ect LEXUS SC300 1991 Service Repair Manual

FUEL EVAPORATIVE EMISSION CONTROL (EVAP) SYSTEM
DESCRIPTION
To reduce HC emission, evaporated fuel from the fuel tank is routed throug\
h the charcoal canister to the
intake manifold for combustion in the cylinders.
OPERATION
CoolantVSVThrottle ValveCanister Check ValveCheck
Valve inEvaporated F el (HC)Coolant
Te m p .VSVThrottle Valve
Opening(1)(2)(3)Valve inCapEvaporated Fuel (HC)
BelowNoFulley closedBelow
40 5C (104 5F)
No
OperationFulley closed.±±±±Small volume of HC from
Fully closed or
bellow Specified air
canister enters air intake
chamber.
Above
bellow Specified air
volume.±±±±chamber.
Above
40 5C (104 5F)Operation
Conditions other
than above.±±±±
HC from canister enters air
intake chamber in the amout
programmed in accordance
with the intake air volume.
High pres-
sure in tank±±±OPENCLOSEDCLOSEDHC from tank is absorbed
into the canister.
High vacuum
in tank±±±CLOSEDOPENOPENAir is led into the fuel tank.
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 leakage.
EC±8
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EMISSION CONTROL SYSTEMS Fuel Evaporative Emission Control (EVAP) System
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3. VISUALLY INSPECT FUEL TANK CAPCheck if the cap and/or gasket are deformed or damaged.
If necessary, repair or replace the cap.
INSPECTION OF CHARCOAL CANISTER
1. REMOVE CHARCOAL CANISTER(a) Disconnect the following hoses:(1) Vacuum hose (from VSV) from charcoal canister
(2) EVAP hose from charcoal canister
(b) Disconnect the grommet on the check valve from the bracket, and remove the charcoal canister.
(c) Remove the check valve from the hose end on the charcoal canister.
2. VISUALLY INSPECT CHARCOAL CANISTER Look for cracks or damage.
3. CHECK FOR CLOGGED FILTER AND STUCK CHECK VA LV E
(a) Using low pressure compressed air, blow into port A and
check that air flows without resistance from the other
ports.
(b) Blow into port B and check that air does not flow from the
other ports.
If a problem is found, replace the charcoal canister.
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EMISSION CONTROL SYSTEMS Fuel Evaporative Emission Control (EVAP) SystemEC±9
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4. CLEAN FILTER IN CANISTERClean the filter by blowing 294 kPa (3 kgf/cm2, 43 psi) of com-
pressed air into port A while holding port B closed.
NOTICE:
w Do not attempt to wash the canister.
w No activated carbon should come out.
5. REINSTALL CHARCOAL CANISTER
HINT: Install the check valve with black port facing the char-
coal canister side.
(a) Install the check valve to the hose end on the charcoalcanister.
(b) Install the charcoal canister.
(c) Install the grommet on the check valve to the bracket.
(d) Connect the following hoses: (1) Vacuum hose (from VSV) to charcoal canister
(2) EVAP hose to charcoal canister
COMPONENTS FOR REMOVAL AND INSTALLATION OF VSV
EC±10±
EMISSION CONTROL SYSTEMS Fuel Evaporative Emission Control (EVAP) System
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INSPECTION OF VSV
1. DISCONNECT CABLE FROM NEGATIVE TERMINAL OFBATTERY
CAUTION: Work must be started after approx. 20 se-
conds or longer from the time the ignition switch is
turned to the ºLOCKº position and the negative (±) termi-
nal cable is disconnected from the battery.
2. REMOVE INTAKE AIR CONNECTOR (a) Disconnect the following hoses:(1) Air hose (from ISC valve) from intake air connector
(2) Air hose (from PS air control valve) from intake air
connector
(b) Remove the bolt holding the intake air connector to the cylinder head cover.
(c) Loosen the two hose clamps.
(d) Disconnect the intake air connector from the throttle
body and air cleaner hose, and remove the intake air
connector.
3. REMOVE VSV (a) Disconnect the VSV connector.
(b) Disconnect the following hoses:(1) Vacuum hose (from vacuum pipe) from VSV
(2) Vacuum hose (from charcoal canister) from VSV
(c) Remove the two bolts and VSV from the cylinder head.
(d) Disconnect the two wire clamps from the VSV bracket, and remove the VSV.
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EMISSION CONTROL SYSTEMS Fuel Evaporative Emission Control (EVAP) SystemEC±11
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4. INSPECT VSV
A. Inspect VSV for open circuitUsing an ohmmeter, check that there is continuity between
the terminals.
Resistance (Cold): 30±34

If there is no continuity, replace the VSV.
B. Inspect VSV for ground Using an ohmmeter, check that there is no continuity be-
tween each terminal and the body.
If there is continuity, replace the VSV.
C. Inspect VSV operation (a) Check that the air flows with difficulty from ports E to F.
(b) Apply battery voltage across the terminals.
(c) Check that the air flows without resistance from port Eto F.
If operation is not as specified, replace the VSV.
5. REINSTALL VSV (a) Install the VSV with the two bolts.
(b) Connect the two wire clamps to the VSV bracket.
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EMISSION CONTROL SYSTEMS Fuel Evaporative Emission Control (EVAP) System
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(c) Connect the following hoses:(1) Vacuum hose (from vacuum pipe) to VSV
(2) Vacuum hose (from charcoal canister) to VSV
(d) Connect the VSV connector.
6. REINSTALL INTAKE AIR CONNECTOR (a) Connect the end portions of the intake air connector tothe throttle body and air cleaner hose.
(b) Tighten the two hose clamps.
(c) Install the bolt holding the intake air connector to the cylinder head cover.
(d) Connect the following hoses: (1) Air hose (from ISC valve) to intake air connector
(2) Air hose (from PS air control valve) to intake air con-
nector
7. RECONNECT CABLE TO NEGATIVE TERMINAL OF BATTERY
INSPECTION OF CHECK VALVE
1. REMOVE CHECK VALVE(a) Disconnect the grommet on the check valve from thebracket.
(b) Remove the check valve from the hose end on the charcoal canister.
(c) Remove the grommet from the check valve.
2. INSPECT CHECK VALVE (a) Check that air flows from the yellow port to the blackport.
(b) Check that air does not flow from the black port to the yellow port.
If operation is not as specified, replace the check valve.
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EMISSION CONTROL SYSTEMS Fuel Evaporative Emission Control (EVAP) SystemEC±13
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INSPECTION OF EGR SYSTEM
1. CHECK AND CLEAN FILTER IN EGR VACUUMMODULATOR
(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 the at-
mospheric side (out ward).
2. INSPECT SYSTEM OPERATION (a) Connect the tachometer to terminal IG ± of the check(ºDIAGNOSISº) connector.
(b) Using SST connect the terminals TE1 and E1 of the check (ºDIAGNOSISº) connector.
SST 09843±18020
(c) Keep the engine at 3,500 rpm with the transmission in ºNº position.
(d) Remove the SST from the check connector.
SST 09843±18020
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EMISSION CONTROL SYSTEMS Exhaust Gas Recirculation (EGR) System
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(e) Check whether the engine rpm increases 100±300 rpmunder the following conditions:
Coolant temp.
Below 45 5C (113 5F) . . . NO increase
Above 50 5C (122 5F) . . . Increases
INSPECTION OF VSV
1. REMOVE VSV
(a) Disconnect the VSV connector.
(b) Disconnect the two vacuum hoses from VSV.
(c) Remove the bolt and VSV from the intake manifold.
2. INSPECT VSV (a) Inspect VSV for open circuit.Using an ohmmeter, check that there is continuity be-
tween the terminals.
Resistance (Cold): 33±39

If there is no continuity, replace the VSV.
(b) Inspect VSV for ground.
Using an ohmmeter, check that there is no continuity be-
tween each terminal and the body.
If there is continuity, replace the VSV.
(c) Inspect VSV operation: 1) Check that the air flows from ports E to G
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EMISSION CONTROL SYSTEMS Exhaust Gas Recirculation (EGR) SystemEC±13
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2) Apply battery voltage across the terminals
3) Check that the air flows from port E to port G
If operation is not as specified, replace the VSV.
3. REINSTALL VSV (a) Install the VSV with the nut.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
(b) Connect the following hoses:
(1) Vacuum hose (from throttle body)
(2) Vacuum hose (from EGR vacuum modulator)
(c) Connect the VSV connector.
INSPECTION OF EGR VACUUM
MODULATOR
1. DISCONNECT VACUUM HOSES FROM EGR VACUUM MODULATOR
Disconnect the three vacuum hoses from ports P, Q and R of
the EGR vacuum modulator.
2. 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 passesthrough to the air filter side freely.
(c) Start the engine, and maintain speed at 2,500 rpm.
(d) Repeat the above test. Check the there is a strong resistance to air flow.
3. RECONNECT VACUUM HOSES TO EGR VACUUM MODULATOR
Connect the three vacuum hoses to the proper locations.
EC±14
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EMISSION CONTROL SYSTEMS Exhaust Gas Recirculation (EGR) System
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INSPECTION OF EGR VALVE
1. REMOVE EGR VALVE(a) Disconnect the following hoses:(1) Vacuum hose from EGR vacuum modulator
(2) Pressure hose from EGR vacuum modulator(USA Spec.)
(b) Disconnect the EGR Gas Temp. Sensor connector
(c) Loosen the nut for EGR pipe.
(d) Remove the two nuts, EGR valve and gasket.
2. INSPECT EGR VALVE Check for sticking and heavy carbon deposits.
If a problem is found, replace the EGR valve assembly.
3. REINSTALL EGR VALVE (a) Place a new gasket on the intake manifold.
(b) Install the EGR valve with the two nuts.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
(c) Torque the nut for EGR pipe.
Torque: 64 N Vm (650 kgf Vcm, 47 ft Vlbf)
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EMISSION CONTROL SYSTEMS Exhaust Gas Recirculation (EGR) SystemEC±15
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