Mitsubishi L200. Manual - part 103

TROUBLESHOOTING

DIESEL FUEL

13A-208

YES : 

Intermittent malfunction (Refer to GROUP 

00 

− How to Use Troubleshooting/

Inspection Service Points 

− How to Cope 

with Intermittent Malfunctions ). 

NO : 

Replace the engine-ECU. When the engine-
ECU is replaced, write the chassis number 
(Refer to GROUP 00 

− Precautions Before 

Service 

− How to Perform Chassis Number 

Writing ). After replacing the engine-ECU, 
register the injector identification code and 
learn fuel injection (Refer to GROUP 00 

− 

Precautions Before Service 

− What The 

Common Rail Engine Learns ). After 
registering the injector identification code, 
carry out the forcible DPF regeneration. 
(Refer to GROUP 17 

− Emission Control − 

Diesel Particulate Filter (DPF) System 

− 

Forcible DPF Regeneration ).

Code No. P0402: EGR Flow Excessive <Euro5>

OPERATION

• Refer to Code No. P0102: Air Flow Sensor Circuit 

Low Input 

P.13A-68

.

• Refer to Code No. P0403: EGR Valve (DC Motor) 

Malfunction 

P.13A-215

.

• Refer to Code No. P0489: EGR Valve Position 

Sensor Circuit Low Input <Euro5> 

P.13A-240

.

FUNCTION

• The engine-ECU monitors the EGR flow rate.

TROUBLE JUDGMENT

Check Conditions

• Engine is running

• Battery positive voltage is 8 − 16 V.

• Vehicle is stopped (transmission: Neutral <M/T>, 

P range <A/T>)

Judgment Criterion

• The EGR flow rate is smaller than target EGR 

flow rate by the rate that is more than the speci-
fied value.

PROBABLE CAUSES

• Failed EGR passage (air suction)

• Harness damage in EGR valve circuit or loose 

connector contact

• Failed EGR valve operation

• Harness damage in air flow sensor circuit or 

loose connector contact

• Failed air flow sensor (abnormal output charac-

teristics)

• Failed engine-ECU

DIAGNOSTIC PROCEDURE

STEP 1. M.U.T.-III diagnosis code

Q: Is the diagnosis code P0403 or P2413 set?

YES : 

Inspection chart for diagnosis codes (Refer 

to 

P.13A-21

).

NO : 

Go to Step 2 .

STEP 2. Connector check: A-45 EGR valve 
assembly connector

Q: Is the check result normal?

YES : 

Go to Step 3 .

NO : 

Repair or replace the connector.

AK501331

1

2

3

4

5

6

AB

Harness side 
connector

A-45 (GR)

Connector: A-45

TROUBLESHOOTING

DIESEL FUEL

13A-209

STEP 3. Connector check: C-103 and C-105 
engine-ECU connectors

Q: Is the check result normal?

YES : 

Go to Step 4 .

NO : 

Repair or replace the connector.

STEP 4. Check harness between C-103 (terminal 
No. 115) engine-ECU connector and A-45 
(terminal No. 6) EGR valve assembly connector.

• Check output line for damage.

Q: Is the check result normal?

YES : 

Go to Step 5 .

NO : 

Repair the damaged harness wire.

AKB00270

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C-105 (B)

C-103 (B)

C-105 (B)

C-103 (B)

<R.H. drive vehicles>

C-105 Harness side connector

C-103 Harness side connector

<L.H. drive vehicles>

Connectors: C-103, C-105

AB

AKA00090

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105

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C-103 (B)

C-103 (B)

<R.H. drive vehicles>

Harness side connector

<L.H. drive vehicles>

Connector: C-103

AB

AK501331

1

2

3

4

5

6

AB

Harness side 
connector

A-45 (GR)

Connector: A-45

TROUBLESHOOTING

DIESEL FUEL

13A-210

STEP 5. Check harness between C-103 (terminal 
No. 130) engine-ECU connector and A-45 
(terminal No. 4) EGR valve assembly connector.

• Check output line for damage.

Q: Is the check result normal?

YES : 

Go to Step 6 .

NO : 

Repair the damaged harness wire.

STEP 6. Check harness between C-105 (terminal 
No. 81) engine-ECU connector and A-45 (terminal 
No. 2) EGR valve assembly connector.

• Check earthing line for damage.

Q: Is the check result normal?

YES : 

Go to Step 7 .

NO : 

Repair the damaged harness wire.

AKA00090

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116

144

C-103 (B)

C-103 (B)

<R.H. drive vehicles>

Harness side connector

<L.H. drive vehicles>

Connector: C-103

AB

AK501331

1

2

3

4

5

6

AB

Harness side 
connector

A-45 (GR)

Connector: A-45

AKA00089

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C-105 (B)

C-105 (B)

<R.H. drive vehicles>

Harness side connector

<L.H. drive vehicles>

Connector: C-105

AB

AK501331

1

2

3

4

5

6

AB

Harness side 
connector

A-45 (GR)

Connector: A-45

TROUBLESHOOTING

DIESEL FUEL

13A-211

STEP 7. Check harness between C-105 (terminal 
No. 71) engine-ECU connector and A-45 (terminal 
No. 3) EGR valve assembly connector.

• Check power supply line for damage.

Q: Is the check result normal?

YES : 

Go to Step 8 .

NO : 

Repair the damaged harness wire.

STEP 8. Check harness between C-105 (terminal 
No. 57) engine-ECU connector and A-45 (terminal 
No. 1) EGR valve assembly connector.

• Check output line for damage.

Q: Is the check result normal?

YES : 

Go to Step 9 .

NO : 

Repair the damaged harness wire.

STEP 9. Check EGR valve itself.

• Check EGR valve itself [Refer to GROUP 17 − 

Emission Control 

− Exhaust Gas Recirculation 

(EGR) System 

− EGR Valve (DC motor) Check ].

Q: Is the check result normal?

YES : 

Go to Step 10 .

NO : 

Replace the EGR valve assembly.

AKA00089

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C-105 (B)

C-105 (B)

<R.H. drive vehicles>

Harness side connector

<L.H. drive vehicles>

Connector: C-105

AB

AK501331

1

2

3

4

5

6

AB

Harness side 
connector

A-45 (GR)

Connector: A-45

AKA00089

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C-105 (B)

C-105 (B)

<R.H. drive vehicles>

Harness side connector

<L.H. drive vehicles>

Connector: C-105

AB

AK501331

1

2

3

4

5

6

AB

Harness side 
connector

A-45 (GR)

Connector: A-45