How to Replace the EGR Valve on a 2003 Mitsubushi Outlander

A fouled exhaust gas recirculation (EGR) valve in your 2003 Mitsubishi Outlander can become a headache when carbon buildup begins to accumulate inside the valve. The computer in your 2003 Mitsubishi Outlander allows small amounts of burned exhaust gases into the combustion chambers to control emissions, using the EGR valve to accomplish this job. However, a blocked valve will not only impact engine operation but also make you fail the emissions test. You can restore engine performance and decrease emission by installing a new EGR valve in your Outlander in a matter of minutes.

• 1

  Open the hood of your Outlander and remove the air cleaner duct assembly to gain access to the EGR valve with a Phillips screwdriver and a ratchet and socket.

• 2

  Look for a metal, disk-shaped component, about 3 inches in diameter, around the top of the engine area near the valve cover and the engine oil filler cap. The valve has a thin vacuum line hooked to the top. This is your EGR valve.

• 3

  Unplug the vacuum line from the EGR valve by hand.

• 4

  Unfasten the two valve mounting bolts with a wrench and remove the valve and gasket.

• 5

  Scrape any carbon or gasket material left on the mating surface of the intake manifold with a gasket scraper. If you see traces of carbon buildup in the intake opening, remove them with a Phillips screwdriver and a soft brush. Use a telescoping mirror and a small flashlight to better look inside the intake opening, if necessary.

• 6

  Position the new EGR valve in place along with a new gasket and start the two mounting bolts by hand. Tighten the bolts with the wrench.

• 7

  Plug in the vacuum line to the EGR valve.

• 8

  Replace the air cleaner duct assembly with the Phillips screwdriver and ratchet and socket. Close the hood.