Engine Intake & Exhaust

Engine Intake & Exhaust
System
Construction and contents
Chapter 1 : Components of intake and exhaust system

Chapter 2 : Measuring equipment of flow rate of intake air
Chapter 3 : Idle speed control system
Chapter 4 : Controlling of excess air ratio (-control)

Chapter 5 : Equipment for controlling evaporative gas and blow-by gas
Chapter 6 : Equipment for exhaust gas recirculation
External appearance of air temperature

sensor
Air temperature sensor (ATS)
Why need?
Inlet air
Thermisto
r
Inside circuit diagram of air temperature sensor
ATS
1
ATS
ATS output signal
Sensor signal
Sensor GND
ground
ECU
Output characteristic of air temperature sensor
5
Air temperature sensor
Output voltage, V
0
-20
20
40
60
Intake air temperature, C
80
100
Terminal of air temperature

sensor
Disconnecting terminal
Connecting terminal
ATS
V
2 1
harness side connector
Examination method of inlet air temperature sensor
Check
terminal
Check list
Connecter and engine state
Duty value
20 (3.2~4.3 V)
40 (2.4~2.6 V)
80 (1.0~1.5 V)
-GND
Output
voltage
check
-GND
Sensor
-
Sensor
output
Ground
Part
check
Resistor
check
Ignition switch ON
(Before or after ignition)
Always
Ignition switch OFF
Separate from sensor
If output
sensor must
short
If output
sensor must
short
indicates 0V,
be fault or
indicates 5V,
be fault or
less than 0.1 V
20
40
connector
60
After taking off sensor, 80
check resistance value caused
90
by air temperature
(2.27~2.73
(1.06~1.28
(0.54~0.65
(0.29~0.35
(0.22~0.27
)
)
)
)
)
External appearance of water temperature

sensor
Water temperature sensor (WTS)
Thermisto
r
Water jacket
Relations between Resistance and

temperature
Thermal transmission
Thermal transmission
High temperature
Low temperature
Resistance
NTC
PTC
Temperature
Measuring principle of water temperature sensor
Power (5V)
Coolant water
WTS
(RT)
R1
ECU
Output voltage
Inside circuit diagram of water temperature

sensor
WTS
WTS
Output signal
Ground
Output characteristic of water temperature sensor
5
Water temperature sensor
Output voltage, V
0
-20
20
40
60
Cooling water temperature, C
80
100
Inside circuit diagram of water temperature

sensor
WTS
1
Sensor GND
Sensor signal
ECU
Terminal of the water temperature

sensor
Connecting terminal
WTS
V
2 1
Examination method of water temperature sensor

Check
termi
nal
Check list
Connector and engine state
Duty value
20
GND
Output
voltage
check
GND
Part
check
Sensor
output
Ignition switch ON
Ground
Always
Ignition switch OFF

separate from sensor
(3.2~4.3 V)
40
(2.4~2.6 V)
80
(1.0~1.5 V)
If output indicates 0V, sensor
must be fault or short
If output indicates 5V, sensor
must be fault or short
less than 0.1 V
20
40
Resistor
connector
60
check
After taking off sensor, 80
put it into hot water and
then check resistance value 90
(2.27~2.73
(1.06~1.28
(0.54~0.65
(0.29~0.35
(0.22~0.27
)
)
)
)
)
External appearance of throttle position

sensor
Throttle position sensor (TPS)
The operating principle of throttle position sensor

(TPS)
Power
TPS output signal

Variable resistance
Slider
Ground
Throttle valve
The operating principle of throttle position sensor

(TPS)
Power (5 V)
Output voltage
(5 V)
Ground
Power (5 V)
Output voltage
(2.5 V)
Ground
Power (5 V)
Output voltage
(0 V)
Ground
Structure of throttle position

sensor
Slider
Close
Open
Slider
Resistor
Inside circuit diagram of throttle position sensor
Power (5 V)
TPS output signal
TPS
Ground
Output characteristic of throttle position sensor
5
Throttle position sensor
Output voltage, V
10
20
30
40
50
60
70
Throttle vale open angle, deg.
80
90
Circuit of throttle position

sensor
TPS
2
Sensor power
Sensor GND
Sensor signal
ECU
Terminal of throttle position

sensor
V
3 2 1
Connecting terminal
TPS
2
Examination method of throttle position sensor

Check
termina
l
-GND
Check list
Output
voltag
e
check
Sensor output
Connector and engine

state
Duty value
Ignition switch ON
Engine rpm
700100rpm
0.25~0.5 V
8~12
During acceleration
change
rate
W/O throttle valve
4.25~4.8 V
88~90
Always
less 0.1 V
Ignition switch ON
4.8~5.2 V
as
constant
-GND
Ground
-GND
Sensor power
Sensor
-
Variable register
check
Ignition switch OFF

connector
0.7~3.0
Check register
between output
and ground
terminal
Ignition switch OFF

connector
Operating
throttle
valve
Change at a fixed rate

Increase open rate
-Resistance reduction
Reduce open rate
-Resistance increment
Sensor
-
Part
check
External appearance of crankshaft position

sensor
Crankshaft position sensor (CPS)
Concept of electronic induction

operating
applied to magnetic sensor method
S
N
Output voltage
Output voltage
Output voltage
Occurrence voltage of pickup coil
Pickup coil
A location
Signal rotor
Magnetic amount
through charged coil
B location Magnetic
A
C location
Structure of crankshaft position

sensor
Crank
shaft
Coil
Permanent
magnet
CPS
Iron
core
Ring gear
Circuit diagram of crankshaft position

sensor
CPS
Output signal
(high)
Output signal
(low)
CPS
Output signal
(high)
Shield terminal
Output signal
(low)
Output waveform of crankshaft position sensor
Rotating
direction
Ring gear teeth

A
Sensor signal
ECU input
Circuit diagram of crankshaft position sensor
CPS
1
Sensor signal
Sensor signal
Terminal of crankshaft position

sensor
Connecting terminal
CPS
1
2 1
Examination method of throttle position sensor
Check
terminal
: (+)
probe
:(-)
probe
sensor
-
Check list

state
Duty value
idle
: 700Hz (VP-P : 8.7V)
Output
voltag
e
check
Sensor
output
Ignition switch ON
(after ignition)
Part
check
Resistor
check
ignition switch OFF

0.486 ~ 0.594
(20 )
connector
3000rpm
: 3000Hz (VP-P
41.2V)
Measuring method of intake air flow rate
Indirect
measuring
method
Measuring equipments of flow rate of intake air
speed-density type
: Bosch D-jetronic
MAP sensor type
throttle-speed type
Direct measuring
method
(mass flow
method)
Volume flow
measuring method
Mass flow measuring

method
vane AFS type

Karmann vortex AFS type
Hot wire AFS type
Hot film AFS type
Method using Inlet manifold

pressure
Surge tank
(MAP sensor)
Inlet manifold pressure (P)
ECU
Engine revolution speed (N)
(Crank Angle Sensor) or

(Crankshaft Position Sensor)
Throttle-speed
type
(Throttle Position
Sensor)
Throttle open degree ()
ECU
Direct measuring
method
(Air Flow Sensor)

Flow rate of intake air (Q)
ECU
Volume flow measuring

Mass flow measuring
Division of Pressure
Manifold Absolute Pressure (MAP sensor)
1.033 kgf /cm2
pressure A
standard atmospheric pressure
1.013 bar
760 mmHg
local atmospheric pressure
0.4 pressure
pressure B
absolute zero pressure = perfect vacuum
0.8 pressure
-0.4 pressure
14.7 psi
Local atmospheric
pressure ( 0.8 )
Gauge
pressure (0.4)
Absolute Pressure (1.2 )
101.3 kPa
Gage pressure and absolute pressure
standard atmospheric pressure
absolute zero pressure = perfect vacuum
Gage
Pressure 0.4
Absolute Pressure
(0.8)
local atmospheric pressure in

location C
Local atmospheric
Pressure (0.4)
Pressure C
local atmospheric pressure in location A

Local atmospheric
pressure ( 0.8 )
Gage
Pressure 0.4
Absolute Pressure (1.2 )
pressure A
Division of pressure measuring form
Operating pressure
Operating pressure
Local atmospheric
pressure
Diaphragm
(a) Gage pressure
Operating pressure
perfect vacuum
Operating pressure
(b) Absolute pressure (c) Difference pressure
Relations between intake manifold

pressure variation and throttle valve
open quantity
Local atmospheric
Throttle valve open quantity increase
Pressure
Intake manifold
pressure
Average intake manifold
pressure
Throttle valve open quantity decrease
Time
External appearance of
MAP sensor and
construction
Operating
pressure
Piezoelectric
resistor
Vacuum
chamber
Pyrex glass
(a) appearance
curtain diagram
(silicon chip)
(b) construction
Inside circuit diagram of

manifold absolute pressure
power (5V)
Piezoelectric resistor
1
+
2
Air Temperature Sensor

MAP sensor
MAP output signal
ATS output signal

ground
Output characteristic of
sensor
Vaccum pressure, kPa

100
5
60
40
20
Manifold absolute pressure
Output voltage, V
80
20
40
60
Pressure, kPa
80
100

ATS
Sensor GND
ATS signal
MAP
sensor
1
MAP signal
Sensor power
(5V)
MAP
ECU
Terminal of the manifold

absolute pressure sensor
V
4 3 2 1
Connecting terminal
MAP
2
Examination method of
manifold absolute sensor
Check
terminal
Check list
Duty value
More than 4V
Ignition switch ON (before
About 101.3 kPa
ignition)
(1013mb, 760mmHg)
-GND
MAP sensor
output
-GND
Sensor power
-GND
ATS output
-GND
Ground
Ignition switch ON (after

ignition)
About 1V
Engine coolant water 26.6~39.9 kPa

temperature 80~95
(250~400 mb)
Engine RPM 700100rpm
(200~300mmHg)
Electric charge off
Neutral steering wheel
Open throttle valve
More than 4V
About 101.3 kPa
Ignition switch ON
(before and after ignition)
4.8~5.2V
Ignition switch ON
(After or before ignition)
Refer to ATS
Always
less than 0.1V
Measuring principle of hot wire type air flow sensor
Hot wire & Hot film type AFS
power
resistance
(R3)
Hot wire
Air temperature ta
Hot wire tH1 resistance R1
Control
circuit
Difference in established
temperature : tH1 - ta
Measuring principle of hot wire type air flow sensor
power
Electric current
resistance
(R3)
air
Hot wire
Air temperature ta
Hot wire temperature tH2 resistance R2
Control
circuit
Difference in temperature : tH2 - ta

electric current increase
Difference in established
temperature : tH1 - ta
Output characteristic of the hot wire type air flow

sensor
5
Hot wire, Hot film type AFS
Output voltage, V
100
200
300
400
500
Mass flow rate of air, kg/h
600
700
Structure of hot wire type air flow

sensor
Control circuit
Measuring tube
Platinum Hot wire
thermistor
Inside circuit of hot wire type air flow

sensor
AFS
resistor
(R3)
Hot wire
Ground
Control
circuit
precision
resistor
Power
(battery voltage)
Clean burning output

AFS output signal
precision
resistor
Ground
Measuring
resistor
External appearance of hot film type air flow sensor
Structure of hot film type air flow

sensor
Control circuit
Hot
film
Protective
curtain
Temperature sensor
Inside circuit diagram of hot film type air flow

sensor
AFS
Resistance
(R3)
Hot wire
ground
Control
circuit
precision
resistor
precision
resistor
power
(battery voltage)
AFS output signal
measuring
resistor
ground
ATS output signal
ATS
Inside circuit diagram of hot wire type air flow

sensor
Hot wire
AFS
sensor
Control
circuit
Sensor powerr
Clean burning
AFS signal
Sensor GND
GND
ECU
Terminal of the hot wire type air flow

sensor
Connecting terminal
Hot wire AFS
V
5 4 3 2 1
Examination method of the hot wire type air flow

sensor
Check
terminal
Check list
-GND
ground
Always
Less
0.1V
than
-GND
ground
Always
Less
0.1V
than
Ignition switch ON
(before ignition)
Less
0.1V
than
-GND
AFS output
Ignition switch ON (After

ignition)
About 0.5V
Engine
coolant
water
About 1 0
temperature 80~95
kg/h
Electric load off
Open throttle valve
-GND
Clean burning
output
-GND
Sensor power
Duty value
About 5V
About 7 3 0
kg/h
After ignition switch off and battery

4~5sec later, then for 1.6sec
voltage
Ignition switch ON
battery
Inside circuit of hot film type air flow

sensor
ATS
AFS
Hot film
AFS
sensor
ATS signal
Sensor GND
AFS signal
Sensor power
GND
ECU
Terminal of hot film type air flow sensor
V
5 4 3 2 1
Connecting terminal
Hot film AFS

2
Examination method of hot film type air flow

sensor
Check
terminal
Check list
-GND
Ground
Always
-GND
Sensor
power
ignition switch ON
ignition switch ON
(Before ignition)
Duty value
Less than 0.1V

battery voltage
Less than 0.1V

-GND
AFS
output
ignition)
Engine coolant 80~95
Electric load off
About 0.5 V
About 10 kg/h
Open throttle valve
About 5 V
About 730 kg/h
Less than 0.1V
-GND
Ground
Always
-GND
ATS
output
Ignition switch ON
Refer to ATS
External appearance of karmann vortex air

flow sensor and construction
Karmann vortex air flow sensor
ATS
Air cleaner
honey comb
Air flow
sensor
Intake chamber
bypass passage
Measuring principle of Karmann vortex air flow

sensor
Honeycomb
ultrasonic departure
ultrasonic transmitter
karmann vortex
air
Intake manifold
Vortex stabilization plate
ultrasonic receiver
Vortex generator
Compressive
modulator
ECU
ultrasonic wave in
bypass passage
comparison with
vortex
Digital signal modulation
Output characteristic of karmann vortex air

flow sensor caused by throttle valve open
rate
In case of large amount of inlet air (high frequency)
In case of small amount of inlet air (low frequency)
Inside circuit diagram of karmann vortex air flow

sensor
power (5V)
AFS
AFS output signal
BPS
1
2
power (12V)
+
-
BPS output signal
ground
ATS
ATS output signal
Inside circuit diagram of karmann vortex air flow

sensor
BPS
ATS
Sensor GND
BPS signal
ATS signal
AFS signal
Karmann
AFS
sensor
AFS
Sensor power
(12V)
Sensor Power
(5V)
ECU
Terminal of karmann vortex air flow

sensor
1 2 3
4 5 6
Connecting terminal
Karmann AFS
2
Examination method of karmann vortex air flow

sensor
Check terminal
Check list
-GND
Sensor
power
Ignition switch ON
4.8~5.2 V
-GND
Sensor
power
Ignition switch ON
battery voltage
Ignition switch ON
(Before ignition)
-GND
AFS
output

ignition)
Engine coolant 80~95

Electric load off
Open throttle valve
-GND
ATS
output
-GND
BPS
output
-GND
Ground
Duty value
Ignition switch ON
Ignition switch ON
Always
Refer to ATS
Refer to MAP
Less than 0.1 V
Description of Idle Speed Control Actuator
Idle Speed Control Actuator (ISCA)
Throttle valve
Throttle valve
at direct driving
method
Air cleaner
Throttle lever
Engine
air
actuator
Throttle valve
Throttle valve
at bypass method
Air cleaner
Engine
actuator
air
Constitution of electric current

and magnetic force line in coil
N
Electric current
Operating principle of step motor
Electric current
Permanent magnet
(rotor)
N
1step = 90
step motor
Construction of step motor
Stator
Iron core B
Shaft
Coil
S
Permanent magnet
Inside circuit diagram of step motor type,

ISCA
ISCA
(step motor)
Battery power
ECU
Open coil
Closed coil
Battery power
Inside circuit diagram of step motor type,

ISCA
Power
12V
2
ISCA
1
6
Close
Open
ECU
Terminal of step motor type, ISCA
Connecting terminal
1
3 2 1
6 5 4
ISCA A type
2
Check process for step motor type

ISCA
Check
terminal
-GND
or
-GND
-GND
or
-GND
-GND
or
-GND
-
-
-
-
Check list
Outpu
t
voltag
e
check
Part
check

state
Control
Ignition
switch
line for ON (before ignition)
actuator Changed engine load
Power
Duty value
Generating regular
wave with regular
frequency (step)
(Refer to duty step)
Ignition
switch
ON
(before and after Battery voltage
ignition)
Control Ignition switch ON

line for
(before ignition)
actuator changed engine load
Check
resistor
Ignition switch OFF

connector
Generating regular
wave with regular
frequency (step)
28~33
(20)
Prescription step number in step motor type,

ISCA
Coolant water
temperature
Load condition
Number of
prescription step
10~20 80~90
Air conditioner
switch off
4 step 14 step
10~20 80~90
Air conditioner
switch on
40 step 60 step
Output waveform
characteristic
of step motor type, ISCA
terminal
Open coil
terminal
terminal
Closed coil
terminal
A
B
Construction of step motor type,

ISCA
Valve
Motor
position
sensor
Spindle
Front bearing
Circuit of DC motor type,

ISCA
ISCA
(DC motor)
Power (5 V)
MPS output signal

Groun
d
Idle signal output
Backward movement
M
Forward movement
Circuit of DC motor type,

ISCA
Idle switch
ISCA
1
Backward
Forward
Sensor power
Sensor signal
Idle signal
Sensor GND
Sensor power
ECU
Terminal of DC motor type,

ISCA
7 6 5 4 3
1 2
Connecting terminal
ISCA B type
3
Prescription voltage value

of DC motor type, ISCA
Coolant water
temperature
Load condition
Regular voltage
value
10~20 80~90
Air conditioner
switch off
1.1 V 0.6 V
10~20 80~90
Air conditioner
switch on
1.5 V 1.0 V
Examination method of DC motor type,

ISCA
Check
termina
l
Check list
Duty value
Ignition switch ON
ignition)
Changed engine load
(before
-GND
Motor
Moving
forward
battery voltage
0V
Ignition switch ON
ignition)
Changed engine load
(before
-GND
Motor
Moving
forward
battery voltage
0V
-GND
MPS
Output
Ignition
ignition)
ON
(before
MPS
Output
Ignition switch ON
ignition)
Changed engine load
(before
-GND
Ignition switch
ON (before and after
ignition)
At acceleration
Idle
Switch
-GND
switch
Ignition switch ON (before and

after ignition)
Idle
5V
Constant output
voltage at 0~5V (Refer
to duty step)
About 0 V
About 5 V
-GND
Ground
Always
About 0 V
-GND
Sensor
voltage
Ignition switch ON (before and

after ignition)
About 5 V
Resistor
Check
Ignition switch OFF

separate from sensor connector
28~33
(20)
-
-
-
-
Part check
Principle of
solenoid
metal
Magnetism
(weak)
spring
Electric current (weak)

voltage (low)
metal
Electric current (strong)

Voltage (high)
Magnetism
(strong)
Control method of
solenoid
12 V
6V
12 V
On
(a)
12 V
Off
(b)
On
Off
T1
T2
On
Off
0V
T
(c)
duty ratio [%]

= T1 / T X 100 ( - duty ratio )
= T2 / T X 100 ( + duty ratio )
Type of solenoid
actuator
Rotary solenoid
actuator
air
Rotary valve
Bellows for vacuum
cancellation
Linear solenoid
actuator
valve
air
Circuit diagram of solenoid type,

ISCA
ISCA
(solenoid)
Battery power
Open coil
Close coil
ECU
Circuit diagram of solenoid type,

ISCA
Power
12V
2
M
ISCA
Open
Close
ECU
Terminal of solenoid type,

ISCA
Connecting terminal
ISCA C type
1
3 2 1
Examination method of solenoid type,

ISCA
Check
terminal
-GND
Output
voltage
check
-GND
-
-

state
Duty value
Closed
coil
Ignition switch ON
(before ignition)
Changed engine load
Generating regular
wave with regular
frequency (step)
Power
Ignition switch ON
(before
and
after battery voltage
ignition)
Open
coil
Generating regular
Ignition switch ON
wave with regular
(before ignition)
frequency (step)
Changed engine load
Check list
-GND
Part
check
Check
resistor
Ignition switch OFF

28~33
Separate from sensor
(20)
connector
Prescription duty ratio of solenoid type,

ISCA
Coolant water
temperature
Load
condition
Open coil
prescription
duty ratio
Close coil
prescription
duty ratio
10~20 80~90
Air condition
switch off
47 %
32 %
53 % 68 %
10~20 80~90
Air condition
switch on
50 %
35 %
50 % 65 %
Output waveform of solenoid type,

ISCA
12 V
Open coil
0V
12 V
Close coil
0V
On
Off
On
Off
NO, CO, and HC concentrations
Concentration change of exhaust

gas
Caused by fuel/air equipment ratio
0.7
O2 sensor
NO
HC
0.8
0.9
CO
1.0
1.1
1.2
Fuel/air equipment ratio
1.3
Control area and performance

of Air/fuel equipment ratio()
sensor
O2 sensor
Harmfulness discharge
sensor voltage
control area
HC
CO
NOX
NOX
CO
HC
Voltage characteristic
curve of the sensor
0.9 0.95 1.0 1.05 1.1

Air/fuel equipment ratio
In case of
non-catalytic
reaction
In case of
catalytic
reaction
Construction of Zirconia Oxygen sensor
O2 sensor
Exterior
Oxygen
atmosphere
atmosphere
Zirconia
polyelectrolyt
e
Exhaust
gas
Exhaust
gas
Platinum
Electrode
Zirconia
polyelectrolyt
e
Exhaust
gas
O2
Sensor
output
Platinum
Electrode
Principle of Zirconia Oxygen

sensor
Large amount of electricity

generation
O2 sensor
Small amount of
electricity generation
Zirconia
Zirconia
Exhaust gas
air
(outer)
(inner)
Exhaust gas
(outer)
platinum
In case of large difference in O2

density
(Combustion of rich mixture)
air
(inner)
platinum
In case of small difference in O2

density
(Combustion of lean mixture)
Operating principle of zirconia oxygen

sensor
Ceramic
coating
O2 sensor
4e-
Pt Zirconia element
Oxygen partial
pressure in
exhaust gas
PO2
Pt
2O2
2O2- O2 + 4e-
O2+ + 4e- 2O2-
Oxygen partial
pressure in
atmosphere
PO2
Circuit of the zirconia oxygen

sensor
O2 sensor
Battery power
O2 sensor
Zirconia
heater
Output signal
ground
ground
Output characteristic of the zirconia oxygen

sensor
rarity
Sensor voltage Ui
density
O2 sensor
0.8
0.9
1.0
1.1
1.2
Construction of titania oxygen sensor

Groun
d
Output
signal
exhaus
t
O2 sensor
Voltage use of
heater
heater
Titania sensor
Principle of Titania oxygen

sensor
O2 sensor
Resistor reduce
Resistor increase
Titania
Titania
Exhaust gas
Exhaust gas Exhaust gas
O2 density is low
(Combustion of rich mixture)
Exhaust gas
O2 density is high
(Combustion of lean mixture)
Circuit of titania oxygen

sensor
O2 sensor
Battery power
O2 sensor
Titania
heater
Power 5V
Ground
Ground
Output characteristic of titania oxygen

sensor
O2 sensor
High
Voltage
[V]
Low
density
=1
rarity
Circuit diagram of titania oxygen

sensor
O2 sensor
Power
12V
1
O2
sensor
3
2
Sensor GND
Sensor signal
Sensor heater
ECU
Terminal of titania oxygen

sensor
O2 sensor
Connecting terminal
O2 sensor
1
2 1
4 3
Examination method of oxygen

sensor
Check
terminal
:(-) probe
-GND
Output
voltage
check
-GND
Sensor
-

state
Duty value
Sensor
output
Ignition switch ON
(after ignition)
After
engine
warming-up
(Coolant water
temperature 80~90)
Idle
: 100mV ~ 900mV
Rapid acceleration
: 600mV ~ 1000mV
Rapid deceleration
: Less than 200mV
Heater
source
Ignition switch ON
(before or after battery voltage
ignition)
Heater
ground
Heater On
Ignition switch ON
: About 0 V
(before or after
Heater Off
ignition)
: battery voltage
Check list
: (+) probe
Part
check
O2 sensor
Ignition switch OFF

Resistor
2~5
Separate
from
check
(Based on 20)
sensor connector
1 Phase oxidation catalytic convert

system
Threeway catalytic converter
Secondary
air
Production
mechanism of
mixture gas
Oxidation
catalytic
converter HC CO
2 Phase catalytic converter

system
Production
mechanism of
mixture gas
Restoration
catalytic converter
NOX
Secondary air
Oxidation
catalytic
converter HC CO
Single phase threeway catalytic converter

system
Ui
ECU
Production
mechanism of
mixture gas
O2 sensor
Threeway catalytic
converter NOX HC CO
Catalyst converter of
metallic porous media type
Thickness of wire
(0.05~0.07mm)
Constitution and principle of

threeway catalytic converter
Catalyst stratum
Catalyst stratum
Middle stratum
Porous media
Ceramic
porous media
Result of conversion rate for

CO and NOX
Performance difference with newold

converter
Lambda control
amplitude
100
%
High control
amplitude
New catalytic
converter
Low control amplitude

100
% New catalytic
converter
50
Old catalytic
converter
Old catalytic
converter
0.98 0.99 1.00 1.01 1.02

Mean Lambda value
+3%
0.98 0.99 1.00 1.01 1.02

Mean Lambda value
%
+0.5
-0.5
+3%
0
2s
2s
Operating of Blow-by gas control

device
Vacuum reduce in intake manifold
Vacuum increase in intake manifold
PCV open
Rapid acceleration /high load
PCV off
Light load/ Medium load
Air filter
Inlet air
Purge Control Solenoid Valve (PCV)
Intake duct
Throttle
body
Bleeder hose
Surge
tank
PCV
Ventilation
Engine head
Engine
Intake
manifold
Operating principle of PCV
Rocker cover part
Intake manifold
(No vacuum)
Engine condition
Stop
PCV valve
Stop
Vacuum passage
Closed
Rocker cover part
Intake manifold
(Proper vacuum)
Rocker cover part
Intake manifold
(High vacuum)
Engine condition
Idle or deceleration
PCV valve
Completely
working
Vacuum passage
Small
Rocker cover part Intake manifold

(low vacuum)
Engine condition
Normal
working
Engine condition
Acceleration or
excessive load
PCV valve
Proper working
PCV valve
Light working
Vacuum passage
large
Vacuum passage
Very large
Flow characteristic of PCV valve
much
Volume of Formation
BLOW-BY gas
PCV flow characteristic
little
Volume of formation blow-by gas
Low
(Full load)
vacuum
Large
(Idle)
Constitution and principle of

evaporative emission control system
Purge Control Solenoid Valve (PCSV)
Evaporative emission
Purge air
PSCV
2-way valve
Air filter
Engine
Charcoal
Fuel tank
Canister
ECU
Groun
d To intake
manifold
From canister

evaporative emission control
system
Purge control solenoid valve (PSCV)
Intake manifold vacuum (MAP sensor)

ECU

Air conditioner switch
Output characteristic of
system
Vacuum
Engine speed (rpm)
Examination parts of
system
Check and duty value for evaporation gas treatment
- Engine coolant temperature : 60

Engine state
Vacuum
Result
0.5/
Keep vacuum state
Idle
3,000rpm
- When engine is warm-up Engine coolant temperature : 70
Engine state
Idle
Vacuum
Result
0.5/
Keep vacuum state
After
engine
rpm
3,000rpm,
and within 3 minutes.
is Force
with
vacuum
Close vacuum state
After
engine
3,000rpm,
and
minutes later.
is
3 0.5/
rpm
then
Close vacuum state as soon

as vacuum state keeps
Circuit of evaporative emission control

system
Power
12V
PCSV
2
PCSV control
ECU
Terminal of PCSV
Connecting terminal
1
2 1
4 3
PCV
2
Production principle of
NOX
Air
O2
Exhaust gas recirculation apparatus (EGR sol. v/v)
Fuel
N2
HC
NOX
O2
N2
High combustion temperature (High load

area)
NOX
High combustion
temperature (high load area)
Poor EGR system
Lean A/F ratio condition
High inlet air temperature
Overheated engine
Excessively advanced
ignition timing
Principle of
EGR
Air
O2
Oxygen reduce, restraining temperature increment

of burned gas, decrement of excess air ratio
Fuel
EGR
N2
H2O
HC
O2
Inactivity gas
HC
N2
CO2
N2
NOX
Definition of EGR
ratio
Fuel
Qa
Qi
Engine
Qegr
Qo
Qe
Constitution of EGR
system
A
Air cleaner
B
Surge tank
Vacuum control valve

(EGR modulator)
Thermal valve
(EGR solenoid)
EGR control valve
Constitution of vacuum
control type EGR system
Inlet air
Air cleaner
Vacuum
Intake
manifold
Throttle
valve
Engine
EGR control
valve
Orifice
Exhaust
manifold
Inlet air
Exhaust gas
Vacuum pressure
Constitution of electronic
control type EGR system
Inlet air
From air cleaner
Pressure
sensor
To
combustion
chamber
Coolant
water
Water
temperature
sensor
Inle
t air
Exhaust gas
Vacuum pressure
ON OFF
electroni
c valve
Position
sensor
Exhaust
gas
EGR valve
ECU
Output characteristic of EGR

valve
EGR Ratio
High
0
Light load
Load
Heavy
load
Check of EGR valve
Link of Thermo valve and carburetor
Assembling
at part
checking.
Air cleaner side

Exhaust manifold side
EGR sol. v/v

Vacuum
Normal
60mmHg
No passing air
172mmHg
Passing air
List
Duty value
Coil resistor for EGR

36~44 (at 20)
control solenoid valve
Inside circuit diagram of EGR

valve
Power
12V
EGR
solenoid
valve
2
EGR solenoid
control
ECU
Output characteristic of EGR

valve
Open coil
Close coil

Engine Intake &amp; Exhaust

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Engine Intake &amp; Exhaust

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Engine Intake & Exhaust

Construction and contents

Chapter 1 : Components of intake and exhaust system

Chapter 4 : Controlling of excess air ratio (-control)

External appearance of air temperature

Air temperature sensor (ATS)

Air temperature sensor (ATS)

Inside circuit diagram of air temperature sensor

Air temperature sensor (ATS)

ATS output signal

Output characteristic of air temperature sensor

Air temperature sensor (ATS)

Intake air temperature, C

Terminal of air temperature

Air temperature sensor (ATS)

Examination method of inlet air temperature sensor

Air temperature sensor (ATS)

Connecter and engine state

(Before or after ignition)

less than 0.1 V

External appearance of water temperature

Water temperature sensor (WTS)

Relations between Resistance and

Water temperature sensor (WTS)

Measuring principle of water temperature sensor

Water temperature sensor (WTS)

Inside circuit diagram of water temperature

Water temperature sensor (WTS)

Output characteristic of water temperature sensor

Water temperature sensor (WTS)

Cooling water temperature, C

Inside circuit diagram of water temperature

Water temperature sensor (WTS)

Terminal of the water temperature

Water temperature sensor (WTS)

Examination method of water temperature sensor

Connector and engine state

Water temperature sensor (WTS)

(Before or after ignition)

Ignition switch OFF

less than 0.1 V

External appearance of throttle position

Throttle position sensor (TPS)

The operating principle of throttle position sensor

Throttle position sensor (TPS)

TPS output signal

The operating principle of throttle position sensor

Throttle position sensor (TPS)

Structure of throttle position

Throttle position sensor (TPS)

Inside circuit diagram of throttle position sensor

Throttle position sensor (TPS)

TPS output signal

Output characteristic of throttle position sensor

Throttle position sensor (TPS)

Throttle vale open angle, deg.

Circuit of throttle position

Throttle position sensor (TPS)

Terminal of throttle position

Throttle position sensor (TPS)

Examination method of throttle position sensor

Connector and engine

Throttle position sensor (TPS)

W/O throttle valve

Engine Intake & Exhaust

Engine Intake & Exhaust