EC−1

EMISSION CONTROL − EMISSION CONTROL SYSTEM

EMISSION CONTROL SYSTEM

EC05E−01

PURPOSE
The emission control systems are installed to reduce the amount of HC, CO and NOx exhausted from the
engine ((3), (4) and (5)), to prevent the atmospheric release of blow−by gas−containing HC (1) and evapo-
rated fuel containing HC being released from the fuel tank (2).
The function of each system is shown in the following table.
System Abbreviation Function
(1) Positive Crankcase Ventilation PCV Reduces HC
(2) Evaporative Emission Control EVAP Reduces evaporated HC
(3) Exhaust Gas Recirculation EGR Reduces NOx
(4) Three−Way Catalytic Converter TWC Reduces HC, CO and NOx
(5) Sequential Multiport Fuel Injection* SFI Injects a precisely timed, optimum amount of fuel for reduced
exhaust emissions

Remark: * For inspection and repair of the SFI system, refer to the SFI section in this manual.

1996 RAV4 (RM447U)

EC−2
EMISSION CONTROL − PARTS LAYOUT AND SCHEMATIC DRAWING

PARTS LAYOUT AND SCHEMATIC DRAWING

EC05F−04

LOCATION

1996 RAV4 (RM447U)

 EC−3
EMISSION CONTROL − PARTS LAYOUT AND SCHEMATIC DRAWING
EC05G−03

DRAWING

1996 RAV4 (RM447U)

EC−4 EMISSION CONTROL − POSITIVE CRANKCASE VENTILATION (PCV)
SYSTEM

POSITIVE CRANKCASE
VENTILATION (PCV) SYSTEM EC05H−04

INSPECTION
1. REMOVE PCV VALVE
2. INSTALL CLEAN HOSE TO PCV VALVE
Clean Hose
3. INSPECT PCV VALVE OPERATION
(a) Blow into the cylinder head side, and check that air
Cylinder Head Side N00929
passes through easily.
CAUTION:
Air Intake Do not suck air through the valve. Petroleum substances
Chamber inside the valve are harmful.
Side
(b) Blow air into the intake manifold side, and check that air
passes through with difficulty.
Clean Hose
If operation is not as specified, replace the PCV valve.
4. REMOVE CLEAN HOSE FROM PCV VALVE
5. REINSTALL PCV VALVE

N00930

6. VISUALLY INSPECT HOSES, CONNECTIONS AND

GASKETS
Check for cracks, leaks or damage.

P00989

1996 RAV4 (RM447U)

 EC−5
EMISSION CONTROL − EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM

EVAPORATIVE EMISSION (EVAP)

CONTROL SYSTEM EC05I−03

INSPECTION
1. VISUALLY INSPECT LINES AND CONNECTIONS
Look for loose connections, sharp bends or damage.
2. VISUALLY INSPECT FUEL TANK
Look for deformation, cracks or fuel leakage.

3. VISUALLY INSPECT FUEL TANK CAP

Check if the cap and/or gasket are deformed or damaged.
If necessary, repair or replace the cap.

Gasket

Check Valve (Vacuum Valve) EC3069

4. DISCONNECT EVAP HOSES FROM CHARCOAL CAN-

ISTER
5. VISUALLY INSPECT CHARCOAL CANISTER
Look for cracks or damage.

S01428

Port E
6. CHECK FOR CLOGGED FILTER, AND STUCK CHECK
Port D VALVE AND DIAPHRAGM
Port A (a) Install a plug to port E.
(b) While holding port B closed, blow air (1.76 kPa, 18
gf/cm2, 0.26 psi) into port A and check that air flows from
Compressed port D.
Air
Port B

S01451

(c) While holding port B and port D closed, blow air (1.76 kPa,
18 gf/cm2, 0.26 psi) into port A and check that air does not
Port A Port D flow from port C.

Port C
Compressed
Air
Port B

S01452

1996 RAV4 (RM447U)

EC−6
EMISSION CONTROL − EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM

(d) Apply vacuum (3.43 kPa, 26 mmHg, 1.01 in.Hg) to port B,

check that the vacuum does not decrease when port C is
closed, and check that the vacuum decreases when port
C is released.

Port B

Port C
S01453

(e) While holding port C closed, apply vacuum (1.23 kPa, 9.2
Port A
mmHg, 0.36 in.Hg) to port A and check that air flows into
Port C
port B.
If a problem is found, replace the charcoal canister.
(f) Remove the plug.
7. RECONNECT EVAP HOSES
Port B 8. INSPECT VSV FOR EVAP (See page SF−45)
9. INSPECT VSV FOR VAPOR PRESSURE SENSOR (See
S01454 page SF−47)
10. INSPECT VAPOR PRESSURE SENSOR (See page
SF−55)

1996 RAV4 (RM447U)

 EC−7
EMISSION CONTROL − EXHAUST GAS RECIRCULATION (EGR) SYSTEM

EXHAUST GAS RECIRCULATION (EGR) SYSTEM

EC05J−03

COMPONENTS

1996 RAV4 (RM447U)

EC−10
EMISSION CONTROL − EXHAUST GAS RECIRCULATION (EGR) SYSTEM

14. REINSTALL EGR VALVE

(a) Install a 2 new gaskets and the EGR valve with the 2 nuts.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
(b) Install the EGR pipe with the 2 union nuts.
Torque: 59 N·m (600 kgf·cm, 43 ft·lbf)
15. REINSTALL THROTTLE BODY (See page SF−33)

S01616

1996 RAV4 (RM447U)

 EMISSION CONTROL − THREE−WAY CATALYTIC CONVERTER (TWC) EC−11
SYSTEM

THREE−WAY CATALYTIC CONVERTER (TWC) SYSTEM

EC0FI−02

COMPONENTS

1996 RAV4 (RM447U)

EC−12 EMISSION CONTROL − THREE−WAY CATALYTIC CONVERTER (TWC)
SYSTEM

1996 RAV4 (RM447U)

 EMISSION CONTROL − THREE−WAY CATALYTIC CONVERTER (TWC) EC−13
SYSTEM
EC05M−02

INSPECTION
1. CHECK CONNECTIONS FOR LOOSENESS OR DAMAGE
2. CHECK CLAMPS FOR WEAKNESS, CRACKS OR DAMAGE
3. CHECK FOR DENTS OR DAMAGE
If any part of the protector is damaged or dented to the extent that it contacts the TWC, repair or replace
it.
4. CHECK HEAT INSULATOR FOR DAMAGE
5. CHECK FOR ADEQUATE CLEARANCE BETWEEN CATALYTIC CONVERTER AND HEAT INSU-
LATOR

1996 RAV4 (RM447U)

 EC−3
EMISSION CONTROL − PARTS LAYOUT AND SCHEMATIC DRAWING
EC05G−03

DRAWING

1997 RAV4 (RM505U)

EC−8
EMISSION CONTROL − EXHAUST GAS RECIRCULATION (EGR) SYSTEM
EC05K−02

INSPECTION
Cap
1. INSPECT AND CLEAN FILTER IN EGR VACUUM
Filter MODULATOR
(a) Remove the cap and filter.
(b) Check the filter for contamination or damage.
(c) Using compressed air, clean the filter.
(d) Reinstall the filter and cap.
HINT:
S01587
Install the filter with the coarser surface facing the atmospheric
side (outward).

Vacuum 2. INSTALL VACUUM GAUGE

Gauge Using a 3−way connector, connect a vacuum gauge to the hose
between the EGR valve and VSV.
3. INSPECT SEATING OF EGR VALVE
Start the engine and check that the engine starts and runs at
idle.

S01588

DLC1 4. CONNECT TERMINALS TE1 AND E1 OF DLC1

Using SST, connect terminals TE1 and E1 of the
TE1 DLC1
SST SST 09843−18020
E1
5. INSPECT VSV OPERATION WITH COLD ENGINE
(a) The engine coolant temperature should be below
55°C (131°F).
(b) Check that the vacuum gauge indicates zero at 2,500
S01261 rpm.

1997 RAV4 (RM505U)

EC−10
EMISSION CONTROL − EXHAUST GAS RECIRCULATION (EGR) SYSTEM

Engine (d) Start the engine, and maintain speed at 2,500 rpm.
Air
2,500 rpm (e) Repeat the above test. Check that there is a strong resis-
tance to air flow.
(f) Reconnect the vacuum hoses to the proper locations.

S01561

11. REMOVE THROTTLE BODY

(See page SF−33)
12. REMOVE EGR VALVE
13. INSPECT EGR VALVE
Check for sticking and heavy carbon deposits.
If a problem is found, replace the valve.

P02553

14. REINSTALL EGR VALVE

(a) Install a 2 new gaskets and the EGR valve with the 2 nuts.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
(b) Install the EGR pipe with the 2 union nuts.
Torque: 59 N·m (600 kgf·cm, 43 ft·lbf)
15. REINSTALL THROTTLE BODY
(See page SF−35)

S01616

1997 RAV4 (RM505U)

EC−2
EMISSION CONTROL − PARTS LAYOUT AND SCHEMATIC DRAWING

PARTS LAYOUT AND SCHEMATIC DRAWING

EC05F−04

LOCATION

1997 RAV4 (RM505U)

 EMISSION SUB SYSTEMS - Exhaust Gas Recirculation

Exhaust Gas Recirculation System

The Exhaust Gas Recirculation (EGR) system is designed to reduce the amount of Oxides of
Nitrogen (NOx) created by the engine during operating periods that usually result in high
combustion temperatures. NOx is formed in high concentrations whenever combustion
temperatures exceed about 2500’F.

The EGR system reduces NOx production by recirculating small amounts of exhaust gases into
the intake manifold where it mixes with the incoming air/fuel charge. By diluting the air/fuel
mixture under these conditions, peak combustion temperatures and pressures are reduced,
resulting in an overall reduction of NOx output. Generally speaking, EGR flow should match the
following operating conditions:

• High EGR flow is necessary during cruising and mid-range acceleration, when
combustion temperatures are typically very high
• Low EGR flow is needed during low speed and light load conditions
• No EGR flow should occur during conditions when EGR operation could adversely affect
engine operating efficiency or vehicle driveability (engine warm up, idle, wide open
throttle, etc.)

EGR Impact on the Engine Control System

The ECM considers the EGR system an integral part of the entire Engine Control System (ECS).
Therefore, the ECM is capable of neutralizing the negative performance aspects of EGR by
programming additional spark advance and decreased fuel injection duration during periods of
high EGR flow. By integrating fuel and spark control with the EGR metering system, engine
performance and fuel economy can actually be enhanced when the EGR system is functioning
as designed.
Page 1 © Toyota Motor Sales, U.S.A., Inc. All Rights Reserved.
 EMISSION SUB SYSTEMS - Exhaust Gas Recirculation

EGR Theory of Operation

The purpose of the EGR system is to precisely regulate EGR flow under different operating
conditions, and to override flow under conditions which would compromise good engine
performance. The precise amount of exhaust gas which must be metered into the intake
manifold varies significantly as engine load changes. This results in the EGR system operating
on a very fine line between good NOx control and good engine performance.

If too much exhaust gas is metered, engine performance will suffer. If too little EGR flows, the
engine may knock and will not meet strict emissions standards. The theoretical volume of
recirculated exhaust gas is referred to as EGR ratio. As the accompanying graph shows, the
EGR ratio increases as engine load increases.

EGR System Components

To achieve this designed control of exhaust gas recirculation, the system uses the following
components:

• Vacuum Actuated EGR Control Valve

• EGR Vacuum Modulator Assembly
• ECM Controlled Vacuum Switching Valve (VSV)

EGR Control Valve

The EGR control valve is used to regulate exhaust gas flow to the intake system by means of a
pintle valve attached to the valve diaphragm. A ported vacuum signal and calibrated spring on
one side of the diaphragm are balanced against atmospheric pressure acting on the other side
of the diaphragm. As the vacuum signal applied to the valve increases, the valve is pulled
further from ifs seat. The key to accurate EGR metering is the EGR vacuum modulator
assembly which precisely controls the strength of the applied vacuum signal.

Page 2 © Toyota Motor Sales, U.S.A., Inc. All Rights Reserved.

 EMISSION SUB SYSTEMS - Exhaust Gas Recirculation

EGR Vacuum Modulator

Because exhaust backpressure increases proportionally with engine load, the EGR vacuum
modulator uses this principle to precisely control the strength of the vacuum signal to the EGR
valve. The typical EGR control system uses two ported vacuum signals from the throttle body.
Port E is the first stage ported vacuum signal and Port R is the second stage ported vacuum
signal uncovered by the opening throttle valve.

When vacuum is applied from port E, the strength of the vacuum signal applied to the EGR
valve will be dependent on the amount of exhaust backpressure acting on chamber A of the
vacuum modulator. When vacuum is applied from port R, the strength of the vacuum signal
applied to the EGR valve will no longer be dependent on the strength of the exhaust
backpressure signal. During this mode, the EGR signal strength is determined solely by

Page 3 © Toyota Motor Sales, U.S.A., Inc. All Rights Reserved.

 EMISSION SUB SYSTEMS - Exhaust Gas Recirculation

the strength of the vacuum signal from port E of the throttle body. The EGR vacuum modulator
provides the ability to precisely match EGR flow rate to amount of load applied to the engine.

ECM Controlled Vacuum Switching Valve (VSV)

In addition to the EGR modulator, an ECM controlled VSV is used to inhibit EGR operation
during conditions where it could adversely affect engine performance and vehicle driveability.
The EGR VSV can be either normally open or closed and installed in series between the
vacuum modulator and EGR valve or installed on a second port on the EGR valve. This VSV
controls an atmospheric bleed which inhibits EGR operation any time a given set of ECM
parameters are met.

ECM Override of EGR

As mentioned, the ECM is capable of inhibiting EGR flow through operation of the VSV bleed.
When the ECM determines an inhibit condition, it de-energizes the VSV, blocking the vacuum
signal to the EGR valve and opening the valve diaphragm to an atmospheric bleed. This
causes the EGR valve to close. Typical EGR inhibit parameters are shown below.

Variations on EGR VSV Placement

There are three basic variations of the EGR vacuum circuit depending on engine application.
All three systems function similarly, the only difference being the placement of the VSV in the
vacuum circuit and the logic of the VSV and ECM.

Page 4 © Toyota Motor Sales, U.S.A., Inc. All Rights Reserved.

 EMISSION SUB SYSTEMS - Exhaust Gas Recirculation

EGR Fault Detection System

An EGR malfunction detection system is incorporated into the TCCS system to warn the driver
when the EGR system is not operating properly. The system uses an Exhaust Gas
Temperature (THG) sensor on the intake side of the EGR valve where it is exposed to exhaust
gas flow whenever the EGR valve opens.

The ECM compares the THG signal with parameters stored in memory. If EGR gas temperature
is determined to be too cold when the ECM has the EGR valve enabled, the MIL will be
illuminated, and a diagnostic code will be stored in ECM memory. This diagnostic configuration
allows the ECM to monitor entire EGR system operation.

EGR Effect On Emissions & Driveability

• Too little EGR flow may cause detonation and IM240 emissions failure for excessive NOx.
Because EGR tends to reduce the volatility of the air/fuel charge, loss of EGR typically
causes detonation to occur. If EGR is commanded but doesn't flow (restricted passage in
manifold, nonfunctional valve, etc.) severe detonation will occur.

• Too much EGR flow and/or excessive flow for driving conditions may cause stumble, flat
spot, hesitation, and surging. Because EGR dilutes the air/fuel charge, too much EGR for
a given engine demand can cause a misfire. It is not uncommon to see tip in hesitation,
stumble and surging when too much EGR is metered.

EGR System Functional Tests

On some OBD-II vehicles, the EGR system can be controlled using the active test feature of the
Diagnostic Tester. This is the easiest way to verify EGR system operation and can generally be
performed as follows:

• Start the engine and allow it to reach operating temperature

• Using the Diagnostic Tester, access the Active Test menu
• Select "EGR System" from the Active Test menu
• Raise engine speed and maintain a steady 3000 rpm
• Activate the EGR VSV (turn EGR On)
• You should notice a slight drop in engine speed and a rise in EGRT gas temperature as
EGR is activated

If engine speed and EGRT gas temperature does not change, the EGR system is not
functioning and the problem may be mechanical or electrical. If the rpm drop is very slight, the
problem may be a partially blocked or restricted EGR passage.

Page 5 © Toyota Motor Sales, U.S.A., Inc. All Rights Reserved.

 EMISSION SUB SYSTEMS - Exhaust Gas Recirculation

EGR System Inspection

On other vehicles, the only way to accurately check the operation of the EGR system is to
perform a systematic inspection of the entire system. The following inspection procedures are
for a 95 5S-FE Camry:

• First, inspect the EGR modulator filter and, if necessary, remove and clean the filter with
compressed air.
• "Tee" a vacuum gauge into the vacuum line between the EGR valve and VSV.
• Start the engine and confirm that it does not run rough at idle. Note: This verifies that the
EGR valve is closed.
• Next, connect terminals TE1 to E1 at DLC 1.

• With coolant temperature cold (A/T: below 140' F, M/T: below 131' F) and engine at 2500
rpm, the vacuum gauge should indicate zero.

Note: This verifies that the VSV is inhibiting EGR flow during cold engine operations.

Page 6 © Toyota Motor Sales, U.S.A., Inc. All Rights Reserved.

 EMISSION SUB SYSTEMS - Exhaust Gas Recirculation

• Next, warm the engine to operating temperature and maintain 2500 rpm. The vacuum
gauge should now indicate low vacuum (typically around 3")

Note: This verifies proper low vacuum signal to the EGR valve during light engine load
conditions.

• Next, with engine speed at 2500 rpm, connect the R port of the EGR modulator directly to
a manifold vacuum source. The vacuum gauge should now indicate high vacuum
(typically around 13") and the engine should run rough.

Note: This verifies proper high signal vacuum to the EGR valve when R port vacuum
overrides the backpressure modulator.

• Disconnect terminals TE1 and El at DLC1 and reattach the EGR hoses to their original
location.

Page 7 © Toyota Motor Sales, U.S.A., Inc. All Rights Reserved.

 EMISSION SUB SYSTEMS - Exhaust Gas Recirculation

If the problem is related to the EGR valve itself, make sure heavy carbon deposits are not
keeping the valve unseated or causing it to stick when opening. Also, if EGR valve control is OK
remove the valve and check the EGR exhaust and intake passages for restrictions. Heavy
carbon deposits can be removed by using a special carbon scrapping tool.

This inspection example systematically confirms the integrity of the EGR valve, VSV,
backpressure modulator, system hoses, and EGR passages. Once the suspect
part/component is identified, it should be individually tested and then repaired or replaced as
necessary. Because slight model to model variations exist between EGR systems, refer to the
Repair Manual for specific EGR system inspection procedures.

Page 8 © Toyota Motor Sales, U.S.A., Inc. All Rights Reserved.

 EC−7
EMISSION CONTROL − EXHAUST GAS RECIRCULATION (EGR) SYSTEM

EXHAUST GAS RECIRCULATION (EGR) SYSTEM

EC05J−03

COMPONENTS

1997 RAV4 (RM505U)