Leak MITSUBISHI LANCER EVOLUTION 2007 Service Owner's Manual

FUEL SUPPLY - On-vehicle Service/Fuel tank13B-3
FUEL PUMP AND GAUGE ASSEMBLY, PIPE
AND GAUGE ASSEMBLY (FUEL GAUGE UNIT)
1. Remove the rear seat cushion assembly.
(Refer to GROUP 52A.)
2. Remove the service hole cover.
3. Disconnect the harness connector, high-pressure fuel
tube, suction hose, and return hose.
4. Unscrew the mounting nuts to remove the fuel pump
and gauge assembly or pipe and gauge assembly.
5. Fuel gauge unit check. (Refer to GROUP 54 -
Combination Meter.)
NOTE
If the inspection shows that the basic resistance and
the height of float are out of the standard value, replace
the gauge unit.
(Refer to P.13B-8.)
6. Install the fuel pump and gauge assembly or pipe and
gauge assembly. Tighten the mounting nuts to the
specified torque.
Specified torque: 2.5± 0.5 N·m
7. Connect the harness connector, high-pressure fuel tube,
suction hose, and return hose.
Caution
(1) Snap the high-pressure fuel hose or suction hose
one-touch joint into place, then pull back slightly
on the hose to assure it is securely fitted. However,
the connection should have a play of approx. 3
mm.
(2) Insert the return hose for 20 - 30 mm for
connection.
8. Install the rear seat cushion assembly.
(Refer to GROUP 52A.)
FUEL TANK
REMOVAL AND INSTALLATION
Pre-removal Operation
DDraining Fuel
DFuel Pump Connector Disconnection
(How To Reduce Fuel Pressure)
(Refer to GROUP 13A - On-vehicle Service.)
DCenter Exhaust Pipe Removal
(Refer to GROUP 15.)Post-installation Operation
DCenter Exhaust Pipe Removal
(Refer to GROUP 15.)
DRefilling Fuel
DChecking for Fuel Leaks
High-pressurefuel tubeHarness
connector
Suction hose
Return hose
Suction hose
Harness connector
<Fuel pump and gauge assembly>
<Pipe and gauge assembly>

14-1
ENGINE COOLING
CONTENTS
GENERAL INFORMATION 2..................
SERVICE SPECIFICATIONS 2.................
LUBRICANT 2...............................
SEALANT 2..................................
SPECIAL TOOLS 3...........................
TROUBLESHOOTING 3.......................
ON-VEHICLE SERVICE 6.....................
Engine Coolant Leak Checking 6................
Radiator Cap Opening Pressure Check 6........Engine Coolant Replacement 6..................
Concentration Measurement 7...................
Radiator Fan Relay Continuity Check 8..........
Radiator Fan Controller Check 8................
Radiator Fan Motor Check 10...................
THERMOSTAT 11............................
WATER PUMP 13............................
WATER HOSE AND WATER PIPE 14..........
RADIATOR 15................................

ENGINE COOLING -On-vehicle Service14-6
ON-VEHICLE SERVICE
ENGINE COOLANT LEAK CHECKING
1. Confirm that the coolant level is up to the filler neck.
Install a radiator cap tester and apply 160 kPa pressure,
and then check for leakage from the radiator hose or
connections.
Caution
(1) Be sure to completely clean away any moisture
from the places checked.
(2) When the tester is taken out, be careful not to
spill any coolant from it.
(3) Be careful, when installing and removing the tester
and when testing, not to deform the filler neck
of the radiator.
2. If there is leakage, repair or replace the appropriate part.
RADIATOR CAP OPENING PRESSURE CHECK
1. Use a cap adapter to attach the cap to the tester.
2. Increase the pressure until the indicator of the gauge
stops moving.
Limit: 83 kPa
Standard value: 93 - 123 kPa
3. Replace the radiator cap if the reading does not remain
at or above the limit.
NOTE
Be sure that the cap is clean before testing, since rust
or other foreign material on the cap seal will cause an
improper indication.
ENGINE COOLANT REPLACEMENT
1. Remove the under cover.
(Refer to GROUP 51 - Front Bumper.)
2. Drain the engine coolant by removing the drain plug and
then the radiator cap.
Cap adapter
Adapter
Cap adapter

INTAKE AND EXHAUST -Service Specifications/Special Tool/On-vehicle Service15-3
SERVICE SPECIFICATIONS
ItemStandard valueLimit
Turbocharger supercharging pressure (waste gate solenoid
valve not operating) kPa59 - 84-
Initial activation pressure of waste gate actuator (at the stroke
of approximately 1 mm) kPaApproximately 100-
Waste gate solenoid valve coil resistance (at 20_C)Ω29 - 35-
Initial activation pressure of air bypass valve kPaApproximately 53-
Secondary air control solenoid valve coil resistance
(at 20_C)Ω29 - 35-
Manifold distortion of the installation surface mm0.15 or less0.20
SPECIAL TOOL
ToolNumberNameUse
MD998770Oxygen sensor wrenchRemoval and installation of oxygen sensor
ON-VEHICLE SERVICE
TURBOCHARGER SUPERCHARGING
PRESSURE CHECK
Caution
Two persons should be in the vehicle when the test is
conducted; the person in the passenger seat should read
the indications shown by the pressure meter.
1. Disconnect the hose (black) from the turbocharger waste
gate solenoid valve, and connect the pressure gauge
to the hose. Plug the nipple of the solenoid valve from
which the hose (black) has been disconnected.
2. Drive at full-throttle acceleration in second gear and then
measure the supercharging pressure when the engine
speed in about 3,000 r/min.
Standard value: 59 – 84 kPa
3. If the supercharging pressure deviates from the standard
value, check the following items for possible cause.
DMalfunction of the waste gate actuator
DLeakage of supercharging pressure
DMalfunction of the turbocharger
Throttle bodyWaste gate
solenoid valve
Plug

INTAKE AND EXHAUST -On-vehicle Service15-4
4. When the indicated supercharging is more than standard
value, supercharging control may be faulty, therefore
check the followings.
DMalfunction of the waste gate actuator
DMalfunction of waste gate valve
DDisconnection or cracks of the waste gate actuator
rubber hose
SUPERCHARGING PRESSURE CONTROL
SYSTEM CHECK
1. Disconnect the hose (black) from the turbocharger waste
gate solenoid valve and connect a three-way joint between
the hose and the solenoid valve.
2. Connect a hand vacuum pump to the three-way joint.
3. Disconnect the hose from the turbocharger waste gate
actuator control boost nipple and plug the nipple.
4. Applying a negative pressure with the hand vacuum pump,
check tightness both when the hose end is closed and
when it is open.
Engine stateHose endNormal state
Stop (Ignition
it h“ON”
OpenedNegative pressure leaks.p(g
switch: “ON”
position)ClosedNegative pressure is
maintained.
Idling (after
warm-up)Negative pressure leaks.
NOTE
If this check indicates an abnormal condition, the
turbocharger waste gate actuator, turbocharger waste
gate solenoid or hose is broken.
WASTE GATE ACTUATOR CHECK
1. Connect a manual pump (pressure-application type) to
nipple.
2. While gradually applying pressure, check the pressure that
begins to activate (approximately 1 mm stroke) the waste
gate actuator rod.
Standard value: Approximately 100 kPa
Caution
In order to avoid damage to the diaphragm, do not
apply a pressure of 117 kPa or higher.
Waste gate
solenoid valveThrottle body
Waste gate
actuator
Boost hose

INTAKE AND EXHAUST -On-vehicle Service15-5
3. If there is a significant deviation from the standard value,
check the actuator or the waste gate valve: replace
actuator or turbocharger assembly if necessary.
WASTE GATE SOLENOID VALVE CHECK
OPERATION CHECK
1. Connect a hand vacuum pump to the solenoid valve nipple
A.
2. Using a jumper wire, connect between the solenoid valve
terminal and battery terminal.
3. Connecting and disconnecting the jumper wire at the
battery negative terminal to apply a negative pressure,
check tightness.
Jumper wireB nipple
conditionNormal condition
ConnectedOpenedNegative pressure leaks.
ClosedNegative pressure is held.
DisconnectedOpenedNegative pressure is held.
COIL RESISTANCE CHECK
Measure the resistance between solenoid valve terminals.
Standard value: 29 – 35Ω(at 20_C)
AIR BYPASS VALVE CHECK
1. Remove the air bypass valve.
2. Connect the hand vacuum pump to the nipple of the
air bypass valve.
3. Apply a negative pressure of approximately 49 kPa, and
check that air tightness is maintained.
4. Also check operation of the valve.
Standard value:
Negative pressureValve operation
Approximately 53 kPaIt starts opening
Battery B A

INTAKE AND EXHAUST -On-vehicle Service15-6
INTAKE MANIFOLD PRESSURE CHECK
Refer to GROUP 11A – On-vehicle Service.
SECONDARY AIR CONTROL SYSTEM CHECK
1. Start the engine and carry out idling.
2. Confirm that the secondary air valve lifts up when the
engine-ECU connector No. 53 terminal is short-circuited
with the earth using a jumper wire.
The engine-ECU connector must be connected at this
time.
SECONDARY AIR CONTROL SOLENOID
VALVE CHECK
OPERATION CHECK
1. Disconnect the vacuum hose (white-striped, yellow-
striped) from the solenoid valve.
2. Separate the harness connector.
3. Connect the hand vacuum pump to the solenoid valve’s
A nipple.
4. Connect the solenoid valve terminal and battery terminal
with a jumper wire.
5. Disconnect the jumper wire between the battery’s ( - )
terminals, apply a negative pressure, and inspect the
tightness.
Jumper wireState of B
nippleNormal state
ConnectedOpenedNegative pressure leaks.
ClosedNegative pressure is
maintained.
DisconnectedClosedNegative pressure leaks.
Vacuum tank
Secondary
air control
solenoid
valve
Battery A B

INTAKE AND EXHAUST -On-vehicle Service15-7
COIL RESISTANCE CHECK
Measure the resistance between the solenoid valve terminals.
Standard value: 29 – 35Ω(at 20_C)
SECONDARY AIR VALVE CHECK
1. Disconnect the secondary air valve.
2. Connect the hand vacuum pump to the secondary air
valve’s nipple.
3. Apply a negative pressure of 67 kPa, and confirm that
the negative pressure is maintained.
4. Blow in air from the (A) side and (B) side of the secondary
air valve, and inspect the ventilation.
Negative pressureAir blow-in
directionAir ventilation
0 kPa
(State without
negative pressure)(A)→(B)Not ventilated
40 kPa or more(A)→(B)Ventilated
(B)→(A)Not ventilated
VACUUM TANK CHECK
1. Connect the hand vacuum pump to the vacuum tank’s
A nipple. Apply a negative pressure of 67 kPa, and confirm
that the negative pressure is maintained.
2. Connect the hand vacuum pump to the vacuum tank’s
B nipple.
3. Plug the A nipple with a finger, and apply a negative
pressure of 67 kPa. Confirm that the negative pressure
leaks immediately when the finger is released.
BA
A
B

INTAKE AND EXHAUST -Exhaust Manifold15-21
"CAOIL RETURN PIPE GASKET INSTALLATION
Install the gasket so that its print part can face towards the
oil pan side.
INSPECTION
Check the following points; replace the part if a problem is
found.
1. EXHAUST MANIFOLD CHECK
(1) Check for damage or cracking of any part.
(2) Using a straight edge and a feeler gauge, check for
distortion of the cylinder head installation surface.
Standard value: 0.15 mm or less
Limit: 0.20 mm
2. TURBOCHARGER ASSEMBLY CHECK
(1) Visually check the turbine wheel and the compressor
wheel for cracking or other damage.
(2) Check whether the turbine wheel and the compressor
wheel can be easily turned by hand.
(3) Check for oil leakage from the turbocharger assembly.
(4) Check whether or not the waste gate valve remains open.
If any problem is found, replace the part after disassembly.
Gasket
Print
Compressor wheel

INTAKE AND EXHAUST -Turbocharger15-23
DISASSEMBLY SERVICE POINTS
AA"SNAP RING REMOVAL
Lay the unit with the compressor cover side facing down
and using snap ring pliers, remove the compressor cover
attaching snap ring.
Caution
When removing the snap ring, hold it with fingers to
prevent it from springing away.
AB"TURBINE WHEEL ASSEMBLY REMOVAL
Remove the turbine wheel assembly, striking the
circumference of the compressor cover with a plastic hammer.
The turbine wheel assembly may be a little hard to remove
due to an O-ring put on the outer circumference.
CLEANING
1. Use a clean cleaning oil commercially available. Do not
use corrosive cleaning oils as they could damage to some
parts.
2. Use a plastic scraper or hard brush to clean aluminum
parts.
REASSEMBLY SERVICE POINTS
"AAO-RING INSTALLATION
Apply a light coat of engine oil to a new O-ring and fit in
the turbine wheel assembly groove.
Caution
When installing the O-ring, use care not to damage it. A
damaged O-ring causes oil leaks.
"BATURBINE WHEEL ASSEMBLY
1. Apply a light coat of engine oil to the periphery of the
O-ring.
2. Install the turbine wheel assembly to the compressor cover
in relation to the dowel pin.
Caution
Use care not to damage the blades of turbine wheel
and compressor wheel.
Snap ring
Turbine
wheel
assembly
O-ring
Dowel pin
Dowel pin hole