EPA-450/3-77-043
November 1977
A PRIMER ON
AUTO EMISSIONS SYSTEMS
FOR HOME MECHANICS
U.S. ENVIRONMENTAL PROTECTION AGENCY
Office of Air and Waste Management
Office of Air Quality Planning and Standards
Research Triangle Park, North Carolina 27711
-------
EPA-450/3-77-043
A PRIMER ON
AUTO EMISSIONS SYSTEMS
FOR HOME MECHANICS
by
B.D. Hayes, Project Director
M.T. Maness, Associate Project Director
R.A. Ragazzi, Principal Investigator
Department of Industrial Sciences
Colorado State University
Fort Collins, Colorado 80523
EPA Grant No. T900621-01-0
EPA Project Officer: Bruce Hogarth
Prepared for
U.S. ENVIRONMENTAL PROTECTION AGENCY
Office of Air and Waste Management
Office of Air Quality Planning and Standards
Control Programs Development .Division
Research Triangle Park, North Carolina 27711
November 1977
-------
Copies of this publication are available free of charge to Federal employees,
current contractors and grantees, and nonprofit organizations as supplies
permit - from the Library Services Office (MD-35) , Environmental Protection
Agency, Research Triangle Park, North Carolina 27711; or, for a fee, from
the National Technical Information Service, 5285 Port Royal Road, Springfield,
Virginia 22161.
This report was furnished to the Environmental Protection Agency by the
Department of Industrial Sciences, Colorado State University, Fort Collins,
Colorado, 80523, through Grant No. T900621-01-0. The contents of this report
are reproduced herein as received from Colorado State University. The opinions,
findings, and conclusions expressed are those of the authors and not necessarily
those of the Environmental Protection Agency. Mention of company or product
names is not to be considered as an endorsement by the Environmental Protection
Agency.
Publication No. EPA-450/3-77-043
11
-------
YOUR. CAR
NEEDS
UUY SMOULD NO)
BE INTERESTED IN
TUIS BOOKLET?
BECAUSE... ,TMA*
BSEM DgSlfrNeDTO MEtP YOU
IM UMOeRSTAWDIMfr TME
5MI66IOW COWTTROL SYSTEM*
AMD HARDWARE FOUND 0KJ
YOU*
rui
LR
D
TUIS )KJFORHAT\OM
-rue FOU.OLOWJ
IM
YOU
to*/* .-
AIR
IT WILL AID YOU |M PERFORMING BASIC VISUAL.
CWECKS OM YOUR. CAR.'S EHISSIOM CONTROL,
MAIkJTEMAWCe YOU PERFOP-h TO COR.R.6CT PROBLEMS
LOILL 6E &eueFICIAL- lk» REDUCIUS AIR POLLUTION, (AUD
LESS Alf^ POLLUTIOW IS DESIRABLE FOR. EVERYONE'S
UEALTU.)
TUE BASIC MAINTENANCE AUD CUECK.S D6SCR.lBeD IU
TUIS BOOklLET COULD AID IM SAVINS YOU HOMEY
IN TLOO
3. YOU COULD ELECT TO COfcfcECT PROBLEMS YOU
FIUD YOURSELF.
MOUEY SAVED
b. YOU COULD ELECT TO HAVE YOUR MECHANIC FIX
TUE SPECIFIC. PROBLEMS YOU WAVE. FOUUD.
iii
-------
ACKNOWLEDGEMENTS
The Motor Vehicle Emissions Control Staff at the Department
of Industrial Sciences would like to acknowledge the efforts
extended by the Environmental Protection Agency, Research
Triangle Park, and the Motor Vehicle Manufacturers Associa-
tions for their contributions to the development of this
booklet.
DISCLAIMER
The opinions, procedures and conclusions are those of the
authors and not necessarily those of the Environmental Pro-
tection Agency. Every attempt has been made to represent
the material in a factual, concise manner. Any mention of
products or organizations does not constitute endorsement
by the Environmental Protection Agency.
IV
-------
SAFETY NOTICE
This booklet contains numerous NOTES, CAUTIONS, and WARNINGS
It is the responsibility of the person using this booklet
to carefully read these important notices to minimize the
chance of personal injury and/or damage to their car.
The NOTES, CAUTIONS, and WARNINGS are NOT all inclusive.
It is the sole responsibility of any person (s) using this
material to exercise their own good judgment in regard to
personal and vehicle safety and consult other reference
material if any doubts are present as to the safety of any
act they may perform when using this booklet.
-------
PREFACE
This booklet has been designed to acquaint the average home
mechanic with the basic emissions control systems and compo-
nents installed on today's cars. Emissions control equip-
ment has been installed to reduce the amount of pollution
discharged to our atmosphere. The primary reason for re-
ducing automobile emissions is to protect your health as
well as your children's and your neighbors' health.
Emissions control equipment, like any mechanical equipment,
needs periodic inspection and preventive maintenance. This
is where YOU the average home mechanic can play an important
role in maintaining the equipment and aiding in the total
effort for '-"^ner air.
This booklet will show you the basic emissions control systems,
It will also point out other components used in conjunction
•»
with emissions control systems to lower emissions.
There are basic step by step procedures you can follow, to
check out various components related to emissions control.
The purpose of these checks can be considered to be two-fold.
vi
-------
First - the checks enable YOU to find malfunctioning parts
and parts that need replacement. If you are handy with tools,
you can make the necessary corrections in many cases and save
yourself some money.
Second - if you choose to have your mechanic make the repairs,
you are now in a position to explain what checks you have
made and which parts you feel are in need of repair.
A little ghost called "VEC" (VEHICLE EMISSION CONTROL) will
lead you through each system and the checks you can make on
each system. VEC will also explain why you should not dis-
connect the emissions control systems or make them inopera-
tive and how this can hurt your car's performance and gas
mileage and possibly shorten the engine's life expectency.
VEC will do his best to show you how keeping these systems
properly maintained can aid in keeping your car running right
and reduce air pollution.
THIS BOOKLET IS NOT INTENDED TO BE A SUBSTITUTE FOR, OR RE-
PLACE A GOOD EMISSIONS CONTROL SERVICE MANUAL OR THE MANUFAC-
TURERS SHOP SERVICE MANUAL. IT IS ONLY INTENDED TO PROVIDE
A BASIC KNOWLEDGE AND UNDERSTANDING OF EMISSIONS CONTROL
SYSTEMS.
Vil
-------
This booklet does not cover basic tuneup procedures. However,
performing a good basic tuneup, such as replacing worn spark
plugs, points and condenser, replacing bad spark plug wires,
and setting basic ignition timing is extremely important for
keeping auto emissions low and fuel economy at its best.
Listed in back of this booklet (Reference Material Section)
are other books that can provide you with this information.
We strongly suggest that you refer to these to enforce your
knowledge of proper tuneup procedures.
Since 1968 nearly every car made in the United States has a
VEHICLE EMISSIONS CONTROL INFORMATION label somewhere in the
engine compartment. The VEHICLE EMISSIONS CONTROL INFORMA-
TION label shown below is used by General Motors Corporation.
DM
250 CU IN
1 881 CARB
CM 12FI3
MAKE ALL ADJUS
OPEN. AIR CLEAN)
SET PARKING
1 DISCONNECT A
1 DISCONNECT
SPECIFED RPN
3 DISCONNECT Ai
NEUTRAL. BENT,
STEP Of CAM
VACUUM HOSI
4 ADJUST CURB
AIRCOND OPI
5 UNPLUG AND
rrnno «uu
VEHICLE EMISSION CONTROL INFORMATION
GENERAL MOTORS CORPORATION fjg]
TMENTS WITH ENGINE AT NORMAL Off RAWG TEMPERATURE CHOICE FULL
R INSTALLED. AND AIR CONDTDONMC OFF EXCEPT WHERE NOTED
BRAKE AND BLOCK DRIVE WHEELS
NO PI IX CARBURETOR AND PCV HOSES AT VAPOR CANISTER
AND PLUG VACUUM HOSE AT DISTRIBUTOR SET IGNITION TIMING AT
(
NO PlUG EGR VACUUM UNE AT EGR VALVE WITH TRANSMISSION W PARK OR
) FAST «XE CAM FOLLOWER TO OBTAM SPECIFTEO FAST IDLE SPEED ON HIGH
UNPLUG AND RECONNECT EGR VACUUM LINE UNPLUG AND RECONNECT
AT DISTRIBUTOR
IDLE SPEED BY TURNING CARBURETOR SOLENOID TO SPECIFIED RPM WITH
RATING ON AUTO TRANS MODELS. IF SO EQUIPPED
ifCONNECT CARBURETOR AND PCV HOSES AT VAPOR CANISTER
EGR-EFE-OC EXHAUST
EMISSION CONTROL
TIMMG CBTC © RPM)
SPARK PLUG GAP (IN )
SOUNCHO ADJ. (RPM)
FAST OLE SPEED (RPM)
TRANSMISSION
AUTOMATK
IO-@5SO
0.060
S50(OR)
ieoo(N)
MANUAL
iir@9oo
0060
WO(N)
IBOCXN)
1 Moit I on Miitun scnvn *u mui win ctmo AT FACTOOT - oo MOT mu
1 ' CAM — UJJUSTMBrt OUIWC IUW UP H NOt HCOWWNMO
KM MAJOB ana ADJUSTING MIXTUH SITTMC IT OTK» THAN APP«OVID ui
VKI MANUil nOCIDUDI MAT VKXATI flOHAl ANIVOt CAIIFODIU 0> OTKI
sitn LAWS
U! i!«VKI MANUAt lot ADOIOIA1 HOMATION
1KB VMCU CO««MS TO U 1 1 ' » AND WKH imiCUU CAHWM4 ttGUUTCXS APfllCAHI !0 I»H HAOOII YtM MT» MOtOI VtWCUS PT NO 357682
Chrysler Corporation, Ford Motor Company, American Motors
Corporation and the imported cars use a similar label with
viii
-------
similar procedures and settings spelled out.
REFER TO THIS LABEL WHEN TUNING UP YOUR CAR.
It can save you time, money and frustration.
ix
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CONTENTS
Introduction 1
Hydrocarbons 3
Oxides of Nitrogen 4
Photochemical Smog 5
Carbon Monoxide 5
Positive Crankcase Ventilation Systems 7
Purpose 9
Open PCV System 10
Closed PCV System 12
System Inspection and Maintenance 13
Caution 17
Thermostatic Air Cleaner Systems 19
Identification 21
Purpose 22
System Components and Function 24
System Inspection and Maintenance 25
Caution 31
Air Injection Reaction Systems 33
Trade Names 35
Purpose 35
System Components and Function . 36
System Inspection and Maintenance 38
Summary 43
-------
Fuel Evaporative Control Systems 45
Purpose 47
System Components and Function 48
System Inspection and Maintenance 53
Summary 55
Exhaust Gas Recirculation Systems 57
Purpose 59
System Components and Function 60
Caution - (Differences In Systems) 63
System Inspection and Maintenance 64
EGR Valve 64
CTO Switch 67
Vacuum Amplifier EGR System 69
Exhaust Back Pressure Sensor 71
Caution 73
Catalytic Converter . . . . ,° 75
Purpose 77
Component Identification 78
Catalytic Converter Construction and
Operation 79
Notice 81
Other Emissions Systems 83
Spark Timing Controls 85
OSAC Valve 87
Vacuum Advance Shutoff 89
xi
-------
Dual Diaphragm Vacuum Advance Unit 90
CTO Switch 92
Summary 94
Appendix 95
Addresses For Manufacturers Service
Manuals 97
-------
INTRODUCTION
TO EMISSIONS
-------
MY KJAME IS VEC AUD I
U)OULD UfcE TO 5MOU) AMD
TELL YOU ABOUT TUB EMIS-
SION CONTROL SYSTEMS
OU TODAY'S CARS.
VEC V£H/CL£
£H/S S /OH
BEFORE U>E&£T INTO
SYSTEMS, | WILL TAKE
A MIMUTE TO EXPLAIN
SO ME TERMS LIKE
AMD
THESE TERMS ARC FOlMD IM ALL MATERIALS
TO EMI 6610 M COMTROL SYSTEMS. A BASIC tOIOUX
LEDGE OF TMSSE TERMS lu>ILL MA ICC TME SYSTEMS EA*>«
TO UNDERSTAND.
/miLLLLlJ
UC=
OR PUEL
(GASOLINE)
crrr rrrrrrf f n ((((f
HC
IS A TERN I U)ILL
OFTEM UC tS A SUO9
U)AY OF SAYIN6
UYDROCARBONS.
UYDROCARSOUS AM TME
GOODICS TMtfT HAKE UP
TME aAftOLtue UXI PUT IN
CARS.
-------
MOT ALL OF THE UYDBOCAfcJSOWS OR
GASOC/UE Aee* BUEJUED iu TUE eru-
. THE DUES TUAT AR.E AJOT
COME OUT THE TAIL.PIPE.
CALLED
UNBURNED
HYDROCARBONS
ILIK.E TOTMIIUK OF THI5 DlCTY
EMI5&IOU AS 6^SOL-I*JE THAT
DIDM'T BUELI.
!S FORMED UWEIU
HOTTE/2. THE Aie AJUD FU£C
AUD
THE
NO
is AM
VIATIOM Foe
-TERM O*tD£6 OF KJITRO*
G&M, KJO* IS TUB UOLD
ItOICL U66 TO IDCMTIFY
TMI6 MA^TY FOB.TIOU
OF OUft CARS' 5XWAU6T
BUJ2L/ IM THE EW6/U6. THE
-------
MC AKJD NJOX EMISSIONS
THE AUTOMOBILE MUST BE"
CONTROLLED BECAUSE
TUEY AJZ.E COMSIDEI^eD A
TO OUR. HEALTN AMD TME
REST iu POULUTIOM
PUOTOCMEMICAL
MC AUD MOX FORM PUQTOCM£H*£AL SHO6 IU TME PR-ESEMCE OF
auM LIGHT T^l^ PMOTOCMEHICAL, 6MO6 MAS A LOT Ot=" UA6TY STUFF
IM IT THAT MAfceS OUE. ^f^^ L>AT£l2. AMD MAfcES BE6ATWIM6. WABD
FOfc PEOPLE CJITM ^1^ R6£>R|ltATOEV DISEASES IT ALSO KOT5
RUBBEE AWD PAHAGES PLAKTTS.
^HWWhV*T!h!HViiV^T^^
AMOTMCR. TCR.H U6
Use 15 QQ CO IS A
SMOfcTEK 'u>6Y
£AVIMO CAR.BOKJ
MOMOXIDE.
-------
0)1 g<
TOO MUCH FUEL
MOT EKIOU6M
AIR.
CO RESULTS LOWEW MOT £.WOUO>H AIR 15 MIXED LOITM THE &A&O
LIME (x)E BUEM IM OUJ2. EMG»lUee>. TMIS CO l£> D/SCWAeAEA6»E.
CO, IM SMALLee. AMOUUT5>, IOILL
GJVE YOU A MEADACWE, O(S COULD
vou eicic TO
VEMTIL-ATED
HOUOXIDC
woXiOxioce> or
K4ITRO66M
THAT YOU UUDEeSTAMD ~TUE
IOILL &E USJW
ow SPEC/P/C
USED TO COUTRLOL MG., (UO/, AUD 6O.
-------
POSITIVE CRANKCASE
VENTILATION SYSTEMS
-------
PCV
POSITIVE
CRAKJKCASE
VENTILATION
U
TWE FIR5T SYSTEM I
UJILL SMOLO YOU \S TUE
PCV. SVSTEM, TME LET
TEES PC.V STAUD F£>fc
POSmVE CRAUK-
C^SE VENTILATION.
PC A/. SYSTEMS UIAVE- BEE/U USED OU AHERICAM
CARS SlklCE THE l^fcO'€>. IT IS OME OF THE
OLDEST SYSTE-MS AMO OME. d>F TUE
NEGLECTED! (TWE U.S. AR.KY USED TUIS
SYSTEM BA^tC /U TWE
TUIS SYSTEM DRAU)5 BLOU>-BY
SASES OUT OF TUE EU6IKJE CRAUIC-
CASE, AMD BACK. IMTO TU4E- EMGIUE
BE BUS.WED. IT ALSO DRAU>6
AIK ILTTC> TUB CRAMVCCA5E.
THIS IS U)HAT IOE REAM BY
CRANJKCASE VENTILATIOKJ
COMPRESS IOM
RDU3ER.
STROICJE
>VeMTLATlOM , OR CNAM6-
IM6 THE AIR-, OCCURS
LOUEWEVER. THE EWGIWE IS
RUklUIMG.
BLOW-BY IS MADE UP OF
GASES THAT SMEAK
PAST TUIE PISTOU
RIM6S AS TME PISTON
SQUEEZES EVER-YTHIU6
IMTO A SHALL. SPACE..
EVEN MOR.G BL-OIO-BY
OCCURS tOWEM TUE
SPAKJC PLUG FJR.65 AUO
THE AIR -FUEL MIXTUEE
J3E&IILIS TO BU&M IM THE
COHBUSTIOU CHAMBER..
-------
CUECK TO SEE IF YOU
HAVE AM OP6U PCV
SYSTEM BY LOOK.JMG FOR
TUE FOLLOIOIU6, PARTS:
A PCV VALVE.
THIS CAM BE FOUkID
PLU66ED IUTO TUE LEFT
OR RlfoWT VALVE COVER,
OR UlDDEU BEMIWO OR
UkJDEfc TME IIUTAVCE
MAUIFOLD. IT IS A SHAUL
ROUMD HETAL.
AMO UOIU- BE AT
EWD OF A RUBBee
ABOUT TUl£> Bib.
A GOC?P SERVIde
MAMUAL, LftlLU HELP VOU
LOdATE THE PC.V VAUVE.
COKJTAIU
tOAT^e AUO
IF ruet>e
AR6 LEFT IMTM6
TUEYFORH ^L-UD^£ AMD
H666 UP T-M€ OIL. TMIS
HCAM6 TMEV CAM ALSO
MC6* UP
IF YOUR CAR U)AS MADE |KJ TWE
EARLY, OR. MID meO'S. IT PfcOB-
AfcLY WAS LOWAT IS KMOU>N AS
TME OP6U PCV SYSTEM
TUE OPEM SYSTEM RECYCLES
MOST OF TUE BLOLJ-BY SASES
BAC.K TO TWE EWGIklE TO BE
BURKJED-
PC.V
10
-------
TUE OTHER END OF THE HOSE
LJILL BE ATTACHED TO THE
INTAKE MAWIFOU.D, CTUE Bl(3 METAL
PART THE CARBURETOR SITS OW.)
LOOK FOR TUAT COMklECTlOkJ
AR.OUMD THE .BOTTOM OF THE.
CARBURETOR-. IT MAY ALSO
BE ATTACUED TO A FITTIM6
SCRELOED INTO TME IN/TAKE
MANIFOLD.
OPCM PCV
Y3T6
roe.
(POU'T
LOOK. OfJ
AKJOTUIER. ITEM TO
CUEC.K IS THE CAP
DUE.p.6 VOU PUT IM TUE
OIL. TUR.W THIS OVER.
AMP LOOK. AT IT IF IT
HAS A LOT OF I4OCES
IM IT, LOITU STUFF BE-
HIND THE WOL-ES THAT
LOO*CS SOHEIOU^T L.IVCE A
5G.oueiMe> PAD YOU
WAVE AU OP6M PCV
OIL PJL.LCR CAP
-------
IF YOU FOUkID TU1E HOSE LOlTU TUE PCV
VALVE, BUT THE OIL. FlL-LEfc. CAP V4A€> MO
HOLES IM IT, YOU PROBABLY UAVE. A
A/0 J-/OLGS!
TUB
OU MOST CAK5 TODAY. TUE
SYSTEM PREVEUTS TUAT
IS ROUUD
- BY
OUT IU.TC>
TO see IF IT is A
LOOK. POR AkJOTUEe UOi>£
FROM A VALVE COVSK. OR. TUE" OIL
FILLER. CAP TO TUE AlE.
UJITW TWE
SYSTEM THE EXTRA
DOES UOT"
IT \5 PULLED
THE UOSS
TUAT RUU€» FROM
VALVE covee. oe.
OIL f=ILLEE.
TO T'-IE
IT
THE
AIK.
SEALED OIL.
rjt-L.ee.
AkID l€> PULLED
BACK. 1UTO TUE
E.M6.1UE TO
BUR.MBO.
5OH6
DO
DO LIOT UAVE A PC-V
VALVE. IF YOU ouou cue
AMD GAU PIUD OWLV OKJE
UO6E. TUAT UO6E* U)I(JL
PeOBABLY RUkl FfcOM TUE
At/S
VALVE COVER. TO TUE
CLEAMER*,, IM5IDE TWAT HOSE
LJILL BE A 5HALL KESTe.lO.Tf OKI TUAT
LIMITS THE AHOUIUT OF
THAT GETS TO TWE AIR..
IF IM DOUBT; DO AS i DO,-
THE MAUUFAC.TUe.efc'6
HAW UAL Oe. A
-------
VOU
I'LL, suoto vou
POLO TO
QP£ U
OF
] Fie-STOFF, [
D
CI-IECK. THE MOSE TUAT TLJE PCV VAL.VE.
IS PLUGGED IIUTO. IS IT VGRV UJARJ> AMD
BRITTLE.? 15 IT C.RAOCGD LOUE.R.E IT B£UD6 ?
DOES IT FIT ovee THE HA.MIFOL.D ufcje: scdcs
OM A R/DOsrreE.? kio Looese oe. SLOPPY FITS
ALL.OU06.O! MO KIMK-S EITHER.,
CRACKS?
-------
IF VOUR CAR. MAS TUB CLOSED
SYSTEM, CMECt TME MOSE TUAT
RUMS FROM TUE VALVE COVETE.
COR. OIL FJLLEfc CAR) TO TME
CLHAWe/e.. ^.erpLAoe IT IF IT
AMY OP TUG: ABOVE.
D
REMOVE. TUE
PCV VALVE .
MOL.D IT IJU
YOUR. MAUD AUD
IT CAM YOU
6>O
RATTLIkKb
VOU CAKJ'T HEAK- A RATTLE
BUY A MGLO PC.V XALVG. EVGM IP IT
RATTLE vou SWOULD REPLACE IT IF IT
MAS seeju oveia. 12., ceo MiLe-s OF
A PCV VALVE "TUAT VS MOT OPSGATlUCb
CAU
TJ-/AT
GOG 5 /AJT1O
IF YOU DO R.epLA£e: THE
VALVE, MAK-E 5UEH YOU
EM6»IME. TWE
VALVE COULD MAK.E ^
Jessie" couu,
BUCJC, AMD SUAKE. (COGLL, AT
LEAST HAKE IT IOUE-
MOST CLOSep PCV SYSTEMS) tOILL UAV£ A
FILTER. OM TUE UME TUAT RUMS FEOH
TUG VALVE covets TO TUE AIR. CLEAMeE.
IF TUAT LIME COHet> FROH THE Ol<- FlU-EE
CAP, Tuenze is peoBABLV A Mesu -TYPE-
IMSIDG THE OIL FlU-EK. OAR
14
-------
FILTEE. IU5IDG TUE AIR. CLEAUeR. 1
SHOULD 136 KePLACED £VERY 6-l2.pOO
THE GUYS TWAT HADE YOUE CAe ,5LKS>C>eST /U
THE FICTeR. 110 THE OIL.
AkJD
LOUAT
GLEAMED ILI A SUITABLE SOL.VEMT AMD
LET IT "D&IP DRY* IF V£»U DOKJ'T MAVe AMV
AIR. TUIS /S
B>LOLO»J OCX, OR
SOLVEUTS ARE
FLAMMABLE
LET '5 CUECVC. OUT TWAT PCV SYS-
TEM AKJD SEE IF IT'S "VEMT1LAT-
IKJG" TUB CRAM VC CASE. (jJAftKJ \K) 6 *
F>esT OF ALL - MAKJE suiae TUE ABSA vcu
6L>oe.ki.iU6> lu is
NEXT - SET TWE PAB.\<.IM6. BEAVCE AMD TUEM START TUE
EU6.IUE. LET TME EUfclue OJARH UP TO MOR.NAL
IF YOU UAVE A CLOSED PCV SVSTEM
R.EMOVE TUE LIME TUAT RUUS
FROM TWE VALVE COVER. TO TWE
AIR, CLEAJUER,.
IF YOU MAVE. TUE OIL- FILLGS2.
TYPE :
REMOVE TUE OIL FILLER.
IF IT'S AM OPeU PC.V
REMOVE THE OIL FILLER. CAP.
TWAT IOASU'T WAR.I? COAS IT?
15
-------
IF THE PAPER IS klOT BEIMk
MELD DOIOKJ, PULL TUIE P£V
VALVE OUT. VOU SUOULD UEAR.
A UlSSIUe. SOUMD AUD FEEL A
sreou^ sucTiou UOUEN YOU
PUT YOUR. FitJ£>ei2. oveie. TUE
VALVE . \P- MOT. PULL. THE
VALVE OUT OP TUE UO6>E AUD
sere IF vou PEEL. A STEOKJC*
SUCTIOU AT TUE EUD OF TUe
MOS6. IF WOT, S^METWIUG |5
PLU66»eD - EJTUee. TUE
Oe THE HAUIF-OLD
iojj. FIWD OUT ooueee AKJD
CLEAU 'eE OUT!
LOITU TUE e:NJC2>IJue
IDLIUG, PLACE A Piece OF
FAIRLV 5TIFP PAPEe , L_|KjE
A P&&T CAe.Dy OVER. TUB
OPEMIkl6> IM THE VALVE.
AFTee A suoeT pee»oo
TIME TWAT Piece OF
SHOULD BE MEL.D DOOOU
LY TI6>WT. (JTWAT 15 IF
TMIM6? IS tOORt.lkl^»
IF IT ie MEL.D DOOOIU,
PEC? pee PLAOS. AXJD TAVC.E
BRGAIC. VOUe. P^V
IS O. kL.
IF TUE PC.V VALVE
OUT o- n., AUD TME: P^pee. \s
STILL. klOT UELD DOIOU TO
TWE VALVE. COVEE., €»TAPLT
LOOVUkJfe FOR. LEAVCY ^A£>^E]«,
LOOSE. VALVE
-------
\^
I II. 11
II J
/
TMEC.E AR.E COMMetZCIAL-
TESTER.S AVAILABLE FOR, TEST1
IMG PCV SYSTEMS IF VOU
FEEL VOU M16UT LIKE OIUE,
CWECIC (jL>lTU VOUR- LOCAL
STOR.E. UE LOILL BE. ABLE TO
VOU OMB.
OKJE LJOR.D OF
EVER PUU G
F3CV SYSTEM, TUIS LJIU.
CAUSe A BUILDUP Op
SUR.E iM THE:
TUI5 PAftSSUMC Foec€6 OK.
AMD BLOUBV <3A^£5 OUT
OP C5ASk.CTED AR6AS AMD
OIL SEALS AKJD HAK.&6 A TEE-
ACIDS AKJD SLUDG>£ TWAT
DILL RESULT U>ILU 5WOBT-
HM voue. EM^iMe'6 LIFE.
M A»JUF"ACTUR.e R1 S
17
-------
THERMOSTATIC
AIR CLEANER SYSTEMS
-------
LETS LOOK. AT AKJOTUER
5YST6 H TMAT d^HB OUT
TOU>AOD6TUe 6KJD OF
rgc 60s. TUIS Okie
STAVJDS
TTJERhOSTATIC
'((muamuffx
CD
TUERMOSTATIC
AIR.
O-EAMER.
IF YOUR. CAR. IS A 1967 OR.
MODEL, TAkCE A LOALK. OUT AMD
OPEIJ TUB HOOD. FIMP TME A1E.
CLEAUEC ASSEMBLY. IT 15 USUALLY
ROUUD. BLA6kL OC. BLUE, AUD SIT6
I m
PIEECTLY OVEE TM£ CAeBUEE-TC3f2.
IT tOILL. PfcOBABL-Y B£ WELD IU
PLACE BY OUE OE. TUX) LJIM6 MUT5.
CWECK AMD
SEE |F THAT
AIR, CLEAUEE. HAS A"V%SMOUT" OE.
^SMoe-iceu'TuBEi" OM IT IF IT
poes, TAice A LOOVC lusioe THAT
TUBE.. IF vou CAW see A
1M TME&e. YOU HAVE A
STATIC - TYPE. Alt CLEAfJES. TWlS
3YSTEH /"S OFTEM CALLEP A
AIR IMDUCTIOM
DOU'T BE CONFUSED.
THJ5 15 JU5T AMOTMEJ2 tOAY OP SAY-
IM6- THE SAME TU/U6..
21
-------
STILL NOT SURE, UUU?
SEE I
OE. FLEXIBLE TUBE
TO GUE-CkL A LI
THER-E 16 A HE"TAL
RUULHIUG* FI2.0H THE BOTTOM OF" TWE"
SUOl2.kl.eL. TUBE DOLOkJ TO TU£
MAM I FOLD.
TJ-llS PAST
DUCT:
ie> THE UGATETD
SAV VOU UAVE OME f BUT
I'LL- BET VOU ARE IOOM-
LOUY THAT 6»AD<&eT
LOAS PUT ^>M VOUE. CAE.. HAX£.
VOU
klOUi
READ OM, AMD PLL
THE. PuePoee OF TUIS
TeAPTIOU.
THE PURPOSE
OF TMIS AIR. GLEALJe:(2.
LY IS TO MAVE UEATE-D AlE.
EUTEE. TNG CAE-BUeETOg. U>HEM
STA/2.T A
HEATED BY
ovee. TUE ex^AUST KAKJJF-OLD
I'M PC>IMTI)J6 OUT
22
-------
TME U>ARM AIR. BElklG.
IMTC> TUE
TO REDUCE WC AMD CO
IOMILE
UP
U;UICM CA/U Be A F£US-
i-e> vie.-
TUAU-V eUHIUATGD E>V
LOAI2.H AIK.
ADVAUTAG^ TO A
AlE CCjSAUeE. IS
THAT IT H/x.e& "»o(-D oe^sie" A
UOT eAsiee. TO DBIVE
TUE toeATwee -rueius
HEATED Ale R.EAUUY HELPS COL.D
TO ieuU BETT6E. BUT1. -AS TWE
U>AeMt> UP IT MEEDS C&OUE&. AlE.. THIS
Ale MEUI5& IU 6>IVlWi> US
Pee cbAO-ow AMD A UTTL-S
Z.JR
IIOOULD LIKE TO &MOIO
WOLO LOE CWAMG>£ FROM
Aie TO cooceis.
TWE e>AHe Tine vou
CAM C.neck£. TO SEE IF
VOUe UEATED Aie
IS
23
-------
THE MAHe OF TWe. <3AH£ 13 ^MOT AiE. LOUEM COCD, AKJD
Aie LOUGXJ MOT;" THE EASIEST LOAY TO DO THIS is LOITH A
BY MOVJM6* -THIS PCOE UP £>E. POLOJU LOE CAM WAVE- USATeD AM2.
C€T'f> cSUe£.k^ IT OUT AUD See ir |T (S
LO^V IT IS ^UPPO&eD TCi
O.K. BACki uuoee THE
A LOOJC AT TUE
TUBE. COBS IT
HAVE A £>KAU- KOUUD CAU
OU IT tOlTM A UO&e AT-
TACWeO TO IT? IP IT DOGS
ucct: jMSioe THE suoe.^jEL-
bOITW TWe eM<=>/UE SHUT
TUG CCOE
I'M
A
IT BUTT
ODD TMER.E ISM'
ROUJUD £AU
UAVE A TUBE
IBLE PIPE RUMMIMG> F»^M
TUE SMOeVCEC. DOLOU TO A/O
THE EXMAUST HA Ml
VOU P£.OBABUy OLOU A
RlGMTf LOOK. IU TUG
OF TWE
DCOE 6>WOULD
MOk)
ENJ6>IME
MOVC
A COCU, -
IF VOU WAVE TUE SMOELGL bOITW THE
CAM OU IT, TUE DOOE SHOULD BE
CU36GD LOITH THE £.M&IIJE
WGAT^D AIE. 15
IUTO Twe cA&BueeT^e. . THG
IS TeUE FOE THE SYSTEM
OUT Tue SHALL CAM ou TME
24
-------
TO
TME PIPE
CAE.EFUL-I.V TOUCH
UWMIkJ(? FR.OM T14E
THE ^*JOE.t.e:C TD
erxuAUST MAJUIFOL.D, IT
Be 60AEH/M(3 UP
FA€»T.
SHOULD
-7-0
r
MOLD BE PATIENT AUD U>ATCW THE
POOR AS TT4E EM6JME LOARHS UP.
IF EVeBYTWlUfc IS LOOei6JUO> PBOP-
EJEL.V rue cxx>e e>wouu> BE&/U TO
OPEM AUD A.LCOLO CLQL.P AlE TO
AUD MIX U>\TM
MEATED
TUE DOOa SWOUL.D COUT/kJUG
OP£M AS TUG EkKbl
FA6T IS, IT SMOUL.D
BLOCkl OFF THE ME AT CD
TO
UR
cceAuee. is soMeu>M6ee
TUiEEU IOO° - I5C^» P.
THAT IS TUE LOAV VOUK. SYSTEM
SMOUCD OPEEATE. LET HG
vou A UTTCE FAETuee. MOUO AUP
TEt-L. VOU UOUAT* TO CWe^kL IF
|T IS MOT
D D DO
LOOkC AT THE PARTf> THAT
COMMOW TO BOTM
Fiasr THESE
PARTS AE.E : TUG (A) PEATED
AIR. IMLET DUCT, AUD TUB
(S) DOOR. IKJ TWE
TUBE.
25
-------
cwecic TME MEATED
IUJLET DUCT
TO
see IF* IT FiTe> TI^WTUV
aouuecTioki OM TME
STOV61. Ci'H POlMTIkJ6» TO TMAT
. ) cuecic Tue COUKJECT/OM
.E IT ATTACUeS TO "TUE: AH2.
TUese Ae.e
AklD IKJ POSITIOM,
AUD
COCD
DE.A(X)»J IKJ AT Tuese
(lT'5 Cite LOEAB-
IM& A COAT BUT MOT
BUTTOUIUfe IT)
TUIS DEL.AVS rue
OPeR-ATIOM OF
TME DOOe AMD
MAkCES TM£ LJWOL£
svsren
ME:*T PAET ioe s WOULD LOot,AT
DOOE.. no oe.Dee. TO OPEW AMD
pee.LV, rue DOOX* MUST MOT
JAMMED AG>AIU«=>T THE
KJOU), TAVCe A LOOK- AT
THE DOOe AUD IkJSlDE
Tue skioexec AUD CMSX
ROE. K.U6 HAtZJCe OR-
BIKJDI u
-------
LET'S LOOkl AT THE
HEATED Alfc. e>V5TeM
THAT DOESM'T HAVE"
-rue "CAM" ou -rue
SUO£K.£L. TUE
CM TUIS oue is
oRee.ATep BV A
TMQe.MOSTAT THET-
IS seusiTive*
IF vou
TUIS TVPG
AMD IT D065-
M'T LOORJC
THAT THE
oooe. i^.u
BIKJDIM(=>.
J IF=^ rue oooe.
\ ISU'T
\ I
Wue TOOO
ACAP sceeios
X-1
TUBE
NEXT-
FIMD A
rue:
~rwe
TMaSHOSTAT 1 6
TO WOU?
-rue
OPEM- IF
F/LL IT
ABOUT
A5SEHBC
-------
LET'5 LOOkL AT TUE UEATED
AlE. SVSTEM TLIAT MAS TWE.
'•"CAM" OKJ -THE SMOQ-fcjETL TUBE..
TUE "VCAM" IS ACTUAULV A
VACUUM MOTOR. THAT
AkID CLOSED TME
VACUUM MOTO&
TAKLG OFF TUE AIE. OLEAUEE.
ASSEHSLY. MOlO F-OL-L-OtO Tl-ie
UO£>E FK.OM TME VACUUM HOTOE.
TO THE BOTTOM OF THE AIE.
cceAueR.. UOT/CE TUAT IT SLIPS,
OVQ2. A SHAU- METAL- TUB^.
RIG?MT? MET^T TO TMAT SMALL
TUB& SMOULP &E. AlUOTUee UC6E.
~TUIS M0f>e SI4OULD BE
ED TO THE BOTTOM OF
THE G>ADGET TM£
COklUeCT TO /S
A "TEMPCBLATUR,e
IT SIMPLY FEELS
MOLO WOT OE. COLX> THE AIE-
is IKJSIDE: TUE A»2. CL.EAJUE/S..
U>MEW TME
TUE TEMPEEA-
VACUUM TO PULL T~Ue DO3E
UP. IHJ TUIS POeiTIOkJ OMLY
MEATEO Ale. CAfJ EUTET2.
TUG
28
-------
LJHEKJ THE TEHPEEATU££. IS
MOT THE TEMPEEATuee:
sE/usoe. DOES WOT ALUXO
MUCH VACUUM TO TUE VACUUM
HtfToe. A LID TWE: ocoe.
TU16 euxuis OPP THE.
Bi,££t>/ut, Ate
THAT VOU KWOU3 LOMAT
TO RUPDIUT
LOUICU OUE MAV BE
YOU
TMG CXDOB. COMES UP
vou STAE.T -voue
BUT MEVER. COMES BACK
DOOM MO MATTEL WOU) MOT
IT6ETT5, UUTIL-VOU SUUT
TUE
SOLUTION
THIS OUE IS EASV, R.lt,MT ?
TUE FACT TUAT IT STAV£>
UP LOMETU TWE e-Ut>lME IS RUU-
Ulklb TEULS U5 TUE TE.H-
PERATUeE SeUtsOR. IS IJOT
DOIW6 ITS JOB. BETTEe
IT
THE DOOR. PO6S IJOT MOVE
LOWEU VOU START THE E/U-
GIME EVEM IP IT lf> VER.V COLD.
IT JUST- SITS Tueee.
|LUJ&T|2.ATIOU*>
29
-------
I LOOULD R.E.G.OMMEUD VOU
TAK.e TME
STEPS:
o
O
CUECK. TME VACUUM UIUE
D COJUMECTiOMe. (^UO
oe BEjC>kce.u
ED. NJO IClMK/b OE.
FITS, errueei) IP TME
is D. ic .....
U)ITU
f^UklMlkl^, R.en^ve TWE
MO5E THAT ©OGS FR.OM
TWE o^R-Buee-ToR. TO THE
TGHPEeATTLiee seiusoe..
Re Move IT" ATT -rue
e^ATuee seuusoe.. A
UOISE IJUDICATTES
VACUUM.
PUT
TMG E"MD OF^ TUE
IT SWOUL-D TR^f TO
TO VOUE. FIKJfoEfS. IP "VOU
WAVE VACUUH AVAICABUH.
IF" MOT SETTEE. PIMP OUT
LOMAT
TO THE:
IF VOU UAVE VACUUM AT
bTWE. WO5E, MeXT R.EHOVE
TME MOSe OFF THE VACUUM
HOTOE..
30
-------
PL.UG TME HOSE FROM THE
cAtz.e>ueeT<2R_ IMTO TME
VACUUM H0TOR.. UJATCM
TUB DOOB,; IF IT
CL.OSES, AMD TMEM OPETUS
LJMEM YOU RE Move TME
VACUUM MOSE, TWEC VAC.
UUH no-roe, is o. n.
MEED A MELO
IF TME DOOR. CXDESU*!" CLO66
lOWEU VOU MOOkL TUE
VACUUM MOSe TO IT) VOU
PtS-OBABL-V MEED A, MELO
VACUUM HOTOK.. CUBCfc-
A6.AIM FOP- BlKJDIU^*. IF
klOTUiM6> APPeAeS TO BE
JAMHeDf VOU
~TMG1 MEUO
JF DOOR. DOES*-/
CL.OS& AMD AJO
A COUPLE OF WORDS OF CAUTION
TUR.M OVER. YOUR.
DQKJ*
TOP L.ID OkJ TWE AAfc.
F="ie.ST OF AL.L. TUlf>
UOT
vou F\N/E:
PEE. <2> ACCOM.
MOTMIMG »S TO BE GAIklED
31
-------
SECOUDL-Y, TUIS> UJHUL. MO~T Ae. TO
STAU_, AMD JU^
HlSEEABL-e' "TO
LoUEIU IT'5 COLD.
"TAK.E TIME AMD TW/WK. BACH ABOUT TME
POV SVSTE1M. Re:HE.HBei2. TME
TO
TUG:
CAHC DUT OH LOHTM TUE CID
OVEK TWAT
esc.Ape ~ro
3AHG ATHOSPUEeGT
-TMAT is "rue
ALL 6»OT TO
HAUY CAK5 MAVE OTHEI2-
TEHPEEATURE
ow T-WE A»E-
WOUf>lKi6>. FUPPIkl6» TUAT
UD ovEie. Messes THESE
UP, "TOO/ "THIS CAM
TUALL.V COST VO
Hi«-eA6?e^ kjoi—ro
TIOM -rwe e>c.TEA
SIOU6 VOUE. <^Ae LOIU-
BE PUTTi/iKo ounr
32
-------
AIR INJECTION
REACTION SYSTEMS
-------
TUE kJBXT SVSTEM
I LUOULD LIKE TO TBJL
YOU ABOUT IS TUE
A I, R, SYSTEM, "TUE
LETTEBS, A. |. R. STAKJD
AIR IMJECT-
IOW REACTIOkl.
THE A.l.R. SYSTEM MAS BEE1U USED
TUE AUTO INDUSTRY SIKJCE. TUEL
lPeO'S. IT MAS KJQT BEEM
USED OM ALL CAeS. SO ' VOue
CAR. MAV OC HA/ MOT M/VE AU
A.l.R SYSTEM. 0)6. (x>lLL CMECkC TUXT
OUT 110 A FE.IO MlklUTES.
TRADE WAME5
TUE A.I.E-. SYSTEM IS CALLED BY
DIFFER-EUT MAHE5. AHGRlCAkJ HO1DR5
(AMC) CALLS IT Aie SUAC.D.
_s IT All*. IK4JIECT-
IOM. FOR.D USES TMERMACTOR
A»JD GEKJEEAL HOTDGS (GH) CAI. I S
IT A.l.R. POkJ'T BE. COUPUSED
B/ THE MAMES! TUE SVSTEM
DOES TUE SAME JOB IUO HATTER.
rr ie CALLED.
^
TECHNICAL INFORMATION AHEAD
TUE A.l.e. SYSTEM'5 JC6 IS TO
REDUCE THE UC AKJD CO
FROM TUE EM&lkJE. |T DOES TMl A 2TTR.EAH OF"
AIE. |kJT^> TUE e^UAUST
ueAV|MG> EACM CYL.IWOQ2-.
35
-------
TWl5*EXTC.A" AIR. WELP5 TO Keep TUG
FIR.E BUftfJJWC?. TUJ5 BU£JUS UP TU£
ULIBU2AJED MYDeOCAR.EOU6 (UC) AUD
cAeBou MOUOXJDE Ceo.) UOUAT ioe
GET COMl/UG OUT THE TAILPIPE TUEU
IS PLAIM COATED VAPOe (fw^O) AUP
ioe
TUAT LOASU'T AS COMPLICATED AS VOU
IT ?
now...
TWAT LJE KMOLO U>L1AT
TJ-JE SVSTGM DOES, LETS
WEAD OUT AMD SEE IP1
LOG CAU FIMD e>OHE OF
-rue Aie SVSTEIH
Okl ^OUe CAE. TUAT
TUE RieST P5AR.T COE U^A/UT TO
FOE. 15 TI4E A.I.R. PUMP
AT TUE F&OMT OF VOUSL
Loueee ALL. TME BELTS
AIZE. TUE A.I.E. PUMP coiu_Be peiwew
BV A BELT TMEEe LOlU- AL-SO BE
OIUE Oe. TLLO MC?e>E£> COM/*J<» OFF
TWE BAct OF TUG RUHR
I'LL ASSUME >TOU FOUMQ l"T I
DIPM*T; voue, CAe PE.OBABLV
DOGSJJ^T HAVE AU A-\. E- SVSTEK
/s AGOL/T -rue.
ZJUAT
AJO /U/Xf<£"€,
EK <
l I
/s
36
-------
THE WEXT PART TO F/IJD IS £-AU_ED
A DIVCfcTEfc VALVE. TUIS CAJU
BE ATTACHED RI^WT OU TUB BACK.
OF TUE PUMP LIK.E___TUE OklE X'H
POIUT1U6. TO UEEE.
IT MAY BE FueTUEe DOUJU TUE
MOSE COHl/U6> F£C>H TUE-A-l. R..
PUMP UIICE TME OUE I'M 5I4OUO-
VC>U
TWE PUR.P^>£>E OR TUE DlVEETEE.
VALVE is TO p&EveuT A
FIE.E. in—TAices TME AIE.
THE PUMP AMD MOMEUTARIL-Y
OUMP6 IT /WTO TUE
VOU TAK-E
TWE 6>A£>. MOR.HALJ-.V TUE
AlE. FROM TUE PUMP <3OE<=> lklT2>
EXUAUST HAM i FOLD.
Bfif
FOLL.OLO TME uose OE.
MOSES OU DOUOU FEOM TME
Diveeren^ VAUVE. vou SMOUL-D
COME TO A CUCCK VALVE
TUAT LOOK.& Llk.E TUI6
ree. ^\
•-*.£>U)&
•"^H
OML.Y /*-/ _J \^
W^
37
-------
SOME V-8'S
TUER.E U)ILL BE A
GUeCK. VAL-VE FOC.
EACH SIDE OF THE
EMG>IUE. ou OTHER.
V-8'S TUEC.E
BE OklLY OKJE
VALVE . OM -4 AlUD
OMLY OUE
VALVE is
U5ED.
MOU> EITWEE.
is
SC> IMTO TME
OR. IT lf>
TC> A D/STE.I&UT/OU
HAWIFOLD LII^E TH/S-.
IF IT is
ITSELF THAT
~rwe
IUT&
AMD
OF £AUT10kl: IF
PAe.Tf> TUAU
TALKED ABOUT TAklE TUE
A MAKJUFACTUR.EIi'S SERVICE
FOe YOUe. CAR. AMD FIMD OUT LJWAT
TUE "EXTRA" PAE.T5 AK.E p-OE.. THIS 15
TE,UE IF YOU OtOU A R7
EQUIPPED LOITU A CATALYTIC COMVeeTEE-. TUIS IS
TO PREVEUUT
MAV£ FOUfJD AUl- TWE
lUfc? TUE SYSTEM Fo& PEOPeE. OPeE.ATlOfJ
38
-------
OF ALL., CHECK. TJ-IE
BELT Foe -THE AH2. PUMP. TU£/U
IT OV6C. AKJD C^ecfc. FOE (£
(E) PIECE6 Hl£S/U<*. Q FKAYS,
IF VOU PIUD AIUY OF THESE
COUDI~TIOIUS, RePcAce TME BEL.T.
NEXT CUECX AUD SEE IF TUB
BELT IS Tlt>WT. IF IT 15 OBVIOUS-
LY U006E, TlfeWTEW |TT TUG
BELT SUOUUD MOT BE SO
TUAT IT TLOAU6>i>" Ulk-E A
STR.IMG.
MQT£ - DOM'T PK.V OKJ TUE A.l.g. PUMP
» MQUSIMG. Pl^Y OU DUE. &MD OJ2- THE
OTUEIS. BUT UOT THE HlDOce". A'-E-
PUMPS
IL|
MAICE 5UE.E
A LOELL VEWTILATED
ARE
^-4
START THE EMG/UE AMD LET IT
CJAeH TO IT'£ UOC.MAL. OPE'EATING
TEHPERATUI2£.. USHUCa TUE PCOPE12.
TOOU, LOOSEW ~TME CLAMP THAT
HOLDS THE Liose TO Tue CMELK.
VALVE. CAUTIOM: ICEEP HAWD6 dlFAE.
OF BELTS, FAW BIAD€S, AMD OTWEE.
HOVIW6.
TUEBE SUOULD BE Aie pL,otoiut> our
OF THE MOSE.
klOLO, SPEED UP THE EM&IME. ~TME.
AIE. FLOIO SHOULD
LET'S CUECK OUT
DIVE.RTER. VALVE
THE
c(
39
-------
AGAIM IMGR-EASE
SPEED AUD THEM LET
TJ-JE TUR£)TTLE SIUAP
SUUT LOWEki rue THROTTLE
CLOSES, AIE. FLOIO FB.OH THE HO6E.
YOU AeE NOLDIU6 SHOULD DEC-CEASS
oe. STOP FOE. 1-3 sedomos. IF IT
Doesu'T 5oMETHiiii£> is ueojuk. LOG
LJILL TALK. ABOUT THIS IM A UTTLE
BIT
UE SAID TUE DIVER-TER
VALVE DUMPED TME Aie
FK.OH TUE PUMP LJUEIU YOU
LIFT YOUC. ROOT OFF THE
0AS PEPAL, (2l6>UT ? LOELL ,
LET'S FIUD OUT IF |T»5
TAKE A LOOK AT THE cwet*c
VALVE YOU J-IAVE PULLED TUE
wose OFF OF MOLD -Youe
wAjjp ovee IT CCAC.CFUU.V)
AJJP see IR vou CAU FEHL_ HOT
E.XMAU5T GAS ESCAPIklfc>. |t=- VOU
CAW, TWE CWE£K- VALVE SHOULD
&EPLA<1ED. IF VOU UAVE, TtOO
VALVES VOU H16>WT LJAMT
TO CUe
-------
TLJE PROBLEM MAY BE TUE DiVER-TEE
VALVE. Ikl OTHER. UJOJ2.DS, IT 15
DUHPlUG PUMP AIR. ALL TUE TlHE.
//= A//S /5 COM/JU& our
L/OL.E5 ALL TLIE TIMS, YOU
A M£.io Div££re.e. VALVE.
TO CMECK. - TAkLE A CLOSE" UOOV-
AT voue DiveeTee.. H06T u>/u-
ux>n Liide oue OF ~rwe TOX> I'M
PDIMTIM6> TO M£R.e. MOTIVE TME
UOLES. TUIS IS U*46E£ TUE Al(^ IS
DUMPED OUT OF TUE PlVEETEe.
VALVE.
CAUTIOM - UAT£M/KJ^ OUT
FOR. MOVIM6 BLADES,
B8TLTS AUD PUL.L6VS, PUT
YOUR. FIWGEKS DOUJM BY TWOSE
MOLES. IF" V£>U CAM FEEL- Alfc-
E5CAPIM6> ALL THE TIME, TWE D\VEKT-
E£ VALVE KJEED5 REPLACIKJ6,.
IF Aie IS MOT ESCAPING OUT OF IT WE
DIVEeTEE. VALVE, AMD THE FLOU> OUT-
OP THE LJOSE IS VEEY LOUJ, YOU
PEOBABLY WEED A MEUO AIE.
DJn^/r^ > /^r^^ ^O)D
ERTER. VALVE DOES JUOT PUMP
Aie UWEM YOU TAKLE YOUE
FCOT OFF THE &AS. LOMEIU YOU
C.U£C.\c£D THE DIVE^TEE. VALV£
OPEKAT/DM, TWE FLoLO OF Aie.
OUT OF TPE woee DID UOT
D£ce.eA&e AT ALL..
FLOW ALL
bjueu
THKOTTL£ /S
41
-------
FIR.ST TWIKJG I'D K-GCOMMEklD VOU DO
IS CUECK TUE VACUUM SEMSIU6> LIU£.
THIS IS TUE SHALL RUBBEfc I4O5G
TUAT Rukl6 FROM TUE DIVEETER. .
VALVE UP TO eoHE PLACS" OM TU£"
IMTAKE MAUIFOLD. TU15 UUE SEIUSeS
INTAKE MAMIFOL.D VACUUM. CUAM6E5
IM IWTAK.6 HAMIFC?LP
TT4E DlVEI2TEe VALVE.
IT? CUECK TUIS uose poe
SPLIT5. CRACKS. KIMK.5. OK BREAK.t>
AKJO LOOSE COM MgCTLQ Mt>. REPLA.de
IF KJECeSSAR.V.
NEXT - R.EHOVE THE MOSE AT TWE
VALVE. CUE^kl AkJD SEE
UAve VACUUM. IF YOUE
~TO TME EMD OF TUE WO5G,
VOURJE ALL. SETT IF MOnr BE
E.
COee.E A^AlMST
coeeecT" AMD eepcAce AS>
42
-------
TUB A.I.R., SYSTEM IS
IVC IU R£DUOM<» MC AUD CO 6M/66JOU6.
IT TAKES VCfcV LITTLE RPUefi (A
LOT cess TWAM v^ue CAes Aie
-r^ pe/ve THS A.I.R
IT ALSO "nilt£5 VKV UTTL6
KfiEP THIS SYSTEM
OPWATIUfr, AUD BY I«CP||J^ (T
YOU
-------
FUEL EVAPORATIVE
CONTROL SYSTEMS
-------
SJOLO
TO L.COJC
TMAT lt>
F.E, C THE
=> TAVLE TIME
AT A SVST&M
FUEL. EVAPORATION
COk/TROL.
BACH CAR. HAlCee UAS
OlOM SPExC-IAL MAM& FOe. THIS
SYSTEM. TUG F>0|UT Jt> ~TMAT
IUO HATTEE LOUAT IT IS
IT'5 JOB \<=>
TO PR.EVgMT FUEL
FUEL TAUkC OK- TME
AMD PC?L-LU~T|IU 6?
VAPO&G
ov= MC oe
AJUP HU5T BE
6.ASOUIU&)
OUT
I'LL BET" VOU'eE
ILI6, IF Y(9UE. CAR WAS TU1S
SYSTEM, R/
-------
L-OOkl AT SOME
OF THE PAR.TS TUAT
AR£ COMHOU ~TO ALL
FE.C. SYSTEMS.
MAMV OF TUESE:
HAV MOT B£
TO FIUD, I'LL EXPLAIN
LOUV Lonew toe
TO THEM.
EL
/JU DAV5 OF OLD, RU&L
VETKJT"EP TO ATM OS -
THE: CAP ALLOLOED
? SOMETIMES
IT ALtO AL-LOLOED AIR
TO BE DeALDU IkJ, AS TWEL
LEVB(_ IM THE FUEL-
TWE RUEL.
VAPDC. LD£>6 TO TUET ATHD6-
TMe FlULCe CAP
FILLED CAP Lx)lU-
A IE. I WTO TMe: TAJUK., OklCf
IF A PROBLEM DEVELOPS
IJUTWE
48
-------
YOU WAVE PKOJ3A&L.Y
Ticeo OJMEIU vou FIL.L Youe.
GAS TANK THAT YOU JLfeT
CAM MOT X%TOP 'EH OFF"
Liice iki TWE OH_D PAYS. FUEL
TAMK.*> A£E DESIGNED €0
THEY CAUMOT BE
LY F"IL-L-EP.
TO peeveUT UGUJID
FIS^H esCAP/KJG>, TH£ MEU)
GAS TAUC.6 ALWAYS MAV6
AM Aie- spAce evew LOMEJU
FULL. THIS Cx^Y, OU A UOT
DAY, (OMEM TUe 6A*> |KJ
TAUId ey.PAKJD3, IT DOES
UOT euM OUT Twe
KJeC.t.. IT SIMPLY
IIUTO THE A»E. SPACE.
WHERE DO THE VAPORS GO ???
I TMOUSWT THAT
UOOULD BE YOLJE.
LET5
TWEeE VARIES AS
THEY LGAVE THE
GAS TAklkl AJUD
•SEE LOMAT MAPP6XJS
TO THEM
AS THE VAPORS LEAVE TWE FUEL
TAJUH THE FIK.5T D&
is A vAPoe
THIS PAE.T IS VE-EY
IU THE FUEL. TAMKL, ABOVE rrt OE. OFF
AUHO5T AUY pLAC£ (jOHES-E TMER-G
FOE. IT.
TO
-------
TWE VAPOte. S£pAeAT£>e IS A
- F72.ee
TO PASS
IT AfJV C.JO^U/D FUSL IS
-THE
TJD
THE
PASS
RR.O/UT
TO A
"TME.
A BLAC.K: PLASTIC.
A ET?UUD
CAU. IT LOIU- HAVE
~rueee ^>ie. pouig. noses
ATTACU6X? TO ITT
TUE CHAe-COAL. IUJSIDE TME
ISTEE. IS USED TO STOee THE
FI2.0H THE FUEL. TAUVC.
SOME, CAfcS |~r STOE.es THE
VAFC3&S FEOM THE
uoeuu. LOHEU THE:
IS STARTED
PeAUJKJ J/UTO THE
AEE THE PAETS THAT
A£E COHMOW TO HO6T ^ASS
LJITH F£..d. CET'5 TA1CG A
LOALU OUT AMD OPSM THE MCOD
AJUD see IF ooe OLAU FIUD ^OMG
PAETS. MAYBE toe CAM eve/u
SOME OF- Twe HVSTG&V
OF AU.. TWose woses FOUAJD
UWDSE THE HCOOV
50
-------
•• K.6EP IM HHLID-* GA^OUtUe VAPOfc^
\
UUDCE TMS MODD
TUE: FuesT Tuiwfo
FIJJD IS TV-4E YST£M6.
OML.V
ATTACweD TO -rwe
TME MO^e klOT GOlUb TD
T14G FUEL TAUfc. IT UDILL LEAD TO
a. T]-ie Alfc
b. T(-l£ BOTTOM OF THE
TMlt? UO6e 16? Foe TAHILI6> TUG VA-
POES OUT OF THE CAJUI6TGE. A/UP
PUTTIMG TMEH BAC1C IUTO THE
Eiu&uue TO e>e euiejue-p. TW/S wose
'id CALLED A>XPUR6C" LlUE.
Tweee COICL Be A pu£6e c/iue OJLJ
ALi- FG. C.
-------
IF THEJ2E
£.OH/IUO» FeOH THE
: 1st - FIJJD THE oue THAT
COME5 F-E.OM TWE FUEL. TALIK. .
CTI-US MO3E IS GOMMoU ~TO
H066 UP TO TM£
UK.e I'M
Meee. TUI^ nose AU
~THE VAPORS F'EdDH THE.
Bueerojs. ~TD BE VEJUTED IUTD
TT4E O4AECOAU CAAJ fbTee . -THE:
3rd UO5E IS FOe REMOVAL. OF*
~TME VAFOe^ IU ~TME
— THE SNPue
-------
IP YOU TRACE TW16 LIIUE YOU
IOILL see TWAT JT Ties /JUT&
THE PCV Liue. THIS lt> THE
LIME. THE, OULY
WITH -THIS OMG is
IT is ATTACHED. TUIS SETUP
A SMALL AHOUUT OF
TO e>& TAneu <3UT
cAMieTee. AMY T/HE
THE eiU&IMe 16
THIS uue UP TO
TWi5 uue i
ACTUALLY A VACUUM
LIU6. IT TOLL'S A
THE £A^u/5Tee ooweju YOU STEP
OM TME
AEG
uucEHASe eM6»/ue
I HOPE TMAT TAW.E5
SOME OF THE.
OUT £>F THE F.E.C.
SYSTEM AJJD
woeee.
MOto PD une TO
YOU aOHE
YOU CAM
THE
SVSTEH.
FIR.5T TMJJU6? TO LOOK AT IS
ALL THE MOSES IOC UAVE
BEEkl TALHIM6 ABOUT CMBCkl
THESE FOe THE FOLC.OU5IJU(»
COUDlTJOUf> :
I. - SLOPPY FITS>
2.- CEACLfc.5
3. - HAI2.D AWO BE-/TTL6:
4. - RUB HAekl5
THEY HAY
coe.eeCT ALIV OF
Tnee>e COUDITIOUS TMAT
YOU FIMD. OUE OF THE B16-
> EMI6SIOU dOUTROL SYSTEMS
15 BAD MOSS dOMUeCTIOILfe.
53
-------
IF VOUR. CAP. MAS TWET BLACK. PL.ASTJC
CAU ISTER. TME^e IS PROBABLY A
FILTER. OM THE BOTTOM OF IT
R.ETACM ULJDec AMD SEE IF VOU CAM
FEEL- A FIBEESCASS FILTEE.
SWOUL.D ©e Kepi-Aceo ABOUT
IS, OOO HICStj. TMIS FICTEK.
TWe A lie. TMAT IS U5GD TO
TUG FUEL ^APoe& FEOH TW6
AKJD IT is
IF
THE EG 15 UO
ABOUT:
METAL.,
OTMEI2. ITEH VOU
LOALIT TO £We-CkL IS TME"
ONVe TV4E
LOOK. AT
TMAT
A TI^UT SEAL
THE CAP AMD THE
IF »T IS
OE A GWUMkC. OF
GA5JCET l€> Hlf>SlU6», R.E PLACE TUE
CAP.
HAK.6
IF YOU RAieic voue
FACfJU6r UPU/CL AUD VOU
see 6>Ae EuuMiU6» o^inr;
A&A//U, eerpLAce TUG CAR.
THE
voue.
54
-------
IF
BMIS6IOKJ
CAM OUL-V HELP
DOkTT D!6COMNeCT I
AUL TMOe6 VAPDR
UJtU- JU6T H656 UP
SHOULD JUST- ce*ve THS
coMMecTCD. iceep IT
MAtMTAIWCO, AMD U6C TMOt*
To w6up BUK; voue
DO,
AP
. VOU
-------
EXHAUST GAS
RECIRCULATION SYSTEMS
-------
E6R=
EXHAUST
RECIRCUUTIOM
IT IS TIME TO LOOK./T
TME SfSTtM TWAT IS
ABBREVIATED E.S.R.
EXWAUST GAS
RECRCULATIOM
LJAY BACVC IkJ THE FeOUT OF
sooc i HeuT/oiuec? A
P^D(-LJJTA(UT CAL.UED
NJOX \S TME STUFF THAT RESULTS LOMEU Aie AMD FUCL- BUEJJ-
T"we AIE. — PUEL. Mixnruee Bueu-b7 nrne HOBE
is
TME PU6.P^>se OF TWE
EOe. SYSTEM IS TO LQU>gg.
TWE
TWE
THE AHOUUT OF
FOK.MEP, LOWICW |JU TUSkl
G>ive*> us CLGAiuee.
TO
ABOUT 3OOO ~4OOO*F
ABOUT
59
-------
R.EDUCE5
AMOUWT OF IUOX PRODUC-
P BV HIX|M<3 A SHALL. A-
MOUUT OF BUEkJGD EXUAUST"
GAS tOITM TWE
IU THE
FOLD. JLfoT GUOU6H
lt> ADDGD TO
TO
-rue
IM
E.&.e.
IM
BEGJU UOeO OM
TUE. UUI~TED
ou HOOT Foe.
STAT£t>. ^30 IF"
THAJd
U5ED o»u
BVG.I2.
ME1AELY
cAet>
CAE. MADB
ALOO
jiu -rue
N-IOCc) THAT LOE KUOLO 6OWAT
TMe ET£,(2. SYSTEM DOEIf).
UET3 Fe^^M TMG TOP Cf
IT7
60
-------
TOP
THIS E.G. K.. VAL.VE COILL
UV BE LOCATED O\J TH&
MAUIF'OLD. IT MAV Be OU TUE"
oe_ je.iG?nT OF
oe. BEHIUD r
IF VOUe OAR- WAS A 6
EMGILie ~TWe BG12. VAL.V£ -Sf/CULP
BE LOCATED FA'CL-Y CCjOfee TO
CMECK Tuee>e LOCA-
TlOUt? FOe TME
VAUVE ou /^ v-a
VACUUH
D L_eT HE.
vou LOU^T TUAT^ VALVE
is CL.oe>eD AS swotou, IT
(SASH'S FEOH
EUTEEIUC* THE IJOTAKE
AMD HDtlUG, lO»~ru THG
VACUUM IS APPLIED , TUG.
VAL-VE 5>TAE.T^) TO OPGM .
AL-L-C>LL>^ -rne e>ue.M6^ EXHAUST
TO MIX UOITM TUG AlE- FUeL.
IM THE IUTAVCH HAMIFOCD.
MOIO THAT LOG. KUOtO LOMAT
IT LOOK.S L/K.E OAJ TUG /HISIDS,
LET6 60 A LITTLE
AMD 656 IF LOE CAJU
SOME 6SJU66 OUT OF SOME
OTM632. I~T~EK€» FOU*JD
SVST EMS. J
VALV£.
61
-------
KJOLO FOULOUJ THE VACUUM
FEO H TME e&E- VALVE TO THE
OTW&E. eiuD. Okl 5OME CA£S IT LOIUL.
SIMPL.Y GO TO THE BOTTOM OF TWE
cAe.8uE.eTOR. eJK-£ PM
Hose peon TM£ e^e
MAY ATTACH TO A DEVIC£ Llk^ THIS.
THIS Device i-s CALCGD A C, T7 O.
VAC.UUH
C.T O. STAMPS FOe.
NJOLO TKACe TW£ LOUOELE. VACUUM
HO&e ou TME oi~rrc.w.
TMIS WO5E 6l-IOU(_O 6O TO A
co/UMecrnofj oiu TWG: e>Ase^ oe.
eoi—TON, OF TUG.
C~ro
MAY 60 T<9 A DEVICE: UIC.E TW/£>.
CUUM AMPLlFiee," IF YOU
OF TUE£>e OkJ YOUfS.
CAR. TAHE A SECOUD AIUD TT2ACS
TW£ OTW£e VACUUM UO&EZz COH-
fo FE(9M TWE- VACUUM
^M6 VACUUM HOt
•20 FeOM THE AMPLIFIED TO TVl£
SHOULD
ED TCT^~ - -~Z/U IUTAtl£
TAP OU THG lUTAtie
62
O3UW6CT-
-------
LET'S LOOK- AT OME
sve>TEM TWAT ie> FAte.-
C.OHHOU.
[F VOU HAVE A SVSTHH
THIS OU VOUE. CAE.
co ILL R.eco6>Miz.e sone OF
rue PAE.TS LOG MAVE
(2HADY TALKED A&OUT
MAHE.L-V TH£ G6.& VAU S/e
AMD THG CTO 5001 "7XM.
VALVE
Piece ie> CACCCD AU
EXMAUST BACK.
A LOOR.D OF CAUTIOM
TUER.E AR.E HAMV DIFFEE.EUCES
ltd GG»F2. eVSTEHS. IR TWE OklG.
ON VOU£- CAE. MAt> MOE.e
PASTS, oe PAR.TS TUAT
THE: OM£/e> rve
VOU,
A
HAM UAL.
ROE.
PAE.TICULAK.
63
-------
. SVSTEM,
TME
THE HAIIU PAET5> OF
e? SEE A&OLJT
FO^ST-
VACUUH
I. - LOOSE FIT5 OK. 5 LOPPY
2.— HO5Et> TWATT AEE MARO AJUD
(=>E.T SACt. -TO
3. - MDe>e^> -TMAT Aee SPUT
OE. C&ACkLGD.
4. - W0t>ee> -THAT ARH K.IUK.GD.
RG PLACE. ALL HOe>ES "TWAT AT2JE |M
BAD
MOUO,
-rue
LET HE STAeT BY e>AYIMb> TWAT
{OM6.U THE eUfelMe |S IDLIM^, TWE
£.6>R. VALVE 5MOULD 66 CLO6ED.
FIEST, ^MEC.t- T"Wlt> BV L-COt//U^ AT
AMD MAe.t//Ufc> TME P^>S>|-TIOU OF
THE e. £». e.. VALVE: STEM UOITH
e>HUT OFF.
; HA.K.G e>URj
Ikl IS
WAVE: A FE-ieuD STAerr voue-
e/Ut>J(ue AMD UE"T IT IDCe. COATCN
THAT VAL.VE, STEM. I"T SHOULD Be
)U THE 6AME PO&IT/OM TMAT IT
IU LOMEM TUG
: KEEP HAUDS CLEAE
BLADe-S, AUD oTwee Hov/iu6»
IF TMEE.E IS OULY A SHOE.T PIECE.
OF VACUUM MOfaE P_UMUIUt> F/2.OM
TMG E. 6. E.. VALVE TO TWE BOTTOM
OF TMC. CAE.BUK.ETOR- - TAklEL THE
-------
n
a KEEP AW EYE OU "THAT Ee«Z. VALVE STEM.
i
3D SL.OLOIY - START IUCeeA£>IU(* THE SPEED
OF TWE EU&IUE. THE VAUVE- £>T£M SHOULD
START TO MCrve UP AS EW6>IUE 6PE.EP
IF IT poes, TWE
DOM'T OV&e-SPEED TME EM&lUE. IF
VOU WAVE A TACWOHETeK. AVAJLABUE"
LJ6E |-77 YOU SHOULDU'T WAVE TO
2.500 R..R H.
IF IT DOEf>U'T OREU
LOWEM YOU IM-
SPEED, CMECfc. TO
see IF vou WAVE
VACUUM TO
1]
a Dlf>COIUME,CT -- THE,
30 LOITM THE
ABL.E TO
lDLJUt>
AMY VACUUM AT THE OP- TME
SL_OU>LY STAK-T
EFO. NE eU6»E eC.we*> 2SOO R.P. H. VC?U SHOUC-D FEEL-
A VACUU M AT TWE EKJD OF TWE WOt>E. IF klQT - CHECK-
A
PL-ufi>e>eD PAseAe?e OE. A e>L-oaceD uose.
F VACUUM \t> AVAILABLE , AMD THE VALVE !•> klOT
E6.J2- VAUVe LOIU- HAVE. TO B€T CLHAUEC? O(2_
R.EPL-ACED. WOtOEVSK., ISEAD OU BEFORjS. VOU E-CPLACe IT/
65
-------
AWOTMER. O_UlCkC CUECIC IS TO
APPL.V Auo-rneR. sou&ce OF
VACUUM TO TM£ e6>.(Z. VAUVE.
IR vou HAVE: A VACUUM OPER-
ATED TU£t2-Hoe>TxVTlC A112- CLE2U-
E"E. "VOU MAve A HAUD^V SOURCE
OF VACUUM. eeMeHBeE. THE
SYSTEM ? C^-evieio TA.C.
>F |U
^ Lr—
/*
f
/-
^1
=^\
^^Oj
\ V
\
\
**
*-—
TO
/r
CALIT/OM: BE
IUSTALLED.
THE DUE TIAAT
TO MAE.H-
AUP MAICE ±>ue.£ ALL VACUUM
a TAK.G THE
UOS& AMD COUMECT IT
TO THE El. 6-E. VALVe
VACUUM LI we
TIOM LIIC£ »'M
vou NE:ee:.
ODD
66
-------
IF xxoce oese>ie" ee&iMt* TO
fiATTLE, COU6H£> AMD HAVBG Dl£6
OU VOU, VOU KIJOCJ TMG G. 6. R.
VALVE it>
MOST E,G,», VALVfcS
CAM be CM60CCD IkJ
16 AL£>O A (SOC?D IWD) -
CATIOM OR LOMV TWe E- G. E..
it> NOT
TO opeeArre AT IDUE.
u
THE
TO
-THE: CTO
COS TAL-kieP ABOUT?
OP* TMG:
it> :
VACUUM
VALVE LOWEIU nrwe eiu-
cyue. it> COLD. -rWEse
L.JTTUE c=oop>ie^ AEJS PUT
IIUTO sveTewt? T-O
Twe UOAV OLE;
COLD.
C. TO. &LOITC.H I
IT AUD
A/U OU - OFF
IF- IT it>
D STAR.T LOITH A COL-t>
67
-------
DI5COMWECT THE: VACUUM
FE.OM -THE e,c».ie.. VALVE:.
WAVE A FE-teklD
voufc. eu£,uue Foe.
vou.
MOTE: -. MAt-E euce
IS
SLOIOLV IUCE.EA6E
D HkKbiue ePEHD TO ABOUT
eooo - as^oo is. R M.
VOU 51-lOULDU'T FEEL
D AMV VACUUM AT THE
EJUD OF" TME M0£>e VOU
REMOV6LD R&OM TMG G.6.E.
VALVE.
AT
C.T.O.
IF" VOU DO FEEL. VACUUM. AMD TW£ EfUGI»J£ 15
(SO0 -GO0 F) BBTTee. TM/ukl A&OUT R.ePAClMt>
cro 5toiTlWe LOA.Mt> UP VOU
LOOIU'T" BE ABLG TO FEEl-
MOLO LET THE
THE EMGIJUE J£e.ACWE^> OP-
SLOUX.Y
SPE^D TO 2000 -aeroo
LJOCO VOU ^>WOULD BG ABLE TO
SOME. VACUUM ow THAT
68
TO THE.
-------
IF MO VACUUM It? FETL-T,
CJITH A UE.LO OKJ6, ALJp
DUCe AlE.
. TWAT
TOO
n
~%s see MOLO u>e
CAN cwecic OUT THE
VACUUM AMPUF-|eE_
vm(U ((U if ((( ((iTTTTT
STAE.T VOUK. eu^iue:
D LET IT LOAE.H UP TO
AT/M6*
U3ATCU TME E.^.e. VAL.VG
n STEM LOHIL.E vou
A60U~T 2.5OO E..RM.
IT/
IF- TME e.e. e.. VALVE
D Moves,
TAK£ TME
D QAV OFF.
OF
AU50 - TeV I7 2.,
LOITW THE
IF THE
VA uve o peLe^kTee , RJE-
THE C.TO. SIOITCR
.f£. SYSTEM
JUOT
LOITW A CO(_D
THE.
69
-------
IF THE e:6»E. VALVE erreH
Move, -TAK.e THE. FOUL-OLOIUC^ STEPS
R.eHove TME VACUUM
FEOH THE e.d,.
COITM THE
RJJU A UOSe FEOH A
HAUIFOL.D VACUUM
Cute LOG DID
TO "rue e:. 6>.i2-. VAL.VE:.
IF TME: eu^iue
DOLOU 0(2. STALLS TWE
IF MOT, &ewove AJUD
IF T"H£
O.K..,
-rue C..TOL
RE: Move TWE uouoee. VACUUM
OJU "THE
~TO 2.OO& - 2.&OO R..RH.
IF VOU FeeL. A VA£UUH
Meee, TWAT MGAM^
toe WAVE: VACUUM TO
C-TO. etOITCH, BUT MO
VAdUUM OUT OF IT -
KKbWT? TW£ E. G.KL. VALV£
STEM DIDM'T MOVE /KJ
oue F/ee>T nrev. TH/S
TeLLA US THE
SLOITCH
IF kio VACUUM i£> Feur lu 3Tep 2.^ THE VACUUM AHP^IFIEK.
pjeoBABLV C5eFec-rive. aeFoeg vou BUV Ajueuo oiue
voue MECHAUIC
MAUUAL- FOE.
TM6
CAK. A/UD FOCL^LO ~TWS
70
-------
A<3AJM, LET HE SAV TUIAT TWEBE
AKH A L.OT OF VAJ2.1ATIOUS iM
E.G.E.. svsTETMt?. l CAM
G>\ve vou
CHECK. A s>eevice. HAUUAL.
LET>5 LOOK. AT THE E. G
SYSTEM TMAT UA6 TM£
EXHAUST &ACIC
S&U5OE- OM ITT
FOJ2- TV-US CH6LCk
MEED TME HELP OF A
5TAR.T 6OITH A C-OUD
A6.AIU
TEMP
START THE ETU^IUE.
UOT£ : HAKJE. SUZJE. AEEA
16
WAVE VOUE. FE.IEUD WOLD
MI6 FOOT OK. A tC^DDED -
UP R.A OVeiS. THE TAIL-
PIPE TO (£-E^>Te.lCT - MOT
S>TOP^ - TUG GXMAU5T
FL.OCO. YOU OOATCM TNG
E.G>.E.. VA4-VE STEM.
CAUTIOU : U6E A CLHAU
CATCH
71
-------
AS VOUR.
TUG EXHAUST OU
SPECD TO
VALVE
Move LOITM "rwe
OOCO. IF IT DOES,
TH£ G.T-O. iSLOlTCR
OF
MOT
U)(TW EM&IME COL-D,
AKJD e^MAusr R.e-
5T-EicTep, e.G.e.
VAL.V6 SHOULD
MOT hove.
c
nrrr
D
MOLO L-ETT THE
AG»AIU, COATCH TME
IOAE.M (JR
5"TEM.
HAVE voue.
I serree
HAUD6J "THAT
: use A
I2A66 ^AU e>e A
E. G>. 12.. VAL.V£
STEM 6MOULD HOVG
UP.
Twe &XMAUST FLOCO
TMGM MOT — TO suexi
TO Be MOT
oe.
ABOUT S.QOO -
IF IT
PEIOSABL.V
O. 1C
IF IT
Move
vou
TH£
STGR6
72
o
O
-------
CWECKL OUT THE 6.
VALVE. DO TWI6 BV
i*jfc> A ^ouece. OF
MAkllFOL-D VACUUM,
vou
£ C..JZ. VAL.VG &Y
£: £>/=" //t/7-.
VACUUM TO /7T
so AMSAD T-O €>~rep
IF MOT; coE.eec-r
E>V CUSAUIU6>
THE eui.e- VALVG.
REMOVE THE VACUUM MO6G
THe. BAGk^ pee55uee
Lite rn e>wotonJ6 weee
~rr>
2.CCO — 2.5CO e.. RM.
IF vou DO MOT pee«-
VACUUH AT THE SUD OF
MOf?e , THE CL.-TTO
15 UOT
AUD
IF vou PO HAVE:
IU THE
THE HAJU U F=ACTU K.-
HAKJUAL- IP
lx ^°
. *^CtJtJM
vou ACE douacs TO AT- (^gag
TEMPT TO FIX IT
IP MCTT; AT
vou CAW -rei_L. ^oui^ HECIHAUIC LOHAT is LOR.oiu6>
AMD L_E:T HJM F^IX
CAUTIOM
UVTE MODEL CAJ2f>
AE.E DG-SI^IUED
TD OPEEATE U3ITH
IT
TO
CAU6E
DGTO-
THE
S4ATE.
Eiut>iue DAMAGE/ Keep THE
TEH OPE-RATIKJ6> PBOPSEL-X THIS
LOILL peevEJJT Fo*>si&(-e
DAHA6>£ AUP neep oue: AIC.
73
-------
CATALYTIC
CONVERTER SYSTEMS
-------
TUEPURPOSE OF TME
CATALYTIC CONVERTER IS TO
REDUCE TUE AMOUkJT OF" UC. AMP
CO EMISSIONS. I UMLL ALSO ADD
TUAT CATALYTIC COUVHRTER5 ARE
eFFic.ieuT iw REDUCIUC. TWESE
A LOOK AT
AMOTUER
5IOM COKJTRA.
DEVICE. TWtS
DEVICE, TWE
CATALYTIC
COMVERTER,
IM W75.
//U
CO
CATALYTIC COMVEeTERS REDUCE
CO BY BU RAJ IMG TUE^E EMIS5l^U
HK»MT WAVE
AUOTUER. -reen
USED IS OXIDIZIU& CATALYTIC.
EfcS. DCXU'T BE COMFUSED BY TU£
iuo(2D OXIDIZIKIG.1 IT is OJJLY
AUOTUEE. lOAY OP S^YIM6.
OE- COHBU6TIOU.
11
-------
MG -I- CO AR.6.
OXIDIZED AVID
CU^kUGCD TO
WATER.
ua AMD c-o
VAPOB-
IF VOU OLOM A 1975 OR
uetoee. cA*t, LE^T^ <=>o o\sr
AUD HTAICE. A LO&*. AT TUE.
CATAi_v~ric-
U3EAK. VCHJR
CLDTUE6
VOU'RE 6>OJiJ6> TO
UAVE TO LOO\C. UUD632.
BE SUKC
TO
LOOK UUDE:^ voue CAR. AUD
FOL.UOUO TUE eXUAUST PIPE
DOLOM peon rue eu
find it?
i r \ i
TUE MUFFLED OMVOUe. CAE.
L.OCATGD F-UBTUEE.
TME EXHAUST SYSTEM
THAU TWE CATAL-YTIC
VER.TE12..
78
-------
-rue CATAL.VTIC couveeTee. \t>
OFTeM CALLED TUE CATALYTIC.
MUFFLEK.. TUIS 15 AM
THE aOUVeET£E. IS JJOT
•sieueD TO GkjJier EXMAUST
MOISE. IT IS OWLY U5ED TO
UP UC AIJD
CATAUYTIC
nan YOU SUOUL.D PULL
UP A CUAICZ. AMD I COILU EXPUA»M A
LITTLE HOR.E ABOUT l4Olx> THE £ATA -
L-VTIC COklVE(2.TE.R. OPejSATES, AJUD
LOUAT YOU CAM DO TO HAK-G 5UJ2J5 IT
FIR.ST, LET ME SUOlO YOU
LOUAT MAK.ES UP A CAT-
ALYTIC.
MOMOLITU COUVEETEe
TYPC*> OF c^>MVQi.Tae6. owe
IS CALLED A HOMOHTM CQU-
VEg.Tge. .
Piece r) TUE OTWGE.
TYRE IS TUE PELLET
TUE IMPO1Z.TAUT
COATIM<:> OM TUE
OK. TME HOJJOLITW
TUI6 ODATIU6>
15 PLAT/UUI^ OB A HIXTU05
OF PLAT (MUM AMD PALLA-
DIUM. TLJESE AeE TUE CAT-
ALYST MATeeiAL-e* TUAT AID
IN REDUCIM& UC- AMD CO
EHIS6IOM6.
PELLET-STYLE
COATED co/rtJ
PAU.AD/UM.
79
-------
TUAT UASNTT BAD, LJAS IT?
TO TWE IMPORTANT PARTI
NOOJ
OME
ITEM THESE
MEED FOR. PROPER. OPER-
ATIONJ is OXVGENJ.
OXY6EU IS ESSEMTIAL FOR.
ANJY BURMIH6 OR. OXIDA-
TlOkJ.
IF NO A.I.R.
SVSTEM, TV4EN
ADJUSTMENT \S
EXTR.EMEUV
IF VOUJ2- C^E. 15 A iq75 OR.
ER. MODEL- AKJD WAf> AKJ A-I.R.
SYSTEM , TJJIS IS IOUER.E
THE EVTR-A AIR. AMD OXY6>Ekl
COME FR.OH FOE. TUE PROPER
OPER.ATIOM OF THE couveer-
IF YOUJZ. CAR. DOeSM'T WAVE
AM A.I. R. SYSTEM, CQR.R.6CT
CAg.6UR.gTOR. ADJUSTHEMT 15
IMPOR.TAKJT
AkJOTUER. ITE.H YOU MI&UT
CUECI6: MAKE SURE ALL
SPAR,iC PLLKiS AMD SPAR.VL PLUG
U)IRE5 A12.E O-fc. A SPAR.VC PLUG
THAT IS MOT Fie.lU6» OJILL MOT
OKJLY CAU5E YOUK- ^AR- TO RUU
R.OU644, BUT LJILL LOASTE
AlJD 6AU RUIM YOUR.
80
-------
A
SAD SPAEkl
PLU6S
COASTED
SAS
POOR.
RUIM6D; j J
ALL TV-MS
RESULTS IU
n LOSS OF MOMCV
LOTS OF A1B-
D FDLLUTIOU
n
DOM'T REMOVE THE
LYTIC <^OUVE.R.TE^ AMD
EXPECT TO CSAIW PeJ2.R±3RM-
AMC6" oe. 6>A5 MILAGE. SIUC£
THE ^OIUVejBTEE. 13 PAE.T OF
TUE EXHAUST SYSTEM AIUD
WOT PART OF TWE EM6.IU6, IT
WAS MO EFFECT OU Ekl^lUE
RESTRICTED.)
ALSO, REMEMBER. -TWE CATALYTIC OOUVEe.TE:j2. OUE.NJS UP MC
AWD CO IM TWE EVUAUST SYSTEM. |T DOES UOT ETpFECT EM6IKJE
peepoeHAMCE. MOUEVER., EMGIKJE PEe.F"oe>HAkJC£ ooes EFFECT
UOIO lOei_L TUE CATAL-YTlC. COMVe^TEE- OPERATES.
Twe coeE.6cvr
ETOC. ADJUSTHEWT IS
CRITICAL OUALJL UEtO
CAE.5 R>e. PJ2OPQS PEE-
AJUD MIUI-
AMduur OF
A/J& co /u youe.
81
-------
"TO PER.FOR.H A PROPER
CARBUR.ETOIZ. XkDOUSTMEMT^
Akl HC/CO EXHAUST AUA-
Lvz.ee. MU€>T BE
THIS EXPENSIVE
OF* eeu-HPMEiuT
BY YOUfc H EC MALI 1C
UA5
CATALYT 1C
MUf>T
user? TO MAKE TUG
dAj2.Bue.eroR.
TWIS
TUG
^012. ox-Ycseu^)
ROE. PR.OP1E1^ FUMC-
6> OF TME cCATA-
L.YTIC
IF YOUR. MeCMAMIC
THIS CORRECTLY, TUG CATA-
LYTIC- COWVER.TEB. IOIL.L
UJOeJL PeOPETRLY AMD VEEY
LITTLE UG AMD C.O
COME OUT OF YOUCt
EXUAUST PIPE - i.e.
AIR.
P5ST - IMPROPERLY ADJUSTED
CATALYTIC- COMVEET£e^> CAkJ
CAUSE TUAT WASTY ^ROTTEkJ
EGG" SHELL. TO COME OUT TU6
TAIL PIPE, AL-OM6> tOITW A
OF W G- AUD CO.
LOT
IF YOue CAR. PA£» Akl A.I.R.. SYSTEM
LOITW PA&VS oOe DIDU'T TALK. ABOUT/
( LOOUL.D 5UC>e>es>T TWC POL^oto»ut>
IMPORTANT STEP:
HAVE TUIf> 5VSTG.M CUEcL^eD SV AU
AUTUORIZED DEALER. OR. MECUAUIC.
MAMY A.I.R-. 5VSTeH€> HAVE DEVICE^ BUILT IUTO THEM TO
PC.OTECT TME ^ATALYTI^ COMveeTE
COMPLICATED FOE. Me TO TALH. A6OUT
TWE DeALEE. CUECk^ TUEH OUT AWD KEEP TUSH OPERATING
LY
TOO
LET
82
-------
OTHER
EMISSION SYSTEMS
-------
OTUEfc.
DEVICES VOU
FIMD
Okl YOUR. CAR.
UJHAT U3E tO ILL. L.OOK. AT
SOME OF TUG
EHISSIOU COkJTt2.OL- AUP/OI2.
3O HAMV DIF=-F*eeEUT
USED HTHAT IT 1S>
~ro covee AU- OF
. CJG ooicu DISC
OUL.V SOME: OF THE noee
I LOIUL. SAV A6AIU, TWAT FO&. A
V£AK. AIU^ HODSL. GAR, , A CbOCP
eiou goMTeoL. MAUUAC^ oe. MAKJU
FAc~rue.ge>e? see.vice HAM UAL.
OMUY AU£>uoEe- TO
~rioue> AMD SPGCIF/C
FlfcftT ITCH6 I (OOULD
-TSCLVOU ABOUT CAM Be
SPARK TIMING CONTROLS
85
-------
ABOUT TUIE OfJ£S
DELAY -rue
ADVANCE. UUI"T7 OE.LAVJU6>
SPAR-tC ADVAUC£
we.
i M PO!
HAXJV s
VACUUM "TO
TUG
MAUY
COLOE5
VOU CA^J CWECX F
PLUGGED
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TO
R.eHOV£ TUE VACUUM MOSE
FK.OM TWE VACUUM AD-
(^ VAJJCE UKJ1T AMD HOLD
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o
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4
IMCR.EASE
SPE.ED TO AC-OUMD 2.OOO —
2500 R..P. H.
IM A FELO SECOMD5 (3-J5
SEC.) TWE WOSE SHOULD
STICK TO VOUK. FIU<2»EC..
CTWie> MEA/U6 "THAT TWE
VALVE,
IF VOU FEEL A
VACUUM IMHEDJATL-V OM
lUCe.EASlM6> EMG»IMe SPEED,
THE SPAekl DELAY VALVG.
SHOULD BE Rj£p A£FD.
IF, AFTee so secoiaDs HAVE
PASSED kJD VACUUM »€> FELT/
"YOU PROBABLY U£ED A MetO
SPAC-kL GOMTfZOL VAUVe. MEA-D
FOE. VOUR- F-{2.ieMOL>f LOOAL
PE-ALGIZ. AMD Be S>UJ2e -TO
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/VO VAC-'.^o'/*/ Af'TTEK 3O
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LET'6 LOOk. AT AMOTME1S. TYPE OF
5PAE.IC DEL.AV VALVfc. TUlS ~TVPE
is FOUUD ou HAKJV
Pec?DUCTE> AUD IS
OSAO, OSAC STAWDb FOE
87
-------
THE PURPOSE OF TWE OS>AC VAUVE.
15 THE SAME AS TMG SPAR.K. DGLAV
\4U_VE. THAT PUERDSE lf> T£> pE-LAY
VACUUM TO THE VACUUM ADVAklCE
UJUJT OM THE D/STJ2.lBUTOe.
VACUU/i
CAIU CME.CIC T"ME
vAi_ve OUST t-nce toe
TMIKJ(=>5 TO
BERQg.£ ^OU C^-ieCKL OUT -- TWC
1]
TUE OSAC VALVE SHOULD
BE ovee. eo°F (MOT
COLD.)
DOIU'T IDLE TW£
FOE- A L.0U6> TIME
THE O£>A<1 VALV6:
DOM'~T OVQBMEAT THE
EIUG/ME.
O.K. AFTE/£_ VOU
EIU6> VACUUM
Okl
DOU'T
S*J&/AJ£
88
-------
YOU F£6L VACUUM
PEOBASLY WEED A,
os AC VALVE:
so sercoMD^ HAVE
PA5SED AMD Y£XI DO
MOT F"£EL VACUUM,
YC>U DO ueeo A
FAULTY
VALVE
a. tjweu VACUUM is
IMMEDIATE
b. uwe/u TWEEE: ie> uo
VACUUM
•30
i (
THE
YOU DO RepLAce -THE: VALVE BE
YOU
Foe >OU
PA&T KJUMBEI26» Old "TUG
PA&T AKJD THE OLJ> PAETTT) IR
THEY ARE DIFFeEEMT, A£>K. TWE
PACTS DEAUET^ CUWY.
Oi-D
AMOTNER CsADGET YOU
MAY FIUD JM TUE VACUUM
uue BE~rLoee.M -rue
VACUUM ADVAMCe UU\T*
AMD THE
is AM ELECTRICALLY
EE.AT&D VALVE.
MO
VACUUM
ADVAMC6
I. JM FJEST GEAR.
3. UWTJL A CEfc-
TA1U SPEED |f»
I. IW MI6H 6EAR.
2. IOWEM A dEE.-
TA/W -SPEED 6
R6ACMED
TME OF TMIS
VALVE lt> ~TO p£AJY
ADVAMCE UMTIL
GET5 IMTO MI6>W
A CejemAlKJ SPEED.
89
-------
C -i e: «i K. ^ -o o- "I" "
DEVice (•£> &E
voue. p-
TO
IkJ
TWAT
AJJD
^i PME.UT AF2£ RJE
CH6OC IT
DUAL
^^'— >5 TO
MAMV
V/A^UUM
A
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WC EHISStDU'b AT IDQg.
TWE.
TO Flg£ CATS U3MEM
/
/
,-H
u
y
i
LOW HC
EMISSIONS
AT IDLE
LET'S LOOK CLOSER AT
DUAL DIAPHRAGM UNIT
90
-------
NOTICE TMAT TMEE6
VACUUM I4OS63 ATTA^UGD TO
TW£ UU|77 IF VOU MAVG
OlOM TfHlM6> LI6WT AMD 5£T
-rueee Aee A
OF TVllMt>e YOU
Be AUDAEE: OF.
YOU SET YOUR.
30TM WO5E5 FCOH TW£
VACUUM ADVAMCG UUl~T
CAUTIOU: IC55P
ASOAV FIZLOM
AMD PULL6V6.
PLUG BOTH L.iue.e> -
Tee^ looet- supee.
D TMIS. DOU»T use
OK. BOl-T£>. THE-S^ MAVUE:
A HE£>6 OUT OF THE IM -
SIDE OF "THE. VACUUM
-rme> CAM CAUSE
COUUECTiOMt> AUD
n
GO AHEAD AMD SET
YOUE- TIMIU(».
YOU
CAME OFF CJWICH COU-
UeCTIOM, FOL-LOIO
STEPS —
u
!
; i I
i i
PI^Z.
njf>".S 77'-
r.~"^
'-/• •,. i •
»•' -"•
. i.....
PACT'.-I...- .-"-t
91
-------
1]
U)|TM THE EMGlklE STILL iPLIUfc
REMOVE- A 60L-F -TEE Ff^OM OUE
Moee. PUT >roue. FiMc^ee c?vee
"rwe e^JD OP -rue nose. IF vou
F=EEL. MO VACUUM OR. \€.g.Y CITTTJ5
VAC.UUH. RUT THfe
TUG
FEOM THE,
r//£
vou PULL TME: GOLF TEE.
OUT OF THE
SUC>ULD FEEL
VACUUM.
TH6
TME DISTK-lSUToe. T"WAT
tOASM'T" TOO DIFFICULT;
tTf
THE MEXT ITEM IS Okie LOG
ALe-GTADV TAi k,FP ABOUT. THAT
ITEM IS THE C"TO SCOITCW
TMAT IjOE Die>CU56>ED IU THE E6»S.
6>VSTE.H. CTO ^LOITCMEe OE-
COOL.AUT TEHPEKATUeg QVgg.e.lD&
510ITCHES WAVE A COUPLE OF
1.
2.
OC. TMEgHAL VACUUM
SLOITCI4
oe PORT&D VACUUM
CTO SOOITCMES AR.E. U6ED IU
THE E:£»E. SYSTEM. I'M TELL/KJ^ "vou Tm
-------
U>E OMLY LOOKED AT TCOO-
iu TWG
UP
ou
HAM^V T-|Me AR.6 U6EO
p-oe Hoee peeci-be cou-
TEOL- OF "THE OPeELATlOM
OF SOME SV5"reH£?; AL_L.OU)-
IUC>
CHAM6»E-e> IU THHP-
, CTC> SLOITCHES
CAU REC*ULATe THE VACUUM
TO HAMY DEVICES oe eveu
SIOIT-CH TMEH TO
OM
H.
oe, iu
AMD
CTO
UCLP TME
DB. \VCABILITY OF
VOUB CAB
93
-------
I'l'l'
, THAT'S IT FOE. UOU).
i MOPG: iv suceeoeD iiu e^4PLAiw/u6> SOME OF THE.
T£5T£> AKJO dUGCliS YOU dAU HAfcjE OM
^vsTEM-b. AL_£»O i MOPE rvE Poi)uTeD OUT
AMD UOMGM VOU SHDUC-D dOUTAcT
is eygg-vou e 't? Re:spou5/e>/t-/-rY AIUD vou
IM TH/6 EFFOe~T
94
-------
APPENDIX
-------
MANUFACTURERS SERVICE MANUALS
Availability and costs of manufacturers service manuals can be
obtained by written request to the following addresses. For cars
not listed, check with your local dealer. He can provide the
address for obtaining manuals.
1. American Motors Corporation
Write to:
2. Chrysler Corporation
Write to:
3. Datsun
Write to:
4. Ford Motor Company
Write to:
5. General Motors Corporation
Write to:
6. Honda
Write to:
American Motors Corporation
14250 Plymouth Road
Detroit, Michigan 48232
Chrysler Corporation
Service Department
P.O. Box 40
Detroit, Michigan
Parker Industries, Inc.
609 Deep Valley Dr.
Rolling Hill Estates, California
90274
Helm Incorporated
P.O. Box 07150
Detroit, Michigan
48207
GMC Truck & Coach
Division Printing, Inc.
Dept. GMC
1179 Sylvertis Road
Pontiac, Michigan 48054
American Honda Motor Company
Incorporated
Automobile Customer Service Dept.
100 West Alondra Blvd.
Gardena, California 90247
213-327-8280
97
-------
7. Toyota
Write to: Toyota Motor Sales USA, Inc.
2055 West 190th Street
Torrance, California 90504
213-532-5010 - Customer Relations
8. Volkswagen
Write to: Robert Bently Incorporated
872 Massachusetts Avenue
Cambridge, Massachusetts 02139
98
-------
TECHNICAL REPORT DATA
(Please read Instructions on tin- re\ ersc he lore corn;
1. REPORT NO. 2.
EPA-450/3-77-043
4. TITLE AND SUBTITLE
A Primer on Auto Emissions Systems for Home
Mechanics
7. AUTHOR(S)
B.D. Hayes R.A. Ragazzi
M.T. Maness
9. PERFORMING ORGANIZATION NAME AND ADDRESS
Department of Industrial Sciences
Colorado State University
Fort Collins, Colorado 80523
12. SPONSORING AGENCY NAME AND ADDRESS
Control Programs Development Division
Office of Air Quality Planning and Standards
Office of Air and Waste Management
U.S. Environmental Protection Agency
is. SUPPLEMENTARY NOTES Research Triangle Park
, N.'C. 27711
leting)
3. RECIPIENT'S ACCESSI ON- NO.
5. REPORT DATE
November 1977
6. PERFORMING ORGANIZATION CODE
8. PERFORMING ORGANIZATION REPORT
NO.
10. PROGRAM ELEMENT NO.
11. CONTRACT/GRANT NO.
T900621-01-0
13. TYPE OF REPORT AND PERIOD COVERED
Final Report
14. SPONSORING AGENCY CODE
EPA 200/04
16. ABSTRACT
This booklet has been designed to acquaint the average home mechanic with the basic
emissions control systems and components installed on today's cars. It stresses
the fact that emissions control equipment has been installed to peduce the amount
of pollution discharged to the atmosphere from automobiles and thus protect the
health of people.
The booklet is only intended to provide a basic knowlege and understanding of
emissions control systems.
17. KEY WORDS AND DOCUMENT ANALYSIS
a. DESCRIPTORS
Pollution
Atmosphere
Hydrocarbons
Oxides of Nitrogen
Photochemical Smog
Carbon Monoxide
Positive Crankcase Ventilation Systems
19. DISTRIBUTION STATEMENT
Release Unlimited
b. IDENTIFIERS/OPEN ENDED TERMS C. COSATI Field/Group
19. SECURITY CLASS (This Report) 21. NO. OF PAGES
Unclassified 109
20. SECURITY CLASS (This page 1 22. PRICE
Unclassified
EPA Form .2220-1 (9-73)
*U.S. GOVERNMENT PRINTING OFFICE: 1 9 7 8 - 7 'i 5 - ?. 2 ty
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