ENGINE EM ISSION CONTROLS 6E-1

SECTION 6E

ENGINE EMISSION CONTROLS

CONTENTS

GENERAL DESCRIPTION OF EMISSION CONTROL

COMPONENTS

CARBURETOR CALIBRATIO N DISTRIBUTOR CALIBRATIO N

C ATALYTIC CONVERTER

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6E-2 ENGINE E M IS SIO N CONTROLS

THE CATALYTIC CONVERTER REQUIRES

THE USE OF UNLEADED FUEL ONLY.

CHOKE SYSTEM

EARLY FUEL EVAPORATION SYSTEM (EFE)

TH E R M O S TA TIC AIR CLEANER (THERMAC)

AIR INJECTIO N REACTOR SYSTEM (AIR)

EXHAUST GAS RECIRCULATION SYSTEM

(EGR)

PULSE AIR INJECTIO N REACTOR SYSTEM

(PAIR)
CLOSED POSITIVE CRANKCASE
VEN TIL ATIO N S YS TEM (PCV)

V A C U U M CONTROLS
NOTICE:

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 ENGINE EM ISSIO N CONTROLS 6E-3

ON-VEHICLE SERVICE
EARLY FUEL EVAPORATION (EFE)

INS PE CTIO N (EXCEPT 4.8 L - 2 9 2 CID)

COO LANT TEMPER ATURE THE RM AL

V A C U U M S W ITC H (TVS) - V 8
Replacem ent

HEAT VALVE INSPECTION (WITH 4.8L - 292

CID)

CHECKING EFE SYSTEM

OIL TEMPERATURE TH ERM A L V A C U U M

S W ITC H (TVS) - L6
Replacem ent

ACTUATOR AN D ROD ASSEMBLY

Replacem ent

EXH AUST HEAT VALVE - V 8

Replacement

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6E-4 ENGINE EM ISSIO N CONTROLS

EXHAUST HEAT VALVE - 4.1 L

M AN IFO LD HEAT VALVE - 4 .8 L

Replacement Replacement

POW ER ACTUATO R

Fig. 6 E -3 -A c tu a to r and Rod 4 5 4 V 8 Fig. 6 E -5 -P o w e r A ctuator

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 ENGINE EM IS SIO N CONTROLS 6E-5

EXHAUST GAS RECIRCULATION (EGR)

GENERAL DESCRIPTION

Operational System Diagnosis

Diaphragm doesn't move:

4.

Diaphragm moves w ith no change in engine speed:

FUNCTIONAL CHECKS
Ported Signal and Negative Backpressure EGR
Valves

EGR VALVE ID E NTIFIC ATIO N

4.
EGR O PERATIONAL SYSTEM CHECK

CAUTIO N: If valve is hot it may be

necessary to w ear gloves to avoid burning
fingers.

Positive Backpressure EGR Valve

4.

NOTICE:
L IG H T T R U C K SE R V IC E M AN U AL
6E-6 ENGINE EM ISSION CONTROLS

PORTED SIGNAL VACUUM EGR VALVE

VACUUM TUBE CONNECTED TO THERMAL VACUUM SWITCH
DIAPHRAGM 1 “-----
COVER
SPRING

VALVE SHAFT

SEAL

VALVE SEAT <

VALVE CHAMBER*

TO INTAKE
MANIFOLD

Fig. 6E-6~Ported S ignal Vacuum EGR Valve

EGR TH ERM AL V A CC U M S W ITC H

Replacement

EGR VALVE REPLACEMENT

Functional Check - Hot

EGR PASSAGE

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 ENGINE EM IS SIO N CONTROLS 6E-7

PO S ITIVE BACK PRESSURE EGR V A LV E

■CONTROL VALVE
OPEN

ORIFICE OPENING .030

(SEE OPTIONAL CONSTRUCTION)
TRANSDUCER

VACUUM SIGNAL TUBE

DIAPHRAGM PLATE

OPTIONAL CONSTRUCTION

SEAT ORIFICE OPENING

EXHAUST
GAS (IN)
t... JEXHA U ST GAS

Fig. 6E-7-Positive Backpressure EGR Valve

Functional Check - Cold

NOTICE:

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6E-8 ENGINE EMISSIO N CONTROLS

Fig. 6E -8 -N e ga tive B ackpressure EGR Valve

PORTED SIGNAL VACUUM EGR V A LV E

NOTE: ID ENTIFY PORTED EGR VA LV E

BY DIAPHRAGM PLATE DESIGN

DIAPHRAGM PLATE ASSEMBLY

Fig. 6E-9~P orted EGR Id en tifica tio n

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 ENGINE EM ISSIO N CONTROLS 6E-9

PO SITIVE BACK PRESSURE EGR V A LV E

DIAPHRAGM PLATE ASSEMBLY

Fig. 6 E -1 0-P o s itive EGR Id e n tific a tio n

N EG ATIV E BACK PRESSURE EGR V A LV E

NOTE: IDE N TIF Y NEGATIVE EGR V A LV E

DIAPHRAGM PLATE ASSEMBLY

Fig. 6E-1 1 -N e g a tiv e EGR Iden tifica tion

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6E-10 ENGINE EM IS SIO N CONTROLS

EXHAUST GAS RECIRCULATION SYSTEM D IA G N O S IS CHART

Condition Possible Cause Correction

Engine idles a b n o rm a lly rough EGR v a lv e vacuum hoses Check EGR v a lv e vacuum hose routing . Correct
a n d /o r stalls. m isrouted. as req u ire d.

Leaking EGR va lv e. Check EGR v a lv e fo r correct o p eratio n .

EGR v a lv e g asket fa ile d or loose Check EGR attach ing bolts fo r tightness.
EGR a ttach ing bolts. Tighten as re qu ire d . If not loose, rem ove EGR
v a lv e an d inspect gasket. Replace as re qu ire d .

EGR the rm a l control v a lve Check vacuum into v a lv e fro m carb uretor EGR
a n d /o r EGR-TVS. po rt w ith eng in e a t no rm al op era tin g
te m p e ra tu re an d a t curb id le speed. Then
check the vacuum out o f the EGR th erm al
control v a lv e to EGR v a lv e . If the tw o vacuum
reading s a re not e q ua l w ith in ± 1 /2 in. Hg.
(1 .7 kPa), then proceed to EGR vacuum control
diagnosis.

Im p ro per vacuum to EGR v a lv e a t Check vacuum from ca rbu reto r EGR port w ith
idle. en g ine a t s ta b ilized o p e ra tin g te m p era tu re a n d
a t curb idle speed. If vacuum is m ore than 1.0
in. H g .( refe r to ca rbu re to r idle diagnosis.

Engine runs rough on lig ht EGR v a lv e vacuum hose Check EGR v a lv e vacuum hose routing. Correct
thro ttle accelera tion a n d has m isrouted. as re qu ire d .
poor p a rt load p e rfo rm an c e.
Check fo r loose va lv e. To rque va lv e.

Fa iled EGR vacuum control v a lve . Sam e as listing in "E ngine Idles Rough"
condition.

(TVS open be lo w 1 3 0 °F .) C lean EGR passage of a ll deposits.

Sticky or bin ding EGR va lve . Remove EGR v a lv e an d inspect. Replace as

req u ire d .

W ron g or no EGR gasket(s) Check and correct as re q u ire d.

a n d /o r Spacer. Install ne w gasket(s), install spacer (if used),
torq ue a tta ch in g parts.

Engine stalls on de celeration s. Control v a lv e blocked or a ir flow Check in te rna l control v a lv e function per
restricted. service procedure.

Restriction in EGR vacuum line or Check EGR vacuum lines fo r kinks, bends, etc.
v a lv e vacuum signal tube. Remove or rep lace hoses as require d . Check
EGR vacuum control v a lv e function.

Check EGR v a lv e fo r excessive deposits causing

sticky or b ind in g op era tio n. Replace va lve .

Sticking or bin ding EGR va lv e. Remove EGR v a lv e and re pla c e v a lve.

P art thro ttle engin e d e ton a tion. Control v a lv e blocked or a ir flow Check in te rn al control v a lv e function per
restricted. service procedure.

Insufficient ex haust gas Check EGR v a lv e hose rou ting. Check EGR
recirculation flo w during p a rt v a lv e o p e ra tio n . R epair or replace as re qu ire d .
throttle accelerations. Check EGR th e rm a l control v a lv e a n d /o r
EGR-TVS as listed in "E ngin e Idles Rough"
section. Replace v a lv e as re qu ire d . Check EGR
passages an d v a lv e for excessive deposit.
C lea n as re qu ire d .
(NOTICE: Non-Functioning EGR va Ive could contrib ute to p a rt throttle deto na tion .)
I Control v a lv e blocked or flo w Check EGR per service procedure,
restricted.
(NOTICE: Deto nation can be caus<id by several o th er engin e v a ria ble s . Pe rform ign ition a n d ca rb ureto r re la te d diagnosis.)

Engine starts but im m e d ia te ly EGR va lve hoses m isrouted. Check EGR v a lv e hose routings.
stalls w h en cold.
EGR TVS system m a lfun ctio nin g Perform check to de te rm in e if the EGR th erm a l
w hen en g ine is cold. control v a lv e a n d /o r EGR-TVS a re op e ra tio n a l.
Replace as require d .
(NOTICE: Stalls a fte r start can als o be caused by c a rb u reto r problem s.)

Fig. 6 E -1 2 -E G R D iagnosis

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 ENGINE E M ISSIO N CONTROLS 6E -11

POSITIVE CRANKCASE VENTILATION SYSTEM (PCV)

G E N E R A L D ESC R IP TIO N
O N-VEH IC LE S E R V IC E

THERMOSTATIC AIR CLEANER (THERMAC)

INS PECTIO N
Vacuum M otor Check

Therm om eter Check of Sensor

Sensor Check (Quick Check of System)

ON VEHICLE SERVICE

Checking Air Cleaner

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6E-12 ENGINE EM ISSIO N CONTROLS

W IN G NUT
TORQUE AT 20 LBS. IN.

Polyurethane Band must wrap

end seals of paper element as

POLYWRAP Alt ELEMENT

CLEAN ER ELEW (PAPER FILTER
(BAND S H O W I,; PORTION)

PAPER FILTER PORTION

OF POLYWRAP AIR
POLYWRAP
AIR CLEANER CLEANER ELEMENT
(BAND

Polyurethane Band must

completely cover the outer screen
surface of paper element as

Fig. 6 E -14 -C le a n ing P o lyw ra p Band

Polywrap Element (P Models)

Fig. 6 E -1 3 -P o lyw ra p A ir Cleaner Element

NOTICE:

NOTICE:

Air Cleaner Replacement

Air Cleaner Element Replacement

Paper Element

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 ENGINE E M IS SIO N CONTROLS 6E-13

GASKET (POSITION
COLORED SURFACE
TO CARBURETOR)

Fig. 6E-16-Air Cleaner-L6

Fig. 6E-15-Air Cleaner-L6

Vacuum M otor

Removal Sensor

Removal

Installation

Installation

Carburetor A ir Intake

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6E-14 ENGINE EM IS SIO N CONTROLS

Fig. 6 E -1 7 -A ir C le a n e r-3 0 5 /3 5 0 /4 0 0 V 8 CK

WING NUT

GASKET
(POSITION RED
SURFACE DOWN)
EXTENSION

GASKET
(POSITION RED
SURFACE DOWN)

STOVE
/

Fig. 6E-1 8 -A ir C lea n er-V 8 G

 ENGINE E M IS SIO N CONTROLS 6E-15

Fig. 6 E -2 0 -A ir Cleaner-P 20(42), P 30(42), P 3 0(32)-V 8

DRILL 7 / 6 4 " HO LE
IN C E N T E R P O S IT IO N
O F S TR A P

SPOTW ELDS
VACUUM
D IA P H R A G M .

IN S T A L L R E P L A C E M E N T
R E T A IN IN G S E N S O R A S S M . IN S A M E
STRAP P O S I T IO N AS O R IG IN A L ASSM .

Fig. 6 E -2 2 -V a c u u m D iaph rag m R eplacem en t

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6E-16 ENGINE E M IS S IO N CONTROLS

T IG H T E N T O
5 0 LBS. I N .
Fig. 6E -2 3-R em oving Sensor U nit

A IR IN T A K E
DUCT

A IR IN L E T

ALL EXC EP T D IE SE L

Fig. 6 E -2 5 -C a rb u re tor A ir Intake - V8

Fig. 6 E -2 4-C a rb u retor A ir lntake-L6

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 ENGINE EM ISSIO N CONTROLS 6E-17

AIR INJECTION REACTOR (AIR) SYSTEM

GENERAL DESCRIPTION

REAR COVER

DRIVE HUB ROTOR SHAFT

Fig. 6 E -2 9 ~A ir Injection Pump

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6E-18 ENGINE E M ISSIO N CONTROLS

EXHAUST A M ANIFO LD
Pump Filter
OUTLET ------------ ►J— ~E /— METERING VALVE
Replace

INLET RELIEF VALVE

NOTICE:

INTERNAL SILENCER

VACUUM
VENT
SIG NAL TUBE

Install
DIAPHRAGM
TIM IN G VALVE

IN T E R N A L M U FF LER TYPE

Fig. 6E -30~ Diverter Valve

ON-VEHICLE SERVICE NOTICE:

Drive Belt
Air Hoses and Tubes
Inspection
Inspection

A d ju s tm e n t

NOTICE:

Replace
R eplace

Install

Pump Pulley
R eplace Check Valve
Inspection

In stall

LIGH T T R U C K S ER V IC E M AN UAL
 ENGINE EM IS SIO N CONTROLS 6E-19

DIAGNOSIS - A IR INJECTION REACTOR SYSTEM

C OND ITIO N POSSIBLE CAUSE CORRECTION
No air supply — accelerate engine to 1. Loose drive belt. 1. T ighten to specifications.
1500 rpm and observe air flo w fro m
2. Leaks in supply hose. 2. Locate leak and repair
hoses. If the flo w increases as the
rpm 's increase, the pump is fu n ctio n in g 3. Leak at fittin g s . 3. Tighten or replace clamps.
n o rm a lly . If n ot, check possible cause.
4. A ir expelled through by-pass
valve.
4a. Connect a vacuum line d ire ctly 4a. If this corrects the problem go to
from engine m anifold vacuum step b. If n o t, replace air by-pass
to by-pass valve. valve.

4b. Connect vacuum line fro m engine 4b. If this corrects the problem , check
m anifold vacuum source to by-pass d iffe re n tia l vacuum , delay and
valve through vacuum d iffe re n tia l separator valve and vacuum
valve d ire c tly , by passing the source line fo r plugging.
d iffe re n tia l vacuum delay and Replace as required.
separator valve. If it doesn't, replace vacuum
d iffe re n tia l valve.

5. Check valve inoperative. 5. Disconnect hose and blo w

thro ugh hose toward check
valve. If air passes, fu n c tio n is
norm al. If air can be sucked
fro m check valve, replace
check valve.
6. Pump failure. 6. Replace pump.

Excessive pum p noise, ch irping, 1. Leak in hose. 1. Locate source o f leak using soap
rum b lin g , knocking, loss o f engine s o lution and correct.
performance.
2. Loose hose. 2. Reassemble and replace or tig hten
hose clam p.

3. Hose touching other engine parts. 3. A dju st hose position.

4. Vacuum d iffe re n tia l valve 4. Replace vacuum diffe ren tia l

inoperative. valve.

5. By-pass valve inoperative 5. Replace by-pass valve.

6. Pump m ounting fasteners loose. 6. T ighten m ou nting screws as

specified.

7. Pump failure. 7. Replace pump.

8. Check valve inoperative. 8. Replace check valve.

Excessive be lt noise. 1. Loose belt 1. Tighten to spec.

2. Seized pump 2. Replace pump.

1. Run vehicle 10-15 miles at

Excessive pum p noise. Chirping 1. In s u ffic ie n t break-in
interstate speeds-recheck.

Centrifugal filte r fan damaged

1. Mechanical damage 1. Replace centrifugal filte r fan.
or broken.

Exhaust tube bent or damaged. 1. Mechanical damage 1. Replace exhaust tube.

Poor idle or d rive a bility. 1. A defective A .I.R . system

cannot cause poor idle 1. Do n ot replace A .I.R . system.
or d riv ea b ility .

Fig. 6 E -3 1 -D ia g n o s is -A ir In jection Reactor System

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6E-20 ENGINE EM ISSIO N CONTROLS

Fig. 6E-32-Removing Centrifugal Filter

Fig. 6E-33-lnstalling Centrifugal Filter
Replace

Diverter Valve and Silencer Assembly

Replace
Inspection

Install

CAU TION: Do not oil AIR pump.

Air Injection Pump

Inspection

Replace

Install
NOTICE:

LIG H T T R U C K S E R V IC E M A N U A L
 ENGINE EM IS SIO N CONTROLS 6E-21

PULSE AIR INJECTION REACTOR SYSTEM - PAIR

FAILURE DIAG NO SIS

NOTICE:

Replacement of Pulse A ir Valve (Fig. 6E-34)

INSPE CTIO N AND CHECKING PULSE AIR

VALVE

L IG HT TR U CK SER VICE M AN U AL
6E-22 ENGINE E M ISSIO N CONTROLS

P L E N U M PIPE HO SE
A IR C L E A N E R

P L E N U M PIP G RO M M E TS

C H E C K V A L V E AS M .
PLENUM T O R Q U E T O 23 N -m (1 7 F T. LBS.)

'B ' PIPE AS M .

'A ' PIPE A S M .

E X T E N S IO N T U B E S
'B ' PIPE ASM .
'A ' PIPE AS M . P LE N U M
T O R Q U E T O 38 N -m (2 8 FT. LBS.) C O N N E C T IN G
PIPE
VIEW

Fig. 6E-34-PAIR System

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ENGINE EM ISSIO N CONTROLS 6E-23

LIG H T T R U C K S ER V IC E M A NUA L
6E-24 ENGINE EM ISSION CONTROLS

THROTTLE RETURN CONTROL SYSTEM (TRC)

How To Check The TRC System

CHECKING AND ADJU S TING TRC SYSTEM

Fig. 6 E -37 --T h ro ttle Return Control System

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 ENGINE EM ISSIO N CONTROLS 6E-25

CARBURETOR
PIPE

Fig. 6E-38~Throttle Valve (L6)

Throttle Lever Actuator - Checking Procedure

Fig. 6E -39--T hrottle V alve (V8)

L IG H T T R U C K SE R V ICE M A NU AL
6E-26 ENGINE EM ISSIO N CONTROLS

V A C UU M ADVANCE CONTROL

TRAPPED V A C U U M SPARK SPARK V A C U U M DELAY

General Description

LIG H T TR U C K SE R V IC E MANU AL
 ENGINE EMISSION CONTROLS 6E-27

o o
CO CO

Fig. 6E-40~Engine Performance Specifications

6E-28 ENGINE EMISSION CONTROLS

Fig. 6E-4 1~Engine Performance Specifications

 ENGINE EM IS SIO N CONTROLS 6E-29
LIG HT DUTY TRUC K ENGINE PERFORMANCE SPECIFICATION CHART (Continued)
D ISTR IB U TO R V A C U U M & M EC H A N IC A L A D V A N C E
EN G IN E & CODE IG N IT IO N SPARK VA C U U M A D V A N C E M EC H A N IC A L
(See Section " 0 " for T IM IN G PLUG SO LEN O ID CURB FAST (In Crank Degrees A D VA N C E (Crank
Locetion of Engine B.T.D.C. TYPE SCREW ID LE ID LE C A RB UR ETO R DIST. VA CU UM @ Inches Degrees @
end V IN Codes) DEGREES & GAP (RPM) (RPM) (RPM) ID E N T IF IC A T IO N M ODE L M ODEL of Vacuum) Engine RPM)

5.7 L (350 C.I .D.) Sf R45TS 700 (N) 1300 (N) 17080205 1103436 691 0°@ 3 " 0 °@ 1 1 0 0
(V IN L) (LS9) 2°@ 7.5 ” 1 2°@ 1600
F E D ./M A N U A L
16°@ 2400
K 10, 20
22°@ 4600
5.7 L (350 C .l D.) 8° R45TS 700 (N) 1300 (N) 17080201 1103372 604 0°@ 4 " 0 °@> 1 1 0 0
(V IN L) (LS9) (.045) 14°@ 8 " 1 2 °@ ?600
F E D ./M A N U A L 16°@ 2400
C10, 2 0 G 1 0 , 20 22° @ 4600
5.7 L (350 C .I.D .) 8° R45TS 700 (N) 1300 (N) 17080524 1103339 626 0° @ 4 " 0 °@ 1 1 0 0
(V IN L) (LS9) (.045) 10 °@ 8 " 1 2 °@ 1600
C A L IF ./M A N U A L 16°@ 2400
K 10 .C 2 0 22°@ 4600
5.7 L (350 C .I.D .) 8° R45TS 700 (N) 1600 (N) 17080291 1103435 644 0 °<a 3 " 0 °@ 1 1 00
(V IN L) (LS9) (.0451 17080503 16°@ 6 .5 " 12 °@ 1600
N A T IO N ./M A N U A L 16°@ 2400
C10, 22° @ 4600
5.7 L (350 C.I .D.) 6° R45TS 700 IN) 1600 (N) 17080201 1103339 626 0°@ 4 ” 0 °@ 1 1 0 0
(V IN L) (LS9) (.045) 17080526 10 °@ 8 " 12 °@ 1600
N A T IO N ./M A N U A L 16°@ 2400
C10, 20 22°@ 4600
5.7 L (350 C .I.D .I 8° R45TS 700 (N) 1600 IN) 17080291 1103436 691 0°@ 3 " 0 °@ 1100
(V IN L) (LS9) (.045) 2° @ 7.5" 12°@ 1600
F E D ./M A N U A L 16°@ 2400
K10 22° @i 4600
5.7 L (350 C.l .D.) 8° R45TS 600 (D) 500 (D) 1600 17080205 1103372 604 0 °<5> 4 " 0 °@ 1 1 0 0
(V IN L) (LS9) (.045) (P) or (N) 17080206 14°<5> 8 " 12 °@ 1600
FE D ./A U T O . 16°@ 2400
CIO , 20 22° @ 4600
G10. 20

LIGHT DUTY TR UC K ENGINE PERFORMANCE SPECIFICATION CHART (Continued)

D IS T R IB U T O R V A C U U M 8t M E C H A N IC A L A D VA N C E
E NG INE & CODE IG N IT IO N SPARK VACUUM ADVANCE M E C H A N IC A L
(See Section "O'* for T IM IN G PLUG S O LENO ID CURB FAST (In Crank Degrees A D VA N C E (Crank
Location of Engine B.T.D .C. TYPE SCREW ID LE ID LE C A RBUR ETO R D IST. VACUUM @ Inches Degrees @
and V IN Codes) DEGREES 8. GAP (RPM) (RPM) (RPM) ID E N T IF IC A T IO N M O DEL M O D EL of Vacuum) Engine RPM)

5.7 L (350 C.I.D .) 4° R 44T *1600 700 (N) 1900 (N) 17080213 1103375 626 0°@ 4 " 0°<°> 1150
(V IN M) (LT 9) (.045) 10 °@ 8 " 17°@ 2900
FE D ./A U T O . 22° <s> 4200
C K20, 30 17080215 1103439 604 0 4" 0 °@> 1000
G30 14° @ 8 " 8 °@ 1600
P20, 30 19°@ 3450

5.7 L (350 C .I.D .) 6° R 44T *15 00 700 (N) 1 9 0 0 (N) 17080513 1103420 681 0 °@ 1 0 ' 0 °@ 1800
(V IN M) (LT 9) (.045) 17080515 10°@ 13” 24° <°> 4000
C A L IF ./A U T O .
C K10, 30
G30

6 .6 L (400 C .I.D .) 4° R 44T *16 00 700 (N) 1 9 0 0 (N) 17080229 1103375 626 0°@ 4 ” 0°@ 1150
(V IN X) (LE 4) (.045) 1 0 °@ 8 ” 1 7° @ 2900
F E D ./A U T O . 22° @ 4200
K 20, 30
G 30

6 .6 L (400 C .I.D .) 6° R 44T *1500 700 (N) 1 9 0 0 (N) 17080529 1103420 681 0 °@ 1 0 ” 0 °@ 1800
(V IN X ) (LE4) (.045) 10P@ 13” 24° @ 4000
C A L IF ./A U T O
K20, 30
G30

7.4 L (454 C.I .D.) 4° R44T *1 500 700 (N) 1 9 0 0 (N) (7 080 212 1103376 682 0 °@ 8 ” 0 °@ 1 1 0 0
(V IN W) (L E 8 ) (.045) 17080213 10°@ 13” 14° @ 2800
N A T IO N ./A U T O ./M A N . 20° @ 4200
C20, 30
P30

*TR C A C T U A T O R SPEED

Fig. 6 E -42 ~E n g ine Perform ance S p ecificatio ns

LIG H T TR U C K S E R V IC E M AN U A L
6E-30 ENGINE EMISSION CONTROLS

EMISSION HOSE ROUTING

L IG H T TR U C K SE R V IC E M AN UA L
 ENGINE EMISSION CONTROLS 6E-31

EM ISSION HOSE ROUTING

AIR CLEANER
EM ISSION
HOSE
ROUTING

PURGE SIGNAL
HOSE
PURGE
HOSE

CANISTER

TRANS
LOCK UP
EGR CONV VAC
Tvs SWITCH

ENGINE

4.1L (LE3) FEDERAL 0 8 F 2 A MANUAL TRANS 4.1 L (LE3J FEDERAL 08F2A AUTO TRANS
-VAC BRK TVS EM ISSION HOSE
ROUTING

FRONT ^
OF ^
ENGINE r TO FUEL TANK

PURGE I CANISTER
r TO FUEL
SIGNAL
HOSE
Tm J x-puR ge H

CANISTER

TRANS
LOCK UP
DISTR CONV
TVS SWITCH
DELAY
VALVE FRONT ^
OF ^
ENGINE

4.1L (LE3) FEDERAL 08F2A MANUAL TRANS 4.1L (LE3) FEDERAL 08F2A AUTO TRANS

Fig. 6E -4 3 -E m is s io n Hoise Routing

L IG H T TR U C K S E R V IC E M AN U AL
6E-32 ENGINE EM ISSION CONTROLS

EMISSION HOSE ROUTING

EM ISS IO N HOSE ROUTING EM IS SI ON HOSE ROUTING
PURGE SIGNAL PURGE SIGNAL
HOSE HOSE

PURGE HOSE PURGE HOSE

CANISTER CANISTER

EFE-TV S

DECEL DECEL
V*LV E VALVE

4.1L (LE3) CALFORN1A 08F2A MAN/AUTO 4.1L (LE3) CALIFORNIA 08F2A MAN/AUTO
E MIS S IO N HOSE E MIS SI O N HOSE
ROUTING ROUTING
DS TE M P SEN SOR

C A N IS T E R

5.0L (LG9) FEDERAL 08Y 2A MANUAL TRANS 5.0L (LG9) FEDERAL 08Y 2 A MANUAL TRANS

Fig. 6E -4 4-E m iss io n Hose Routing

L IG H T T R U C K SE R V IC E M AN U AL
 ENGINE EM ISSIO N CONTROLS 6E-33

EMISSIO N HOSE ROUTING

-A IR CLEANER EM IS SIO N HOSE
VN ROUTING

5.0L (LG9) FEDERAL 0 8Y 2A AUTO TRANS 5.0L (LG9) FEDERAL 08Y 2A MANUAL TRANS
EMISSI ON HOSE EM IS S IO N HOSE
ROUTING ROUTING
VR

ENGINE

5.0L (LG9) FEDERAL 08Y 2 A AUTO TRANS 5.7L (LS9) FEDERAL 08K 4G MANUAL TRANS

Fig. 4 5 -E m is s io n Hose Routing

LIG H T TR U C K S ER V IC E M ANUAL
6E-34 ENGINE EM ISS IO N CONTROLS

EMISSIO N HOSE ROUTING

EM ISSIO N HOSE EM ISSI O N HOSE
ROUTING ROUTING
CANISTER

PURGE HOSE

CANISTER

ENGINE

5.7 (LS9) FEDERAL 08K 4G MANUAL TRANS 5.7L (LS9) FEDERAL 08K 4G AUTO TRANS
EM ISSI ON HOSE EM IS SI O N HOSE
ROUTING ROUTING
CANISTER

•PURGE HOSE

CANISTER

VAC MO'

EFE

5.7L (LS9) FEDERAL 08K 4G AUTO TRANS 6.6L (LF4) FEDERAL 08K 4G AUTO TRANS

Fig. 6 E -4 6 -E m iss io n Hose Routing

LIG H T T R U C K S E R V IC E M AN UA L
 ENGINE E M IS SIO N CONTROLS 6E-35

EMISSION HOSE ROUTING

EM IS SI O N HOSE E MIS SI O N HOSE
ROUTING

PURGE HOSE

ENGINE

5.7L (LS9) FEDERAL 08K4AA MANUAL TRANS 5.7L ( l S9) FEDERAL 08K4AA MANUAL TRANS
EMI SS IO N HOSE EMISS IO N HOSE
PURGE HOSE CANISTER
ROUTING
R 0 U T IN C -T O FUEL

CHECK
VALVE

TRANS
LOCK-UP
CONVERTER
FRONT FRONT k
VACUUM
SWITCH OF ^
ENGINE

5.7L (LS9) FEDERAL 084KAA AUTO TRANS 5.7L (LS9) FEDERAL 084K AA AUTO TRANS

Fig. 6 E -47 -E m iss io n Hose Routing

l ig h t t r u c k s e r v ic e m a n u a l
6E-36 ENGINE EM IS SIO N CONTROLS

EMISSION HOSE ROUTING

E M IS SI O N HOSE TO FUEL TANK E MIS SI O N HOSE TO FUEL TANK
PURGE HOSE ROUTING PURGE HOSE

CANISTER

5.7L (LS9) CALIFORNIA 084KAA AUTO TRANS 5.7L (LS9) CALIFORNIA 084KAA MANUAL TRANS
E MIS SI O N HOSE TO FUEL TANK
ROUT INC PURGE HOSE

CANISTER

5.7L (LS9) CALIFORNIA 084KAA AUTO TRANS 5.7L (LS9) CALIFORNIA 084KAA MANUAL TRANS

E M I S S I O N HO SE t o fu e l ta n k
RO UTING PURGE HOSE

6.6L (LF4) CALIFORNIA 084KAA MANUAL TRANS

Fig. 6E -48~E m ission Hose Routing

LIG H T T R U CK S ERV
 ENGINE E MISSIO N CONTROLS 6E-37

EMISSION HOSE ROUTING - INCOMPLETE VEHICLES *

EMISS IO N HOSE EM IS SI O N HOSE
ROUTING

5.7L (LS9) FEDERAL 08K4AA MANUAL TRANS 5.7L (LS9) FEDERAL 08K4AA MANUAL TRANS
EM ISS IO N HOSE EMIS SI ON HOSE
rPURGE HOSE ROUTING
R 0 U T ,N G r-TO FUEL

PURGE HOSE
CANISTER

TRANS
LOCK-UP
CONVERTER
VACUUM
SWITCH

5.7L (LS9) FEDERAL 08K4AA AUTO TRANS 5L7L (LS9) FEDERAL 08K4AA AUTO TRANS

* LABELS RELATE TO CAB & CHASSIS ONLY

Fig. 6E -49 -E m is s ion Hose Routing

LIGH T TR U CK S ERV IC E M AN UAL

6E-38 ENGINE EMISSION CONTROLS

EMISSION HOSE ROUTING - INCOMPLETE VEHICLES*

TO FUEL TANK EM ISSIO N HOSE TO FUEL TANK
.. .A EM ISSIO N HOSE
WA ROUTING PURGE HOSE
WB ROUTING PURGE HOSE

C A N IS T E R

5.7L (LS9) CALIFORNIA 08K4AA MANUAL TRANS 5.7L (LS9) CALIFORNIA 08K4AA AUTO TRANS

* LABELS RELATE TO CAB & CHASSIS ONLY

Fig. 6E-50--Em ission Hose Routing

LIG H T T R U C K S E R V IC E M AN UAL
 ENGINE E M ISSIO N CONTRO LS 6E-39

EMISSION HOSE ROUTING

VAC MOTOR

FRONT * V l f E M IS S IO N HOSE PURGE HOSE-

ROUTING PURGE S IG N A L ^ -
VAC M O TO R -^ HOSE

AIR CLEANE

TEMP SENSOR
THROTTLE RETURN
CONTROL VALVE

4.8L (L25) FEDERAL GM112 MAN/AUTO 4.8L (L25) CALIFORNIA GM112 MAN/AUTO

EMIS SIO N PURGE SIGNAL HOSE- ’ URGE HOSE

E MIS SI O N HOSE
w u r o u t in g th ro ttle

DVTR
VALVE A.I.R.
PUMP

CLEANER * WHERE EQUIPPED

5.7L (LT9) FEDERAL G M113 MAN/AUTO 5.7L (LT9) CALIFORNIA GM 113 MAN/AUTO

Fig. 6E-5 1-Em ission Hose Routing

LIGH T T R U C K S ER V IC E M AN UA L
6E-40 ENGINE EMISSION CONTROLS

EMISSION HOSE ROUTING

PURGE SIGNAL HOSE- PURGE HOSE

EM ISSI ON HOSE prv EMISSION
ROUT INC THROTTLE
FRO NTS LEVER
OF ^ ACTUATOR

OVTR
VALVE A.I.R.
PUMP
* WHERE EQUIPPED
CLEANER

6 .6 L (LE4) FEDERAL GM 113 AUTO TRANS 6.6L (LE4) CALIFORNIA GM113 AUTO TRANS

PURGE SIGNAL HOSE- PURGE HOSE-

THROTTLE LEVER PCV
XM ACTUATOR TRC SOLENOID
CONT VALVE
EM ISSION
HOSE SECONDARY
ROUTING ^ V A C U U M
BREA

DVTR
A/CL VALVE

7.4L (LE8) FEDERAL G M 115 MAN/AUTO 7.4 (LE8) CALIFORNIA G M 115 MAN/AUTO

Fig. 6E-52~Em ission Hose Routing

LIG H T TR U C K S E R V IC E M AN UAL
 ENGINE EMISSION CONTROLS 6E-41

EMISSION HOSE ROUTING

VAC MOTOR
VA/1, EM ISSI ON HOSE pc v
FRONT ^ W l\. ROUTING
OF ^
ENGINE

f WHERE EQUIPPED

4.8L (L25) FEDERAL G M 112 MAN/AUTO 5.7L (LT9) FEDERAL G M 113 MAN/AUTO

EMISSION HOSE
WM ROUTING SF

DVTR
VALVE

§ WHERE EQUIPPED

6.6L (LT9) FEDERAL GM113 AUTO TRANS 5.7L (LF9) CALIFORNIA 0 9 J 92 AUTO TRANS

Fig. 53--Em ission Hose Routing

LIG H T T R U C K S ERV IC E M AN UAL

 ENGINE EXHAU ST SYSTEM 6F-1

SECTION 6F

ENGINE EXHAUST SYSTEM

GENERAL DESCRIPTION

CATALYTIC CONVERTER

CONVERTER SHELL

Fig. 6F-2 — U nderfloor Converter

LIG H T T R U C K S E RV IC E M AN UAL
6F-2 ENGINE EXHAUST SYSTEM

CONDITION POSSIBLE CAUSE CORRECTION

Leaking Exhaust Gases Leaks at pipe joints. Tighten U-bolt nuts at

leaking joints to 30 lb. ft.
(40 N-m).

Damaged or improperly Replace seals or packing

installed seals or packing. as necessary.

Loose exhaust pipe heat tube Replace seals or packing as

extension connections. required. Tighten
stud nuts or bolts
to specifications.

Burned or rusted out exhaust Replace heat tube extensions

pipe heat tube extensions. as required.

Tighten clamps at leaking

connections to specified
Exhaust Noises Leaks at manifold
or pipe connections. torque. Replace gasket or
packing as required.

Burned or blown out Replace muffler

muffler. assembly.

Burned or rusted out Replace exhaust pipe.

exhaust pipe.

Exhaust pipe leaking Tighten attaching

at manifold flange. bolts nuts to 17 lb.ft.
(23 N-m )

Exhaust manifold Replace manifold.

cracked or broken.

Leak between manifold Tighten manifold to

and cylinder head. cylinder head stud
nuts or bolts to specifications.

Loss of engine power and/or Dislodged turning tubes and or Replace muffler.
internal rattles in muffler. baffles in muffler.

Loss of engine power. Imploding (inner wall collapse) Replace exhaust pipe.
of exhaust pipe (except" P"
Truck)

L IG H T T R U C K S ER V IC E M AN U AL
 ENGINE EXH AU ST SYSTEM 6F-3

ON-VEHICLE SERVICE

Fig. 6F-3 — Catalytic Converter - CK Series

CATALYST (Figs. 6F-3 & 6F-4) NOTICE:

Removal (Off Vehicle)

Installation (Off Vehicle)

Fig. 6F-4 — Catalytic Converter - G Series

LIG H T T R U C K S ERV ICE M AN UAL

 6F-4 ENGINE EXHAUST SYSTEM

BOTTOM COVER REPLACEMENT

Fig. 6F-5 — Removing Pressed Plug

BOTTOM COVER

DO NOT PRY FILL PLUG

FROM CONVERTFR

Fig. 6F-6 — Rem oving Pressed Plug With Pliers Fig. 6F-8 — Service Fill Plug

LIG H T T R U C K S E RV IC E M AN UAL
 ENGINE EXHAUST SYSTEM 6F-5

Fig. 6F-11 — Removing Bottom Cover

Fig. 6F-9 — Positioning Fill Plug Bridge

5. Install replacement cover on converter (Fig. 6F-14).

6. Install cover retaining channels on both sides of the
converter (Fig. 6F-15).
7. Attach 2 clamps over retaining channels at each end of
the converter (Fig. 6F-16).

Fig. 6F-12 — Catalytic Converter Insulation

Fig. 6F-13 — Catalytic Converter Inner Shell

Fig. 6F-10 — Installing Fill Plug

LIGHT TR U CK SER V IC E M AN UAL

6F-6 ENGINE EXHAUST SYSTEM

Fig. 6F-14 — Installing Bottom Cover Replacement

Fig. 6F-15 — Installing Bottom Cover Retaining Channels

LIG H T TR U C K S ER V IC E MAN UAL