MITSUBISHI LANCER 2005 Workshop Manual

EMISSION CONTROL
ENGINE AND EMISSION CONTROL17-13
EXHAUST GAS RECIRCULATION
(EGR) SYSTEM
GENERAL INFORMATION (EGR SYSTEM)M1173005200327
The exhaust gas recirculation (EGR) system lowers
the nitrogen oxide (NOx) emission level.
When the air/fuel mixture combustion temperature is
high, a large quantity of nitrogen oxides (NOx) is
generated in the combustion chamber.
Therefore, this system recirculates part of emission
gas from the exhaust port of the cylinder head to the
combustion chamber through the intake manifold to
decrease the air/fuel mixture combustion
temperature, resulting in reduction of NOx.The EGR flow rate is controlled by the EGR valve so
as not to decrease the driveability.
OPERATION
The EGR valve is being closed and does not
recirculate exhaust gases under one of the following
conditions.
Otherwise, the EGR valve is opened and recirculates
exhaust gases.
•The engine coolant temperature is low.
•The engine is at idle.
•The throttle valve is widely opened.
SYSTEM DIAGRAM
AK300775
Manifold absolute
pressure (MAP) sensor Engine-ECU ,
Engine-A/T-ECU
Engine coolant
temperature sensor
Crank angle sensor EGR
control
solenoid
valve
EGR valveOFF
ON
Control
relay
Battery
AB
<4G1>

EMISSION CONTROL
ENGINE AND EMISSION CONTROL17-14
COMPONENT LOCATION (EGR SYSTEM)M1173007600224
AK302349AB
<4G6>
EGR
control
Solenoid
valve
EGR valveOFF
ON
Control
relay
BatteryEngine-ECU
Barometric pressure
sensor
Air flow sensor
Engine coolant
temperature sensor
Crank angle sensor
AK300776
<4G1>
AB
EGR control
solenoid valve
AK300778
<4G6>
AB
EGR control
solenoid valve
AK300777
<4G1>
AB
EGR valve
AK300779AB
<4G6>
EGR valve

EMISSION CONTROL
ENGINE AND EMISSION CONTROL17-15
EGR SYSTEM CHECKM1173002600348
1. Disconnect the vacuum hose (Green stripe) from
the EGR valve, and then connect a hand vacuum
pump via the three-way terminal.
2. When the engine is hot or cold, check the
condition of vacuum by racing the engine.
When engine is cold
(Engine coolant temperature: 20°C or less)
When engine is hot
(Engine coolant temperature: 80°C or higher)
3. Disconnect the three-way terminal.4. Connect the hand vacuum pump to the EGR
valve nipple.
5. Check whether the engine stalls or the idling is
unstable when a vacuum of 30 kPa or higher is
applied during idling.
EGR VALVE CHECKM1173002800223
1. Remove the EGR valve and inspect for sticking,
carbon deposits, etc. If found, clean with a
suitable solvent so that the valve seats correctly.
2. Connect a hand vacuum pump to the EGR valve.
3. Apply 67 kPa of vacuum, and check that the
vacuum is maintained.
4. Apply a vacuum and check the passage of air by
blowing through one side of the EGR passage. Throttle valve Normal vacuum condition
Open quickly No vacuum will generate (the
same as barometric pressure.)
Throttle valve Normal vacuum condition
Open quickly It will momentarily rise over 13
kPa
AK300780AB
<4G1>
EGR valve
Green stripe
Three-way
terminal
AK300781AB
<4G6>
EGR valve
Green stripe
Three-way
terminal
Vacuum Passage of air
5.3 kPa or less Air is not blown out
27 kPa or more Air is blown out
AK300782AB
<4G1>
EGR valve
Green stripe
AK300783AB
<4G6>
EGR valve
Green stripe
AKX00348

EMISSION CONTROL
ENGINE AND EMISSION CONTROL17-16
5. Replace the gasket, and tighten to the specified
torque.
Tightening torque:
<4G1> 21 ± 4 N⋅m
<4G6> 20 ± 2 N⋅m
EGR PORT VACUUM CHECK <4G1>M1173002900167
1. Disconnect the vacuum hose (Green stripe) from
the throttle body EGR vacuum nipple and connect
a hand vacuum pump to the nipple.
2. Plug the vacuum hose (Green stripe).
3. Start the engine and check that, after raising the
engine speed by racing the engine, purge vacuum
raises according to engine speed.
NOTE: If there is a problem with change in
vacuum, the throttle body purge port may be
clogged and require cleaning.
EGR PORT VACUUM CHECK <4G6>M1173002900156
1. Disconnect the vacuum hose (White stripe) from
the throttle body EGR vacuum nipple and connect
a hand vacuum pump to the nipple.
2. Plug the vacuum hose (White stripe).
3. Start the engine.
4. Check that a fairly constant negative is generated
regardless of the engine speed.
5. If no negative pressure is generated, the port is
probably blocked and should be cleaned.
EGR CONTROL SOLENOID VALVE
CHECK <4G1>
M1173003100238
NOTE: When disconnecting the vacuum hose,
always make a mark so that it can be reconnected at
original position.
1. Disconnect the vacuum hose from the solenoid
valve.
2. Disconnect the harness connector.
3. Connect a hand vacuum pump to nipple (A) of the
solenoid valve (refer to the illustration at left).
4. Check air tightness by applying a vacuum with
voltage applied directly from the battery to the
EGR control solenoid valve and without applying
voltage.
AK300784AB
Green strip
AK201224AB
Vac-
uum
Engine speed (r/min)
AK300786AB
White stripe
Battery voltage Normal condition
Applied Vacuum leaks
Not applied Vacuum maintained
AK100011AC
Vac-
uum
Engine speed (r/min)
AKX00351
A
B
AE
Battery

EMISSION CONTROL
ENGINE AND EMISSION CONTROL17-17
5. Measure the resistance between the terminals of
the solenoid valve.
Standard value: 29 − 35 Ω (at 20°C)
EGR CONTROL SOLENOID VALVE
CHECK <4G6>
M1173003100249
NOTE: When disconnecting the vacuum hose,
always make a mark so that it can be reconnected at
original position.1. Disconnect the vacuum hose from the solenoid
valve.
2. Disconnect the harness connector.
3. Connect a hand vacuum pump to nipple (A) of the
solenoid valve (refer to the illustration at left).
4. Check air tightness by applying a vacuum with
voltage applied directly from the battery to the
EGR control solenoid valve and without applying
voltage.
5. Measure the resistance between the terminals of
the solenoid valve.
Standard value: 29 − 35 Ω (at 20°C)
AKX00352
AK201251AB
A
B
C
Battery
Battery
voltageB nipple
conditionNormal condition
Not applied Open Vacuum
maintained
Applied Open Vacuum leaks
Closed Vacuum
maintained
AK100016

EMISSION CONTROL
ENGINE AND EMISSION CONTROL17-18
EXHAUST GAS RECIRCULATION (EGR)
VALVE REMOVAL AND INSTALLATION
M1173010500175
CATALYTIC CONVERTER
REMOVAL AND INSTALLATIONM1173003900386
Refer to GROUP 15 - Exhaust Pipe and Main Muffler P.15-11.
Pre-removal and Post-installation Operation
Air Cleaner Assembly Removal and Installation (Refer to
GROUP 15 P.15-3).
AC208130
21 ± 4 N·m
2 13
N
AC
<4G1>
AC301219
19 ± 3 N·m2 1
3
N
AC
<4G6>
Removal steps
1. Emission vacuum hose connection2. EGR valve
3. EGR valve gasketRemoval steps (Continued)

21-1
GROUP 21
CLUTCH
CONTENTS
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21A
CLUTCH OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21B

NOTES

22-1
GROUP 22
MANUAL
TRANSMISSION
CONTENTS
MANUAL TRANSMISSION (FF) . . . . . . . . . . . . . . . . . . . . . . . . .22A
MANUAL TRANSMISSION OVERHAUL . . . . . . . . . . . . . . . . . .22B

NOTES