Page 943 of 2062
Downloaded from www.Manualslib.com manuals search engine EC0GF−01
EC3069Check Valve (Vacuum Valve)
Gasket
− EMISSION CONTROL (3RZ−FE)EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM
EC−5
933 Author: Date:
1996 TOYOTA T100 (RM449U)
EVAPORATIVE EMISSION (EVAP)
CONTROL SYSTEM
INSPECTION
1. VISUALLY INSPECT LINES AND CONNECTIONS
Look for loosen 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
Remove the screw from the charcoal canister.
5. REMOVE CHARCOAL CANISTER
6. REMOVE CAP FROM CHARCOAL CANISTER
7. VISUALLY INSPECT CHARCOAL CANISTER
Look for cracks or damage.
8. INSPECT 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 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 and air
flows without resistance from the other pipe.
If a problem is found, replace the charcoal canister.
Page 945 of 2062
Downloaded from www.Manualslib.com manuals search engine P23029
Cap
Filter
EC0JU−01
P15107
P22300
TOYOTA Hand−Held Tester
DLC3
− EMISSION CONTROL (3RZ−FE)EXHAUST GAS RECIRCULATION (EGR) SYSTEM
EC−7
935 Author: Date:
1996 TOYOTA T100 (RM449U)
EXHAUST GAS RECIRCULATION
(EGR) SYSTEM
INSPECTION
1. INSPECT 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) Install the filter and cap.
HINT:
Install the filter with the coarser surface facing the atmospheric
side (outward).
2. INSTALL VACUUM GAUGE
Using a 3−way connector, connect a vacuum gauge to the hose
between the EGR valve and EGR vacuum modulator.
3. INSPECT SEATING OF EGR VALVE
Start the engine and check that the engine starts and runs at
idle.
4. CONNECT TOYOTA HAND−HELD TESTER OR OBDII
SCAN TOOL
(a) Connect the TOYOTA hand−held tester or OBDII scan
tool to the DLC3.
(b) Please refer to the TOYOTA hand−held tester or OBDII
scan tool operators manual for further details.
5. INSPECT VSV OPERATION WITH COLD ENGINE
(a) The engine coolant temperature should be below 50°C
(122°F).
(b) Check that the vacuum gauge indicates zero at 3,500
rpm.
(c) Check that the EGR pipe is not hot.
6. INSPECT OPERATION OF VSV AND EGR VACUUM
MODULATOR
(a) Select the active test mode on the TOYOTA hand−held
tester (VSV is closed.).
Page 946 of 2062
Downloaded from www.Manualslib.com manuals search engine P23481
3−Wa y
Plug
Port Q
Low Vacuum
Z15471
B A
AB
EC−8
− EMISSION CONTROL (3RZ−FE)EXHAUST GAS RECIRCULATION (EGR) SYSTEM
936 Author: Date:
1996 TOYOTA T100 (RM449U)
(b) If you have no TOYOTA hand−held tester, check these
procedures:
(1) Remove the 3−way connector with the vacuum
hose.
(2) Connect the vacuum hose (from port Q of EGR vac-
uum modulator) to the EGR valve.
(3) Plug the vacuum hose (from VSV for EGR).
(c) Check that the vacuum gauge indicates low vacuum at
3,500 rpm.
7. DISCONNECT TOYOTA HAND−HELD TESTER OR
OBDII SCAN TOOL
8. REMOVE VACUUM GAUGE
Remove the vacuum gauge, and reconnect the vacuum hoses
to the proper locations.
9. INSPECT EGR VALVE
(a) Apply vacuum directly to the EGR valve with the engine
idling.
(b) Check that the engine runs rough or dies.
(c) Reconnect the vacuum hoses to the proper locations.
If no problem is found with this inspection, system is normal;
otherwise inspect each part.
10. REMOVE EGR PIPE
Remove the bolt, 4 nuts, EGR pipe and 2 gaskets.
HINT:
Install 2 new gaskets.
Torque:
Bolt: 18 N·m (185 kgf·cm, 13 ft·lbf)
Nut A: 19 N·m (195 kgf·cm, 14 ft·lbf)
Nut B: 20 N·m (200 kgf·cm, 15 ft·lbf)
11. REMOVE EGR VALVE
(a) Disconnect these hoses:
2 Vacuum hoses
2 Water bypass hoses
(b) Remove the 2 nuts, EGR valve and gasket.
Torque: 19 N·m (195 kgf·cm, 14 ft·lbf)
Page 947 of 2062
Downloaded from www.Manualslib.com manuals search engine EC0107
Orange Pipe
Black Pipe
− EMISSION CONTROL (3RZ−FE)EXHAUST GAS RECIRCULATION (EGR) SYSTEM
EC−9
937 Author: Date:
1996 TOYOTA T100 (RM449U)
12. DISCONNECT VACUUM HOSES FROM EGR VACUUM
MODULATOR
13. 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.
If operation is not as specified, replace the EGR vacuum modu-
lator.
14. RECONNECT VACUUM HOSES TO EGR VACUUM
MODULATOR
15. REMOVE CHECK VALVE
16. INSPECT CHECK VALVE
(a) Check that air flows from the orange pipe to the black
pipe.
(b) Check that air does not flow from the black pipe to the
orange pipe.
If operation is not as specified, replace the check valve.
17. INSTALL CHECK VALVE
HINT:
Install the check valve with the orange pipe facing the EGR vac-
uum modulator side.
18. INSPECT VSV FOR EGR (See page MF−44)
Page 948 of 2062
Downloaded from www.Manualslib.com manuals search engine EC02T−01
EC−10− EMISSION CONTROL (3RZ−FE)THREE−WAY CATALYTIC CONVERTER (TWC)
SYSTEM
938 Author: Date:
1996 TOYOTA T100 (RM449U)
THREE−WAY CATALYTIC CONVERTER (TWC) SYSTEM
INSPECTION
1. CHECK TWC FOR DENTS OR DAMAGE
If any part of the protector is damaged or dented to the extent that it touches the three−way catalytic convert-
er, repair or replace it.
2. CHECK EXHAUST PIPE CONNECTIONS FOR
LOOSENESS OR DAMAGE
3. CHECK EXHAUST PIPE CLUMPS FOR WEAKNESS,CRACKS OR DAMAGE
4. CHECK HEAT INSULATOR FOR DAMAGE
5. CHECK FOR ADEQUATE CLEARANCE BETWEEN CATALYTIC CONVERTER AND HEAT INSU-
LATOR
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 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.
