Mitsubishi MOTORS Lancer 2004 Instruction manual

GROUP INDEX
00
General . . . . . . . . . . . . . . . . . . . . . . . .
11
Engine. . . . . . . . . . . . . . . . . . . . . . . . .
12
Engine Lubrication . . . . . . . . . . . . . .
13
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
Engine Cooling . . . . . . . . . . . . . . . . .
15
Intake and Exhaust . . . . . . . . . . . . . .
16
Engine Electrical . . . . . . . . . . . . . . . .
17
Engine and Emission Control . . . . .
21
Clutch . . . . . . . . . . . . . . . . . . . . . . . . .
22
Manual Transmission . . . . . . . . . . . .
23
Automatic Transmission. . . . . . . . . .
26
Front Axle. . . . . . . . . . . . . . . . . . . . . .
27
Rear Axle . . . . . . . . . . . . . . . . . . . . . .
31
Wheel and Tyre . . . . . . . . . . . . . . . . .
32
Power Plant Mount . . . . . . . . . . . . . .
33
Front Suspension . . . . . . . . . . . . . . .
34
Rear Suspension . . . . . . . . . . . . . . . .
35
Service Brakes. . . . . . . . . . . . . . . . . .
36
Parking Brakes . . . . . . . . . . . . . . . . .
37
Power Steering . . . . . . . . . . . . . . . . .
42
Body . . . . . . . . . . . . . . . . . . . . . . . . . .
51
Exterior . . . . . . . . . . . . . . . . . . . . . . . .
52
. . . . . . . . . .
54
Chassis Electrical . . . . . . . . . . . . . . .
55
. . . . . . .
70
Component Locations. . . . . . . . . . . .
80
Configration Diagrams . . . . . . . . . . .
90
Circuit Diagrams . . . . . . . . . . . . . . . .
LANCER /
LANCER WAGON
WORKSHOP MANUAL
FOREWORD
This Workshop manual contains procedures for
service mechanics, including removal, disassembly,
inspection, adjustment, reassembly and installation.
Use the following manuals in combination with this
manual as required.
TECHNICAL INFORMATION MANUAL
PYME0302
PYME0302-A
WORKSHOP MANUAL
CHASSIS GROUP PWME0302
BODY REPAIR MANUAL
PBME0302
PBME0302-A
PARTS CATALOGUE
B606K005A_
All information, illustrations and product descriptions
contained in this manual are current as at the time of
publication. We, however, reserve the right to make
changes at any time without prior notice or obligation.
Mitsubishi Motors Corporation May 2004
Heater, Air Conditioner and
Ventilation
Interior and Supplemental
Restraint System (SRS)

WARNINGS REGARDING SERVICING OF SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) EQUIPPED VEHICLES
(1) Improper service or maintenance of any component of the SRS or any SRS-related component,
can lead to personal injury or death to service personnel (from inadvertent firing of the air bag)
or to the driver and passenger (from rendering the SRS inoperative).
(2) The SRS components and seat belt with pretensioner should not be subjected to heat, so
remove the SRS-ECU, driverís and front passengerís air bag modules, clock spring, side air bag
modules, and seat belt -pre-tensioner before drying or baking the vehicle after painting.
ï SRS-ECU, air bag module and clock spring 93°C or more
ï Seat belt with pre-tensioner: 90°C or more
(3) Service or maintenance of any SRS component or SRS-related component must be performed
only at an authorized MITSUBISHI dealer.
(4) MITSUBISHI dealer personnel must thoroughly review this Manual, and especially its GROUP
52B - Supplemental Restraint System (SRS), before beginning any service or maintenance of
any component of the SRS or any SRS-related component.
NOTE
Section titles with asterisks (*) in the table of contents in each group indicate operations requiring warnings.

17-1
GROUP 17
ENGINE AND
EMISSION
CONTROL
CONTENTS
ENGINE CONTROL . . . . . . . . . . 17-2
GENERAL INFORMATION . . . . . . 17-2
SERVICE SPECIFICATIONS. . . . . 17-2
ON-VEHICLE SERVICE. . . . . . . . . 17-2
ACCEL CABLE CHECK AND
ADJUSTMENT. . . . . . . . . . . . . . . . . . . . 17-2
ACCELERATOR CABLE AND
PEDAL . . . . . . . . . . . . . . . . . . . . . . 17-3
REMOVAL AND INSTALLATION . . . . . 17-3
EMISSION CONTROL MPI . . . . 17-5
GENERAL INFORMATION . . . . . . 17-5
EMISSION CONTROL DEVICE
REFERENCE TABLE . . . . . . . . . . 17-5
SERVICE SPECIFICATION(S) . . . 17-5
VACUUM HOSE. . . . . . . . . . . . . . . 17-6
VACUUM HOSE PIPING DIAGRAM . . . 17-6
VACUUM CIRCUIT DIAGRAM . . . . . . . 17-7
VACUUM HOSE CHECK. . . . . . . . . . . . 17-8
VACUUM HOSE INSTALLATION . . . . . 17-8
CRANKCASE EMISSION CONTROL
SYSTEM. . . . . . . . . . . . . . . . . . . . . 17-8
GENERAL INFORMATION (CRANKCASE
EMISSION CONTROL SYSTEM) . . . . . 17-8
COMPONENT LOCATION (CRANKCASE
EMISSION CONTROL SYSTEM) . . . . . 17-9
POSITIVE CRANKCASE VENTILATION
SYSTEM CHECK . . . . . . . . . . . . . . . . . . 17-9
POSITIVE CRANKCASE VENTILATION
(PCV) VALVE CHECK . . . . . . . . . . . . . . 17-9
EVAPORATIVE EMISSION CONTROL
SYSTEM . . . . . . . . . . . . . . . . . . . . . 17-9
GENERAL INFORMATION (EVAPORATIVE
EMISSION CONTROL SYSTEM) . . . . . 17-9
COMPONENT LOCATION (EVAPORATIVE
EMISSION CONTROL SYSTEM) . . . . . 17-10
PURGE CONTROL SYSTEM CHECK. . 17-10
PURGE PORT VACUUM CHECK . . . . . 17-11
PURGE CONTROL SOLENOID VALVE
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . 17-11
FUEL VAPOUR CANISTER REMOVAL
AND INSTALLATION . . . . . . . . . . . . . . . 17-12
EXHAUST GAS RECIRCULATION
(EGR) SYSTEM . . . . . . . . . . . . . . . 17-13
GENERAL INFORMATION
(EGR SYSTEM) . . . . . . . . . . . . . . . . . . . 17-13
COMPONENT LOCATION
(EGR SYSTEM) . . . . . . . . . . . . . . . . . . . 17-14
EGR SYSTEM CHECK . . . . . . . . . . . . . 17-15
EGR VALVE CHECK . . . . . . . . . . . . . . . 17-15
EGR PORT VACUUM CHECK <4G1>. . 17-16
EGR CONTROL SOLENOID VALVE
CHECK <4G1> . . . . . . . . . . . . . . . . . . . . 17-16
EGR CONTROL SOLENOID VALVE
CHECK <4G6> . . . . . . . . . . . . . . . . . . . . 17-17
EXHAUST GAS RECIRCULATION (EGR)
VALVE REMOVAL AND
INSTALLATION . . . . . . . . . . . . . . . . . . . 17-18
CATALYTIC CONVERTER . . . . . . 17-18
REMOVAL AND INSTALLATION. . . . . . 17-18

ENGINE CONTROL
ENGINE AND EMISSION CONTROL
17-2
ENGINE CONTROL
GENERAL INFORMATION
M1171000100277
A cable-type accelerator mechanical
suspended-type pedal has been adopted.
SERVICE SPECIFICATIONS
M1171000300088
ON-VEHICLE SERVICE
ACCEL CABLE CHECK AND
ADJUSTMENT
M1171000900314
1. Turn A/C and lights OFF. Inspect and adjust at no
load.
2. Warm engine until stabilized at idle.
3. Confirm idle speed is at standard value.
Standard value:
750 ±50 r/min <4G1>
750 ±100 r/min <4G6>
4. Stop engine. [ignition switch: LOCK (OFF)
position].
5. Confirm there are no sharp bends in the
accelerator cable.
6. Check the inner cable for correct slack.
Standard value: 1.0 −2.0 mm
7. If there is too much slack or no slack, adjust play
by the following procedures. (1) Loosen the adjusting bolts to release the
cable.
(2) Move the plate until the inner cable play is at
the standard value, and then tighten the
adjusting bolts.
(3) After adjusting, check that the throttle lever is
touching the stopper.
Item Standard value
Accel cable play mm 1.0 −2.0
Engine idle speed r/min 4G1 750 ±50
4G6 750 ±100
AC207966
Adjusting bolts
Plate
Accel cable
AC
<4G1>
AC301055
Adjusting bolts
Plate
Accel cable
AC
<4G6>

ENGINE CONTROL
ENGINE AND EMISSION CONTROL 17-3
ACCELERATOR CABLE AND PEDAL
REMOVAL AND INSTALLATION
M1171001200341
Post-installation Operation
Adjusting the Accelerator Cable (Refer to P.17-2).
Y1059AU
Y1060AU
AC304070
N
4
5
78
10 11
N
12
13 AB
1
2
3
5.0 ± 1.0 N·m
6
12 ± 2 N·m 9
7
1
2
3
5.0 ± 1.0 N·m
<R.H. drive vehicles>
<L.H. drive vehicles>
N
4
5
7
8
10
11
N
12
13
6
12 ± 2 N·m
9
7
Accelerator cable assembly
removal steps
1. Inner cable connection (Accelerator
pedal side)
2. Inner cable connection (Throttle body
side)
3. Accelerator cable assembly
Accelerator pedal assembly
removal steps
1. Inner cable connection (Accelerator
pedal side)
4. Accelerator pedal assembly
5. Accelerator control equip nut
6. Accelerator pedal arm and
accelerator pedal pad assembly

ENGINE CONTROL
ENGINE AND EMISSION CONTROL
17-4
INSTALLATION SERVICE POINT
>>A<< ACCEL PEDAL PAD
INSTALLATION
CAUTION
To prevent damages to the accelerator pedal pad,
warm the thumb area of the accelerator pedal
pad with a dryer, etc. prior to assembling it.
NOTE: If it is difficult to assemble, apply soapy water
to the thumb area to enhance the assembling
process.
7. Accelerator control equip bushing
8. Accelerator pedal arm return spring
9. Accelerator pedal arm stopper
Accelerator pedal assembly
removal steps (Continued)
10. Accelerator pedal arm bracket
11. Accelerator pedal arm
>>A<<
12. Accelerator pedal pad
13. Accelerator pedal arm stopper
Accelerator pedal assembly
removal steps (Continued)

EMISSION CONTROL <MPI>
ENGINE AND EMISSION CONTROL 17-5
EMISSION CONTROL <MPI>
GENERAL INFORMATION
M1173000100370
The emission control system consists of the following
subsystems:
•Crankcase emission control system
•Evaporative emission control system
•Exhaust emission control system
EMISSION CONTROL DEVICE
REFERENCE TABLE
M1173006600135
SERVICE SPECIFICATION(S)
M1173000300288
Items Name Specification
Crankcase emission control
system
Positive crankcase ventilation
(PCV) valve
Variable flow type
(Purpose: HC reduction)
Evaporative emission control
system
Canister
Purge control solenoid valve
Equipped
Duty cycle type solenoid valve
(Purpose: HC reduction)
Exhaust emission control system Air-fuel ratio control device - MPI
system
Oxygen sensor feedback type
(Purpose: CO, HC, NOx reduction)
Exhaust gas recirculation system
•EGR valve
•EGR control solenoid valve
Equipped
Single type
Duty cycle type solenoid valve
(Purpose: NOx reduction)
Catalytic converter Monolith type
(Purpose: CO, HC, NOx reduction)
Related parts Crankcase
emission
control
system
Evaporative
emission
control
system
Air/fuel ratio
control
system
Catalytic
converter
Exhaust gas
recirculation
system
PCV valve ×
Purge control solenoid valve ×
MPI system component ××
Catalytic converter ×
EGR valve ×
EGR control solenoid valve ×
Items Standard value
Purge control solenoid valve coil resistance (at 20°C) Ω30 −34
EGR control solenoid valve coil resistance (at 20°C) Ω29 −35

EMISSION CONTROL <MPI>
ENGINE AND EMISSION CONTROL
17-6
VACUUM HOSE
VACUUM HOSE PIPING DIAGRAM
M1173000900417
AK300964
To
fuel tank
Fuel pressure
regulator
From
fuel pump
Catalytic
converter
Catalytic
converter
Oxygen sensor
(front)
Oxygen sensor (rear)
EGR valve
<4G1>
EGR control
solenoid valve
Purge control
solenoid valve
Canister
Air
AB
Air cleaner
AK204364AC
Air cleaner
Air
Canister
Purge control
solenoid valve
EGR control
solenoid valve
EGR valve
From
fuel pump
To
fuel tank
Fuel pressure
regulator
PCV valve
Oxygen sensor
(front)
Oxygen sensor (rear)
Catalytic
converter
Catalytic
converter
<4G6>

EMISSION CONTROL <MPI>
ENGINE AND EMISSION CONTROL 17-7
VACUUM CIRCUIT DIAGRAM
M1173007100263
AK300765
From
air
cleaner
To
combustion
chamber
Throttle body
B
R
AB
Intake manifold
Y
G
G
G
R
L
Fuel
pressure
regulator
EGR
valve
EGR
control
solenoid
valve Purge
control
solenoid
valve
Canister
Vacuum hose colour
B: Black
G: Green
R: Red
Y: Yellow
L: Blue
<4G1>
AK300766
From
air
cleaner
To
combustion
chamber
Throttle body
B
B
AB
Intake manifold
Y
R
G
W
L
Fuel
pressure
regulator
EGR
valve
EGR
control
solenoid
valve Purge
control
solenoid
valve
Canister
Vacuum hose colour
B: Black
G: Green
R: Red
W: White
Y: Yellow
L: Blue
<4G6>
B

EMISSION CONTROL <MPI>
ENGINE AND EMISSION CONTROL
17-8
VACUUM HOSE CHECK
M1173007300159
1. Using the piping diagram as a guide, check to be
sure that the vacuum hoses are correctly
connected.
2. Check the connection condition of the vacuum
hoses, (removed, loose, etc.) and check to be
sure that there are no bends or damage.
VACUUM HOSE INSTALLATION
M1173007200107
1. When connecting the vacuum hoses, they should
be securely inserted onto the nipples.
2. Connect the hoses correctly, using the vacuum
hose piping diagram as a guide.
CRANKCASE EMISSION CONTROL
SYSTEM
GENERAL INFORMATION (CRANKCASE
EMISSION CONTROL SYSTEM)
M1173005000237
The crankcase emission control system prevents
blow-by gases from escaping inside the crankcase
into the atmosphere.
Fresh air is sent from the air cleaner into the
crankcase through the breather hose.
The air becomes mixed with the blow-by gases
inside the crankcase.
The blow-by gas inside the crankcase is drawn into
the intake manifold through the positive crankcase
ventilation (PCV) valve.
The PCV valve lifts the plunger according to the
intake manifold vacuum so as to regulate the flow of
blow-by gas properly.
In other words, the blow-by gas flow is regulated
during low load engine operation to maintain engine
stability, while the flow is increased during high load
operation to improve the ventilation performance.
SYSTEM DIAGRAM
AK204365
Air cleaner
Air
Ventilation hose Breather hose
PCV valve
AB

EMISSION CONTROL <MPI>
ENGINE AND EMISSION CONTROL 17-9
COMPONENT LOCATION (CRANKCASE
EMISSION CONTROL SYSTEM)
M1173007400208
POSITIVE CRANKCASE VENTILATION
SYSTEM CHECK
M1173001100179
1. Remove the ventilation hose from the PCV valve.
2. Remove the PCV valve from the rocker cover.
3. Reinstall the PCV valve at the ventilation hose.
4. Start the engine and run at idle.
5. Place a finger at the opening of the PCV valve
and check that vacuum of the intake manifold is
felt.
NOTE: At this moment, the plunger in the PCV
valve moves back and forth.
6. If vacuum is not felt, clean the PCV valve or
replace it.
POSITIVE CRANKCASE VENTILATION
(PCV) VALVE CHECK
M1173001200187
1. Insert a thin rod into the PCV valve from the side
shown in the illustration (rocker cover installation
side), and move the rod back and forth to check
that the plunger moves.
2. If the plunger does not move, there is a clogging
in the PCV valve. In this case, clean or replace
the PCV valve.
EVAPORATIVE EMISSION CONTROL
SYSTEM
GENERAL INFORMATION (EVAPORATIVE
EMISSION CONTROL SYSTEM)
M1173005100405
The evaporative emission control system prevents
fuel vapours generated in the fuel tank from escaping
into the atmosphere.
Fuel vapours from the fuel tank flow through the fuel
tank pressure control valve and vapour pipe/hose to
be stored temporarily in the canister.
When driving the vehicle, fuel vapours stored in the
canister flow through the purge solenoid and purge
port and go into the intake manifold to be sent to the
combustion chamber.
When the engine coolant temperature is low or when
the intake air quantity is small (when the engine is at
idle, for example), the engine control unit turns the
purge solenoid off to shut off the fuel vapour flow to
the intake manifold.
This does not only insure the driveability when the
engine is cold or running under low load but also
stabilize the emission level.
AK300767
<4G1>
AB
PCV valve
AK204366
<4G6>
AC
PCV valve
AKX00336
PCV valve
AD
AK100010
PCV valve
AC

EMISSION CONTROL <MPI>
ENGINE AND EMISSION CONTROL
17-10
SYSTEM DIAGRAM
COMPONENT LOCATION (EVAPORATIVE
EMISSION CONTROL SYSTEM)
M1173007500216
PURGE CONTROL SYSTEM CHECK
M1173001400299
AK204367AC
Throttle body
Canister
From
fuel
tank OFF
ON
Purge
control
solenoid
valve Control
relay
Battery
Engine-ECU <4G1-M/T, 4G6>,
Engine-A/T-ECU <4G1-A/T>
Air flow sensor <4G6>
Engine coolant
temperature sensor
Intake air
temperature sensor
Barometric pressure
sensor <4G6>
Manifold absolute pressure
(MAP) sensor <4G1>
AK300769
<4G1>
AB
Purge control
solenoid valve
AK300770
<4G6>
AB
Purge control
solenoid valve
AK300771
<4G1>
AB
Plug
Vacuum hose
AK300772
<4G6>
AB
Plug
Vacuum hose

EMISSION CONTROL <MPI>
ENGINE AND EMISSION CONTROL 17-11
1. Disconnect the vacuum hose (red stripe) from
throttle body and connect it to a hand vacuum
pump.
2. Plug the nipple from which the vacuum hose was
removed.
3. When the engine is cold or hot, apply a vacuum of
53 kPa, and check the condition of the vacuum.
When engine is cold
(Engine coolant temperature: 40°C or less)
When engine is hot
(Engine coolant temperature: 80°C or higher)
PURGE PORT VACUUM CHECK
M1173001500177
1. Disconnect the vacuum hose (red stripe) from the
throttle body and connect a hand vacuum pump to
the nipple.
2. Plug the vacuum hose (red stripe).
3. Start the engine.
4. Check that a fairly constant negative pressure is
generated regardless of the engine speed.
5. If no negative pressure is generated, the port is
probably blocked and should be cleaned.
PURGE CONTROL SOLENOID VALVE
CHECK
M1173001700193
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).
Engine condition Normal condition
At idle Vacuum is maintained.
3,000 r/min
Engine condition Normal condition
At idle Vacuum is maintained.
3,000 r/min (within 3
minutes after engine
starts)
Vacuum will leak.
AK300773
<4G1>
AB
Plug
Vacuum hose
AK300774
<4G6>
AB
Plug
Vacuum hose
AK100011
AC
Vac-
uum
Engine speed (r/min)
AK100012 AC
Battery
A
AK100013

EMISSION CONTROL <MPI>
ENGINE AND EMISSION CONTROL
17-12
4. Check airtightness by applying a vacuum with
voltage applied directly from the battery to the
purge control solenoid valve and without applying
voltage.
5. Measure the resistance between the terminals of
the solenoid valve.
Standard value: 30 −34 Ω(at 20°C)
FUEL VAPOUR CANISTER REMOVAL
AND INSTALLATION
M1173004200153
Battery voltage Normal condition
Applied Vacuum leaks
Not applied Vacuum maintained
Pre-removal and Post-installation Operation
Air Cleaner Assembly Removal and Installation (Refer to
GROUP 15 P.15-3).
AC208253
1
2
3
4
5
6
7
8
AD
Removal steps
1. Emission vacuum hose connection
2. Fuel vapour control line hose
3. Fuel vapour control check valve
4. Fuel vapour control line hose
5. Fuel vapour control line clamp
6. Fuel vapour canister
7. Fuel high-pressure hose clamp
8. Fuel vapour canister bracket
Removal steps (Continued)

EMISSION CONTROL <MPI>
ENGINE AND EMISSION CONTROL 17-13
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 <M/T>,
Engine-A/T-ECU <A/T>
Engine coolant
temperature sensor
Crank angle sensor
EGR
control
solenoid
valve
EGR valve
OFF
ON
Control
relay
Battery
AB
<4G1>

EMISSION CONTROL <MPI>
ENGINE AND EMISSION CONTROL
17-14
COMPONENT LOCATION (EGR SYSTEM)
M1173007600224
AK302349 AB
<4G6>
EGR
control
Solenoid
valve
EGR valve
OFF
ON
Control
relay
Battery
Engine-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 <MPI>
ENGINE AND EMISSION CONTROL 17-15
EGR SYSTEM CHECK
M1173002600348
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 CHECK
M1173002800223
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
AK300780 AB
<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
AK300782 AB
<4G1>
EGR valve
Green stripe
AK300783AB
<4G6>
EGR valve
Green stripe
AKX00348

EMISSION CONTROL <MPI>
ENGINE AND EMISSION CONTROL
17-16
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
AK100011
AC
Vac-
uum
Engine speed (r/min)
AKX00351
A
B
AE
Battery

EMISSION CONTROL <MPI>
ENGINE AND EMISSION CONTROL 17-17
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
voltage
B nipple
condition
Normal condition
Not applied Open Vacuum
maintained
Applied Open Vacuum leaks
Closed Vacuum
maintained
AK100016

EMISSION CONTROL <MPI>
ENGINE AND EMISSION CONTROL
17-18
EXHAUST GAS RECIRCULATION (EGR)
VALVE REMOVAL AND INSTALLATION
M1173010500175
CATALYTIC CONVERTER
REMOVAL AND INSTALLATION
M1173003900386
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
1
3
N
AC
<4G1>
AC301219
19 ± 3 N·m
2
1
3
N
AC
<4G6>
Removal steps
1. Emission vacuum hose connection 2. EGR valve
3. EGR valve gasket
Removal steps (Continued)