Page 953 of 2062
Downloaded from www.Manualslib.com manuals search engine EC034−03
B13075
− EMISSION CONTROL (5VZ−FE)PARTS LAYOUT AND SCHEMATIC DRAWING
EC−3
1996 TOYOTA T100 (RM449U)
DRAWING
Page 954 of 2062
Downloaded from www.Manualslib.com manuals search engine P20280
PCV Valve
EC035−04
P21212
Cylinder Head Cover Side
Clean Hose
P21213
Air Intake
Chamber Side
P21214
Air Intake
Chamber Side
P21676
EC−4− EMISSION CONTROL (5VZ−FE)POSITIVE CRANKCASE VENTILATION (PCV)
SYSTEM
943 Author: Date:
1996 TOYOTA T100 (RM449U)
POSITIVE CRANKCASE
VENTILATION (PCV) SYSTEM
INSPECTION
1. REMOVE PCV VALVE
(a) Disconnect the PCV hose from the PCV valve.
(b) Remove the PCV valve.
2. INSTALL CLEAN HOSE TO PCV VALVE
3. INSPECT PCV VALVE OPERATION
(a) Blow air into the cylinder head cover side, and check that
air passes through easily.
CAUTION:
Do not suck air through the valve.
Petroleum substances inside the valve are harmful.
(b) Blow air into the air intake chamber side, and check that
air passes through with difficulty.
(c) Blow air into the air intake chamber side when lift up the
inside valve, and check that there is a strong resistance
to air flow.
If operation is not as specified, replace the PCV valve.
4. REMOVE CLEAN HOSE FROM PCV VALVE
5. REINSTALL PCV VALVE
6. VISUALLY INSPECT HOSES, CONNECTIONS AND
GASKETS
Check for cracks, leaks or damage.
Page 955 of 2062
Downloaded from www.Manualslib.com manuals search engine EC0JV−01
EC3069
Gasket
Check Valve (Vacuum Valve)
− EMISSION CONTROL (5VZ−FE)EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM
EC−5
944 Author: Date:
1996 TOYOTA T100 (RM449U)
EVAPORATIVE EMISSION (EVAP)
CONTROL SYSTEM
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.
4. REMOVE VSV
5. REMOVE CHARCOAL CANISTER
6. VISUALLY INSPECT CHARCOAL CANISTER
Look for cracks or damage.
7. CHECK FOR CLOGGED FILTER, AND STUCK
CHECK VALVE
(a) Using low pressure compressed air (4.71 kPa, 48 gf/cm
2,
0.68 psi), blow into tank pipe and check that air flows with-
out resistance from the other pipes.
(b) Blow low pressure compressed air (4.71 kPa, 48 gf/cm
2,
0.68 psi) into purge pipe and check that air does not flow
from the tank pipe.
But the air flows without resistance from the other pipe.
If a problem is found, replace the charcoal canister.
Page 956 of 2062
Downloaded from www.Manualslib.com manuals search engine EC−6
− EMISSION CONTROL (5VZ−FE)EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM
945 Author: Date:
1996 TOYOTA T100 (RM449U)
8. CLEAN FILTER IN CANISTER
Clean the filter by blowing 294 kPa (3 gf/cm
2, 43 psi) of com-
pressed air into tank pipe while holding purge pipe closed.
NOTICE:
Do not attempt to wash the canister.
No activated carbon should come out.
9. INSPECT VSV FOR EVAP
(See page SF−50)
10. REINSTALL VSV
11. REINSTALL CHARCOAL CANISTER
Page 957 of 2062
Downloaded from www.Manualslib.com manuals search engine EC02V−02
P21189
− EMISSION CONTROL (5VZ−FE)EXHAUST GAS RECIRCULATION (EGR) SYSTEM
EC−7
946 Author: Date:
1996 TOYOTA T100 (RM449U)
EXHAUST GAS RECIRCULATION (EGR) SYSTEM
COMPONENTS
Page 958 of 2062
Downloaded from www.Manualslib.com manuals search engine EC02Z−03
S05202
EC−8
− EMISSION CONTROL (5VZ−FE)EXHAUST GAS RECIRCULATION (EGR) SYSTEM
1996 TOYOTA T100 (RM449U)
REMOVAL
1. DRAIN ENGINE COOLANT
2. REMOVE EGR PIPE
Remove the 6 nuts, EGR pipe and 2 gaskets.
HINT:
At the time of installation, please refer to the following item.Ins-
tall 2 new gaskets.
Torque:
Nut A: 18.5 N·m (185 kgf·cm, 14 ft·lbf)
Nut B: 8.0 N·m (80 kgf·cm, 71 in.·lbf)
3. REMOVE EGR GAS TEMPERATURE SENSOR
4. REMOVE EGR VALVE
(a) Disconnect these hoses from the EGR valve:
Vacuum hose (from VSV for EGR)
EGR hose (from EGR vacuum modulator)
Water hose (from water bypass pipe)
Water bypass hose (from IAC valve)
(b) Remove the 2 nuts, EGR valve and gasket.
Torque: 18.5 N·m (185 kgf·cm, 14 ft·lbf)
HINT:
Use a new gasket.
At the time of installation, please refer to the following item.
(c) Check for sticking and heavy carbon deposits. If problem
is found, replace the EGR valve.
Page 959 of 2062
Downloaded from www.Manualslib.com manuals search engine P23552
P23553
EC02W−02
P19970
DLC1
DLC1 TE1E1SST
P19945
P23554
− EMISSION CONTROL (5VZ−FE)EXHAUST GAS RECIRCULATION (EGR) SYSTEM
EC−9
1996 TOYOTA T100 (RM449U)
INSPECTION
1. CHECK AND CLEAN FILTER IN EGR VACUUM MOD-
ULATOR
(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:
Install the filter with the coarser surface facing out to the atmo-
spheric side.
2. INSTALL VACUUM 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
Check that the engine starts and runs at idle.
4. CONNECT TERMINALS TE1 AND E1
Using SST, connect terminals TE1 and E1 of the DLC1.
SST 09843−18020
5. INSPECT VSV OPERATION WITH COLD ENGINE
(a) The engine coolant temperature should be below 45°C
(113°F).
(b) Check that the vacuum gauge indicates zero at 2,800
rpm.
(c) Check that the EGR pipe is not hot.
6. INSPECT OPERATION OF VSV AND EGR VACUUM
MODULATOR WITH HOT ENGINE
(a) Warm up the engine to above 80°C (176°F).
(b) Check that the vacuum gauge indicates low vacuum at
2,800 rpm.
(c) Disconnect the vacuum hose from port R of the EGR vac-
uum modulator and connect port R directly to the intake
manifold with another hose.
Page 960 of 2062
Downloaded from www.Manualslib.com manuals search engine P23555
P23551
P23556
P23557
EC−10
− EMISSION CONTROL (5VZ−FE)EXHAUST GAS RECIRCULATION (EGR) SYSTEM
1996 TOYOTA T100 (RM449U)
(d) Check that the vacuum gauge indicates high vacuum at
3,500 rpm.
HINT:
As exhaust gas is increasingly recirculated, the engine will start
to misfire.
7. DISCONNECT TERMINALS TE1 AND E1
Remove the SST from the DLC1.
SST 09843−18020
8. REMOVE VACUUM GAUGE
Remove the vacuum gauge, and reconnect the vacuum hoses
to their proper locations.
9. INSPECT EGR VALVE
(a) Apply vacuum directly to the EGR valve with the engine
idle.
(b) Check that the engine runs rough or dies.
(c) Reconnect the vacuum hoses to their proper locations.
If no problem is found during this inspection, system is normal;
otherwise inspect each part.
10. DISCONNECT VACUUM HOSES FROM EGR VACUUM
MODULATOR
Disconnect these vacuum hoses:
(1) Vacuum hose from R port
(2) Vacuum hose from Q port
(3) Vacuum hose from P port
11. INSPECT EGR VACUUM MODULATOR OPERATION
(a) Block ports P and R with your finger.
(b) Blow air into port Q, and check that the air passes through
to the air filter side freely.
(c) Start the engine, and maintain speed at 3,500 rpm.
(d) Repeat the above test. Check that there is a strong resis-
tance to air flow.
12. RECONNECT VACUUM HOSES TO EGR VACUUM
MODULATOR
Connect these vacuum hoses:
(1) Vacuum hose to R port
(2) Vacuum hose to Q port
(3) Vacuum hose to P port
