EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO)>PCV Hose>INSTALLATION > PCV HOSE NO. 1

8.

Install the throttle body. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Throttle Body>INSTALLATION

9.

Install the stud bolt.

Tightening torque:

6.4N·m (0.7kgf-m, 4.7ft-lb)

10.

Connect the water hose (A).

11.

Set new gasket to the stud bolt.

12.

Set the EGR cooler, and temporarily tighten the nuts and bolts securing the EGR cooler to the EGR control valve and cylinder head RH.

13.

Tighten the nuts and bolts securing the EGR cooler in the numerical order shown in the figure.

Tightening torque:

T1: 9 N·m (0.9kgf-m, 6.6ft-lb)

T2: 19 N·m (1.9kgf-m, 14.0ft-lb)

T3: 6.4N·m (0.7kgf-m, 4.7ft-lb)

14.

Connect the water hose (A), water hose (B) and the water hose (C).

15.

Install the air intake boot. INTAKE (INDUCTION)(H4DO)>Air Intake Boot>INSTALLATION

16.

Install the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>INSTALLATION

17.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

18.

Fill engine coolant. COOLING(H4DO)>Engine Coolant>REPLACEMENT > FILLING OF ENGINE COOLANT

EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO) > EGR Cooler　

INSPECTION

1.

Check that the EGR cooler has no deformation, cracks or other damages.

2.

Check that the hose has no cracks, damage or loose part.

EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO) > Drain Filter　

REMOVAL

1.

Remove the rear wheel RH. WHEEL AND TIRE SYSTEM>Tire and Wheel>REMOVAL

2.

Lift up the vehicle.

3.

Remove the mud guard rear RH. EXTERIOR/INTERIOR TRIM>Mud Guard>REMOVAL

4.

Disconnect the drain tube (A). FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Delivery and Evaporation Lines>REMOVAL > QUICK CONNECTOR DISCONNECTION (TYPE F)

5.

Remove the bolts which hold the drain filter bracket, and remove the drain filter.

Using a marker pen, make alignment marks (a) on the fuel filler pipe and the drain filter bracket.

EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO) > Drain Filter　

INSTALLATION

1.

Install the bolts which hold the drain filter bracket to install the drain filter.

Install the drain filter bracket to the fuel filler pipe by aligning the alignment mark (a).

Tightening torque:

7.5N·m (0.8kgf-m, 5.5ft-lb)

2.

Connect the drain tube (A). FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Delivery and Evaporation Lines>INSTALLATION > QUICK CONNECTOR CONNECTION (TYPE F)

3.

Install the mud guard rear RH. EXTERIOR/INTERIOR TRIM>Mud Guard>INSTALLATION

4.

Lower the vehicle.

5.

Install the rear wheel RH. WHEEL AND TIRE SYSTEM>Tire and Wheel>INSTALLATION

EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO) > Drain Filter　

INSPECTION

1.

Check that the drain filter and drain tube have no deformation, cracks or other damages.

2.

Check that no foreign substances are clogged in the drain filter.

EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO) > Leak Check Valve Assembly　

REMOVAL

1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Lift up the vehicle.

3.

Disconnect drain tube A (A) and drain tube B (B). FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Delivery and Evaporation Lines>REMOVAL > QUICK CONNECTOR DISCONNECTION (TYPE F)

4.

Remove the circulate tube (D) from the clip (C).

5.

Disconnect the connector (E).

6.

Remove the leak check valve assembly.

7.

Disconnect the drain tube A from the leak check valve assembly. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Delivery and Evaporation Lines>REMOVAL > QUICK CONNECTOR DISCONNECTION (TYPE F)

8.

Remove the leak check valve assembly bracket.

EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO) > Leak Check Valve Assembly　

INSTALLATION

1.

Install the leak check valve assembly bracket.

Tightening torque:

8 N·m (0.8kgf-m, 5.9ft-lb)

2.

Connect the drain tube A to the leak check valve assembly. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Delivery and Evaporation Lines>INSTALLATION > QUICK CONNECTOR CONNECTION (TYPE F)

3.

Install the leak check valve assembly.

Tightening torque:

8 N·m (0.8kgf-m, 5.9ft-lb)

4.

Connect the connector (E).

5.

Install the circulate tube (D) to the clip (C).

6.

Connect drain tube A (A) and drain tube B (B). FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Delivery and Evaporation Lines>INSTALLATION > QUICK CONNECTOR CONNECTION (TYPE F)

7.

Lower the vehicle.

8.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO) > Leak Check Valve Assembly　

INSPECTION

1. CHECK SWITCHING VALVE

1.

Check the resistance between switching valve terminals.

Terminals No.	Standard
1 and 5	27⁺³₋₂ Ω (when 20°C (68°F))
1 and 5	31±4 Ω (when 60°C (140°F))

2.

Check that air is discharged from (B) when air is blown into (A).

3.

Connect the battery positive terminal to the terminal No. 5 and the battery negative terminal to the terminal No. 1. Check that air is not discharged from (B), when supplying air to (A).

The purpose of this inspection is to check the valve movement, and it would be success if a large change of flow can be checked resulting from valve opening/closing. Therefore, it does not indicate a malfunction if a small amount of flow from (B) is detected when the valve is closed.

2. CHECK VACUUM PUMP

1.

Connect the battery positive terminal to terminal No. 3 and the battery ground terminal to terminal No. 4, and inspect the vacuum pump operation.

Do not operate the vacuum pump for 5 minutes or more.

3. CHECK PRESSURE SENSOR

1.

Using new dry cell batteries, connect the battery positive terminal to terminal No. 6 and the battery ground terminal to terminal No. 8, and connect the circuit tester positive terminal to terminal No. 7 and the circuit tester ground terminal to terminal No. 8.

Using a circuit tester, check that the initial voltage of each dry-cell battery is 1.6 V or more. And also check that the voltage of three batteries in series is between 4.8 — 5.2 V.
For power supply, 5 V DC constant voltage power source can also be used.

2.

Check the voltage at a normal atmospheric pressure.

The atmospheric pressure at higher altitude is lower than normal. Therefore, the voltage is lower than the standard value.

Terminals No.	Standard
7 (+) and 8 (−)	Approx. 3.5 V (when 25°C (77°F))

3.

Connect the battery positive terminal to terminal No. 3 and the battery ground terminal to terminal No. 4, and check that there is a voltage drop from the voltage measured in step 2) when the vacuum pump is operated.

4. OTHER INSPECTIONS

Check that the leak check valve assembly has no deformation, cracks or other damages.

EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO) > PCV Connector　

REMOVAL

1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Drain engine coolant. COOLING(H4DO)>Engine Coolant>REPLACEMENT > DRAINING OF ENGINE COOLANT

3.

Move the A/C compressor aside so that it does not interfere with the work.

This procedure is required to remove the PCV connector.

(1)

Remove the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>REMOVAL

(2)

Disconnect the connector (A), connector (B) and terminal (C).

(3)

Remove the clip (D) and clip (E) securing the battery cable assembly, and place it aside so that it does not interfere with work.

(4)

Remove the V-belts. MECHANICAL(H4DO)>V-belt>REMOVAL > V-BELT

(5)

Remove the bolt securing the A/C compressor.

(6)

Move the A/C compressor as shown in the figure.

Do not bend the pipe portion of the hose pressure discharge and the hose pressure suction.

4.

Disconnect the water hose (A) and PCV hose No. 2 (B), and remove the PCV connector (C).

EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO) > PCV Connector　

INSTALLATION

1.

By using new O-rings, install the PCV connector, and connect the water hose and PCV hose No. 2.

Tightening torque:

6.4N·m (0.7kgf-m, 4.7ft-lb)

2.

Install the A/C compressor. AIR CONDITIONER>Compressor>INSTALLATION

3.

Install the V-belts. MECHANICAL(H4DO)>V-belt>INSTALLATION > V-BELT

4.

Secure the battery cable assembly with the clip (A) and clip (B).

5.

Connect the connector (C), connector (D), and the terminal (E).

Tightening torque:

15.5N·m (1.6kfg-m, 11.4ft-lb)

6.

Install the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>INSTALLATION

7.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

8.

Fill engine coolant. COOLING(H4DO)>Engine Coolant>REPLACEMENT > FILLING OF ENGINE COOLANT

9.

Check refrigerant leaks. AIR CONDITIONER>Refrigerant Leak Check>INSPECTION

EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO) > PCV Connector　

INSPECTION

Check that the PCV connector has no deformation, cracks or other damages.

EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO) > PCV Hose　

REMOVAL

1. PCV HOSE NO. 1

Do not remove except when the PCV hose is broken.

1.

Remove the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>REMOVAL

2.

Remove the clip from the air intake boot, and loosen the clamp.

3.

Remove the air intake boot, and place it aside so that it does not interfere with the work.

Be careful not to pull out the PCV hose.

4.

Remove the PCV hose No. 1 from the intake manifold assembly and the PCV valve.

2. PCV HOSE NO. 2

Do not remove except when the PCV hose is broken.

1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Remove the intake manifold assembly. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Intake Manifold Assembly>REMOVAL

3.

Move the A/C compressor aside so that it does not interfere with the work.

This procedure is required to remove the PCV hose No. 2.

(1)

Remove the V-belts. MECHANICAL(H4DO)>V-belt>REMOVAL > V-BELT

(2)

Remove the bolt securing the A/C compressor.

(3)

Move the A/C compressor as shown in the figure.

Do not bend the pipe portion of the hose pressure discharge and the hose pressure suction.

4.

Remove the PCV hose No. 2 from the PCV connector and the air intake boot.

EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO) > PCV Hose　

INSTALLATION

1. PCV HOSE NO. 1

1.

Connect the PCV hose No. 1 to the intake manifold assembly and the PCV valve.

2.

Install the air intake boot. INTAKE (INDUCTION)(H4DO)>Air Intake Boot>INSTALLATION

3.

Install the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>INSTALLATION

2. PCV HOSE NO. 2

1.

Install the PCV hose No. 2 to the PCV connector and the air intake boot.

2.

Install the intake manifold assembly. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Intake Manifold Assembly>INSTALLATION

3.

Install the A/C compressor. AIR CONDITIONER>Compressor>INSTALLATION

4.

Install the V-belts. MECHANICAL(H4DO)>V-belt>INSTALLATION > V-BELT

5.

Install the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>INSTALLATION

6.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

7.

Check refrigerant leaks. AIR CONDITIONER>Refrigerant Leak Check>INSPECTION

EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO) > PCV Hose　

INSPECTION

Check that the PCV hose has no cracks, damage or loose part.

EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO) > PCV Valve　

REMOVAL

Do not remove unless the PCV valve is broken.

1.

Remove the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>REMOVAL

2.

Remove the clip from the air intake boot, and loosen the clamp.

3.

Remove the air intake boot, and place it aside so that it does not interfere with the work.

Be careful not to pull out the PCV hose.

4.

Remove the PCV hose No. 1. EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO)>PCV Hose>REMOVAL > PCV HOSE NO. 1

5.

Remove the PCV valve from the cylinder block RH.

6.

Remove liquid gasket from the PCV valve and the mating surface of the cylinder block RH.

EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO) > PCV Valve　

INSTALLATION

1.

Apply liquid gasket to the bolt threads of PCV valve, and install the PCV valve onto the cylinder block RH.

Before applying liquid gasket, degrease bolt threads of PCV valve and the mating surface of the cylinder block RH.

Liquid gasket:

THREE BOND 1217G (Part No. K0877Y0100), THREE BOND 1217H or equivalent

Tightening torque:

23 N·m (2.3kgf-m, 17.0ft-lb)

2.

Connect the PCV hose No. 1. EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO)>PCV Hose>INSTALLATION > PCV HOSE NO. 1

3.

Install the air intake boot. INTAKE (INDUCTION)(H4DO)>Air Intake Boot>INSTALLATION

4.

Install the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>INSTALLATION

EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO) > PCV Valve　

INSPECTION

1. PCV VALVE

1.

Check that the PCV valve has no deformation, cracks or other damages.

2.

Check that air is discharged from (B) when air is blown into (A).

3.

Check that air does not come out from (B) when air is blown into (A).

2. OTHER INSPECTIONS

Check that the PCV hose has no cracks, damage or loose part.