Foreign Service

Dan continues his comprehensive dissection of Toyota EGR

systems. The vacuum-modulator system has already gone under
the knife. This time, the constant-vacuum system is on the table.

Dan
Marinucci
dmarinucci@motor.com

f youre just joining us now, Im in

the middle of a mini series on troubleshooting Toyotas most common
vacuum-operated EGR systems. I
already covered operation and diagnosis of the vacuum modulator type
EGR in my last two columns (August and
September). Here Ill focus on operation of
Toyotas constant-vacuum EGR system,
which appears on its popular 3.0L V6
(1MZ-FE) engine.
Much of this system looks different from
the vacuum modulator type EGR. However,
the constant-vacuum setup is much simpler
overall.
The vacuum source for the constant-vacuum system is a manifold vacuum port on
top of the engine. Yep, this system relies on
manifold vacuum instead of the more common ported vacuum technique. Manifold

8
4

3
This photo shows the layout of Toyotas vacuum-operated EGR system: 1. Vacuum Control Valve (VCV); 2. manifold vacuum supply hose
for VCV; 3. regulated vacuum output hose; 4. EGR VSV; 5. regulated
vacuum supply into VSV; 6. VSV vacuum output to EGR valve; 7. VSV
vent hose leading to air cleaner; 8. vacuum surge tank.

Photos: Dan Marinucci

vacuum feeds a port in the center of the

Vacuum Control Valve (VCV), a purple
plastic component smack dab on top of the
engine. The VCV regulates manifold vacuum down to 5 in./Hg and then supplies it to
the rest of the circuit. When the system is
working correctly, the vacuum output from
the VCV is a constant 5 in./Hg, regardless
of engine load. This means that the maximum available control vacuum for this
EGR valve is only 5 in./Hg.
This constant vacuum supply flows to the
EGR Vacuum Switching Valve (VSV), which
also sits on top of the engine, very close to
the purple VCV. This EGR VSV looks like
the one used on the vacuum modulator system but it has three hoses on it instead of
two. One comes into the EGR VSV from
the VCV. Another hose leads out of it to the
EGR valve. Finally, theres no vent filter on
this VSV. Instead, a third vacuum hose goes
from its vent port over to the air cleaner
housing or air filter box. So here the conventional air filter does double duty as an
EGR VSV vent filter.
The EGR VSV on the constant-vacuum
system differs from the one on the vacuum
modulator setup in two other important
ways. First, the EGR VSV on the constantvacuum system is electrically off when no
EGR flow is needed. (The EGR VSV on the
vacuum modulator system is electrically on
when no EGR is needed.)
Second, the ECM pulses the EGR VSV
on and off when EGR flow is needed on the
constant-vacuum system. The computer
does this by pulsing or toggling the ground
side of the EGR VSV. Remember that control vacuum flows from the EGR VSV to
the EGR valve whenever the ECM pulses
this VSV on and off. Suppose you tee a vacuum gauge into the EGR hose right at the
EGR valve. You also connect a duty cycle
meter to the ground side of the EGR VSV.
If you road-test the vehicle, you should see
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Foreign Service

The hose connected to the vacuum port in the center of

the VCV (the round purple component) supplies it with
manifold vacuum. The VCV hose on the left carries a regulated, constant 5 in./Hg to the rest of the EGR system.

The yellow pen on the left indicates the vacuum supply

hose leading into the EGR VSV. The silver pen on the right
indicates the vent hose leading to the air cleaner. Meanwhile, the vacuum hose with the braided sheath on it
leads to the vacuum surge tank and EGR valve.

both a vacuum reading and a duty

the EGR valve by pulsing the EGR
is the little round black component
cycle reading when the ECM comVSV on and off. Got all that now?
spliced into the hose between the
mands EGR operation during lightYou may recall that on the vacuEGR VSV and the EGR valve. Bathrottle driving. Depending on enum modulator EGR system, the
sically, it serves as a little vacuum
reservoir.
gine load and rpm, youll see 2.0 to
ECM does not pulse the EGR VSV;
This EGR valve assembly may re4.0 in./Hg during light-throttle drivelectrically, this VSV is either on or
mind some techs of the earlier Honing.
off. Its turned off when the EGR
da design because it has a position
Many techs are confused by this
valve opens.
sensor on top of it. Like the Honda
constant-vacuum EGR system, so
Okay, the only remaining composensoror a common TPS, for that
let me recap these key points. Elecnents in the constant-vacuum sysmatterthe sensor receives a 5.00trically, its EGR VSV is normally
tem are the vacuum surge tank, the
off. When its electrically off, the
EGR valve assembly and the EGR
volt reference from the ECM. Then
VSV vents supply vacuum to the attemperature sensor. The surge tank
it produces a linear, analog response
mosphere via the air cleanbased on how much the
er. Obviously, the EGR
EGR valve has opened.
valve cant open when conThe most typical signals I
trol vacuum is vented off.
have noted on these senPredictably, the EGR valve
sors are 1.00 volt on a
should not open when the
closed EGR valve and 4.00
engine is cold or during
volts on a wide-open valve.
idle, heavy acceleration or
(According to the manual,
deceleration. Therefore,
the allowable ranges are
the EGR VSV is electrical.40 to 1.60 volts on a closed
ly off during these novalve and 3.20 to 5.10 volts
EGR conditions.
on a wide-open valve.)
But the EGR valve
Remember that this
should open during lightEGR valve has something
throttle driving with a
in common with the one
warm engine. Thats when
used on the vacuum moduthe system should send
lator system: Typically, the
control vacuum to the
valve begins opening at 2.0
EGR valve. The ECM The EGR position sensor s output signal to the ECM to 3.0 in./Hg. If this V6s
routes control vacuum ranges from about 1.00 volt with the EGR valve closed to EGR system is working
(base value of 5 in./Hg) to about 4.00 volts with the valve wide open.
correctly and you apply 2.0
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The EGR temperature sensor threads into this lower leg of

the EGR assembly. This sensors signal may be 4.00 volts or
more when the passage is cold, 1.00 volt or less when its hot.

to 3.0 in./Hg directly to the EGR

valve at idle with a hand-held vacuum
pump, normally, the EGR valve will
open far enough that youll hear and
feel the engine misfiring as a result.
Finally, the constant-vacuum EGR

Usually, it takes only 2.0 to 3.0 in./Hg to begin opening

the EGR valve on the constant-vacuum system.

setup has an EGR temperature sensor threaded into one leg of the EGR
assembly casting near the throttle
lever. This sensors output signal is
generally around 4.00 volts when
cold. It may drop to 1.00 volt or less

Circle #15

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October 2009

when the EGR valve opens and exhaust gas flows.

Thats all for this month. Tune in
next time when Ill discuss diagnosing
the constant-vacuum EGR system.
See you then!