! QFENGINE | | EMISSION CONTROL CS REPAIR MANUAL 1981 move. TOYOTA MOTOR CORPORATION . FOR USA Pub, No. 3FOREWORD This repair manual has been prepared to provide information covering general service repairs for the Emission Contral System of the 2F Engine, Applicable models: 1981 FJ40L series 1981 FJ40LV series 1981 FJGOLG series For service of the 2F Engine, refer to the following repair manual, 2F Engine Repair Menual (Pub, No. 98126E) All information contained in this manual is the most up-to-date at the time of publication. However specifications and pro- cedures are subject to change without notice, TOYOTA MOTOR CORPORATION1981 TOYOTA 2F ENGINE EMISSION CONTROL REPAIR MANUAL INTRODUCTION Ki TROUBLESHOOTING M2 EMISSION CONTROL SYSTEM [EB ENGINE ADJUSTMENT [Zl SPECIFICATIONS —Eq © 1986 TOYOTA MOTOR CORPORATION All rights reserved. This book may not be Feproduced or copied, in whole or in part, without the written ‘permission of ‘Toyota Motor Corporation. EEE EEE HE EEE eee eee eee eee eee eee eee ee eee eee ee eee ee eee eee ee eee eee ee eee eee eee eee ee44 INTRODUCTION Page GENERAL PRECAUTIONS ....... 12 PRECAUTIONS FOR VEHICLES EQUIPPED WITH A CATALYTIC CONVERTER .13 ABBREVIATIONS USED IN THIS MANUAL12 INTRODUCTION — General Precautions CORRECT GENERAL PRECAUTIONS 1. Know the importance of periodic maintenance. (2) Every service item in the periodic maintenance list must be performed. (b) Failing to do even one item can cause the engine to run poorly and increase exhaust emissions, 2, Listen to the customers comments carefully. Always determine exactly what the customer complaint is, if any, and verify it before proceeding with repairs. Determine if you have an engine or emission system pro- blem. (a) Engine problems are usually not caused by the emis- sion control systems. (b) When troubleshooting, always check the engine end the ignition system first, 4. Check hose and wiring connections first. The most frequent cause of problems is simply a bad con nection in wiring or vacuum hoses. Always make sure that connections are secure end correct. 5. Observe the following precautions to avoid damage to the parts: {a) To disconnect vacuum hoses, pull on the end, not the middle of the hose. {b) To pull apart electrical connectors, pull on the con: hector itself, not the wires. {c)_ Be careful not to drop electrical components, such as, sensors or relays. If they are dropped on a hard floor, they should be replaced and not reused. (d) When steam cleaning an engine, protect the distri butor, coil, air filter, carburetor intake, air pump and EGR vacuum modulator from water. {e) Never use an impact wrench to remove or install thermo switches or thermo sensors. (f) When checking for continuity at a wire connector, insert the tester probe carefully to prevent terminals, from bending. (a) When using @ vacuum gauge, never force the hose ‘onto a connector that is too large. Use a step-down adapter instead, Once the hose has been stretched, it may leak. INTRODUCTION — General Precautions, Precautions for Vehicles Equipped with @ Catalytic Converter 1.3 6, Tag hoses before disconnecting them: {a} When disconnecting vacuum hoses, use tags to identi fy how they should be reconnected. {b) After completing a job, double check that the vacuum hoses are properly connected, A label under the hood shows the proper layout. PRECAUTIONS FOR VEHICLES EQUIPPED WITH A CATALYTIC CONVERTER WARNING: If large amounts of unburned gasoline flow into the catalytic converter, it may overheat and create a fire hazard. To prevent this, observe the following precautions and explain them to your customer. 1. _ Use only unleaded gasoline. 2. Avoid prolonged idling, ‘Avoid running the engine at fast idle speed for more than 10 minutes and at idle speed for more than 20 minutes. 3. Avoid spark jump test, (a) Spark jump only when absolutely necessary. Perform this test as rapidly as possible. (b) While testing, never race the engine. 4, Avoid protonged engine compression measurement. Engine compression tests must be made as repidly as possible, 5. Do not run engine when fuel tank is nearly empty. This may cause the engine to misfire and create an extra load on the catalytic converter 6. Avoid coasting with ignition turned off and prolonged engine braking, 7. Do not dispose of used catalytic converter along with parts contaminated with gasoline or oil.ABV ACV Al ASV roc Bvsv ce EGR eEVAP EX. HAC HAL Hic IN, IG MAS oc Pcv sc ssT sv ™ vev vsv vIV w/ wid INTRODUCTION — Abbreviations Used In This Manual ABBREVIATIONS USED IN THIS MANUAL Air Bypass Valve Air Control Valve Air Injection Air Switching Valve Before Top Dead Center Bi-metal Vacuum Switching Valve Choke Breaker Exhaust Gas Recirculation Evaporative (Emission Control) Exhaust (manifold or valve) or Except High Altitude Compensation Hot Air Intake Hot Idle Compensation Intake (manifold or valve) or Inch Ignition Mixture Adjusting Screw Oxidation Catalyst Positive Crankcase Ventilation Spark Control Special Service Tool Switeh Transmission Vacuum Control Vaive Vacuum Switching Valve Vacuum Transmitting Valve With Without TROUBLESHOOTING Page ENGINE OVERHEATING . HARD STARTING ... ROUGH IDLING ......... ENGINE HESITATES/POOR ACCELERATION . ENGINE DIESELING ......- AFTER FIRE, BACKFIRE .... EXCESSIVE OIL CONSUMPTION POOR GASOLINE MILEAGE . 2 24BEERS EEE eo eee EE Eee eee Eee eee eee eee 22 TROUBLESHOOTING — Engine Overheating, Hard Starting, Rough Idling TROUBLESHOOTING — Rough Idling, Engine Hesitates /Poor Acceleration 2:3 ENGINE OVERHEATING ROUGH IDLING (CONT'D) Faiom Ponca T Reveal = Praia Posie caus Tonal Pan Zine overheats Cooling sytem oly Troubeshoo: cooling system rh ie orale] Tocoectavedeores ‘alta cerarce Incorrect ignition timing Rosot timing [42 {cont'd} Carburetor problems Repair as necessary ote sped cerrok 4s HARD STARTING 5 Siw it sons a & terre nee FA - ‘Fuel cut solenoid valve not open 344 Prabom Posie on ae Romedy ee © Fast idle speed setting incorrect a Ensinewil not ark {Serine fy Troubleshoot sting arom tcldensne or cranks slowly i i Hot sir intake system faulty Cheek HAL system 3.36 Engine - net an No fuel supply to carburetor (Check fuel line Engine overhests Cheek cooling system {eranks okay) Cerburetor problems Repair as necessary EGR valve faulty Lbaetebet debe Ea Croke option Compression fw hack comprsion 2 osing 5 Neel vibe sicko or eased oewum hos disomectes ENGINE HESITATES/POOR ACCELERATION Samer . Ignition problems Probie Possible cause | Remedy Page © Ignition coil Inspect coil Engine hesitates! ‘Spark plugs faulty Inspect plugs © Igniter Inspect igniter Poor acceleration \ ct wir ier ties ai leiton wiring faut ispet ina Soak gta sa ee acum es Rena a nessa ark play Inet la parr a lion wings iconnectd ot inet wings cone oa broker © HAC line 331 Vacuum leaks: | Repair as necessary poe 388 2 FOV Ine a 2 Inake most | & EGRiine 343 Incorrect ignition timin: Reset timing ® ake asta aie books 7 | Compression low Check compression | ae | Fus tine loge eck fu line : Carburetor problems Repair as necessary, Tica tee to ow ROUGH IDLING {ctr pump ay * ower aie uty i Prom Pose coe Remedy Emission cont system poten | Rows le or stls | Spark pgs eulty rope las Al syste aweyson Rovere] | Onc HA sytem 998 iin wing uty Ime wa 2 EGRaystem olwaysonelsemae) | hesk GOR to 38 ogton cll ingest eo Compresion ow heck eomoresion 2 ter Inet pie + Oswroute Inspet utr Incoret ston ning oe a2 | vaca aks Reps as ecsary je poy tin a 2 Eon ine | 23 S hiacine sar ot ine 233 & nate mend24 TROUBLESHOOTING — Engine Dieseling, After Fire, Backfire, Excessive Qil Consumption TROUBLESHOOTING ~ Poor Gasoline Mileage 25 ENGINE DIESELING POOR GASOLINE MILEAGE Problem Possible cause Remedy | Page Problem Remedy Pose Engine dieseling Carburetor problems Repair as necessery Poor gasoline mileage Fuel leak Repair a5 necessary (Continues running after © Linkage sticking Air eleaner clogged ‘Check air leaner Ignition switch is turned 1 Ine speed or fast ide out of 43,44 a ‘eine Incorrect ignition timing Reset timing 42 (Fuel cut solenoid faulty 3.44 Carburetor problems Repair as necessary © Iolo spoed too high Ingoreeet ignition timin Reset timin 42 . : ae 1 Daceleration ful cut system faulty 43 © Power valve always open 3.44 AFTER FIRE, BACKFIRE aa at ~ ~ EGR system always on (Check EGR system 343) Problem ossibo causo = age [esi Ree poe steel eum Compression low Check compression Matreeouon | Alsen fuk Check Al system 319 Tites improperly inflated Inflate ties to proper pressure | ee Deoolaration fuel cut system always off Cheek fusl cut system 3.44 eee icuuieeee dceh Muffler explosion Air dloanor clogged heck air eleanor Brokes drag a “Troubleshoot brakes (after fee) al the time | ncorrect ignition timing Reset timing 42 Incorrect valve clearance Adjust valve clearance Engine beckfires ‘arburetor vacuum leak (Check hoses and repair as necessary Insufficient fue flow Troubleshoot fuel system Incorrect ignition timing Reset timing 42 Incorrect valve clearance Carbon deposits in combustion chambers Adjust valve clearance Inspect cylinder head EXCESSIVE OIL CONSUMPTIO! IN Problem Excessive oil onsumption Oil leak PCV Tine clogged Possible cause Remedy Page Repair as necessary Check POV system 34 Piston ring worn or dameged ‘cheek rings Valve stem oil seal worn or damaged Check oil seat \Valve stem and guide worn Check values and guides34 EMISSION CONTROL SYSTEM SYSTEM PURPOSE Page - 32 COMPONENT LAYOUT AND SCHEMATIC . 33 POSITIVE CRANKCASE VENTILATION (PCV) FUEL EVAPORATIVE EMISSION CONTROL (EVAP) SYSTEM .... SPARK CONTROL (SC) SYSTEM 34 36 - 340 EXHAUST GAS RECIRCULATION (EGR) 3.13 . 319 AIR INJECTION (Al) SYSTEM : OXIDATION CATALYST (OC) SYSTEM. HIGH ALTITUDE COMPENSATION (HAC) AUXILIARY SYSTEMS ....... : . Automatic Hot Air Intake (HAI) System ...... . Hot Idle Compensation (HIC) System on the 3.28 331 1. 3:36 3:36 + 338 . 3.40 Choke Breaker (CB) System ‘Choke Opener System Deceleration Fuel Cut System . . Heat Control Valve... 342 344 34732 EMISSION CONTROL SYSTEM ~ System Purpose SYSTEM PURPOSE System Positive crankcase ventilation Fuel evaporative emission control Spark control Exhaust gas recirculation Air injection Oxidation catalyst High altitude compensation Auxiliary system ‘Automatic hot air intake Hot idle compensation Choke breaker Choke opener Devoleration fuel eut Heat control valve Abbreviation | Purpose | pov Reduces blow-by gas (HC) evap | Reduces evaporative HC se Reduces NOx and HC EGR Reduces NOx | AL Reduces HC and CO oc | Reduces HC and CO HAC) Insures air-fuel mixture at high altitude HAI Improves civeabity ~ cold wie Controls atu mixture — hot ce Improves driveability — cold Improves diveabilty ~ hot Prevents overheating OC and ster burning Improves driveability ~ cold EMISSION CONTROL SYSTEM ~ Component Layout and Schematic Drawing 33 COMPONENT LAYOUT AND SCHEMATIC DRAWING ayancer Port Outer Vent Control Valve HIC Valve Ev" Peace HAI Ditrean \ ftGigd | Fapicur Port | coma! tae 4 vw ceo a) | edn aren sc stu fort ave [Violet / waw\ |} Bao \_ ly | viv | EGR vacuum V8) (e] Beiee La el OO—G qemu aon re |S a Sue =34 EMISSION CONTROL SYSTEM — Positive Crankcase Ventilation (PCV) System Ventilation Hose Air Cleaner Frame arrestor Noh \_ Ni Ventilation Hose PCV Valve 4 Frame Ancester — Blow-by Gas += Fresh Air EMISSION CONTROL SYSTEM — Positive Crankcase Ventilation (PCV) System 35 Push Rod Cover Side Intake Manifold Side To reduce HC emissions, crankcase blow-by gas (HC) is routed through the PCV valve to the intake manifold for combustion in the eylinders, Engine not Running or in Case of Backfire Normal Operation To Intake Manifold Meculuatue ig eLGaeD. PCV VALVE IS OPEN. © VACUUM PASSAGE 1S LARGE To Push Rod Cover Idling or Decelerating Acceleration or High Load © PCY VALVE 1S OPEN. fF) orev vatve ts oven © PCV VALVE 1S FULLY © VACUUM PASSAGE IS open, SMALL. INSPECTION OF PCV VALVE 1, REMOVE PCV VALVE 2. ATTACH A CLEAN HOSE TO PCV VALVE 3. BLOW FROM PUSH ROD COVER SIDE Check thet air passes through easily. CAUTION: Do not suck air through the valve. Potroleum substances inside the valve are harmful. 4. BLOW FROM INTAKE MANIFOLD SIDE Check that air passes through with difficulty, If the PCV valve fails either of the checks, replace it. 5. INSTALL PCV VALVE INSPECTION OF PCV HOSES AND CONNECTIONS VISUALLY INSPECT HOSES, CONNECTIONS AND GASKETS: Check for cracks, leaks or damage.36 EMISSION CONTROL SYSTEM — Fuel Eveporative Emission Control (EVAP) System, FUEL EVAPORATIVE EMISSION CONTROL (EVAP) SYSTEM Hardtop and Softtop Ful Filler Cap ‘Vapor Separator Carburetor ” Charcoal Canister Outer Vent Contal Vave— Station Wagon Ful Filler Cap Vapor Separator Carburetor Charcoal Canister Sea \ Fuel Tank Outer Vent Contra! EMISSION CONTROL SYSTEM — Fuel Evanorati sion Contro! (EVAP) System 37 Outer Vent Control Valve Charcoal Canister carburetor for combustion in the cylinders. To reduce HC emissions, evaporated fuol from fual tank and float chamber is routed through the chereoal canister to the oa ‘Check Vawve evsy vev Setety Valve ace o fe incap Evanorated Fuel cLoseo HC from tenk and float ehembar i ‘Sorbo ino the Below gop) [CLOSED i cLoseo He trom tank i rorbod int the Below SdrmmH (1.97 eg) | CLPSEP | — | open 7 ‘bow L FOmmig (2.76 inHg) | OPEN ate HC Tam eanitor Ted into Take ariel. High pressure in tank | — — 7 — | open |ctoseo| chose HC from tank is ab forbed Into the High vecoum in teak | - a — |evoseo| orew OPEN Tar ised int the teak} eee38 EMISSION CONTROL SYSTEM — Fuel Evaporative Emission Control {EVAP) System, Sofety Valve Gather Pure Pigs tf Tank Pipe N INSPECTION OF FUEL VAPOR LINES, FUEL TANK AND TANK CAP 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 leekage, VISUALLY INSPECT FUEL FILLER CAP (a) Remove four screws and protector. {b} Look for damaged or deformed gasket, (c) Look for stuck safety valve, (d}__ Install the protector. If the safety valve is stuck, repair or replace the cap. 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 VALVE (a) Using low pressure compressed air, blow into the tank pipe and check that the air flows without resistance from the other pipes. (b) Blow into the purge pipe and check that the air flows without resistance from the other pipes. If a problem is found, replace the charcoal canister. 4, CLEAN FILTER IN CANISTER Clean the filter by blowing 3 kg/cm? (43 psi) air into the pipe to the outer vent cantro! valve, while holding the other upper canister pipes closed. NOTE: ‘# Do not attempt to wash the canister. © No activated carbon should come out. 5, INSTALL CHARCOAL CANISTER EMISSION CONTROL SYSTEM — Fuel Evaporative Emi jon Control {EVAP) System 39 coo IG sw “ore” CH No Vacuum INSPECTION OF OUTER VENT CONTROL VALVE CHECK OUTER VENT CONTROL VALVE OPERATION {a) Disconnect the hoses from the valve, {b} Check that the vaive is open when the ignition switch is "OFF", (c) Check that the valve is closed when the ignition switch is “ON”. (d}_ Reconnect hoses to proper locations. If the valve does not operate, check the fuse and the wiring connections. INSPECTION OF BVSV CHECK BVSV BY BLOWING AIR INTO PIPES {a) With coolant temperature below 30°C (86°F), blow air into a pipe and check that the BVSV is closed, {b) After warmingup the engine, blow air into a pipe and check that the BVSV is open. If a problem is found, replace the BYSV, INSPECTION OF VCV CHECK VCV BY BLOWING AIR INTO PIPE fe) Apply vacuum above 70 mmHg (2.76 inHg) to pipe S. {b) Blow air into pipe Y and check that air comes out of pipe Z. (c)_ Stop the applied vacuum. (d) Blow air into pipe Y and check that air does not come out of pipe Z. If problem is found, replace the VCV.3-10 EMISSION CONTROL SYSTEM — Spark Control (SC) System EMISSION CONTROL SYSTEM — Spark Control (SC) System au SPARK CONTROL (SC) SYSTEM 7 wePection oF # evsren \\ Main Diaphragm Steer 1, CONNECT VACUUM GAUGE TO DISTRIBUTOR MAIN DIAPHRAGM HOSE Advancer Port vv jeeeeees | 2. CHECK BVSV WITH COLD ENGINE la) The coolant temperature should be below 30°C (86°F). (b) Start the engine. [c) Check that the vacuum gauge indicates zero regard: less of whether the throttle valve is open or closed. LET ENGINE WARM-UP TO NORMAL OPERATING TEMPERATURE CHECK BVSV AND VTV WITH HOT ENGINE (a) With the engine warm and idling, pinch the hose between the VTV and the vacuum pipe. {b) Increase the engine speed to 2,500 rpm. {c) Within 2-5 seconds atter the hose is released, check that the vacuum gauge indicates high vecuum. Main Diaphragm Sub diaphragm {d) With the engine at 2,500 rom, check that the vacuum To reduce NOx and HG emissions, this system delays the vacuum advance for a given time and lowers the maximum nh gauge indicates zero quickly’ when the hose is dis- Seveastion teaparaay z= is connected between the VTV and vacuum pipe at Coolant Temp. Bvsv Vacuum fgition Timing the VTV side, Cota ae : DISCONNECT VACUUM GAUGE AND RECONNECT Below 30°C (86°F) CLOSED | = NOT ADVANCED HOSES: Hot Positioned below advancer port | NOT ADVANCED pia OPEN Above L eee ee [_ Positioned above advance port | DELAYED by VTVEMISSION CONTROL SYSTEM — Spark Control (SC} System ADVANCER | {a) Remove the distributor cap and rotor, (b) Apply vacuum to the diaphragms, and check that the vacuum advancer moves in accordance with the vacuum. (c)_ Reinstall the rotor and distributor cap. IF NO PROBLEM IS FOUND WITH THIS INSPECTION, THE SYSTEM IS OKAY; OTHERWISE INSPECT EACH PART 6, CHECK OPERATION OF DISTRIBUTOR VACUUM INSPECTION OF BVSV g CHECK BVSV BY BLOWING AIR INTO PIPE 1 No Air (a) Drain the coolant from the radiator into @ suitable container. en (b) Remove the BVSV. (c) Cool the BYSV to below 30°C (86°F) with cool water. (a) Blow air into pipe and check that the BVSV is closed, FE (2) Hest the BYSV to above 44°C (111°F) with hot water. (f) Blow air into pipe and check that the BVSV is open. a) Apply liquid seater to the threads of the BVSV and reinstall. (h) Fill the radiator with coolant, fa problem is found, replace the BVSV. OX INSPECTION OF VTV CS CHECK VTV BY BLOWING AIR INTO EACH SIDE S (a) Check that air flows without resistance from B to A, {b) Check that air flows with difficulty from A to 8. If @ problem is found, replace the VTV. Bvsv EMISSION CONTROL SYSTEM — Exhaust Gas Recirculation (EGR) System 3.13 EXHAUST GAS RECIRCULATION (EGR) SYSTEM EGR Vacu Modulator Advancer Port EGR R Port a To VSV Port F To EGR Vacuum Modulator Port P EGR Valve EGR Cooler Ms vsv (Closed 0 Ar Cleaner Computer © Is coil NN (Goer) h S| EGA Vecuum Modulstor a ® EGR Valve (Closed) EGR Valve Pressure Chamber I ‘Advancar Port EGR Cooler314 EMISSION CONTROL SYSTEM — Exhaust Gas Recirculation (EGR) System EMISSION CONTROL SYSTEM ~ Exhaust Gas Recirculation (EGR) System 3-15 (2) TA Cleaner Pore cece ~~~) INSPECTION OF EGR SYSTEM vsv Computer a 1. CHECK AND CLEAN FILTER IN EGR VACUUM (Gown ) Oe 1G Coit ER Vacuum MODULATOR HLA = . {a) Chock the filter for contamination or damage. {b} Using compressed air, clean the filter. sen a evsv {Open << Sway Connector 2. PREPARATION Using a S.way connector, connect a vacuum gauge to the hose between the EGR vaive and EGR vacuum modurator. 3. CHECK SEATING OF EGR VALVE EGR Valve Pressure Chamber Advancer Port EGR Cooler ; see Toc Coun Start the engine and check that the engine starts and runs vsv | EGR Valve at idle. Computer iON) 1G coil {Open}, frat aI i EGR Vacuum EGR Vacuum | Modulator Modulator i coLD ~ 4, CHECK BVSV WITH COLD ENGINE Vacuum Gauge (a) The coolant temperature should be below 30°C (86°F). {b} Check that the vacuum gauge indicates zero at r 2,500 rpm. + =F Advancer Port | 5 E SVSV AND EGR VACUUM MODULATOR Tora NOx smn, pi of ws ai a eel web EGR va eine mao ne oa 5. CHECK BVSV AND & lower the maximum combustion temperature. : — — (a) Warm up the engine. ov yan | Tiuetats ales | eee rec EGR Vacuum | EGR | exhaust Gat (b} Check that the vacuum gauge indicates low vacuum Tam. Opening Angle | Valve Pressure Chamber Modulator | Valve : 32.500 rpm, Below j i Not 30°C te6°r) | CLOSED 7 CLOSED | ecincULATED i : = Positioned below ft | | wor advancar port ee |CLOSED) ReciRCULATED Above on, OPEN | | + Pressure OPENS passe? | crosep| NOT eee {c) Disconnect the vacuum hose from port R of the EGR aor) ** Positioned —| Low | constantly | to atmosphere RECIRCULATED ‘Vacuum Gauge; vacuum modulator and connect port R directly to the eon i: alternating intake manifold with another hose. advancer port between low i ; : Per] | Gratin. | CLOSES Passe | OpeN | RECIACULATED () Check that the vacuum gauge indicates high at 2,600 HIGH to atmosphere rpm. Remarks; * increase > Modulator closes > EGR valve opens ~ Pressure drops + Modulator opens ake ie As canara of EGR gas enters, the engine * EGR valve closes —- mnifol is time, ** When the throttle valve is positioned sbove the EGR R port and the engine speed is above 1,500 rpm, the cane {e) Disconnect the vacuum gauge and reconnect the EGR vacuum modulator will close the atmosphere passage and open the EGR valve to increase the EGR ges, Modueter vacuum hoses <0 the proper locations. ven i the exhaust pressure is low.3:16 EMISSION CONTROL SYSTEM — Exhaust Gas Recirculation (EGR) System Gas Filter Vsv for EGR 1,500 rpm 6. CHECK EGR VALVE {a} Apply vacuum directly to the EGR valve with the engine idling. {b)Cheok that the engine runs rough or dies, {c}_ Reconnect the vacuum hoses to the proper location, 7. CHECK COMPUTER TO VSV (2) Disconnect the vacuum hoses from pipe E and pipe F of the VSV. (b) With the engine idling, blow air into pipe F and check that the VSV is closed. {c) Increase the engine speed to above 1,500 rpm. {d}_ Blow air into pipe F and check that the VSV is open. (e) Reconnect the vacuum hoses to the proper locations. IF NO PROBLEM IS FOUND WITH THIS INSPECTION, THE SYSTEM IS OKAY; OTHERWISE INSPECT EACH PART EMISSION CONTROL SYSTEM — Exhaust Gas Recirculation (EGR) System. 3.17 Engine Stopped V8Vv for EGR. INSPECTION OF BVSV See paye 3-12. INSPECTION OF EGR VALVE 1. REMOVE EGR VALVE Check the valve for sticking and heavy carbon deposits, Ifa problem is found, replace it. 2. REINSTALL EGR VALVE INSPECTION OF EGR VACUUM MODULATOR CHECK EGR VACUUM MODULATOR OPERATION (a) Disconnect the vacuum hoses from port P, Q and R of the EGR vacuum modulator. (b) Plug port P and R with your finger. {c) Blow air into port Q, Check that the air passes through to the air filter side freely. (d) Start the engine and maintain the engine speed at 2,500 rpm. fe} Repeat the above test. Check that there is a strong resistance to air flow. INSPECTION OF VSV 1. CHECK VACUUM CIRCUIT CONTINUITY IN VSV BY BLOWING AIR INTO PIPE (2) Connect the VSV terminals to the battery terminals, as shown. (b) Blow air into pipe E and check that air comes out of pipe F.EMISSION CONTROL SYSTEM — Exhaust Gas Recirculation (EGR) System {c)_ Disconnect the battery connections. (d) Blow air into pipe E and check that air comes out of pipe G. If a problem is found, replace the VSV. CHECK FOR SHORT CIRCUIT Using an ohmmeter, check that there is no continuity between the positive (+) terminal and the VSV body. If there is continuity, replace the VSV. CHECK FOR OPEN CIRCUIT Using an ohmmeter, measure the resistance between the positive (+) terminal and the other terminal as shown, Specified resistance: 38 — 43 ohms at 20°C (68°F) If the resistance is not within specification, replace the vsv. EMISSION CONTROL SYSTEM — Air Injection (Al) System AIR INJECTION (Al) SYSTEM ‘ACV VSVI2)_ vsv (1) ———_— To ABV (Lower Chamber) To VSV (1) Port F vivEMISSION CONTROL SYSTEM ~ Air Injection (Al) System EMISSION CONTROL SYSTEM ~ Air Injection (Al) System 3.21 (2) and (3) Computer Air Cleaner al ; a Leelee a i et hee om Senor = a (4) acy, TABY. Closed) sv (1 5) iF oo For reburning the unburnt HC and CO in the exhaust gos, compressed air from the alt ports during low-middle vehicle speed, During high vehicle speod, air is blown into the ‘pump is Blown into the exhaust ‘exhaust pipe (Just ahead of OG) = Air Pure cocteme. | vehictespoea | -2aeration | vevin | vsvin | asy av Ale from Ate Pars on e403 cuose® Brion 98 mph | L. : Below ond Injected to EXHAUST Bee, | ee son ges [St | oven [orem | re a) ° ve 50 mr to EXHAUST | se con) 7 a) oven i) ‘CLOSED a Bypassed to AIR noe Cama eee paces exoseo | GYeawen ta) 7a8%C, oe (er ‘cLOBED EXHAUST taster) vow ore oven enn * ink cn bow 388 e857 Haan orion od above 1800 rm, Wiring of OC Thermo Sensor INSPECTION OF Al SYSTEM 1. 6 VISUALLY CHECK HOSES AND TUBES FOR CRACKS, KINKS, DAMAGE OR LOOSE CONNECTIONS DISCONNECT AIR BYPASS HOSE FROM AIR CLEANER START ENGINE CHECK VTV AND ASV (a) With the engine idling, check that air is not di charged from the air bypass hose. (b) Disconnect the vacuum hose from the VTV et the blue side. Check that air is discharged from the air bypass hose within 3-10 seconds (c}_ Reconnect the vacuum hose to the VTV. Check that air stops quickly. CHECK ABV (a) Disconnect the air hose between the ABV and ex- haust pipe at the ABV side, (b) Disconnect the vacuum hose between the ABV and VSV(2) at the ABV side, and plug the ABV. (c) Race the engine and quickly close the throttle valve. Check that air is discharged momentarily from the ABV, (a) Reconnect the vacuum hose to the ABV. CHECK OC THERMO SENSOR TO VSV(1) (a) With the engine idling, connect a wire to both OC thermo sensor terminals. (b) Check that air is discharged from the air bypass hose, [c)_ Disconnect the wire from the OC thermo sensor terminals, CHECK DECELERATION FUEL CUT SYSTEM TO vswi2) (a) Pinch the vacuum hose to the vacuum switch at idle. (b) Gradually increase the engine speed to 2,000 rpm. (c)_ Check that air is discharged from the ABV, NOTE: ‘* Perform this inspection in as short a time as possibl ‘© The engine will misfire slightly at the same time,Exhaust Pipe Side INSPECTION OF ACV 1. CHECK ABV OPERATION {a) Disconnect the air hose between the ABV and exhaust pipe at the ABV side, {b} Disconnect the vacuum hose between the ABV and VSV (2) at the ABV side, and plug the ABV. {c)_ With the engine idling disconnect the vacuum hose between the ABV and vacuum pipe at the ABV side and reconnect it (d} Check that compressed air comes out temporarily from the ABV. {e) Reconnect the air hose to the ABV. 2. CHECK ASV OPERATION (a) Disconnect the air hose from the check valve, (b) Disconnect the vacuum hose from the ASV. (c) With the engine idling, apply vacuum directly to the ASV, (a) Check that compressed air comes out of the air hose to the check valve, 3. CHECK OPENING PRESSURE OF RELIEF VALVE (a) Disconnect the air bypass hose from the air cleaner. {b) Connect the air pump tester” to the eir hose to check valve, *SsT 0925814010 (c) Close the orifice on the SST with your finger. (a) Increase the engine speed gradually and measure the relief valve opening pressure, Opening pressure: 0.40 — 0.60 kg/cm? (6.7 — 8.5 psi) (c) Remove the SST. (f) Reconnect the vacuum hoses and air hoses to the proper locations, INSPECTION OF VTV CHECK VTV BY BLOWING AIR FROM EACH SIDE (a) Check that air flows without resistance from 8 to A, (b) Check that air flows with difficulty from A to B. If a problem is found, replace the VTV. INSPECTION OF CHECK VALVES CHECK VALVES BY BLOWING AIR FROM EACH SIDE (a) Check that air flows from the AGV side to manifold {or exhaust pipe) side. (b) Check that air does not flow from the manifold (or ‘exhaust pipe) side to ACV side. If a problem is found, replace the valve. EMISSION CONTROL SYSTEM — Air Injection (Al) System 3.25 INSPECTION OF VSV (1) 1. CHECK VACUUM CIRCUIT CONTINUITY IN THE VSV(1} BY BLOWING AIR INTO PIPE (a) Connect the VSV{1) terminals to the battery terminals as illustrated. (b} Blow into pipe E and check that air comes out of pipe F. (c) Disconnect the battery. (d} Blow into pipe E and check that air comes out of the air filter If a problem is found, replace the VSV{1). oi ‘000000 2. CHECK FOR SHORT CIRCUIT Using an ohmmeter, check that there is no continuity = between the positive (+) terminal and the VSV(1) body. a If there is continuity, replace the VSV(1). ‘Ohmmeter 3. CHECK FOR OPEN CIRCUIT Using an ohmmeter, measure the resistance between the positive (+) terminal and the other terminal as shown. Specified resistance: 38 — 43 ohms at 20°C (68°F) If the resistance is not within specification, replace the vsvi1). INSPECTION OF VSV (2) 4. CHECK VACUUM CIRCUIT CONTINUITY IN VSV(2) BY BLOWING AIR INTO PIPE (a) Connect the VSV{2) terminals to the battery terminals as shown, {b) Blow into the pipe, and check that the VSV(2) is open.ciowiy | Ohmmeter \REs 000000 Ohmmeter EMISSION CONTROL SYSTEM ~ Air Injection (Al) System (c) Disconnect the battery positive (+) terminal. [d) Blow into the pipe and check that the VSV(2) is closed. If a problem is found, replace the VSV(2). 2. CHECK FOR SHORT CIRCUIT 1g an ohmmeter, check that there is no continuity between the positive (+) terminal and the VSV(2) body. If there is continuity, replace the VSV(2). 3. CHECK FOR OPEN CIRCUIT Using an ohmmeter, measure the resistance between the positive (+) terminal and the other terminals as shown. Specified resistance: 38 — 43 ohms at 20°C (68°F) If the resistance is not within specification, replace the vsv(2), INSPECTION OF OC THERMO SENSOR 1, MEASURE RESISTANCE (a) Unplug the wiring connector. {b} Using an ohmmeter, measure the resistance betwoen both terminals at idling, Resistance: 2 — 200 kilohm CAUTION: The ohmmeter probe should be inserted from the rear side of the connector. (c) Plug in the wiring connector. 2, CHECK SENSOR WIRING (2) Look for damage {b) Check for loose connection. EMISSION CONTROL SYSTEM — Air Injection (Al) System 3.27 INSPECTION OF SPEED SENSOR 1, JACK UP ONE REAR WHEEL OFF THE GROUND 2, RELEASE PARKING BRAKE 3. SET SHIFT LEVER INTO NEUTRAL 4, UNPLUG WIRING CONNECTOR FROM COMPUTER The location of computer is on the left cowl, 5, CHECK ON-OFF CYCLES OF SPEED SENSOR fa} Place (+) terminal of the ohmmeter on the wiring connector terminal and (-) terminal on ground. (b) Turn the rear wheel slowly. (c) Check that the ohmmeter needle deflects consistent- ly, CAUTION: The ohmmeter probe should be inserted from the rear side of the connector. If the ohmmeter needle does not deflect, check that the speed sensor terminals at the back side of the speedometer are properly connected. If the connection is OK, replace the speedometer assembly. 6, RECONNECT WIRING CONNECTOR TO COMPUTER INSPECTION OF DECELERATION FUEL CUT SYSTEM Soe page 3-44.3:28 EMISSION CONTROL SYSTEM — Oxidation Catalyst (OC) System : OXIDATION CATALYST (OC) SYSTEM HC CO_AIR- Thermo Sensor i © To reduey HC and CO emission, HC and CO are oxidized and converted to water (H;0) and carbon dioxide (CO;) In tho oxidation catalyst © If the catalyst is overheated (above 785°C or 1,445°F}, the thermo sensor in the catalyst turns the Al system OFF. Exhaust Port Catalyst Exhaust Gas UNBURNT HC, CO AND AIR Proper Temperature OXIDATION Temperature is increased, INSPECTION OF EXHAUST PIPE ASSEMBLY 1. CHECK CONNECTIONS FOR LOOSENESS OR DAMAGE 2. CHECK CLAMPS FOR WEAKNESS, CRACKS OR DAMAGE INSPECTION OF CATALYTIC CONVERTER 1. CHECK OUTER SURFACE FOR DENTS OR DAMAGE Ge Dent limit: 20 mm (0.79 in.) 20 mm | EMISSION CONTROL SYSTEM — Oxidation Catalyst (OC) System 3.29 Use WOODEN Lock if Converter is HEATED Heat Insulator ‘Onmmeter 7 2, SHAKE CATALYTIC CONVERTER, AND CHECK FOR EXCESSIVE RATTLING If there is an excessive rattling noise, replace the converter. INSPECTION OF HEAT INSULATOR 1. CHECK HEAT INSULATOR FOR DAMAGE, 2, CHECK FOR ADEQUATE CLEARANCE BETWEEN CATALYTIC CONVERTER AND HEAT INSULATOR INSPECTION OF THERMO SENSOR {IN CATALYST) 1. MEASURE RESISTANCE (a) Unplug the wiring connector. (b) Using an ohmmeter, measure the resistance between both terminals at idling Resistance: 2 — 200 kilohm CAUTION: The ohmmeter probe should be inserted from the rear side of the connector. (c) Plug in the wiring connector. 2. CHECK SENSOR WIRING (a) Look for damage. (b) Check that connections are tight, REMOVAL OF CATALYTIC CONVERTER 1, UNPLUG THERMO SENSOR WIRING CONNECTOR INSIDE VEHICLE 2, REMOVE WIRING GROMMET FROM FLOOR, AND PULL CONNECTOR FROM INTERIOR3:30 EMISSION CONTROL SYSTEM — Oxidation Catalyst (OC) System EMISSION CONTROL SYSTEM — High Altitude Compensation (HAC) System 3:31 REMOVE CATALYTIC CONVERTER WITH HIGH ALTITUDE COMPENSATION (HAC) SYSTEM THERMO SENSOR {a) Jack up the vehicle. (b} Check that the converter is cool, Distrib Hi (c) Remove the bolts at the front and rear of the conwer: ‘art OC 7 eC (a) Remove the rubber rings. (2) Remove the converter and gaskets, c ToHAC Vane fone {Upper Center) 4, REMOVE THERMO SENSOR | NIE { ° i (a) Hold the converter with the thermo sensor positioned FES coco] upward, < & 4 ~ | (b) Remove the thermo sensor and gasket from the ? > \ ‘ \ converter, ht UN SSS LE NN w- SVC ] To HAC Valve| To HAC Valve ee Se 4 ad vove ToHAG Vave | (Lower! INSTALLATION OF CATALYTIC CONVERTER Primary High | i 1. INSTALL THERMO SENSOR ‘Speed Circuit | (a) Place a new gasket on the thermo sensor. Sub-diaphragm ‘Sensor Guide NOTE: Service replacement converters are fitted with a a quide. ! (b) Push the sensor into the converter and tighten two bolts. Port A, oe Torque: 0.6 ~ 0.9 kg-m (53 — 78 in.-Ib} [Atmosphere Secondary High 2. INSTALL CATALYTIC CONVERTER WITH THERMO Speed Circuit SENSOR (a) Place new gaskets on the converter front and rear pipes, and connect the converter to the exhaust pipes. (b) Tighten the bolts. Torque: 3.5 ~ 4.5 kg-m (26 — 32 ftb} Primary Low Speed Circuit As altitude increases, the air-fuel mixture becomes richer. This system insures proper air-fuel mixture by supplying additional air to the primary fow and high speed circuits of the carburetor, and advances the ignition timing to J (c) Secure the converter to the body with the rubber improve driveability at high sticude (above 1,198 m (3,030 ft). rings. yo 7 zr az Bellowsin | Port Ain [Distributor Sub-| Port Bin irfrom | Subvacuum (a) Plug in the thermo sensor connector, and install the Altitude AACVavo | HACVshe °“Glaphegm | HAGVake | HACVahe | Advenge floor grommet. ~ ! - NOTE: After installing, check the sensor wire to see that HIGH Ledinto pris | anyanceo it is not excessively bent and that it is not interfering with Above 1,1988m | EXPANDED | CLOSED PULLED open | man lows ey other parts 3.930 1 circuits, Low Novy : Below 783m —|contracteo| open NoT PULLED} cLoseo | sToPPeD [NOT y 25704) {EMISSION CONTROL SYSTEM — High Altitude Compensation (HAC) System INSPECTION OF HAC SYSTEM PRECHECK: Before checking the HAC system, determine the position of the HAC valve, This can be done by blowing into any one of the three ports on top of the HAC valve with the engine idling. If the passage is open, the valve is in the HIGH ALTITUDE position, Hin. (See"page 3:33) A. AT HIGH ALTITUDE 1, CHECK IGNITION TIMING AT IDLE fa) Warm up the engine. diaphragm, and plug the hose end. (c) Check the ignition timing, {d) Reconnect the hose to the sub-diaphragm. is in the LOW ALTITUDE posi EMISSION CONTROL SYSTEM. (e) a) tb) te) (b) Disconnect the hose from the distributor sub- HAC Valve {ab (b) ( tude Compensa Check that the timing mark on the flywheel moves toward advance. Advance angle: 6° 1n (HAC) System 2, CHECK THE CHECK VALVE Disconnect the vacuum hose from the check valve at the black side and plug the hose end. Check that the ignition timing remains stationary for more than one minute. Stop the engine and reconnect the hose to the check valve, 3, CHECK CARBURETOR Disconnect three hoses from the pipes on top of the HAC valve. Blow air into each hose and check that air flows into the carburetor. Reconnect the hoses to the proper locations. Ignition timing: 7° BTDC (Mark on flywhoel) AT LOW ALTITUDE CHECK IGNITION TIMING AT IDLE (a) Warm up the engine (b) Check the ignition timing. Ignition timing: 7° BTDC (Mark on flywheel) (c) Disconnect the vacuum hose from lower port of the HAC valve and plug the hose end,334 EMISSION CONTROL SYSTEM — High Altitude Compensation (HAC) System (White) (Black). Check Valve eecee <— Open Closed {d) Check that the timing mark on the flywheel moves toward advance. Advance angle: 6° 2. CHECK THE CHECK VALVE fa) Disconnect the vacuum hose from the check valve at tho black side and plug the hose end, in the condition described in 1-(c} above. {b) Check that the ignition timing remains stationary for more than one minute. {c) Stop the engine and reconnect the hoses to the proper locations. 3. CHECK CARBURETOR (a) Disconnect three hoses fram the pipes on top of the HAC valve. (b) Blow air into each hose and check that air flows into the carburetor, (c) Reconnect the hoses to the proper locations. IF NO PROBLEM IS FOUND WITH THIS INSPECTION, THE SYSTEM IS OKAY; OTHERWISE INSPECT EACH PART INSPECTION OF HAC VALVE VISUALLY CHECK AND CLEAN AIR FILTER IN HAC VALVE INSPECTION OF CHECK VALVE CHECK VALVE BY BLOWING AIR INTO EACH PIPE (a) Check that air flows from the white pipe to the black pipe. (b) Check that air does not flow from the black pipe to ‘the white pipe. EMISSION CONTROL SYSTEM — High Altitude Compensation (HAC) System 3:35 INSPECTION OF DISTRIBUTOR VACUUM ADVANCER CHECK OPERATION OF VACUUM ADVANCER, (a) Remove the distributor cap and rotor. {b) Apply vacuum to the diaphragms, and check that the vacuum advancer moves in accordance with the vacuum, (c} Reinstall the rotor and distributor cap. IF NO PROBLEM IS FOUND WITH THIS INSPECTION, THE SYSTEM IS OKAY; OTHERWISE INSPECT EACH PART3.36 EMISSION CONTROL SYSTEM — Auxiliary Systems AUXILIARY SYSTEMS 1. Automatic Hot Air Intake (HAI) System HIC Valve coo HoT HIC Valve