EMISSION CONTROL SYSTEM

CONTENTS
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EXHAUST EMISSION CONTROLS2. 5L DIESEL
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ON-BOARD DIAGNOSTICS2. 5L DIESEL
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
ON-BOARD DIAGNOSTICS2.5L DIESEL ENGINE
INDEX
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GENERAL INFORMATION
SYSTEM DESCRIPTION2.5L DIESEL ENGINE . 1
DESCRIPTION AND OPERATION
DIAGNOSTIC TROUBLE CODES . . . . . . . . . . . . . 2
GENERAL INFORMATION
SYSTEM DESCRIPTION2. 5L DIESEL ENGINE
The 2.5L di esel MSA control l er and Powertrai n
Control Modul e (PCM) moni tor and control many di f-
ferent ci rcui ts i n the fuel i njecti on pump and engi ne
systems. I f the MSA senses a probl em wi th a moni -
tored ci rcui t that i ndi cates an actual probl em, a
Di agnosti c Troubl e Code (DTC) wi l l be stored i n the
PCMs memory, and eventual l y may i l l umi nate the
Di esel Gl ow Pl ug l amp constantl y whi l e the key i s
on. I f the probl em i s repai red, or i s i ntermi ttent, the
PCM wi l l erase the DTC after 40 warm-up cycl es. A
warm-up cycl e consi sts of starti ng the vehi cl e when
the engi ne i s col d, then the engi ne to warms up to a
certai n temperature, and fi nal l y, the engi ne tempera-
ture fal l s to a normal operati ng temperature, then
the key i s turned off.
Certai n cri teri a must be met for a DTC to be
entered i nto PCM memory. The cri teri a may be a
speci fi c range of engi ne rpm, engi ne or fuel tempera-
ture and/or i nput vol tage to the PCM. A DTC i ndi -
cates that the PCM has i denti fi ed an abnormal
si gnal i n a ci rcui t or the system. A DTC may i ndi cate
the resul t of a fai l ure, but never i denti fy the fai l ed
component di rectl y.
There are several operati ng condi ti ons that the
MSA does not moni tor and set a DTC for. Refer to
the fol l owi ng Moni tored Ci rcui ts and NonMoni tored
Ci rcui ts i n thi s secti on.
MONITORED CIRCUITS
The MSA can detect certai n probl ems i n the el ec-
tri cal system.
Open or Shorted Circuit The MSA can deter-
mi ne i f sensor output (whi ch i s the i nput to MSA i s
wi thi n proper range. I t al so determi nes i f the ci rcui t
i s open or shorted.
Output Device Current Flow The MSA senses
whether the output devi ces are el ectri cal l y connected.
I f there i s a probl em wi th the ci rcui t, the MSA
senses whether the ci rcui t i s open, shorted to ground
(), or shorted to (+) vol tage.
NONMONITORED CIRCUITS
The MSA does not moni tor the fol l owi ng ci rcui ts,
systems or condi ti ons that coul d have mal functi ons
that resul t i n dri veabi l i ty probl ems. A DTC wi l l not
be di spl ayed for these condi ti ons.
Fuel Pressure: Fuel pressure i s control l ed by the
fuel i njecti on pump. The PCM cannot detect prob-
l ems i n thi s component.
Cylinder Compression: The MSA cannot detect
uneven, l ow, or hi gh engi ne cyl i nder compressi on.
Exhaust System: The MSA cannot detect a
pl ugged, restri cted or l eaki ng exhaust system.
Fuel Injector Malfunctions: The MSA cannot
determi ne i f the fuel i njector i s cl ogged, or the wrong
i njector i s i nstal l ed. The fuel i njectors on the di esel
engi ne are not controlled by the MSA, al though a
defecti ve fuel i njector sensor is monitored by the
PCM.
ZG EMISSION CONTROL SYSTEM 25 - 1
Vacuum Assist: Leaks or restri cti ons i n the vac-
uum ci rcui ts of vacuum assi sted engi ne control sys-
tem devi ces are not moni tored by the MSA.
MSA System Ground: The MSA cannot deter-
mi ne a poor system ground. However, a DTC may be
generated as a resul t of thi s condi ti on.
MSA/PCM Connector Engagement: The MSA
cannot determi ne spread or damaged connector pi ns.
However, a DTC may be generated as a resul t of thi s
condi ti on.
HIGH AND LOW LIMITS
The MSA compares i nput si gnal vol tages from each
i nput devi ce. I t wi l l establ i sh hi gh and l ow l i mi ts
that are programmed i nto i t for that devi ce. I f the
i nput vol tage i s not wi thi n speci fi cati ons and other
DTC cri teri a are met, a DTC wi l l be stored i n mem-
ory. Other DTC cri teri a mi ght i ncl ude engi ne rpm
l i mi ts or i nput vol tages from other sensors or
swi tches. The other i nputs mi ght have to be sensed
by the MSA when i t senses a hi gh or l ow i nput vol t-
age from the control system devi ce i n questi on.
DESCRIPTION AND OPERATION
DIAGNOSTIC TROUBLE CODES
On the fol l owi ng pages, a l i st of DTCs i s provi ded
for the 2.5L di esel engi ne. A DTC i ndi cates that the
PCM has recogni zed an abnormal si gnal i n a ci rcui t
or the system. A DTC may i ndi cate the resul t of a
fai l ure, but most l i kel y wi l l not i denti fy the fai l ed
component di rectl y.
ACCESSING DIAGNOSTIC TROUBLE CODES
A stored DTC can be di spl ayed through the use of
the DRB I I I scan tool . The DRB I I I connects to the
data l i nk connector. The data l i nk connector i s
l ocated under the i nstrument panel near bottom of
the steeri ng col umn (Fi g. 1).
ERASING TROUBLE CODES
After the probl em has been repai red, use the DRB
I I I scan tool to erase a DTC.
Fig. 1 Data Link Connector LocationTypical
25 - 2 EMISSION CONTROL SYSTEM ZG
GENERAL INFORMATION (Continued)
MSA CONTROLLER DRBIII CODES
Generic Scan Tool Code DRB III Scan Tool Display
P0100 Mass of Volumes of Air Flow Plausibility
Mass of Volumes of Air Flow Signal High Exceeded
Mass of Volumes of Air Flow Signal Low Exceeded
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 High Exceeded
Vehcle Speed Sensor Plausibility
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 High Exceeded
Needle Movement Sensor 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 Control Negative Governing Governor Deviation
Timing Control Positive Governing Governor Deviation
P1515 Accelerator Pedal Postion 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
ZG EMISSION CONTROL SYSTEM 25 - 3
DESCRIPTION AND OPERATION (Continued)
Generic Scan Tool Code DRB III Scan Tool Display
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 Solenoid Valve Controller Open Circuit
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
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
EEPROM Plausibility Ver Number Not Corresponding
P1685 Vehicle Theft Alarm Code Line Breakdown
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
PCM DRBIII CODES
Generic Scan
Tool Code
DRBIII Scan Tool Display
P0117 Engine Coolant Volts Lo
P0118 Engine Coolant Volts Hi
P0500 Vehicle Speed Signal
P0601 Internal Self Test
P1296 5 VDC Output
P1391 Loss of Cam or Crank
25 - 4 EMISSION CONTROL SYSTEM ZG
DESCRIPTION AND OPERATION (Continued)
EXHAUST EMISSION CONTROLS2.5L DIESEL ENGINE
INDEX
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DESCRIPTION AND OPERATION
EXHAUST GAS RECIRCULATION (EGR)
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
VACUUM HOSE ROUTING SCHEMATIC . . . . . . . 5
DIAGNOSIS AND TESTING
EGR GAS FLOW TEST . . . . . . . . . . . . . . . . . . . . 6
EGR SOLENOID TEST . . . . . . . . . . . . . . . . . . . . . 6
REMOVAL AND INSTALLATION
EGR TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
EGR VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ELECTRIC VACUUM MODULATOR (EVM) . . . . . . 7
SPECIFICATIONS
TORQUE CHART2.5L DIESEL . . . . . . . . . . . . . . 7
DESCRIPTION AND OPERATION
VACUUM HOSE ROUTING SCHEMATIC
Vacuum for the EGR system i s suppl i ed by the
i nternal engi ne mounted vacuum pump. Refer to
EGR System Operati on for vacuum pump i nforma-
ti on. Vacuum harness routi ng for emi ssi on rel ated
components i s di spl ayed i n (Fi g. 1).
EXHAUST GAS RECIRCULATION (EGR) SYSTEM
GENERAL INFORMATION
The EGR system reduces oxi des of ni trogen (NOx)
i n the engi ne exhaust. Thi s i s accompl i shed by al l ow-
i ng a predetermi ned amount of hot exhaust gas to
reci rcul ate and di l ute the i ncomi ng fuel /ai r mi xture.
A mal functi oni ng EGR system can cause engi ne
stumbl e, sags or hesi tati on, rough i dl e, engi ne stal l -
i ng and poor dri veabi l i ty.
EGR SYSTEM OPERATION
The system consi sts of:
An EGR val ve assembl y. The val ve i s l ocated
behi nd the i ntake mani fol d (Fi g. 2).
An El ectri c Vacuum Modul ator (EVM). The EVM
i s someti mes referred to as the EGR control sol enoi d
or EGR duty cycl e sol enoi d. The EVM serves two di f-
ferent functi ons. One i s to control vacuum bl eedoff
of the EGR val ve. The other i s to control the on
ti me of the EGR val ve.
The MSA operates the EVM. The MSA i s l ocated
i s l ocated i nsi de the vehi cl e i n the center consul e.
An EGR tube (Fi g. 2) connecti ng a passage i n
the EGR val ve to the rear of the exhaust mani fol d.
Fig. 1 Typical Hose Routing
Fig. 2 EGR Valve and Tube Location
ZG EMISSION CONTROL SYSTEM 25 - 5
The vacuum pump suppl i es vacuum for the
EVM and the EGR val ve. Thi s pump al so suppl i es
vacuum for operati on of the power brake booster. The
pump i s l ocated i nternal l y i n the front of the engi ne
bl ock (Fi g. 3) and i s dri ven by the crankshaft gear.
Vacuum l i nes and hoses to connect the vari ous
components.
When the MSA suppl i es a vari abl e ground si gnal
to the EVM, EGR system operati on starts to occur.
The MSA wi l l moni tor and determi ne when to suppl y
and remove thi s vari abl e ground si gnal . Thi s wi l l
depend on i nputs from the engi ne cool ant tempera-
ture, throttl e posi ti on and engi ne speed sensors.
When the vari abl e ground si gnal i s suppl i ed to the
EVM, vacuum from the vacuum pump wi l l be
al l owed to pass through the EVM and on to the EGR
val ve wi th a connecti ng hose.
Exhaust gas reci rcul ati on wi l l begi n i n thi s order
when:
The MSA determi nes that EGR system operati on
i s necessary.
The engi ne i s runni ng to operate the vacuum
pump.
A vari abl e ground si gnal i s suppl i ed to the EVM.
Vari abl e vacuum passes through the EVM to the
EGR val ve.
The i nl et seat (poppet val ve) at the bottom of
the EGR val ve opens to di l ute and reci rcul ate
exhaust gas back i nto the i ntake mani fol d.
The EGR system wi l l be shut down by the MSA
after 60 seconds of conti nuous engi ne i dl i ng to
i mprove i dl e qual i ty.
DIAGNOSIS AND TESTING
EGR GAS FLOW TEST
Refer to the 1998 XJ/ZG Di esel Powertrai n Di ag-
nosti c Manual for compl ete test procedure.
EGR SOLENOID TEST
VACUUM TEST
Wi th the engi ne runni ng, di sconnect the vacuum
suppl y l i ne at the fi tti ng on the EVM. Mi ni mum vac-
uum shoul d be no l ess than 20 i nches. I f vacuum i s
l ower, check for l eaks i n vacuum suppl y l i ne. I f l eaks
cannot be found, check for l ow vacuum at vacuum
pump. Refer to Group 5, Brake System for proce-
dures.
REMOVAL AND INSTALLATION
EGR VALVE
REMOVAL
(1) Remove the rubber hose from turbocharger to
metal tube.
(2) Di sconnect vacuum l i ne at EGR val ve vacuum
suppl y fi tti ng (Fi g. 2).
(3) Loosen the tube fi tti ng at exhaust mani fol d end
of EGR tube (Fi g. 2).
(4) Remove the two bol ts retai ni ng the EGR tube
to the si de of EGR val ve (Fi g. 2).
(5) Remove the two EGR val ve mounti ng bol ts
(Fi g. 2) and remove EGR val ve.
(6) Di scard both of the ol d EGR mounti ng gaskets.
INSTALLATION
(1) Cl ean the i ntake mani fol d of any ol d gasket
materi al .
(2) Cl ean the end of EGR tube of any ol d gasket
materi al .
(3) Posi ti on the EGR val ve and new gasket to the
i ntake mani fol d.
(4) I nstal l two EGR val ve mounti ng bol ts. Do not
ti ghten bol ts at thi s ti me.
(5) Posi ti on new gasket between EGR val ve and
EGR tube.
(6) I nstal l two EGR tube bol ts. Ti ghten al l four
mounti ng bol ts to 23 Nm (204 i n. l bs.).
(7) Ti ghten EGR tube fi tti ng at exhaust mani fol d.
(8) Connect vacuum l i ne to EGR val ve.
(9) I nstal l the rubber hose from turbocharger to
metal tube.
EGR TUBE
The EGR tube connects the EGR val ve to the rear
of the exhaust mani fol d (Fi g. 2).
REMOVAL
(1) Remove rubber hose from turbocharger to
metal tube.
(2) Remove two EGR tube mounti ng bol ts at EGR
val ve end of tube (Fi g. 2).
Fig. 3 Internal Vacuum Pump
25 - 6 EMISSION CONTROL SYSTEM ZG
DESCRIPTION AND OPERATION (Continued)
(3) Loosen fi tti ng at exhaust mani fol d end of tube
(Fi g. 2).
(4) Remove EGR tube and di scard ol d gasket.
(5) Cl ean gasket mati ng surfaces and EGR tube
fl ange gasket surfaces.
(6) Check for si gns of l eakage or cracked surfaces
at both ends of tube, exhaust mani fol d and EGR
val ve.
INSTALLATION
(1) I nstal l a new gasket to EGR val ve end of EGR
tube.
(2) Posi ti on EGR tube to engi ne.
(3) Loosel y ti ghten fi tti ng at exhaust mani fol d end
of tube.
(4) I nstal l 2 mounti ng bol ts at EGR val ve end of
tube. Ti ghten bol ts to 23 Nm (204 i n. l bs.) torque.
(5) Ti ghten fi tti ng at exhaust mani fol d end of tube.
(6) I nstal l hose from turbocharger to metal tube.
ELECTRIC VACUUM MODULATOR (EVM)
The EVM (EGR Duty Cycl e Purge Sol enoi d) i s
mounted to the si de of the PDC.
REMOVAL
(1) Di sconnect both cabl es from battery, negati ve
cabl e fi rst.
(2) Remove 2 screws hol di ng PDC to bracket,
swi ng out of way.
(3) Remove nut and cl amp hol di ng battery to bat-
tery tray (Fi g. 4).
(4) Remove battery from vehi cl e.
(5) Di sconnect two vacuum hoses at EVM.
(6) Remove mounti ng screws of EVM.
(7) Remove the EVM to gai n access to the EVM
el ectri cal connector.
(8) Remove el ectri cal connector at EVM.
INSTALLATION
(1) I nstal l el ectri cal connector to EVM.
(2) I nstal l EVM and ti ghten mounti ng screws.
(3) Connect vacuum hoses.
(4) I nstal l PDC to bracket and ti ghten mounti ng
screws.
(5) I nstal l battery.
(6) Connect battery cabl es posi ti ve fi rst.
SPECIFICATIONS
TORQUE CHART2. 5L DIESEL
Description Torque
EGR Val ve Mounti ng Bol ts . . . 23 Nm (204 i n. l bs.)
EGR Tube Mounti ng Bol ts . . . . 23 Nm (204 i n. l bs.)
EVM (El ectri c Vacuum Modul ator)
Mounti ng Bol t . . . . . . . . . . . . . . . 2 Nm (20 i n. l bs.)
Fig. 4 Battery Clamp
ZG EMISSION CONTROL SYSTEM 25 - 7
REMOVAL AND INSTALLATION (Continued)