Halderman J.D., Linder J. Automotive Fuel and Emissions Control Systems

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EXHAUST GAS RECIRCULATION SYSTEMS 331

and closing the EGR valve. The PCM monitors either the oxygen

or MAP sensor for a change in signal voltage. If the EGR system

fails, a diagnostic trouble code (DTC) is set. If the system fails

two consecutive times, the malfunction indicator lamp (MIL) is lit.

MONITORING STRATEGIES EGR monitoring strategies

include the following:



Some vehicle manufacturers, such as Chrysler, monitor the

difference in the exhaust oxygen sensor’s voltage activity

as the EGR valve opens and closes. Oxygen in the exhaust

decreases when the EGR valve is open and increases when

the EGR valve is closed because exhaust gas is inert (con-

tains very little oxygen) and actually displaces oxygen. The

PCM sets a DTC if the sensor signal does not change.



Most Fords use an EGR monitor test sensor called a

delta pressure feedback EGR (DPFE) sensor. This

sensor measures the pressure differential between two

sides of a metered orifice positioned just below the EGR

valve’s exhaust side. Pressure between the orifice and

the EGR valve decreases when the EGR opens because

it becomes exposed to the lower pressure in the intake.

The DPFE sensor recognizes this pressure drop, com-

pares it to the relatively higher pressure on the exhaust

side of the orifice, and signals the value of the pressure

difference to the PCM.

 SEE FIGURE 26–9 .



Many vehicle manufacturers use the manifold absolute

pressure (MAP) sensor as the EGR monitor on some

applications. After meeting the enable criteria (operat-

ing condition requirements), the EGR monitor is run.

The PCM monitors the MAP sensor while it commands

the EGR valve to open. The MAP sensor signal should

change in response to the sudden change in manifold

pressure or the fuel trim changes created by a change

inthe oxygen sensor voltage. If the signal value falls out-

side the acceptable value in the lookup table, a DTC sets.

If the EGR fails on two consecutive trips, the PCM lights

the MIL.

 SEE FIGURE 26–10 .

LINEAR EGR VALVE

PINTLE

POSITION

SENSOR

5 VOLTS

SENSOR OUT

PCM

B

GROUND

PULSE-WIDTH

MODULATED

SOLENOID

FIGURE 26–8 The EGR valve pintle is pulse-width modu-

lated and a three-wire potentiometer provides pintle-position

information back to the PCM.

PCM

DPFE

SENSOR

DPFE INTAKE MANIFOLD SIDE (IMS) SIGNAL

DPFE EXHAUST MANIFOLD SIDE (EMS) SIGNAL

EVR

VPWR

ELECTRONIC

VACUUM

REGULATOR

(EVR)

VREF

SIG RTN

SIG

EGR

VALVE

EGR

TUBE

INTAKE

ORIFICE

EXHAUST

AIR INTAKE

FIGURE 26–9 A typical Ford DPFE sensor and related components.

DIAGNOSING A DEFECTIVE

EGR SYSTEM

SYMPTOMS If the EGR valve is not opening or the flow of the

exhaust gas is restricted, then the following symptoms are likely:



Detonation (spark knock or ping) during acceleration or

during cruise (steady-speed driving)



Excessive oxides of nitrogen (NO

) exhaust emissions

332 CHAPTER 26

If the EGR valve is stuck open or partially open, then the

following symptoms are likely:



Rough idle or frequent stalling



Poor performance/low power, especially at low engine

speed

EGR TESTING PROCEDURES The first step in almost

any diagnosis is to perform a thorough visual inspection. To

check for proper operation of a vacuum-operated EGR valve,

follow these steps:

STEP 1 Check the vacuum diaphragm of the EGR valve to

see if it can hold vacuum. Because many EGR valves

require exhaust back pressure to function correctly,

theengine should be running at a fast idle during this

test.

STEP 2 Apply vacuum from a hand-operated vacuum

pump and check for proper operation. The valve

itself should move when vacuum is applied, and the

CLOSED

TIME IN SECONDS

CLOSED

OPEN

RPM

MAP

EGR

FIGURE 26–10 An OBD-II active test. The PCM opens the

EGR valve and then monitors the MAP sensor and/or engine

speed (RPM) to verify that it meets acceptable values.

Watch Out for Carbon Balls!

EGR valves can get stuck partially open by a chunk

of carbon, and the valve or solenoid will test as

defective. When the valve (or solenoid) is removed,

small chunks or balls of carbon often fall into the

exhaust manifold passage. When the replacement

valve is installed, the carbon balls can be drawn

into the new valve again, causing the engine to idle

roughly or stall.

To help prevent this problem, start the engine

with the EGR valve or solenoid removed. Any balls

or chunks of carbon will be blown out of the passage

by the exhaust. Stop the engine and install the re-

placement EGR valve or solenoid.

TECH TIP

The Blazer Story

The owner of a Chevrolet Blazer equipped with a

4.3-L, V-6 engine complained that the engine would

stumble and hesitate at times. Everything seemed

to be functioning correctly, except that the service

technician discovered a weak vacuum going to the

EGR valve at idle. This vehicle was equipped with

an EGR valve-control solenoid, called an electronic

vacuum regulator valve (EVRV) by General Motors

Corporation. The PCM pulses the solenoid to control

the vacuum that regulates the operation of the EGR

valve. The technician checked the service manual for

details on the workings of the system. The techni-

cian discovered that vacuum should be present at

the EGR valve only when the gear selector indicates

a drive gear (drive, low, reverse). Because the techni-

cian discovered the vacuum at the solenoid to be

leaking, the solenoid was obviously defective and

required replacement. After replacement of the sole-

noid (EVRV), the hesitation problem was solved.

NOTE: The technician also discovered in the

service manual that blower-type exhaust hoses

should not be connected to the tailpipe on any

vehicle while performing an inspection of the

EGR system. The vacuum created by the system

could cause false EGR valve operation to occur.

REAL WORLD FIX

engine operation should be affected. The EGR valve

should be able to hold the vacuum that was applied.

If the vacuum drops off, then the valve is likely to be

defective.

STEP 3 Monitor engine vacuum drop. Connect a vacuum

gauge to an intake manifold vacuum source and moni-

tor the engine vacuum at idle (should be 17 to 21 in.

Hg at sea level). Raise the speed of the engine to 2,500

RPM and note the vacuum reading (should be 17 to 21

in. Hg or higher).

Activate the EGR valve using a scan tool or vacuum pump,

if vacuum controlled, and observe the vacuum gauge. The re-

sults are as follows:



The vacuum should drop 6 to 8 in. Hg.



If the vacuum drops less than 6 to 8 in. Hg, the valve or

the EGR passages are clogged.



If the EGR valve is able to hold vacuum but the engine is

not affected when the valve is opened, then the exhaust

passage(s) must be checked for restriction.

See the Tech Tip “The Snake Trick.” If the EGR valve will

not hold vacuum, the valve itself is likely to be defective and

require replacement.

EXHAUST GAS RECIRCULATION SYSTEMS 333

FIGURE 26–11 Removing the EGR passage plugs from the

intake manifold on a Honda.

The Snake Trick

The EGR passages on many intake manifolds be-

come clogged with carbon, which reduces the flow

of exhaust and the amount of exhaust gases in the

cylinders. This reduction can cause spark knock

(detonation) and increased emissions of oxides of

nitrogen (NO

) (especially important in areas with

enhanced exhaust emissions testing).

To quickly and easily remove carbon from

exhaust passages, cut an approximately 1-foot

(30-cm) length from stranded wire, such as garage

door guidewire or an old speedometer cable. Flare

the end and place the end of the wire into the pas-

sage. Set your drill on reverse and turn it on, and the

wire will pull its way through the passage, cleaning

the carbon as it goes, just like a snake in a drainpipe.

Some vehicles, such as Hondas, require that plugs

be drilled out to gain access to the EGR passages.

 SEE FIGURE 26–11 .

TECH TIP

Diagnostic

Trouble Code Description Possible Causes

P0400 Exhaust gas

recirculation

flow problems

• EGR valve

• EGR valve hose

or electrical

connection

• Defective PCM

P0401 Exhaust gas

recirculation

flow insufficient

• EGR valve

•

Clogged EGR ports

or passages

P0402 Exhaust gas

recirculation

flow excessive

• Stuck-open

EGR valve

• Vacuum hose(s)

misrouted

• Electrical wiring

shorted

EGR-RELATED OBD-II

DIAGNOSTIC TROUBLE

CODES

5. Many EGR systems use a feedback potentiometer to sig-

nal the PCM about the position of the EGR valve pintle.

6. Some EGR valves are solenoids or pulse-width modulated

pintles.

7. OBD-II requires that the flow rate be tested, which can

be achieved by opening the EGR valve and observing the

reaction of the MAP sensor.

1. Oxides of nitrogen (NO

) are formed inside the combustion

chamber because of heat exceeding 2,500°F (1,370°C).

2. Recirculating 6% to 10% inert exhaust gases back

into the intake system reduces peak temperature in-

side the combustion chamber and reduces NO

exhaust

emissions.

3. EGR is usually not needed during cold engine operation, at

idle speeds or during wide-open throttle conditions.

4. Vacuum-operated EGR valves are usually exhaust back

pressure controlled to help match EGR flow into the intake

with the load on the engine.

SUMMARY

334 CHAPTER 26

3. How does the DPFE sensor work?

4. How does the PCM determine that the exhaust flow

through the EGR system meets OBD-II regulations?

1. What causes the formation of oxides of nitrogen?

2. How does the use of exhaust gas reduce NO

exhaust

emission?

REVIEW QUESTIONS

7. Two technicians are discussing clogged EGR passages.

Technician A says clogged EGR passages can cause ex-

cessive NO

exhaust emission. Technician B says that

clogged EGR passages can cause the engine to ping

(spark knock or detonation). Which technician is correct?

a. Technician A only

b. Technician B only

c. Both Technicians A and B

d. Neither Technician A nor B

8. An EGR valve that is partially stuck open would most likely

cause what condition?

a. Rough idle/stalling

b. Excessive NO

exhaust emissions

c. Ping (spark knock or detonation)

d. Missing at highway speed

9. When testing an EGR system for proper operation using a

vacuum gauge, how much should the vacuum drop when

the EGR is commanded on by a scan tool?

a. 1 to 2 in. Hg

b. 3 to 5 in. Hg

c. 6 to 8 in. Hg

d. 8 to 10 in. Hg

10. A P0401 DTC (exhaust gas recirculation flow insufficient) is

being discussed. Technician A says that a defective EGR

valve could be the cause. Technician B says that clogged

EGR passages could be the cause. Which technician is

correct?

a. Technician A only

b. Technician B only

c. Both Technicians A and B

d. Neither Technician A nor B

1. What causes the nitrogen and the oxygen in the air to

combine and form NO

a. Sunlight

b. Any spark will cause this to occur

c. Heat above 2,500°F (1,370°C)

d. Chemical reaction in the catalytic converter

2. Exhaust gas recirculation (EGR) is generally not needed

under all the following conditions except ______________ .

a. Idle speed

b. Cold engine

c. Cruise speed

d. Wide-open throttle (WOT)

3. Technician A says that a low-restriction exhaust system

could prevent a back pressure-type vacuum-controlled

EGR valve from opening correctly. Technician B says re-

stricted exhaust can cause the EGR valve position sensor

to fail. Which technician is correct?

a. Technician A only

b. Technician B only

c. Both Technicians A and B

d. Neither Technician A nor B

4. EGR is used to control which exhaust emission?

a. Unburned hydrocarbons (HC)

b. Oxides of nitrogen (NO

)

c. Carbon monoxide (CO)

d. Both NO

and CO

5. A typical EGR pintle-position sensor is what type of sensor?

a. Rheostat c. Wheatstone bridge

b. Piezoelectric d. Potentiometer

6. OBD-II regulations require that the EGR system be tested.

Technician A says that the PCM can monitor the com-

manded position of the EGR valve to determine if it is

functioning correctly. Technician B says that the PCM can

open the EGR valve and monitor for a change in the MAP

sensor or oxygen sensor reading to detect if the system is

functioning correctly. Which technician is correct?

a. Technician A only

b. Technician B only

c. Both Technicians A and B

d. Neither Technician A nor B

CHAPTER QUIZ

POSITIVE CRANKCASE VENTILATION AND SECONDARY AIR-INJECTION SYSTEMS 335

chapter

POSITIVE CRANKCASE

VENTILATION

AND SECONDARY AIR-

INJECTION SYSTEMS

OBJECTIVES: After studying Chapter 27 , the reader should be able to: • Prepare for the ASE Engine Performance (A8)

certification test content area “D” (Emission Control Systems). • Describe the purpose and function of the positive crankcase

ventilation (PCV) and seconday air-injection (SAI) systems. • Discuss how the PCV and SAI systems are tested under OBD-II

regulations. • Explain methods for diagnosing and testing faults in the PCV and secondary air injection (SAI) systems.

KEY TERMS: Air-injection reaction (AIR) 339 • Blowby 335 • Check valve 339 • Positive crankcase ventilation (PCV) 335

• Secondary air injection (SAI) 339 • Smog pump 339 • Thermactor pump 339

PURPOSE AND FUNCTION The problem of crankcase

ventilation has existed since the beginning of the automobile

because no piston ring, new or old, can provide a perfect seal

between the piston and the cylinder wall. When an engine is

running, the pressure of combustion forces the piston down-

ward. This same pressure also forces gases and unburned fuel

from the combustion chamber, past the piston rings, and into

the crankcase. This process of gases leaking past the rings is

called blowby, and the gases form crankcase vapors.

These combustion by-products, particularly unburned hy-

drocarbons (HC) caused by blowby, must be ventilated from the

crankcase. However, the crankcase cannot be vented directly

to the atmosphere because the hydrocarbon vapors add to air

pollution. Positive crankcase ventilation (PCV) systems were

developed to ventilate the crankcase and recirculate the vapors

to the engine’s induction system so they can be burned in the

cylinders. PCV systems help reduce HC and CO emissions.

All systems use the following:

1. PCV valve or calibrated orifice, or orifice and separator

2. PCV inlet air filter plus all connecting hoses

 SEE FIGURE 27–1 .

An oil/vapor or oil/water separator is used in some systems

instead of a valve or orifice, particularly with turbocharged and

fuel-injected engines. The oil/vapor separator lets oil condense

and drain back into the crankcase. The oil/water separator ac-

cumulates moisture and prevents it from freezing during cold

engine starts.

The air for the PCV system is drawn after the air cleaner

filter, which acts as a PCV filter.

NOTE: Some older designs drew from the dirty side of

the air cleaner, where a separate crankcase ventilation

filter was used.

PCV VALVES The PCV valve in most systems is a one-way

valve containing a spring-operated plunger that controls valve

flow rate.

 SEE FIGURE 27–2 .

Flow rate is established for each engine, and a valve for

a different engine should not be substituted. The flow rate is

CRANKCASE VENTILATION

FIGURE 27–1 A PCV valve in a cutaway valve cover, show-

ing the baffles that prevent liquid oil from being drawn into the

intake manifold.

336 CHAPTER 27

While most orifice flow control systems work the same as a

PCV valve system, they may not use fresh air scavenging of the

crankcase. Crankcase vapors are drawn into the intake mani-

fold in calibrated amounts depending on manifold pressure and

the orifice size. If vapor availability is low, as during idle, air is

drawn in with the vapors. During off-idle operation, excess va-

pors are sent to the air cleaner.

At idle, PCV flow is controlled by a 0.05-inch (1.3-mm) ori-

fice. As the engine moves off idle, ported vacuum pulls a spring-

loaded valve off of its seat, allowing PCV flow to pass through

a 0.09-inch (2.3-mm) orifice.

SEPARATOR SYSTEMS Turbocharged and many fuel-injected

engines use an oil/vapor or oil/water separator and a calibrated

orifice instead of a PCV valve. In the most common applica-

tions, the air intake throttle body acts as the source for crank-

case ventilation vacuum, and a calibrated orifice acts as the

metering device.

PCV SYSTEM DIAGNOSIS

SYMPTOMS If the PCV valve or orifice is not clogged, intake

air flows freely and the PCV system functions properly. Engine

design includes the air and vapor flow as a calibrated part of

determined by the size of the plunger and the holes inside the

valve. PCV valves usually are located in the valve cover or intake

manifold.

The PCV valve regulates airflow through the crankcase un-

der all driving conditions and speeds. When manifold vacuum is

high (at idle, cruising, and light-load operation), the PCV valve

restricts the airflow to maintain a balanced air-fuel ratio.

 SEE

FIGURE 27–3 .

It also prevents high intake manifold vacuum from pulling

oil out of the crankcase and into the intake manifold. Under high

speed or heavy loads, the valve opens and allows maximum

airflow.

 SEE FIGURE 27–4 .

If the engine backfires, the valve will close instantly to pre-

vent a crankcase explosion.

 SEE FIGURE 27–5 .

ORIFICE-CONTROLLED SYSTEMS The closed PCV system used

on some 4-cylinder engines contains a calibrated orifice instead

of a PCV valve. The orifice may be located in the valve cover or

intake manifold or in a hose connected between the valve cover,

air cleaner, and intake manifold.

THIS END OF THE PCV VALVE

IS SUBJECT TO CRANKCASE

PRESSURE THAT TENDS TO

CLOSE THE VALVE.

THIS END IS SUBJECT

TO INTAKE MANIFOLD

VACUUM THAT TENDS

TO CLOSE THE VALVE.

THE SPRING FORCE OPERATES TO

OPEN THE VALVE TO MANIFOLD

VACUUM AND CRANKCASE PRESSURE.

FIGURE 27–2 Spring force, crankcase pressure, and intake

manifold vacuum work together to regulate the flow rate

through the PCV valve.

AT IDLE AND LOW SPEED,

MANIFOLD VACUUM PULLS

THE VALVE TOWARD THE

RESTRICTED POSITION.

THE FLOW RATE IS LOW;

ABOUT 1 TO 5 CUBIC

FEET PER MINUTE.

FIGURE 27–3 Air flows through the PCV valve during idle,

cruising, and light-load conditions.

FLOW THROUGH THE VALVE INCREASES—

M 3 T

UBI

FEET PER MINUTE.

AT HIGHER SPEED OR IN A HEAVY

LOAD CONDITION, MANIFOLD

VACUUM DROPS. THE SPRING MOVES

THE VALVE OPEN.

FIGURE 27–4 Air flows through the PCV valve during accel-

eration and when the engine is under a heavy load.

IF THE ENGINE BACKFIRES DURING

CRANKING, IT CAUSES A HIGH

PRESSURE IN THE INTAKE MANIFOLD.

PRESSURE CAUSES THE VALVE TO BACK-SEAT

AND SEAL OFF THE INLET. THIS KEEPS THE

BACKFIRE OUT OF THE CRANKCASE.

FIGURE 27–5 PCV valve operation in the event of a backfire.

POSITIVE CRANKCASE VENTILATION AND SECONDARY AIR-INJECTION SYSTEMS 337

the air-fuel mixture. In fact, some engines receive as much as

30% of the idle air through the PCV system. For this reason, a

flow problem in the PCV system results in driveability problems.

A blocked or plugged PCV system may cause the follow-

ing to occur:



Rough or unstable idle



Excessive oil consumption



Oil in the air filter housing



Oil leaks due to excessive crankcase pressure

Before attempting expensive engine repairs, check the

condition of the PCV system.

PCV SYSTEM PERFORMANCE CHECK A properly operating posi-

tive crankcase ventilation system should be able to draw vapors

from the crankcase and into the intake manifold. If the pipes,

hoses, and PCV valve itself are not restricted, vacuum is applied

to the crankcase. A slight vacuum is created in the crankcase

(usually less than 1 in. Hg if measured at the dipstick) and is also

applied to other areas of the engine. Oil drainback holes provide

a path for oil to drain back into the oil pan. These holes also

allow crankcase vacuum to be applied under the rocker covers

and in the valley area of most V-type engines. Several methods

can be used to test a PCV system.

RATTLE TEST The rattle test is performed by simply removing

the PCV valve and giving it a shake:



If the PCV valve does not rattle, it is definitely defective

and must be replaced.



If the PCV valve does rattle, it does not necessarily

mean that the PCV valve is good. All PCV valves contain

springs that can become weaker with age and with heat-

ing and cooling cycles. Replace any PCV valve with the

exact replacement according to the vehicle manufac-

turer’s recommended intervals.

THE 3  5 CARD TEST Remove the oil-fill cap (where oil is

added to the engine) and start the engine.

NOTE: Use care on some overhead camshaft engines.

With the engine running, oil may be sprayed from the

open oil-fill opening.

Hold a 3  5 card over the opening (a dollar bill or any other

piece of paper can be used for this test):



If the PCV system, including the valve and hoses, is func-

tioning correctly, the card should be held down on the

oil-fill opening by the slight vacuum inside the crankcase.



If the card will not stay, carefully inspect the PCV valve,

hose(s), and manifold vacuum port for carbon buildup

(restriction). Clean or replace as necessary.

The Whistling Engine

An older vehicle was being diagnosed for a whistling

sound whenever the engine was running, especially

at idle. It was finally discovered that the breather in

the valve cover was plugged and caused high vac-

uum in the crankcase. The engine was sucking air

from what was likely the rear main seal lip, making

the “whistle” noise. After replacing the breather and

PCV, the noise stopped.

REAL WORLD FIX

The Oil-Burning Chevrolet Astro Van

An automotive instructor was driving a Chevrolet Astro

van to Fairbanks, Alaska, in January. It was cold,

around 32°F (36°C). As he pulled into Fairbanks

and stopped at a traffic light, he smelled burning oil.

He thought it was the vehicle ahead of him because it

was an older model and in poor condition. However,

when he stopped at the hotel he still smelled burning

oil. He looked under the van and discovered a large

pool of oil. After checking the oil and finding very lit-

tle left, he called a local shop and was told to bring it

in. The technician looked over the situation and said,

“You need to put some cardboard across the grill

to stop the PCV valve from freezing up.” Apparently

the PCV valve froze, which then caused the normal

blowby gases to force several quarts out the dipstick

tube. After installing the cardboard, the instructor had

no further problems.

CAUTION: Do not cover the radiator when

driving unless under severe cold conditions

and carefully watch the coolant temperature

to avoid overheating the engine.

REAL WORLD FIX

Check for Oil Leaks with the Engine Off

The owner of an older vehicle equipped with a V-6

engine complained to his technician that he smelled

burning oil, but only after shutting off the engine. The

technician found that the rocker cover gaskets were

leaking. But why did the owner only notice the smell

of hot oil when the engine was shut off? Because

of the positive crankcase ventilation (PCV) system,

engine vacuum tends to draw oil away from gasket

surfaces. When the engine stops, however, engine

vacuum disappears, and the oil remaining in the up-

per regions of the engine will tend to flow down and

out through any opening. Therefore, a good techni-

cian should check an engine for oil leaks not only with

the engine running but also shortly after shutdown.

TECH TIP

338 CHAPTER 27

NOTE: On some 4-cylinder engines, the 3  5 card may

vibrate on the oil-fill opening when the engine is run-

ning at idle speed. This is normal because of the time

intervals between intake strokes on a 4-cylinder engine.

SNAP-BACK TEST The proper operation of the PCV valve can

be checked by placing a finger over the inlet hole in the valve

when the engine is running and removing the finger rapidly.

Repeat several times. The valve should “snap back.” If the valve

does not snap back, replace the valve.

CRANKCASE VACUUM TEST Sometimes the PCV system can be

checked by testing for a weak vacuum at the oil dipstick tube

using an inches-of-water manometer or gauge as follows:

STEP 1 Remove the oil-fill cap or vent PCV opening and cover

the opening.

STEP 2 Remove the oil dipstick (oil level indicator).

STEP 3 Connect a water manometer or gauge to the dipstick

tube.

STEP 4 Start the engine and observe the gauge at idle and at

2,500 RPM.

 SEE FIGURE 27–6 .

The gauge should show some vacuum, especially at

2,500 RPM. If not, carefully inspect the PCV system for block-

ages or other faults.

PCV MONITOR Starting with 2004 and newer vehicles, all vehi-

cle PCMs monitor the PCV system for proper operation as

part of the OBD-II system. The PCV monitor will fail if the PCM

detects an opening between the crankcase and the PCV valve

or between the PCV valve and the intake manifold.

 SEE

FIGURE 27–7 .

FIGURE 27–6 Using a gauge that measures vacuum in units

of inches of water to test the vacuum at the dipstick tube, be-

ing sure that the PCV system is capable of drawing a vacuum

on the crankcase (28 in. H

O  1 PSI, or about 2 in. Hg of

vacuum).

RIVET HOLDING

PCV VALVE

RETAINER

FIGURE 27–7 Most PCV valves used on newer vehicles are

secured with fasteners, making it more difficult to disconnect

and thereby less likely to increase emissions.

FREQUENTLY ASKED QUESTION

What Are the Wires for at the PCV Valve?

Ford uses an electric heater to prevent ice from

forming inside the PCV valve and causing

blockage.

Water is a by-product of combustion, and

resulting moisture can freeze when the outside air

temperature is low. General Motors and others clip

a heater hose to the PCV hose to provide the heat

needed to prevent an ice blockage.

Diagnostic

Trouble Code

Description

Possible Causes

P0101 MAF or airflow

circuit range

problem

• Defective PCV

valve or hose/

connections or

MAF circuit fault

P0505 Idle control

system problem

• Defective PCV

valve or hose/

connections

PCV-RELATED

DIAGNOSTIC TROUBLE

CODES

POSITIVE CRANKCASE VENTILATION AND SECONDARY AIR-INJECTION SYSTEMS 339

PURPOSE AND FUNCTION The secondary air-injection

(SAI) system provides the air necessary for the oxidizing process

either at the exhaust manifold or inside the catalytic converter.

NOTE: This system is commonly called AIR, meaning air-

injection reaction. Therefore, an AIR pump does pump air.

PARTS AND OPERATION The SAI pump, also called an

AIR pump, a smog pump, or thermactor pump, is mounted

at the front of the engine and can be driven by a belt from the

crankshaft pulley. It pulls fresh air in through an external filter

and pumps the air under slight pressure to each exhaust port

through connecting hoses or a manifold. The typical SAI system

includes the following components:



A belt-driven pump with inlet air filter (older models)

(

 SEE FIGURE 27–8 . )



An electrically driven air pump (newer models)



One or more air distribution manifolds and nozzles



One or more exhaust check valves



Connecting hoses for air distribution



Air management valves and solenoids on all newer

applications

With the introduction of NO

reduction converters (also

called dual-bed, three-way converters, or TWC), the output of

the SAI pump is sent to the center of the converter, where

the extra air can help oxidize unburned hydrocarbons (HC)

and carbon monoxide (CO) into water vapor (H

O) and carbon

dioxide (CO

The computer controls the airflow from the pump by

switching on and off various solenoid valves.

AIR DISTRIBUTION MANIFOLDS AND NOZZLES The

secondary air-injection system sends air from the pump to a

nozzle installed near each exhaust port in the cylinder head.

This provides equal air injection for the exhaust from each

cylinder and makes it available at a point in the system where

exhaust gases are the hottest.

Air is delivered to the exhaust system in one of two ways:

1. An external air manifold, or manifolds, distributes the air

through injection tubes with stainless-steel nozzles. The

nozzles are threaded into the cylinder heads or exhaust

manifolds close to each exhaust valve. This method is

used primarily with smaller engines.

2. An internal air manifold distributes the air to the exhaust

ports near each exhaust valve through passages cast in

the cylinder head or the exhaust manifold. This method is

used mainly with larger engines.

EXHAUST CHECK VALVES All air-injection systems use

one or more one-way check valves to protect the air pump and

other components from reverse exhaust flow. A check valve

contains a spring-type metallic disc or reed that closes under

exhaust back pressure. Check valves are located between the

air manifold and the switching valve(s). If exhaust pressure

exceeds injection pressure or if the air pump fails, the check

valve spring closes the valve to prevent reverse exhaust flow.

 SEE FIGURE 27–9 .

SECONDARY

AIR-INJECTION SYSTEM

HOUSING

CENTRIFUGAL

FILTER FAN

ROTOR SHAFT

DRIVE HUB

VENT HOLE

(DO NOT OIL)

FIGURE 27–8 A typical belt-driven AIR pump. Air enters

through the revolving fins behind the drive pulley. The fins act

as an air filter because dirt is heavier than air, and therefore

the dirt is deflected off of the fins at the same time air is being

drawn into the pump.

AIR MANIFOLD

EXHAUST

CHECK

VALVE

AIR HOSE

FROM AIR

PUMP

FIGURE 27–9 The external air manifold and exhaust check

valve on a restored muscle car engine.

340 CHAPTER 27

The air flowing to the exhaust manifold also helps to warm the

three-way catalytic converters quickly on engine start-up so

conversion of exhaust gases may occur sooner:



The SAI pump solenoids are controlled by the PCM. The

PCM turns on the SAI pump by providing the ground

to complete the circuit, which energizes the SAI pump

solenoid relay. When air to the exhaust ports is desired,

the PCM energizes the relay in order to turn on the sole-

noid and the SAI pump.

 SEE FIGURE 27–11 .



The PCM turns on the SAI pump during start-up any time

the engine coolant temperature is above 32°F (0°C). A

typical electric SAI pump operates for a maximum of four

minutes or until the system enters closed-loop operation.

NOTE: These check valves commonly fail, resulting in

excessive exhaust emissions (CO, especially). When the

check valve fails, hot exhaust can travel up to and de-

stroy the switching valve(s) and air pump itself.

BELT-DRIVEN AIR PUMPS The belt-driven air pump

uses a centrifugal filter just behind the drive pulley. As the

pump rotates, underhood air is drawn into the pump and slightly

compressed. The system uses either vacuum- or solenoid-

controlled diverter valves to air directed to the following:



The exhaust manifold, when the engine is cold to help

oxidize carbon monoxide (CO) and unburned hydrocar-

bons (HC) into carbon dioxide (CO

) and water vapor



The catalytic converter when the engine is warm on some

models to help provide the extra oxygen needed for the

efficient conversion of CO and HC into CO

and H



The air cleaner, during deceleration or wide-open throttle

(WOT) engine operation

 SEE FIGURE 27–10 .

ELECTRIC MOTOR–DRIVEN AIR PUMPS This style of

pump is generally used only during cold engine operation and is

computer controlled. The secondary air-injection (SAI) system

helps reduce hydrocarbons (HC) and carbon monoxide (CO).

CATALYTIC

CONVERTER

EXHAUST

MANIFOLD

CHECK

VALVE

CHECK

VALVE

BYPASS DIVERTER

VALVE (SOLENOID)

ELECTRICAL

SIGNALS

FROM THE

COMPUTER

COLD ENGINE

(a)

CATALYTIC

CONVERTER

EXHAUST

MANIFOLD

CHECK

VALVE

CHECK

VALVE

BYPASS DIVERTER

VALVE (SOLENOID)

ELECTRICAL

SIGNALS

FROM THE

COMPUTER

HOT ENGINE

(b)

FIGURE 27–10 (a) When the engine is cold and before the

oxygen sensor is hot enough to achieve closed loop, the air-

flow from the air pump is directed to the exhaust manifold(s)

through the one-way check valves, which keep the exhaust

gases from entering the switching solenoids and the pump

itself. (b) When the engine achieves closed loop, the air is

directed to the catalytic converter.

SECONDARY AIR INJECTION PUMP

FIGURE 27–11 A typical electric motor–driven SAI pump.

This unit is on a Chevrolet Corvette and only works when the

engine is cold.

SECONDARY AIR-INJECTION

SYSTEM DIAGNOSIS

SYMPTOMS The air pump system should be inspected if

an exhaust emissions test failure occurs. In severe cases, the

exhaust will enter the air cleaner assembly, resulting in a horribly

running engine because the extra exhaust displaces the oxygen

needed for proper combustion. With the engine running, check

for normal operation.

 SEE CHART 27–1 .

VISUAL INSPECTION Carefully inspect all parts of the SAI

system, including the following:



Hoses and pipes (Any that have holes and leak air or ex-

haust require replacement.)



Check valve(s), when a pump has become inoperative



Exhaust gases, which could have gotten past the check

valve and damaged the pump (Look for signs of over-

heated areas upstream from the check valves. In severe

cases, the exhaust can enter the air cleaner assembly,