EMISSION CONTROL

SYSTEMS
Page
SYSTEM PURPOSE ............................................. EC-2
COMPONENT LAYOUT AND SCHEMATIC
DRAWING (7M-GE) ......................................... EC-3
COMPONENT LAYOUT AND SCHEMATIC
DRAWING (7M-GTE) ...................................... EC-4
POSITIVE CRANKCASE VENTILATION (PCV)
SYSTEM ........................................................EC-5
FUEL EVAPORATIVE EMISSION CONTROL
(EVAP) SYSTEM ........................................ EC-6
DASH POT (DP) SYSTEM .................................... EC-8
EXHAUST GAS RECIRCULATION (EGR)
SYSTEM (7M-GE) ............................................ EC-12
EXHAUST GAS RECIRCULATION (EGR)
SYSTEM (7M-GTE) .......................................... EC-16
THREE-WAY CATALYST (TWC) SYSTEM .............. EC-20

NOTE: TROUBLESHOOTING
(See pages EM-4 to 6)
EC-2 EMISSION CONTROL SYSTEMS - Svstem P u r ~ o s e

SYSTEM PURPOSE
System Abbreviation 1 Purpose
-
. -- - -- -- -- - -- .-

Positive crankcase ventilation PCV Reduces blow-by gas (HC)

Fuel evaporative emission control EVAP Reduces evaporative HC

Dash pot DP Reduces HC and CO

Exhaust gas recirculation EG R Reduces NOx

Three-way catalyst TWC Reduces HC, CO and NOx

Electronic fuel injection * EFI Regulates all engine conditions for

reduction of exhaust emissions.

* For inspection and repair o f the EFI system, refer t o EFI Section.
 EMISSION CONTROL SYSTEMS - Component Layout and Schematic Drawing (7M-GE) EC-3

COMPONENT LAYOUT AND SCHEMATIC DRAWING (7M-GE)

TWC
I
Sub-oxygen Sensor EGR Cooler
(Calif. only)
EC3341
EC-4 EMISSION CONTROL SYSTEMS - Component Layout and Schematic Drawing (7M-GTE)

COMPONENT LAYOUT AND SCHEMATIC DRAWING (7M-GTE)

I il vsv

EGR Vacuum

EGR Cooler
 EMISSION CONTROL SYSTEMS - Positive Crankcase Ventilation (PCV) System EC-5

POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM

7M-GTE
Air Cleaner Air Cleaner

PCV Hose

Hose

Blow-By Gas-
Fresh Air ----

To reduce HC emlsslons, crankcase blow-by gas ( H C ) i s routed to the intake manifold for combustion In the cylinders.

INSPECTION OF PCV HOSE AND

CONNECTIONS
1. VISUALLY INSPECT HOSE AND CONNECTIONS
Check for cracks, leaks or damage.

2. CLEAN ORIFICE(S)
Clean off any g u m deposits in the orifice(s1 w i t h solvent
and b l o w out w i t h compressed air.

Orifice

Air

\
'\
EC-6 EMISSION CONTROL SYSTEMS - Fuel Evaporative Emission Control (EVAP) System

FUEL EVAPORATIVE EMISSION CONTROL (EVAP) SYSTEM

-Fuel Vapor
--- Fresh Air

-- - - --

T o reduce HC emlsslons, evaporated fuel from the fuel tank IS routed through the charcoal canlster to the Intake m a n ~ f o l d
for combustion In the cylinders

Coolant Temp. T
BVSV
1
Throttle V a l v e O p e n ~ n g ;
~ a n s t e check
r valve 1, Check
Valve ~n
~ Evaporated Fuel (HCI
I I (1) (21

Below -
3 5 ' ~( 9 5 ' ~ ) I I HC from tank IS absorbed lnto
1 1 1
I
I
Positoned below purge - I - 1 -
the canlster
CLOSED
Above port
OPEN
5 4 ' ~( 1 2 9 ' ~ ) Pos~t~oned
above purge - - - I HC from canlster IS led Into alr
OPEN
port ~ n t a k echamber

H ~ g hpressure 1 HC from tank IS absorbed lnto

In tank

High vacuum
in tank
-
I - 1 - CLOSED OPEN OPEN ,411I S led ~ n t othe fuel tank

INSPECTION OF FUEL VAPOR LINES, FUEL

TANK A N D T A N K C A P
1. VISUALLY INSPECT LINES AND CONNECTIONS
Look for loose connections, kinks or damage.

2. VISUALLY INSPECT FUEL TANK

Look for deformation, cracks or fuel leakage

3. VISUALLY INSPECT FUEL TANK CAP

Check if t h e cap andlor gasket are deformed or damaged.
If necessary, repair or replace t h e cap.

check'valve
(Vacuum Valve)
EC3070
 EMISSION CONTROL SYSTEMS - Fuel E v a ~ o r a t i v eEmission Control (EVAP) Svstem EC-7

INSPECTION OF CHARCOAL CANISTER

1. REMOVE CHARCOAL CANISTER

2. VISUALLY INSPECT CHARCOAL CANISTER CASE

Look for cracks or damage.

3. CHECK FOR CLOGGED FILTER AND STUCK CHECK

Tank P i ~ e
VALVE
(a) Using l o w pressure compressed air, blow into the tank
pipe and check that air f l o w s w i t h o u t resistance f r o m
t h e other pipes.
Purge Pipe I I (b) B l o w into the purge pipe and check that air does n o t
f l o w f r o m the other pipes.
If a problem is found, replace the charcoal canister.

4. CLEAN FILTER IN CANISTER

Clean the filter b y blowing 3 k g i c m 2 ( 4 3 psi, 2 9 4 kPa)of
compressed air into the tank pipe while holding the other
upper canister pipe closed.
HINT:
D o n o t attempt t o w a s h t h e canister.
No activated carbon should come out.

5. INSTALL CHARCOAL CANISTER

INSPECTION OF BVSV
Below
CHECK BVSV BY BLOWING AIR INTO PIPE
(a) Drain the coolant from the radiator into a suitable con-
tainer.
Closed
(b) Remove t h e BVSV.
(c) Cool the BVSV t o below 35OC (95OF) w i t h cool water.
- Cool Water
(d) Blow air into a pipe and check that the BVSV is closed.

(e) Heat the BVSV t o above 54OC ( 1 2 g ° F ) w i t h hot

Above 54'~ ( 1 2 9 " ~ )
water.
(f) B l o w air into a pipe and check that the BVSV is open.
If a problem is found, replace the BVSV.
(g) Apply sealant t o the threads of the BVSV and reinstall.
Sealant: Part N o . 0 8 8 3 3 - 0 0 0 7 0 , THREE BOND 1 3 2 4
or equivalent
(h) Fill the radiator w i t h coolant.
EC-8 EMISSION CONTROL SYSTEMS - Dash Pot (DP) System

DASH POT (DP) SYSTEM

Normal Driving Deceleration

I I
DP Diaphragm DP Diaphragm

To reduce HC and Co emissions, when decelerating the dash pot opens the throttle valve slightly more than at idle.
This causes the air-fuel mixtu re to burn completely.

Condition Diaphragm VTV Throttle Valve

Idling
I
Pushed in by return force of throttle
valve
1 CLOSED 1
I
Idle speed position

1
I

Normal driving Pushed out by diaphragm spring OPEN High speed position

Deceleration
Pushed in by return force of throttle
valve / Slightly opens and then slowly closes
to idle position
 EMISSION CONTROL SYSTEMS - D a s h P o t (DP) S v s t e m EC-9

INSPECTION OF DP SYSTEM
1. WARM UP ENGINE

2. CHECK IDLING SPEED

3. CHECK DP SETTING SPEED

7M-GE DP Diaphragm
I (a) M a i n t a i n t h e engine speed a t 3,000 r p m .
(bl Pinch t h e v a c u u m hose b e t w e e n t h e DP and VTV.
Throttle Valve
!open

VTV I
I 13,0001

Throttle Valve

(c) Release t h e t h r o t t l e valve.

(d) C h e c k t h a t t h e DP is set.
DP setting speed: 2,000 rprn
Valve
EC-10 EMISSION CONTROL SYSTEMS - Dash Pot (DP) Svstem

If n o t at the specified speed, adjust w i t h the DP adjusting

screw.

4. CHECK OPERATION OF VTV

7M-GE Release '
(a) Set the DP speed in the same procedure as above; (a)
t o (c).
(b) Release the pinched hose and check t h a t the engine
returns t o idle speed in approx. 1 second.

Approx.
1 Second

IF NO PROBLEM IS FOUND WITH THIS INSPECTION, THE

SYSTEM IS OKAY; OTHERWISE INSPECT EACH PART
 EMISSION CONTROL SYSTEMS - Dash Pot (DP) Svstem EC-11

INSPECTION OF VTV
CHECK AND CLEAN FILTER ON VTV
(a) Check t h e filter for contamination or damage
( b ) Using compressed air, clean the filter.

CHECK V T V BY BLOWING AIR INTO EACH SIDE

(a) Check that air f l o w s w i t h o u t resistance f r o m B t o A.
( b ) Check that air f l o w s w i t h difficulty f r o m A t o 6.

(Black)

-
Air

ECOlO
EC-12 EMISSION CONTROL SYSTEMS - Exhaust Gas Recirculation (EGR) S y s t e m ( 7 M - G E )

EXHAUST GAS RECIRCULATION (EGR) SYSTEM (7M-GE)

EG R EGR Port

EGR Port R Port

Vacuum
Modulator
GR
/ R, Port

alve

(3)

EGR Port
/
R Port EGR Port

T o reduce NOx emissions, part of the exhaust gases are recirculated through the EGR valve t o the intake manifold to lower
combustion temperature.

1
Coolant *Engine
VSv
T h r o t t l e Valve
1 Pressure i n the EGR EGR v a c u u m EGR
Exhaust Gas

'
RPM Opening Angle Valve Pressure Chamber Modulator Valve
I I
- OPEN - - -
%>cuated
Above OPEN - - -
5,200 r p m CLOSED
I reclrculated

Above 6 3 ' ~
(145'~) Below
CLOSED
Pos~tionedbelow
EGR p o r t

Positioned be-
tween EGR p o r t
and R p o r t
HIGH
-

* * ~ r e s con-
e
stantly alter-
1 -

oPENs Passage
atmosphere
nating between CLOSES passage
low and high t o atmos~here
CLOSED

OPEN
Z L l a t e d

recirculated

Reclrculated
Positioned above
R port
(3)
HIGH
,! CLOSES passage
t o atmosphere
1 OPEN 1 Recirculated
(increase)
Engine RPM control is for Calif. only.
** Pressure increase-Modulator closes --EGR valve opens---Pressure drops
RGE : valve close- Modulator opens-
* * * When the throttle valve i s positioned above the R port, the EGR vacuum modulator will close the atmosphere
passage and open the EGR valve t o increase the EGR gas, even if the exhaust pressure is insufficiently low.
 EMISSION CONTROL SYSTEMS - Exhaust Gas Recirculation (EGR) System (7M-GE) EC-13

INSPECTION OF EGR SYSTEM

Filter CHECK A N D CLEAN FILTER I N EGR V A C U U M
MODULATOR
(a) Check the filter for contamination or damage.
(b) Using compressed air, clean t h e filter.

PREPARATION
Using a 3 - w a y connector, connect a vacuum gauge t o t h e
- Vacuum Gauge I hose between t h e EGR valve and EGR vacuum modulator.

CHECK SEATING OF EGR VALVE

Start t h e engine and check that t h e engine starts and runs
a t idle.

CHECK VSV WlTH COLD ENGINE

I 2,500 rpm No Vacuum (a) The coolant temperature should be below 57OC
( 1 35OF).
( b ) Check that the vacuum gauge indicates is zero at
2 , 5 0 0 rpm.

Tachometer Vacuum Gauge

HOT CHECK VSV AND EGR VACUUM MODULATOR WlTH

2,500 rpm Low Vacuum WARM ENGINE
(a) W a r m u p the engine.
( b ) Check that the vacuum gauge indication is approx.
7 0 m m H g ( 2 . 7 6 in.Hg, 9 . 3 kPa) at 2 , 5 0 0 rpm.
(c) Check that the vacuum gauge indication is zero at idle.

Tachometer Vacuum Gauge

EC0137 EC0129

(d) Disconnect the vacuum hose f r o m R port of the EGR

vacuum modulator and connect R port directly t o the
intake manifold w i t h another hose.
(el Check that the vacuum gauge indicates high vacuum
at 2 , 5 0 0 rpm.
HINT: A s a large amount of EGR gas enters, t h e engine
will misfire slightly.
(f) Disconnect t h e vacuum gauge and reconnect the
vacuum hoses t o t h e proper locations.
EC-14 EMISSION CONTROL SYSTEMS - Exhaust Gas Recirculation (EGR) System (7M-GE)

6. CHECK EGR VALVE

(a) Apply vacuum directly t o the EGR valve w i t h the en-
gine idling.
( b ) Check that the engine runs rough or dies.
(c) Reconnect the vacuum hoses t o t h e proper location.

IF NO PROBLEM IS FOUND WITH THIS INSPECTION, THE

SYSTEM IS OKAY; OTHERWISE INSPECT EACH PART

Engine Stopped INSPECTION OF EGR VACUUM MODULATOR

CHECK EGR VACUUM MODULATOR OPERATION
(a) Disconnect the vacuum hoses from ports P, Q and R
of t h e EGR vacuum modulator.
(b) Block ports P and R w i t h your finger.
(c) Blow air into port Q. Check that the air passes through
t o t h e air filter freely.

EC212'

Engine at (d) Start the engine and maintain speed at 2,500 rpm.
(el Repeat t h e above test. Check t h a t there is a strong
resistance t o air f l o w .
If a problem is found, replace t h e EGR vacuum modulator.
(f) Reconnect the vacuum hoses t o the proper locations.

INSPECTION OF VSV
1. CHECK VACUUM CIRCUIT CONTINUITY IN VSV BY
BLOWING AIR INTO PIPE
(a) Connect the VSV terminals t o the battery terminals
as illustrated.
(b) B l o w air into a pipe and check that the VSV is open.

(c) Disconnect the battery.

(dl Blow air into a pipe and check that the VSV is closed.
If a problem is found, replace the V S V .

Battery
 EMISSION CONTROL SYSTEMS - Exhaust Gas Recirculation (EGR) System (7M-GE) EC-15

2. CHECK FOR SHORT CIRCUIT

No continuity
I Using an ohmmeter, check that there is n o continuity be-
t w e e n t h e terminals and the V S V body.
If there is continuity, replace the V S V .

Ohmmeter 3. CHECK FOR OPEN CIRCUIT

R
Using an ohmmeter, measure the resistance between the
terminals.
Specified resistance: 3 8 - 44 R at 2 0 ° C (68OF)
If the resistance is n o t w i t h i n specification, replace t h e
VSV.

INSPECTION OF EGR VALVE

1. REMOVE EGR VALVE
Check the valve for sticking and heavy carbon deposits.
If a problem is found, replace it.

2. INSTALL EGR VALVE WITH NEW GASKET

INSPECTION OF WATER TEMP. SENSOR

(See page FI-113)
-
EC-16 EMISSION CONTROL SYSTEMS - Exhaust Gas Recirculation (EGR) System (7M-GTE)

EXHAUST GAS RECIRCULATION (EGR) SYSTEM (7M-GTE)

EGR Vacuum
Modulator
EGR Port

(2)
EGR Port

To reduce NOx emissions, part of the exhaust gases are recirculated through the EGR valve t o the intake manifold t o lower
the maximum combustion temperature.

Coolant Throttle Valve Pressure in the E G R E G R Vacuum EG R

VSV Exhaust Gas
Temp. Opening Angle Valve Pressure Chamber Modulator Valve

1 Not
recirculated
Positioned below Not
(1) - -
~bov6
e 3'~ OPEN . EGR p o r t recirculated
(145'~) (E-G) Positioned above CLOSES passage
i Recircu lated
(2) OPEN
EGR p o r t t o atmosphere (increase)

* When the throttle valve is positioned above the EGR port, the EGR vacuum modulator will close the atmosphere
passage and open the EGR valve t o increase the EGR gas, even i f the exhaust pressure is insufficiently low.
I
 EMISSION CONTROL SYSTEMS - Exhaust Gas Recirculation (EGR) System (7M-GTE) EC-17

INSPECTION OF EGR SYSTEM

CHECK AND CLEAN FILTERS IN EGR VACUUM
MODULATOR
(a) Check the filter for contamination or damage.
(b) Using compressed air, clean t h e filter.

Vacuum Gauge PREPARATION

Using a 3 - w a y connector, connect a vacuum gauge t o the
hose b e t w e e n t h e EGR valve and EGR vacuum modulator.

CHECK SEATING OF EGR VALVE

Start t h e engine and check that the engine starts and runs
at idle.

COLD
CHECK VSV WlTH COLD ENGINE
2.500 r ~ m No Vacuum (a) The coolant temperature should be below 57OC
( 1 35OF).
( b ) Check that the vacuum gauge indication is zero at
2 , 5 0 0 rpm.

Tachometer Vacuum Gauge

HOT
CHECK VSV AND EGR VACUUM MODULATOR WlTH HOT
ENGINE
2,500 rpm Low Vacuum
(a) W a r m u p the engine.
( b ) Check that the vacuum gauge indication is approx.
7 0 m m H g ( 2 . 7 6 in.Hg, 9 . 3 kPa) at 2 , 5 0 0 rpm.
(c) Disconnect t h e vacuum gauge and reconnect t h e
vacuum hose t o the proper location.

Tachometer Vacuum Gauge

E C O l 3 7 EC012'

CHECK EGR VALVE

(a) Apply vacuum directly t o the EGR valve w i t h the en-
gine idling.
( b ) Check that the engine runs rough or dies.
(c) Reconnect the vacuum hoses t o t h e proper location.

IF NO PROBLEM IS FOUND WlTH THIS INSPECTION, THE

SYSTEM IS OKAY; OTHERWISE INSPECT EACH PART
EC-18 EMISSION CONTROL SYSTEMS - Exhaust Gas Recirculation (EGR) Svstem (7M-GTE)

I Engine 1 INSPECTION OF EGR VACUUM MODULATOR

CHECK EGR VACUUM MODULATOR OPERATION
(a) Disconnect the vacuum hoses f r o m the EGR vacuum
modulator.
(b) Block port P w i t h your finger.
(c) B l o w air into t h e other pipe. Check that the air pass-
es through t o t h e air filter freely.

(dl Start the engine and maintain speed at 2,500 rpm.

(e) Repeat the above test. Check that there is a strong
resistance t o air f l o w .
If a problem is found, replace t h e EGR vacuum modulator.
(f) Reconnect the vacuum hoses t o the proper locations.

INSPECTION OF VSV
1. CHECK VACUUM CIRCUIT CONTINUITY IN VSV BY
BLOWING AIR INTO PIPE
(a) Connect t h e VSV terminals t o the battery terminals
as illustrated.
(b) B l o w into pipe E and check that air comes o u t of the
air filter.

(c) Disconnect the battery.

(d) B l o w into pipe E and check t h a t air comes o u t of
pipe G.
If a problem is found, replace the V S V .

N o continuity 2. CHECK FOR SHORT CIRCUIT

Using an ohmmeter, check that there is n o continuity be-
t w e e n the terminals and t h e VSV body.
If there is continuity, replace the V S V .
EMISSION CONTROL SYSTEMS - Exhaust Gas Recirculation (EGR) Svstem (7M-GTE) EC-19

3. CHECK FOR OPEN CIRCUIT

Using an ohmmeter, measure the resistance b e t w e e n t h e
terminals.
Specified resistance: 38 - 44 fl at 2 0 ° C (68OF)
If the resistance is n o t w i t h i n specification, replace the
VSV.

INSPECTION OF EGR VALVE

1. REMOVE EGR VALVE
Check the valve for sticking and heavy carbon deposits.
if a problem is found, replace i t .

2. INSTALL EGR VALVE WITH NEW GASKET

INSPECTION OF WATER TEMP. SENSOR

(See page FI-113)
EC-20 EMISSION CONTROL SYSTEMS - T h r e e - W a v C a t a l v s t ( T W C ) S v s t e r n

THREE-WAY CATALYST (TWC) SYSTEM

7M-GE (Federal and Canada)

Three-Way Catalyst
7M-GE (California) (Monolithic)

l-7
NOx, CO, HC

COZ. N2. H z 0 1-
Three-Wav Catalvst
(~onolithic) ' Three-Way Catalyst
Iblnnnlithir)
7M-GTE
n

- E

Three-Wav Catalvst
(~onolithic) Three-Way Catalyst
(Monolithic)
- COz,Nz.HzO , l

To reduce HC, CO and NOx emissions, they are oxidized, reduced and converted t o nitrogen ( N 2), carbon dioxide ( C 0 2)
and water ( H 2 0 ) by the catalyst.

Exhaust Port

HC, CO, A N D NOx , OXIDATION AND

REDUCTION
1 Exhaust Gas

co2
H2 0
N2
EC3427
EC3340
EC2907

I
EMISSION CONTROL SYSTEMS - Three-Wav Catalvst ( T W C ) System EC-2 1

INSPECTION OF EXHAUST PIPE ASSEMBLY

1. CHECK CONNECTIONS FOR LOOSENESS OR DAMAGE

2. CHECK CLAMPS FOR WEAKNESS, CRACKS OR DAMAGE

INSPECTION OF CATALYTIC CONVERTER

CHECK FOR DENTS OR DAMAGE
If any part of the protector is damaged or dented t o the
extent that i t touches the catalyst, repair or replace it.

INSPECTION OF HEAT INSULATOR

H e a t l nsu lator 1. CHECK HEAT INSULATOR FOR DAMAGE

2. CHECK FOR ADEQUATE CLEARANCE BETWEEN CATA-

LYTIC CONVERTER AND HEAT INSULATOR

REPLACEMENT OF CATALYTIC CONVERTER

1. REMOVE CONVERTER
(a) Jack u p the vehicle.
( b ) Check that the converter is cool.
(c) Remove the bolts at the front and rear of the con-
verter.
(d) Remove the converter and gaskets.

2. INSTALL CONVERTER
(a) Place n e w gaskets o n the converter front and rear
pipes, and connect the converter t o the exhaust pipes.
( b ) Tighten the bolts.
Torque: Catalyst-Exhaust pipe
440 kg-cm ( 3 2 ft-lb, 4 3 N - m )
- MEMO -