Emission Control - Lancer Mitsubishi Lancer Evolution IX

GENERAL DESCRIPTION

The emission control system consists of the following subsystems

1. Positive crankcase ventilation system
2. Evaporative emission system
3. Exhaust emission control system

DIAGNOSIS

PROBLEM SYMPTOM CHART

SPECIAL TOOLS

SPECIAL TOOLS SPECIFICATIONS TOOL TOOL NUMBER AND NAME SUPERSESSION APPLICATION MD998770 Oxygen sensor wrench MD998770-01 or General service tool Removal/installation of heated oxygen sensor MB995061 Purge flow indicator MLR6890A Part of MIT280220 Inspection of purge control system MB991658 Test harness set Tool not available Inspection of EGR valve (Stepper Motor)

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VACUUM HOSE INSTALLATION

1. When connecting the vacuum hoses, they should be securely inserted onto the nipples.
2. Connect the hoses correctly, using the VACUUM HOSE ROUTING diagram as a guide.

VACUUM HOSE CHECK

1. Using the VACUUM HOSE ROUTING diagram as a guide, check that the vacuum hoses are correctly connected.
2. Check the connection of the vacuum hoses, (removed, loose, etc.) and confirm that there are no sharp bends or damage.

GENERAL DESCRIPTION (POSITIVE CRANKCASE VENTILATION SYSTEM)

The positive crankcase ventilation (PCV) system prevents the escape of blow-by gases from inside the crankcase into the atmosphere.

Fresh air is sent from the air cleaner into the crankcase through the breather hose to be mixed with the blow-by gas inside the crankcase.

The blow-by gas inside the crankcase is drawn into the intake manifold through the PCV valve.

The PCV valve is designed to lift 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.

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1. Remove the positive crankcase ventilation (PCV) valve from the rocker cover, then reconnect the PCV valve to the vacuum supply hose.
2. With the engine idling, put your finger on the open end of the PCV valve, and check for negative pressure (vacuum). NOTE: At this time, the plunger in the PCV valve should move back and forth as the open end is covered and uncovered.
3. If negative pressure is not felt, clean or replace the PCV valve. Inspect the vacuum supply hose and vacuum supply hose port for restriction or plugged condition.

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1. Hold the positive crankcase ventilation (PCV) valve with the vacuum side down. Insert a thin rod, and using light pressure, depress the end of the PCV valve spring by 5 - 10 mm (0.2 - 0.3 inch). Release pressure on the rod to see if the PCV valve spring will lift the rod to its original position.
2. If the rod returns quickly to its original position, the PCV valve is OK. If the stick does not return quickly, clean or replace the PCV valve.

GENERAL DESCRIPTION (EVAPORATIVE EMISSION SYSTEM)

The evaporative emission (EVAP) system prevents fuel vapors generated in the fuel tank from escaping into the atmosphere.

Fuel vapors from the fuel tank flow through the vapor pipe/hose to be stored temporarily in the EVAP canister.

When the vehicle is in operation, fuel vapors stored in the EVAP canister flow through the EVAP purge solenoid, purge port and intake manifold plenum 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 module (ECM) or powertrain control module (PCM) brings the EVAP purge solenoid into the OFF state to shut off the fuel vapor flow to the intake manifold plenum. This ensures driveability when the engine is cold or running under low load and also stabilizes the emission level.

An EVAP ventilation solenoid is provided between the EVAP canister and atmosphere to monitor for OBD-II EVAP leaks. This solenoid is normally OFF. However, it turns ON when monitoring the OBD-II EVAP leaks and shuts off the atmosphere flow to the EVAP canister. Then the fuel tank differential pressure sensor monitors the fuel vapor pressure to detect OBD-II EVAP leaks. The fuel overflow limiter valve and the leveling valve prevent fuel from being overfilled. The fuel overflow limiter valve and the leveling valve prevents fuel leaks if the vehicle is rolled over in an accident.

The EVAP ventilation valve releases the air from the fuel tank through the EVAP canister into the atmosphere when the fuel tank pressure increases due to refueling, etc. The EVAP ventilation valve and the air filter supply the atmospheric air to the EVAP canister when the fuel tank pressure decreases.

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Required Special Tool

MB995061: Purge Flow Indicator

1. Disconnect the purge hose from the evaporative emission (EVAP) purge solenoid, and connect special tool MB995061 between the EVAP purge solenoid and the purge hose.
2. Before inspection, set the vehicle in the following conditions: Engine coolant temperature: 80 - 95°C (176 - 203°F) Lights, electric cooling fan and accessories: OFF Transaxle: P range NOTE: Vehicles for Canada, the headlight, taillight, etc. remain lit even when the lighting switch is in "OFF" position but this is no problem for checks.
3. Run the engine at idle for more than four minutes.
4. Check the purge flow volume when engine is revved suddenly several times. Standard value: Momentarily 20 cm 3 /s (2.5 SCFH) or more.
5. If the purge flow volume is less than the standard value, check it again with the vacuum hose disconnected from the EVAP canister. If the purge flow volume is less than the standard value, check the vacuum port and the vacuum hose for clogging. Also check the EVAP purge solenoid. If the purge flow volume is at the standard value, replace the EVAP canister.

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1. Disconnect the vacuum hose from the evaporative emission (EVAP) purge solenoid. NOTE: When disconnecting the vacuum hose, always place an identification mark so that it can be reconnected at its original position.
2. Disconnect the harness connector.
3. Connect a hand vacuum pump to nipple (A) of the EVAP purge solenoid (refer to the illustration at left).
4. As described in the chart below, check airtightness by applying a vacuum with voltage applied directly from the battery to the EVAP purge solenoid valve and without applying voltage. EVAPORATIVE EMISSION PURGE SOLENOID CHECK BATTERY POSITIVE VOLTAGE NORMAL CONDITION Applied Vacuum leaks Not applied Vacuum maintained
5. Measure the resistance between the terminals of the EVAP purge solenoid. Standard value: 22 - 26 ohms [at 20°C (68°F)]
6. Replace the solenoid if resistance is out of specification.

< 2.0L ENGINE>

To inspect the sensor, refer to DIAGNOSTIC TROUBLE CODE CHART .

< 2.4L ENGINE>

To inspect these parts, refer to DIAGNOSTIC TROUBLE CODE CHART .

To inspect the sensor, refer to DIAGNOSTIC TROUBLE CODE CHART .

To inspect the sensor, refer to DIAGNOSTIC TROUBLE CODE CHART .

To inspect the sensor, refer to DIAGNOSTIC TROUBLE CODE CHART .

To inspect the sensor, refer to DIAGNOSTIC TROUBLE CODE CHART .

To inspect the sensor, refer to DIAGNOSTIC TROUBLE CODE CHART .

To inspect the sensor, refer to DIAGNOSTIC TROUBLE CODE CHART .

FUEL TANK DIFFERENTIAL PRESSURE SENSOR CHECK

To inspect the sensor, refer to FUEL TANK DIFFERENTIAL PRESSURE SENSOR CHECK.

EVAPORATIVE EMISSION VENTILATION SOLENOID CHECK

Refer to INSPECTION - EVAPORATIVE EMISSION VENTILATION SOLENOID CHECK

GENERAL DESCRIPTION (EXHAUST GAS RECIRCULATION SYSTEM)

The exhaust gas recirculation (EGR) system lowers the nitrogen oxides (NOx) emission level. When the air/fuel mixture combustion temperature is high, a large quantity of NOx is generated in the combustion chamber. Therefore, this system recirculates part of exhaust 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 for driveability quality.

OPERATION

When the engine coolant temperature is low, when the engine is at idle or when a wide open throttle operation is performed, the EGR valve is kept closed, achieving no EGR.

After warming up of the engine, the EGR valve can be opened by the engine control module (ECM) or powertrain control module (PCM).

The ECM or PCM monitors the EGR system and illuminates the Malfunction Indicator Lamp (SERVICE ENGINE SOON or Check Engine Lamp) to indicate that there is a malfunction.

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1. Disconnect the vacuum hose (green) from the EGR valve, and then connect a hand vacuum pump via the Tee-fitting.
2. Start the engine. As described in the chart below, check the vacuum condition when the throttle valve is opened suddenly (revving) during cold and hot engine conditions. If the engine is hot and the vacuum does not rise over 13 kPa (3.9 in Hg), perform the vacuum control valve check and EGR port vacuum check. Then continue to Step 3 . If vacuum rises momentarily, proceed to Step 3 . When engine is cold [Engine coolant temperature: 20°C (68°F) or less] THROTTLE VALVE NORMAL VACUUM CONDITION CHART THROTTLE VALVE NORMAL VACUUM CONDITION Open quickly No vacuum (Remained as barometric pressure). When engine is hot [Engine coolant temperature: 80°C (176°F) or more] THROTTLE VALVE NORMAL VACUUM CONDITION CHART THROTTLE VALVE NORMAL VACUUM CONDITION Open quickly Momentarily rises over 13 kPa (3.9 in Hg)
3. Stop the engine. Remove the Tee-fitting and the hand vacuum pump.
4. Connect the hand vacuum pump directly to the EGR valve.
5. Start the engine and run at idle until warm.
6. The engine idling speed should be rough when a vacuum of 27 kPa (7.9 in Hg) or more is applied to the EGR valve.
7. If engine idles rough, EGR passage is open and the system is OK. If engine idle is not rough, the EGR passage and the valve must be checked for restrictions. Perform the EGR valve check. Then repeat the exhaust gas recirculation system check.

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1. Disconnect the vacuum hose (white stripe) from the vacuum control valve and connect the hand vacuum pump to the vacuum control valve.
2. Plug the end of the removed vacuum hose.
3. Start the engine and run at idle.
4. As described in the chart below, check the vacuum condition. ENGINE CONDITION NORMAL VACUUM CONDITION CHART ENGINE CONDITION NORMAL VACUUM CONDITION Idling Approximately 21.3 - 24.0 kPa (6.3 - 7.1 in Hg)

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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 (20 in Hg) of vacuum, and check to be sure that the vacuum is maintained.
4. As described in the chart below, apply a vacuum and check the passage of air by blowing through one side of the EGR passage. VACUUM PASSAGE OF AIR VACUUM PASSAGE OF AIR 5.3 kPa (1.6 in Hg) or less Air is not blown out 27 kPa (7.9 in Hg) or more Air is blown out NOTE: Passage of air should be checked by blowing the valve port.
5. Reinstall the EGR valve, using a new gasket, and tighten to the specified torque. Tightening torque: 22 +/- 4 N.m (16 +/- 3 ft-lb)

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1. Disconnect the vacuum hose (green stripe) from the throttle body EGR vacuum nipple and connect a hand vacuum pump to the nipple.
2. Start the engine.
3. Measure engine vacuum at idle. Standard value: 51 kPa (15 in Hg) or more
4. Reset the vacuum pump to "0" (Release vacuum).
5. Using a stop watch, measure how long it takes for the vacuum gauge to reach 51 kPa (15 in Hg). Standard value: 1.0 second or less
6. If it takes more than 1.0 second for the gauge to reach 51 kPa (15 in Hg), the EGR may be restricted and should be cleaned.

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1. Disconnect the vacuum hose from the EGR vacuum regulator solenoid valve. NOTE: When disconnecting the vacuum hose, always make sure that it can be reconnected at its original position.
2. Disconnect the harness connector.
3. Connect a hand vacuum pump to nipple (A) of the «EGR VACUUM REGULATOR SOLENOID VALVE»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/testing-diagnostics/#emission-control-lancer) . (Refer to the illustration at left.)
4. As described in the chart below, check airtightness by applying a vacuum with voltage applied directly from the battery to the EGR vacuum regulator solenoid valve and without applying voltage. EGR VACUUM REGULATOR SOLENOID VALVE CHECK BATTERY POSITIVE VOLTAGE NORMAL CONDITION Not applied Vacuum leaks Applied Vacuum maintained
5. Measure the resistance between the terminals of the EGR vacuum regulator solenoid valve. Standard value: 29 - 35 ohms [at 20°C (68°F)]
6. Replace the EGR vacuum regulator solenoid valve if resistance is out of specification.

Required Special Tool

MB991658: Test Harness Set

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 operation sound is not heard, and the circuit is normal, either the stepper motor or the PCM may have failed.

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1. Remove the EGR valve.
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 ohms [at 20°C (68°F)]
3. If the resistance is not within the standard, replace the EGR valve.
4. 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 ohms [at 20°C (68°F)]
5. If the resistance is not within the standard, replace the EGR valve.

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1. Remove the EGR valve.
2. Connect special tool MB991658 to the EGR valve.
3. Connect the positive (+) terminal the battery to terminal No. 2. CAUTION: Connecting battery voltage to the EGR valve for a long term could damage the coil.
4. Connect terminals 1 and 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.
5. Connect the positive (+) terminal the battery to terminal No. 5. CAUTION: Connecting battery voltage to the EGR valve for a long term could damage the coil.
6. Connect terminals 4 and 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 vibrations can be felt as a result of the test, the stepper motor is determined to be normal.

Note. DO not use solvents or other cleaning agents, which will enter the motor and cause a malfunction.

Remove the EGR valve and make sure that it is not stuck and does not have any carbon deposits. If there are any carbon deposits, use a wire brush to clean it.

To inspect the sensor, refer to DIAGNOSTIC TROUBLE CODE CHART .

To inspect these parts, refer to DIAGNOSTIC TROUBLE CODE CHART .

To inspect the sensor, refer to DIAGNOSTIC TROUBLE CODE CHART .

To inspect the sensor, refer to DIAGNOSTIC TROUBLE CODE CHART .

To inspect the sensor, refer to DIAGNOSTIC TROUBLE CODE CHART .

To inspect the sensor, refer to DIAGNOSTIC TROUBLE CODE CHART .

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>>A<< EGR VALVE GASKET INSTALLATION

Install the EGR valve gasket as shown in the illustration.

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1. Connect a hand vacuum pump to nipple (A) of the solenoid.
2. Check air tightness by applying a vacuum with voltage applied directly from the battery to the evaporative emission ventilation solenoid and without applying voltage. BATTERY VOLTAGE NORMAL CONDITION CHART BATTERY VOLTAGE NORMAL CONDITION Applied Vacuum maintained Not applied Vacuum leaks
3. Measure the resistance between the terminals of the solenoid. Standard value: 17 - 21 ohms [at 20°C (68°F)]

GENERAL DESCRIPTION (CATALYTIC CONVERTER)

The three way catalytic converter, together with the closed loop air-fuel ratio control based on the oxygen sensor signal, oxidizes carbon monoxides (CO) and hydrocarbons (HC), also reduces nitrogen oxides (NOx).

When the mixture is controlled at stoichiometric air-fuel ratio, the three way catalytic converter provides the highest purification against the three constituents, namely, CO, HC and NOx.

REMOVAL AND INSTALLATION < EXCEPT FOR CALIFORNIA>

Refer to for the removal and installation of catalytic converter because it is integrated in the exhaust manifold and the front exhaust pipe.

1. Exhaust manifold side (the vehicles with 2.0L engine): Refer to «EXHAUST MANIFOLD»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/exhaust/#intake-and-exhaust-lancer) .
2. Front exhaust pipe side : Refer to «EXHAUST PIPE AND MAIN MUFFLER»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/exhaust/#intake-and-exhaust-lancer)

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Required Special Tool

1. MD998770: Oxygen Sensor Wrench

<< A >> HEATED OXYGEN SENSOR (FRONT) REMOVAL

Use special tool MD998770 to remove the oxygen sensor.

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>> A<< HEATED OXYGEN SENSOR (FRONT) INSTALLATION

Use special tool MD998770 to installation the oxygen sensor.

See also:
• DIAGNOSTIC TROUBLE CODE CHART
• DIAGNOSTIC TROUBLE CODE CHART
• EXHAUST MANIFOLD
• FUEL TANK DIFFERENTIAL PRESSURE SENSOR CHECK.
• INSPECTION