Evaporative Emission Control Systems: Section 5
Evaporative Emission Control Systems: Section 5
Evaporative Emission Control Systems: Section 5
Purge
VSV
T852f244
Lesson Objectives 1. Determine the condition of the EVAP system operation based on engine
data
2. Determine the condition of the EGR system based on engine data
3. Determine the root cause of a failure(s) in the EGR system using
appropriate diagnostic procedures
EMISSION SYSTEMS
Evaporative Approximately 20% of all hydrocarbon (HC) emissions from the automo-
Emissions bile originate from evaporative sources. The Evaporative Emission
Control Control (EVAP) system is designed to store and dispose of fuel vapors
Systems normally created in the fuel system and prevent their escape to the
atmosphere.
Non-ECM TVV
Check
Valve (3) (2)
(1)
Charcoal
Canister
Fuel Tank
Non-ECM Non-ECM controlled EVAP systems typically use the following compo-
Controlled EVAP nents:
Systems
Fuel tank.
Under some conditions, the fuel tank operates under a slight pressure
to reduce the possibility of pump cavitation due to fuel vaporization.
Pressure is created by unused fuel returning to the tank and is main-
tained by check valve No. 2 in the charcoal canister and the check valve
in the fuel tank cap.
Under other conditions; as fuel is drawn from the tank, a vacuum can
be created in the tank causing it to collapse. This is prevented by allow-
ing atmospheric pressure to enter the tank through check valve No. 3 in
the charcoal canister or the fuel tank cap check valve. The EVAP system
is designed to limit maximum vacuum and pressure in the fuel tank in
this manner.
When the engine is running, stored fuel vapors are purged from the
canister whenever the throttle has opened past the purge port (port P)
and coolant temperature is above a certain point (usually around 54C
(129F )). Fuel vapors flow from the high pressure area in the canister,
past check valve No.1 in the canister, through the Thermo Vacuum
Valve (TVV), to the low pressure area in the throttle body. Atmospheric
pressure is allowed into the canister through a filter located on the bot-
tom of the canister. This ensures that purge flow is constantly main-
tained whenever purge vacuum is applied to the canister. When coolant
temperature falls below a certain pointusually around 35C (95F), the
TVV prevents purge from taking place by blocking the vacuum signal to
check valve No.1.
Purge Port
From Fuel Tank
Throttle VSV
Valve Charcoal
Canister
ECM Controlled ECM controlled EVAP systems were introduced to provide a more precise
EVAP Systems control and maintain driveability. The ECM will adjust the fuel injection
duration based on oxygen sensor or air/fuel ratio sensor signal.
Fuel tank.
Early ECM EVAP systems used a ported vacuum purge port with
in-line check valve (port A; on throttle body).
The ECM will change the duty ratio cycle of the purge VSV thus control-
ling purge flow volume. Purge flow volume is determined by manifold
pressure and the duty ratio cycle of the purge VSV. Atmospheric pressure
is allowed into the canister to ensure that purge flow is constantly main-
tained whenever purge vacuum is applied to the canister.
Purge
VSV
Tank Tank
Air Inlet Fill Check
Condition Purge Port Vacuum Pressure Air Drain
Valve Valve
Ball Check Port
VSV Purge OPEN (V) OPEN (V) CLOSED CLOSED CLOSED CLOSED
Valve On
VSV Purge CLOSED CLOSED
CLOSED CLOSED CLOSED CLOSED
(NV) (NV)
Valve Off
Pressure In CLOSED CLOSED CLOSED OPEN CLOSED CLOSED
Tank
Charcoal Canister The charcoal canister is filled with activated charcoal. This charcoal has
the ability to absorb gasoline vapors and release these vapors when fresh
air passes through the canister. Mounted on the charcoal canister are
check valves to control vapor flow. The table on the previous page shows
the action of each valve according to engine operation and fuel tank
conditions.
Check Valve
Engine Compartment
Purge VSV
From Air
Cleaner
Fig. 5-04
T852f245
Check Valve
Purge VSV
From Air
Cleaner
Engine Compartment
Purge Line Fuel Tank Fresh Air Intake Line Atmospheric Pressure Valve
OPEN
Rear of Vehicle Tank Inside Pressure
Control Valve (CLOSED)
Differential
Pressure Canister
Valve
Check Valve
Purge VSV
From Air
Cleaner
Engine Compartment
Fig. 5-05
Purge Line Fuel Tank Fresh Air Intake Line
T852f246/T852f334
Purge Mode
OPEN
Purge VSV
From Air
Cleaner
OPEN
Engine Compartment Air Inlet Valve Fig. 5-06
Purge Line Fuel Tank Fresh Air Intake Line
(OPEN) T852f247
Refueling Mode
Check Valve
Purge VSV
From Air
Cleaner
Engine Compartment Purge Line Fuel Tank Atmospheric Pressure Fig. 5-07
Fresh Air Intake Line Valve (OPEN) T852f248
EVAP There is no routine maintenance for the EVAP system. It is critical that
System Service the proper diameter hoses and parts are used. Failure to do so can result
in driveability problems. There are diagnostic procedures for checking the
valves listed in the Repair Manual.
Exhaust Gas The Exhaust Gas Recirculation (EGR) system is used for reducing oxides of
Recirculation nitrogen and for engine knock control. By recirculating a controlled
System amount of exhaust gases into the intake air-fuel mixture, combustion tem-
perature is lowered. This, in turn, reduces the amount of NO X emission.
Exhaust manifold
Exhaust
gases
Fig. 5-08
T852f249
Diaphragm
Vacuum
EGR Valve
Engine Exhaust
Fig. 5-09
T852f250
EGR Valve Also, the exhaust gases help prevent engine knock and allow for more
advanced ignition timing.
The EGR valve opens and closes the passage between the exhaust mani-
fold and intake manifold. Vacuum is used to move the EGR valves.
Inside the vacuum actuated EGR valve is a valve, diaphragm, and spring.
When vacuum is applied to the diaphragm the diaphragm lifts the valve
off its seat allowing exhaust gases into the intake air stream. When vacu-
um is removed the spring forces the diaphragm and valve downward clos-
ing the exhaust passage.
For proper engine operation, the EGR valve must open to the proper
height, and when closed seal the intake manifold from exhaust gases.
CAUTION The EGR valve can get very hot. Handle with care.
Throttle Body
Engine
Speed
R Port
Throttle Valve Coolant Temperature
E Port ECM Throttle Opening
Inlet Air Valve
EGR Valve
Diaphragm
EGR
Vacuum
Modulator
! Constant
Intake Air Exhaust Pressure
Chamber Gas Chamber
O
A Passage
Fig. 5-10
T852f251
Cut-Off Some EGR valve's are water cooled and this is done to cool the exhaust
Control EGR gases. Cooling the exhaust gases increases the exhaust gases effective-
System ness in reducing NOX and engine knock.
Operation
In the Cutoff Control EGR system, the amount of exhaust gas to be
recirculated is controlled by the EGR vacuum modulator. The EGR mod-
ulator is needed because of the changes in engine vacuum and exhaust
backpressure. The vacuum available at ports E and R changes with
throttle opening. As the throttle valve opens and intake air
volume/speed increases, the vacuum signals from ports E and R
increases. As engine load increases the amount of exhaust backpres-
sure increases.
For the above reasons, an EGR vacuum modulator controls the amount
of vacuum reaching the EGR valve lifting the EGR valve to the correct
height.
Fig. 5-11
EGR Cut-Off
Engine
Speed
E Port R Port Coolant Temperature
ECM Throttle Opening
Inlet Air Valve
Fig. 5-12
T852f252
EGR Cut-Off To close the EGR valve, the VSV is turned on by a signal from the ECM.
Operation This opens the vacuum line to atmospheric pressure closing the EGR
valve and shutting off the exhaust gas flow. This is done when EGR is not
needed and to maintain driveability. This operation (EGR cut-off) is imple-
mented when the following conditions exist:
Variations in exhaust
pressure. Large Load without EGR gas
+
+
Positive
Pressure
Exhaust
Negative
Atmospheric
Pressure
_
Crankshaft Angle
Fig. 5-13
T852f253
EGR Vacuum
Modulator
Filter
Modulated
Vacuum To Q P
EGR Valve Throttle Body Port E
Diaphragm Throttle Body Port R
R
Orifice
Chamber A
A Passage
Exhaust Pressure
Chamber
Fig. 5-14
T852f254
EGR Vacuum The exhaust gas pressure increases in proportion to the amount of
Modulator intake air. As the throttle valve opens and the amount of intake air vol-
ume increases, a higher exhaust gas pressure is applied to the constant
pressure chamber of the EGR vacuum modulator. It pushes the
diaphragm of the EGR vacuum modulator upward to narrow the "A"
passage. Since vacuum acts then on the E and R ports of the throttle
body, the vacuum is modulated by the size of the "A" passage. This
modulated vacuum causes the EGR valve to open, which, in turn, allows
exhaust gas into the intake manifold. This also causes the gas pressure
inside the exhaust pressure chamber to go down, which in turn, lowers
the EGR vacuum modulator diaphragm.
The EGR valve is now under less vacuum and the valve moves until the
vacuum balances with the spring tension and the amount of EGR gas is
regulated. Therefore, the amount of EGR is regulated according to the
exhaust gas pressure and the vacuum signal strength.
Intake VCV
VSV
Atmosphere
ECM
Vacuum
Surge Tank Mass Air Flow
Meter
EGR Valve Engine Coolant
Temp. Sensor
Fig. 5-15
T852f255
Constant This type of ECM EGR controlled system uses a Vacuum Control Valve
Vacuum System (VCV), an EGR VSV, and an EGR valve position sensor to regulate
Operation exhaust gas flow.
Vacuum Control
Valve (VCV) Filter
Spring
Diaphragm
S Port Z Port
Vacuum Control The VCV is a valve that regulates the intake manifold vacuum applied to
Valve (VCV) the VSV to a constant level (-17 kPa, -l30 mmHg, -5 inHg).
EGR Valve The EGR valve position sensor is a potentiometer sensor mounted on the
Position Sensor EGR valve. The EGR valve and signal arm in the position sensor move
together. As the EGR valve opens, the voltage signal of the EGR valve
position sensor increases.
EGR VSV
Atmosphere
Fig. 5-18
T852f257
Operation The ECM uses the EGR valve position sensor signal to control EGR
valve position height and to detect excessive EGR flow. EGR valve height
is controlled by the strength of the vacuum signal and the ECM controls
vacuum signal strength by varying the pulsewidth signal sent to the
EGR VSV. If greater EGR flow is needed, the ECM increases the
pulsewidth signal to the EGR VSV. This applies more vacuum to the
EGR valve.
Under the following conditions the ECM turns off the VSV and closes
the EGR valve:
Engine idling.
Technician Objectives
With this worksheet, you will learn to test EVAP systems using the required tools and equipment, retrieve and
apply the needed service information, retrieve and interpret service data information.
Diagnostic Tester
Vacuum Gauge
Section 1
EVAP Identification
Use the Repair Manual and Technician Handbook to answer the following questions on the vehicle you are
working on.
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Section 2
Purge VSV Operation
1. Select ACTIVE TEST.
2. Set to EVAP VSV and turn the VSV ON using the left and right arrow keys.
3. Disconnect the purge hose from the canister side of the purge VSV and listen for a duty cycle pulsing
sound from the VSV.
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5. Turn the purge VSV OFF using the left and right arrow keys. Check for vacuum on the VSV with a
vacuum gauge. If vacuum is present, the purge VSV is
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Note: If a purge valve were stuck, open or closed, the following steps are recommended:
1. If the valve is stuck open or closed, this could be the result of active charcoal contamination or metal
flakes from manufacturing inside the purge VSV.
2. If charcoal is found in the purge lines, all hoses must be cleaned of charcoal and the canister and purge
VSV must be replaced.
3. If metal is found in the purge VSV, blow the metal lines out between canister and engine and replace the
VSV.
Section 3
Vapor Pressure Sensor
1. Refer to SF section in the Repair Manual on vapor pressure sensor inspection.
4. Connect a voltmeter to terminals PTNK and E2. According to the RM, measure the voltage under specified
conditions.
Below Atmospheric
Pressure
Atmospheric Pressure
Above Atmospheric
Pressure
5. Predict the PTNK signal voltage if the PTNK wire were to become disconnected. Voltage will
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7. Record the voltage between PTNK and E2 terminals at the ECM: ____________
_________________________________________________________________________________________________________
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Topic Comment
Technician Objectives
With this worksheet, you will learn to test the EGR cutoff control system using the required tools and
equipment, retrieve and apply the needed service information, retrieve and interpret service data
information.
Vehicle EWD
Diagnostic Tester
Section 1
Component Tests
VSV Component Check
2. According to the Repair Manual, perform the Inspect VSV operation test procedure. Test procedure
and specifications are found in what section?
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3. When the engine is cold, does the EGR valve have vacuum applied to it?
5. When the EGR valve is open, the EGR VSV is ON/OFF and OPEN/CLOSED to atmosphere.
2. With the engine OFF and Ports P and R blocked, should air pass freely from Port Q to atmosphere?
Why? _______________________________________________________________________________________________
3. With the engine ON and Ports P and R blocked, should air pass freely from Port Q to atmosphere?
Why? ________________________________________________________________________________________________
4. If the atmospheric port were blocked, what would be the engine symptoms?
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EGR Valve
1. With the engine idling and warm, slowly apply vacuum to the EGR valve, so that the engine runs
rough. What happened to EGR temperature?
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2. On MAP sensor equipped engines, what happens to intake manifold pressure when the EGR valve
is opened?
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_________________________________________________________________________________________________
Topic Comment
Technician Objectives
With this worksheet, you will learn to test the EGR constant vacuum system using the required tools and
equipment, retrieve and apply the needed service information, retrieve and interpret service data information.
Vehicle EWD
Diagnostic Tester
Section 1
Component Tests:
VCV Component Check
1. According to the Repair Manual, perform the VCV test procedure for operation.
_________________________________________________________________________________________________________
2. What port has vacuum applied to it? Did it match the Repair Manual?
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2. From the voltage readings, is the EGR valve position sensor voltage signal normal?
EGR VSV
1. Connect the positive (+) lead of the DVOM to EGR VSV, terminal.
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Is the EGR VSV open to atmosphere pressure with the EGR valve off?
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Section 3
EGR Operation
1. With the DT, go to Active Test and select EGR. In User Data select EGR Temp, EGR valve position sensor.
2. Connect the positive (+) lead of the DVOM to EGR VSV connector/terminal.
Engine RPM EGR Temperature EGR Valve Position VSV Voltage EGR Gas Flow (Y/N)
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9. What happened to EGR VSV voltage as the EGR valve height increased?
_________________________________________________________________________________________________________
10. If the EGR VSV were disconnected, what would be common engine symptoms, and what DTC would set?
_________________________________________________________________________________________________________
Topic Comment