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The optimization on an engine-three way catalyst-vehicle system for best fuel economy under the constraints of emissions and driveability, has been studied for a smaller passenger car with 1.6 litter 4 cylinder engine. Full utilization of a computer was intended for the accumulation of basic data and a search for optimum calibration. An automatic Engine Test System ( AETS ) was developed. The optimum calibration was calculated for the engine-vehicle system with three-way catalyst based on the optimal control theory, and was implemented on an actual vehicle by an engine controller in which a 16 bits microprocessor was used. The results showed good agreement.

A reliability analysis was conducted by means of the failure mode effect analysis technique on the catalytic converter which has been adopted in the 1975 Toyota models. A series of vehicle tests was conducted to determine the failure modes criticality. The study was performed on a precious metal pelleted catalyst. Critical durability failure modes to the durability of the catalytic converter and their criticality were classified and substantiated through this study. The results are presented and discussed. The results obtained by this analysis are useful for improving the reliability of the catalytic converter.