Mitsubishi Outlander (2003+). Manual - part 151

EMISSION CONTROL <MPI>

ENGINE AND EMISSION CONTROL

17-23

<4G69>

COMPONENT LOCATION (EGR SYSTEM)

M1173007600246

AK204431AC

EGR valve
(stepper motor)

Control
relay

Battery

Engine-ECU <M/T> or
Engine-A/T-ECU <A/T>

Throttle position sensor

Air flow sensor

Engine coolant
temperature sensor

Crank angle sensor

AK201234AD

<4G63>

EGR control
solenoid valve

AK303696AB

EGR valve

<4G63>

AK302840AB

EGR valve
(stepper motor)

<4G69>

EMISSION CONTROL <MPI>

ENGINE AND EMISSION CONTROL

17-24

EGR SYSTEM CHECK <4G63>

M1173002600360

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 PORT VACUUM CHECK<4G63>

M1173002900178

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 pressure is 

generated regardless of the engine speed.

5. If no negative pressure is generated, the port is 

probably blocked and should be cleaned.

EGR VALVE CHECK <4G63>

M1173002800234

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.

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

AK200375AE

Three-way terminal

EGR valve

Green stripe

AK200376

Green stripe

AC

EGR valve

AK201247

white stripe

AC

AK100011

AC

Vac-
uum

Engine speed (r/min)

AKX00348

EMISSION CONTROL <MPI>

ENGINE AND EMISSION CONTROL

17-25

4. Apply a vacuum and check the passage of air by 

blowing through one side of the EGR passage.

5. Replace the gasket, and tighten to the specified 

torque.

Tightening torque: 20 

±

 2 N

⋅

m

EGR CONTROL SOLENOID VALVE 
CHECK <4G63>

M1173003100261

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)

EGR VALVE (STEPPER MOTOR) CHECK 
<4G69>

M1173050200134

Checking the Operation Sound

1. Check that the operation sound of the stepper 

motor can be heard from the EGR valve when the 
ignition switch is turned ON (without starting the 
engine).

2. If the operation sound cannot be heard, inspect 

the drive circuit of the stepper motor.

NOTE: If the circuit is normal, either the stepper 
motor or the engine-ECU <M/T> or engine-A/T-ECU 
<A/T> may have failed.

Checking the Coil Resistance

1. Remove the EGR valve.

Vacuum

Passage of air

5.3 kPa or less

Air is not blown out

27 kPa or more

Air is blown out

AK201251AB

A

B

C

Battery

AK304447

Battery 
voltage

B nipple 
condition

Normal condition

Not applied

Open

Vacuum 
maintained

Applied

Open

Vacuum leaks

Closed

Vacuum 
maintained

AK302877AB

EGR valve
(stepper motor)

AK200805

1 2 3
4 5 6

1 2 3
4 5 6

AC

EMISSION CONTROL <MPI>

ENGINE AND EMISSION CONTROL

17-26

2. Measure the resistance between terminal No. 2 

and either terminal No. 1 or terminal No. 3 of the 
connector at the EGR valve.

Standard value: 20 

−

 24 

Ω

 (at 20

°

C)

3. Measure the resistance between terminal No. 5 

and either terminal No. 6 or terminal No. 4 of the 
connector at the EGR valve.

Standard value: 20 

−

 24 

Ω

 (at 20

°

C)

4. Using a new gasket, install the EGR valve by 

tightening its mounting bolts to the specified 
torque.

Tightening Torque: 24 

±

 4 N

⋅

m

Operation Check

1. Remove the EGR valve.
2. Attach a test wiring harness (special tool 

MB991658) to the connector at the EGR valve.

CAUTION

Connecting battery voltage to the EGR valve for a 
long term could damage the coil.
3. Connect the positive (+) terminal of the battery to 

terminal No. 2.

4. Connect terminals No. 1 and No. 3 to the negative 

(-) terminal of the battery, in order to test whether 
the stepper motor vibrates (with a slight shudder), 
indicating that the stepper motor is operating.

CAUTION

Connecting battery voltage to the EGR valve for a 
long term could damage the coil.

5. Connect the positive (+) terminal of the battery to 

terminal No. 5.

6. Connect terminals No. 4 and No. 6 to the negative 

(-) terminal of the battery, in order to test whether 
the stepper motor vibrates (with a slight shudder), 
indicating that the stepper motor is operating.

7. If a vibration can be felt during the test, the 

stepper motor is normal.

8. Using a new gasket, install the EGR valve by 

tightening its mounting bolts to the specified 
torque.

Tightening torque: 24 

±

 3 N

⋅

m

Cleaning the EGR Valve

CAUTION

Do not use a solvent or detergent, which could 
enter the motor and cause it to malfunction.
1. Remove the EGR valve and check that the EGR 

valve is not stuck or clogged with carbon deposits. 
Use a wire brush to clean the valve if necessary.

2.  Using a new gasket, install the EGR valve by 

tightening its mounting bolts to the specified 
torque.

Tightening torque: 24 

±

 3 N

⋅

m

1 2 3

4 5 6

AK203698

1 2 3

4 5 6

AK203698

EGR valve

AC

AK302886

Battery

MB991658

AB

AK304039

Battery

MB991658

AB