2005 MITSUBISHI LANCER check engine

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) . . . . . 17-8COMPONENT 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 CONTROL17-2
ENGINE CONTROL
GENERAL INFORMATIONM1171000100277
A cable-type accelerator mechanical
suspended-type pedal has been adopted.
SERVICE SPECIFICATIONSM1171000300088
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>

EMISSION CONTROL
ENGINE AND EMISSION CONTROL17-8
VACUUM HOSE CHECKM1173007300159
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 INSTALLATIONM1173007200107
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
ENGINE AND EMISSION CONTROL17-9
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
ENGINE AND EMISSION CONTROL17-10
SYSTEM DIAGRAM
COMPONENT LOCATION (EVAPORATIVE
EMISSION CONTROL SYSTEM)
M1173007500216
PURGE CONTROL SYSTEM CHECKM1173001400299
AK204367AC
Throttle body
Canister
From
fuel
tank
OFF
ONPurge
control
solenoid
valveControl
relay
BatteryEngine-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
ENGINE AND EMISSION CONTROL17-11
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 CHECKM1173001500177
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
AK100011AC
Vac-
uum
Engine speed (r/min)
AK100012AC
Battery A
AK100013

EMISSION CONTROL
ENGINE AND EMISSION CONTROL17-12
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
56
78
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 hose5. Fuel vapour control line clamp
6. Fuel vapour canister
7. Fuel high-pressure hose clamp
8. Fuel vapour canister bracketRemoval steps (Continued)

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