DTC    P0420    Catalyst System Efficiency Below Threshold (Bank 1)

for Preparation Click here


DESCRIPTION

The ECM uses sensors mounted in front of and behind the Three-Way Catalytic Converter (TWC) to monitor its efficiency.
The first sensor, the Air Fuel Ratio (A/F) sensor, sends pre-catalyst information to the ECM. The second sensor, the Heated Oxygen (HO2) sensor, sends post-catalyst information to the ECM.
In order to detect any deterioration in the TWC, the ECM calculates the Oxygen Storage Capacity (OSC) of the TWC. This calculation is based on the voltage output of the HO2 sensor while performing active air fuel ratio control, rather than the conventional detecting method, which uses the locus ratio.
The OSC value is an indication of the oxygen storage capacity of the TWC. When the vehicle is being driven with a warm engine, active air fuel ratio control is performed for approximately 15 to 20 seconds. When it is performed, the ECM deliberately sets the air fuel ratio to lean or rich levels. If the rich-lean cycle of the HO2 sensor is long, the OSC becomes greater. There is a direct correlation between the OSCs of the HO2 sensor and the TWC.
The ECM uses the OSC value to determine the state of the TWC. If any deterioration has occurred, it illuminates the MIL and sets the DTC.

DTC No.
DTC Detection Condition
Trouble Area
P0420
Oxygen Storage Capacity (OSC) value smaller than standard value under active air fuel ratio control
(2-trip detection logic)
  1. Gas leak from exhaust system
  2. Air fuel ratio sensor (sensor 1)
  3. Heated oxygen sensor (sensor 2)
  4. Exhaust manifold assembly (TWC: Front catalyst)
  5. Front exhaust pipe assembly (TWC: Rear catalyst)
  6. EGR valve assembly

CATALYST LOCATION


A237086E01


Text in Illustration 
*1
Air fuel ratio sensor (bank1 sensor 1)
*4
Front exhaust pipe assembly (TWC: Rear catalyst)
*2
Exhaust manifold assembly (TWC: Front catalyst)
*5
Tail exhaust pipe assembly
*3
Heated oxygen sensor (bank1 sensor 2)



CONFIRMATION DRIVING PATTERN

HINT:
Performing this confirmation driving pattern will activate the catalyst monitor. This is very useful for verifying the completion of a repair.


A231470E03

  1. Connect the intelligent tester to the DLC3.
  2. Turn the ignition switch to ON.
  3. Turn the tester on.
  4. Clear DTCs (even if no DTCs are stored, perform the clear DTC operation).
  5. Turn the ignition switch off and wait for at least 30 seconds.
  6. Turn the ignition switch to ON and turn the tester on.
  7. Start the engine and warm it up until the engine coolant temperature is 75°C (167°F) or higher [A].
  8. Drive the vehicle at approximately 60 km/h (38 mph) for 10 minutes or more [B].

    HINT:
    Drive the vehicle while keeping the engine load as constant as possible.

    CAUTION:
    When performing the confirmation driving pattern, obey all speed limits and traffic laws.

  9. Enter the following menus: Powertrain / Engine and ECT / DTC [C].
  10. Read pending DTCs.

    HINT:
    1. If a pending DTC is output, the system is malfunctioning.
    2. If a pending DTC is not output, perform the following procedure.

  11. Enter the following menus: Powertrain / Engine and ECT / Utility / All Readiness.
  12. Input the DTC: P0420.
  13. Check the DTC judgment result.

    Tester Display
    		Description
    NORMAL
    1. DTC judgment completed
    2. System normal
    ABNORMAL
    1. DTC judgment completed
    2. System abnormal
    INCOMPLETE
    1. DTC judgment not completed
    2. Perform driving pattern after confirming DTC enabling conditions
    UNKNOWN
    1. Unable to perform DTC judgment
    2. Number of DTCs which do not fulfill DTC preconditions has reached ECU memory limit

    HINT:
    1. If the judgment result shows NORMAL, the system is normal.
    2. If the judgment result shows ABNORMAL, the system has a malfunction.
    3. If the judgment result shows INCOMPLETE or UNKNOWN, perform steps [D] through [E].

  14. Drive the vehicle at a speed between 75 and 100 km/h (47 and 63 mph) for 10 minutes or more [D].

    HINT:
    Drive the vehicle while keeping the engine load as constant as possible.

    CAUTION:
    When performing the confirmation driving pattern, obey all speed limits and traffic laws.

  15. Check the DTC judgment result again [E].

CONDITIONING FOR SENSOR TESTING

HINT:
Perform the operation with the engine speeds and time durations described below prior to checking the waveforms of the Air Fuel Ratio (A/F) and Heated Oxygen (HO2) sensors. This is in order to activate the sensors sufficiently to obtain the appropriate inspection results.


A118003E43

  1. (a) Connect an intelligent tester to the DLC3.
  2. (b) Start the engine and warm it up with all the accessories switched OFF, until the engine coolant temperature stabilizes.
  3. (c) Run the engine at an engine speed of between 2500 rpm and 3000 rpm for at least 3 minutes.
  4. (d) While running the engine at 3000 rpm and 2000 rpm alternating at 2 second intervals, check the waveforms of the A/F and HO2 sensors using the tester.

HINT:
  1. If either voltage output of the A/F or HO2 sensor does not fluctuate, or there is a noise in the waveform of either sensor the sensor may be malfunctioning.
  2. If the voltage outputs of both the sensors remain lean or rich, the air-fuel ratio may be extremely lean or rich. In such cases, enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Injection Volume for A/F Sensor.
  3. If the Three-Way Catalytic Converter (TWC) has deteriorated, the HO2 sensor (located behind the TWC) voltage output fluctuates up and down frequently, even under normal driving conditions (active air-fuel ratio control is not performed).


A121610E27


INSPECTION PROCEDURE

HINT:
Read freeze frame data using an intelligent tester. The ECM records vehicle and driving condition information as freeze frame data the moment a DTC is stored. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred.

1.CHECK ANY OTHER DTCS OUTPUT (IN ADDITION TO P0420)

  1. Connect the intelligent tester to the DLC3.

  1. Turn the ignition switch to ON.

  1. Turn the tester on.

  1. Enter the following menus: Powertrain / Engine and ECT / DTC.

  1. Read the DTC.

Result 
Result
Proceed to
P0420
A
P0420 and other DTCs
B


B
GO TO DTC CHART (Click here)
A


2.PERFORM ACTIVE TEST USING INTELLIGENT TESTER (CONTROL THE INJECTION VOLUME FOR A/F SENSOR)

  1. Connect the intelligent tester to the DLC3.

  1. Start the engine and turn the tester on.

  1. Warm up the engine at an engine speed of 2500 rpm for approximately 90 seconds.

  1. Enter the following menus: Powertrain / Engine / Active Test / Control the Injection Volume for A/F Sensor.

  1. Perform the Control the Injection Volume for A/F Sensor operation with the engine in an idling condition (press the RIGHT or LEFT button to change the fuel injection volume).

  1. Monitor the voltage outputs of the A/F and HO2 sensors (AFS Voltage B1S1 and O2S B1S2) displayed on the tester.

    HINT:
    1. The Control the Injection Volume for A/F Sensor operation lowers the fuel injection volume by 12.5% or increases the injection volume by 25%.
    2. Each sensor reacts in accordance with increases and decreases in the fuel injection volume.

      Standard:

      Tester Display
      (Sensor)
      		Injection Volume
      		Status
      		Voltage
      AFS Voltage B1S1
      (A/F)
      		+25%
      		Rich
      		Less than 3.1 V
      AFS Voltage B1S1
      (A/F)
      		-12.5%
      		Lean
      		More than 3.4 V
      O2S B1S2
      (HO2)
      		+25%
      		Rich
      		More than 0.55 V
      O2S B1S2
      (HO2)
      		-12.5%
      		Lean
      		Less than 0.4 V


      Result 
      Status
      AFS Voltage B1S1
      		Status
      O2S B1S2
      		A/F Condition and A/F and
      HO2 Sensor Conditions
      		Misfires
      		Main Suspected Trouble Area
      		Proceed to
      Lean/Rich
      		Lean/Rich
      		Normal
      		-
      1. Three-Way Catalytic Converter (TWC)
      2. Gas leak from exhaust system
      		A
      Lean
      		Lean/Rich
      		A/F sensor malfunction
      		-
      1. A/F sensor
      		B
      Rich
      		Lean/Rich
      		A/F sensor malfunction
      		-
      1. A/F sensor
      Lean/Rich
      		Lean
      		HO2 sensor malfunction
      		-
      1. HO2 sensor
      2. Gas leak from exhaust system
      		C
      Lean/Rich
      		Rich
      		HO2 sensor malfunction
      		-
      1. HO2 sensor
      2. Gas leak from exhaust system
      Lean
      		Lean
      		Actual air-fuel ratio lean
      		May occur
      1. Extremely rich or lean actual air fuel ratio
      2. Gas leak from exhaust system
      		D
      Rich
      		Rich
      		Actual air-fuel ratio rich
      		-
      1. Extremely rich or lean actual air fuel ratio
      2. Gas leak from exhaust system
      Lean: During Control the Injection Volume for A/F Sensor, the air fuel ratio sensor output voltage (AFS) is consistently more than 3.4 V, and the heated oxygen sensor output voltage (O2S) is consistently less than 0.4 V.
      Rich: During Control the Injection Volume for A/F Sensor, the AFS is consistently less than 3.1 V, and the O2S is consistently more than 0.55 V.
      Lean/Rich: During Control the Injection Volume for A/F Sensor of the Active Test, the output voltage of the air fuel ratio sensor and heated oxygen sensor alternates correctly.



B
REPLACE AIR FUEL RATIO SENSOR (Click here)

C
Go to step 7

D
Go to step 8
A


3.CHECK FOR EXHAUST GAS LEAK

  1. Check for exhaust gas leak.

    OK:
    No gas leaks.



NG
REPAIR OR REPLACE EXHAUST GAS LEAK POINT
OK


4.PERFORM ACTIVE TEST USING INTELLIGENT TESTER (CONTROL THE EGR STEP POSITION)

  1. Connect the intelligent tester to the DLC3.

  1. Start the engine and warm it up until the engine coolant temperature reaches 75°C (167°F) or higher.

    HINT:
    The A/C switch and all accessory switches should be off.

  1. Turn the tester on.

  1. Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the EGR Step Position.

  1. Check the MAP in Data List and the idling condition while performing Active Test.

    OK:
    MAP and idling condition change in response to EGR step position.


Standard:

-
EGR Step Position (Active Test)
0 Steps
0 to 30 Steps
30 to 40 Steps or Higher
Idling condition
Steady idling
Engine changes from steady to rough idling
Engine changes from rough idling to engine stall
MAP value
(Data List)
28 to 48 kPa
(EGR valve is fully closed)
MAP value is at least +10 to 15 kPa higher than when EGR valve is fully closed
80 to 110 kPa
(After engine stall)

HINT:
  1. Do not leave the EGR valve open for 10 seconds or more during the Active Test.
  2. Be sure to return the EGR valve to step 0 when Active Test is completed.

Result 
Result
Proceed to
Outside standard range
A
Within standard range
B


B
Go to step 6
A


5.INSPECT EGR VALVE ASSEMBLY

  1. Remove the EGR valve assembly (Click here).

  1. Check if the EGR valve is stuck open.

    OK:
    EGR valve is tightly closed (It is not stuck open).

  1. Reinstall the EGR valve assembly (Click here).



NG
REPLACE EGR VALVE ASSEMBLY (Click here)
OK


6.REPLACE EXHAUST MANIFOLD ASSEMBLY (TWC: FRONT CATALYST)

  1. Replace the exhaust manifold assembly (Click here).


NEXT

REPLACE FRONT EXHAUST PIPE ASSEMBLY (TWC: REAR CATALYST) (Click here)  

7.CHECK FOR EXHAUST GAS LEAK

  1. Check for exhaust gas leak.

    OK:
    No gas leaks.



NG
REPAIR OR REPLACE EXHAUST GAS LEAK POINT
OK

REPLACE HEATED OXYGEN SENSOR (Click here)  

8.CHECK FOR EXHAUST GAS LEAK

  1. Check for exhaust gas leak.

    OK:
    No gas leaks.



NG
REPAIR OR REPLACE EXHAUST GAS LEAK POINT
OK


9.PERFORM ACTIVE TEST USING INTELLIGENT TESTER (CONTROL THE EGR STEP POSITION)

  1. Connect the intelligent tester to the DLC3.

  1. Start the engine and warm it up until the engine coolant temperature reaches 75°C (167°F) or higher.

    HINT:
    The A/C switch and all accessory switches should be off.

  1. Turn the tester on.

  1. Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the EGR Step Position.

  1. Check the MAP in Data List and the idling condition while performing Active Test.

    OK:
    MAP and idling condition change in response to EGR step position.


Standard:

-
EGR Step Position (Active Test)
0 Steps
0 to 30 Steps
30 to 40 Steps or Higher
Idling condition
Steady idling
Engine changes from steady to rough idling
Engine changes from rough idling to engine stall
MAP value
(Data List)
28 to 48 kPa
(EGR valve is fully closed)
MAP value is at least +10 to 15 kPa higher than when EGR valve is fully closed
80 to 110 kPa
(After engine stall)

HINT:
  1. Do not leave the EGR valve open for 10 seconds or more during the Active Test.
  2. Be sure to return the EGR valve to step 0 when Active Test is completed.

Result 
Result
Proceed to
Outside standard range
A
Within standard range
B


B
CHECK CAUSE OF EXTREMELY RICH OR LEAN ACTUAL AIR FUEL RATIO (Click here)
A


10.INSPECT EGR VALVE ASSEMBLY

  1. Remove the EGR valve assembly (Click here).

  1. Check if the EGR valve is stuck open.

    OK:
    EGR valve is tightly closed (It is not stuck open).

  1. Reinstall the EGR valve assembly (Click here).



NG
REPLACE EGR VALVE ASSEMBLY (Click here)
OK

CHECK CAUSE OF EXTREMELY RICH OR LEAN ACTUAL AIR FUEL RATIO (Click here)