fuel MITSUBISHI LANCER EVOLUTION IX 2005 User Guide

MPI – GENERAL13A-2
MPI system diagram
Engine ECU
H1. O
2 sensor
H2. Air flow sensor
H3. Intake air temp.
sensor
H4. Throttle position
sensor
H5. Intake Cam position
sensor
H6. Exhaust Cam
position sensor
H7. Crank angle
sensor
H8. Atmospheric
pressure sensor
H9. Water temp.
sensor
H10. Knock sensor
H11. Manifold absolute
pressure (MAP)
sensor
H12. Air temp. sensor• Power supply
• Ignition switch IG
• Ignition switch ST
• Vehicle speed
sensor
• A/C switch
• A/C load signal
• Power steering
fluid pressure switch
• Alternator FR signal
• Inter-cooler water spray
switch (auto)
•Inter-cooler water spray
switch (manual)I1. Injector
I2. ISC servo (Stepper
motor)
I3. Fuel pressure
control solenoid valve
I4. No. 1 Waste gate
solenoid valve
I5. No. 2 Waste gate
solenoid valve
I6. Purge control
solenoid valve
I7. Secondary air
control solenoid valve
I8. Oil feeder control
valve• Engine control relay
• Fuel pump relay 2,3
(ON/OFF)
• Fuel pump relay (HI/LO
switch)
• A/C relay
• Ignition coil
• Fan controller
• Condenser fan relay (HI)
• Condenser fan relay
(LO)
• Engine warning light
• Diagnosis output
terminal
• Alternator G terminal
• Inter-cooler water spray
relay
•Inter-cooler water spray
lamp
• O
2sensor heater
ÈÈ
I 6. Purge control
solenoid valve
I 7. Secondary
air control
solenoid valveCheck
valve
Secondary air
valve
To fuel
tank
H 6. Exhaust cam
position sensor
H 8. Atmospheric
pressure sensor
H 2. Air flow sensor
Intake
Waste gate actuator
I 4. No.1 waste gate
solenoid valve H 3. Intake air
temperature
sensor
I 5. No.2 waste gate
solenoid valve
H 1. O
2sensor
H 5. Intake cam
position sensorCatalyst
H 7. Crank angle sensor
H 10. Knock sensor
H 9. Water temperature sensor
I 1. Injector From fuel
pump
Fuel pressure
regulatorI 8. Oil feeder control
valve I 3. Fuel pressure
control solenoid
valve
Vacuum
tank
I 2. ISC servoH 11. MAP sensor
H 12. Air temperature sensor
H 4. Throttle
position
sensor
From fuel tank
Canister
By-pass valve

MPI – TROUBLESHOOTING
13A-5
TROUBLESHOOTING
1. Diagnosis Functions
1-1 Engine warning light (Check engine lamp)
Changes have been made to engine warning lights.
Checklist for engine warning lights.
1-2 Checking of freeze frame data
Additions have been made to the freeze frame data tables.
Checklist for data tables
1-3 Failsafe and back-up functions
If one of the diagnosis functions detects that one of the main sensors is malfunctioning, it will ensure that the car can be driven
safely, in accordance with the pre-set control logic.
Engine ECU
Air flow sensor (AFS)
Manifold absolute pressure (MAP) sensor system
Intake air temperature sensor
Throttle position sensor (TPS)
Water temperature sensor
Crank angle sensor
Exhaust cam position sensor
Injector
Ignition coil (with built-in power transistor)
Atmospheric pressure sensor
O
2sensor
O
2sensor heater
Fuel system malfunction
Knock sensor
Intake cam position sensor system
Oil feeder control valve system
Item numberType of data Units/condition
95MAP sensorkPa
Malfunctioning itemControl measures taken when a malfunction occurs
Air temperature sensorRegulation of the intake air temperature at 25ºC.
Exhaust cam position sensor(1) Simultaneous flushing out of all fuel pipes.
(But only if the No. 1 cylinder has not been detected in the
TDC position after the ignition switch has been turned "ON".)
(2) Cutting off the fuel 4 seconds after the malfunction has been
detected.
(But only if the No. 1 cylinder has not been detected in the
TDC position after the ignition switch has been turned "ON".)
Intake cam position sensorThe oil feeder control valve should be switched "OFF", and the
angle of the cam should be in the reset position.

13A-16MPI – TROUBLESHOOTING
Check the purge control solenoid valve (Refer to Section
17: Checking the exhaust gas purification system)
MUT-II/III Service data
•No.11 O
2sensor (Ref: P13A-83)*
Refer to the diagnosis code classification table (P13A-6)MUT-II/III diagnosis code
•Is the diagnosis code displayed?
Check the timing of ignition (Ref Section 11, Engine
tuning)
Check the sound made by the injector (using a
soundscope)
Check the crank angle sensor and the fitting of the timing
belt cover
If there is abnormality in the exhaust gases and code
Nos. P0201~P0204 are recorded, check the injector
system
If abnormal sensor data is recorded, carry out inspections
for each diagnosis code in order (Ref: P13A-6)
Replace the purge control solenoid valve
Code No.P0130: O
2sensor system inspection (Ref:
P13A-16)*
Go on to next page.
MUT-II/III Service data
•No.13: Intake air temperature sensor
•No.14: TPS
•No.21: Water temperature sensor
•No.25: Atmospheric pressure sensor
•No.95: MAP sensor
(Ref: P13A-24)
<Reference>
Proceed to OK if all service data levels are normal.
Proceed via NG even if only one of the service data
levels is abnormal.
*: Refer to the 03-1 Service Manual for the Lancer Evolution VIII (No.1036K07)
NO
OK
OK
OK
OK
OK
YES
NG
NG
NG
NG
Inspection procedureFault to be checkedReference page
11
Engine seems hesitant
13A-16Acceleration malfunction
Engine seems to stumble
Engine has a power surge
15Mis-timed ignition13A-18
35Inter-cooler water spray circuit system13A-19
37No.2 waste gate solenoid valve system13A-21
38Air temperature sensor system13A-22
Engine seems hesitant, acceleration malfunction, engine
seems to stumble, engine has a power surgeProbable causes of the malfunction
Probable causes of the malfunction are noted in the right hand
column.•Malfunction of the air/fuel mixing control system
•Malfunction of the ignition system
•Malfunction of the fuel system
•Malfunction of the intake system
•Malfunction of the exhaust gas purification system
•Failure of compression pressure
•Malfunction of the turbocharger system
5. Inspection procedure for each type of fault
Inspection procedure 11
4. Checklist of faults

13A-17MPI – TROUBLESHOOTING
*: Refer to the 01-1 Service Manual for the Lancer Evolution VIII (No.1036K02)
*: Refer to the 03-1 Service Manual for the Lancer Evolution VIII (No.1036K07)
Repair
Repair
Repair
Repair
Repair
Repair
Continued from previous page
Replace the spark plug wire
Replace the spark plug
Replace the ignition coil
Inspection procedure 33: Inspection of the No.1 waste
gate solenoid valve (Ref: P13A-78) *2
Inspection procedure 37: Inspection of the No.2 waste
gate solenoid valve (Ref: P13A-21)
Inspection procedure 31: Inspection of the fuel control
solenoid valve (Ref: P13A-76) *2
Inspection procedure 38: Inspection of the air
temperature sensor (Ref: P13A-22)
Check the spark plug wire (Ref: Section 16: Ignition
apparatus)
Check the spark plug (Ref: Section 16: Ignition
apparatus)
Check connectors B-123 & B-119
Check the ignition coil (Ref: Section 16: Ignition
Apparatus)
Inspect the harness and the connectors between each
cylinder’s ignition coil and the body earth, and between
the engine ECU and the ignition coil. Check for cut or
short circuited wires, or other damage.
MUT-II/III Actuator test
•No.12: Waste gate solenoid valve (Ref: P13A-87)*2
Check the supercharge pressure of the turbo charger
(Ref: Section 15: Intake/Exhaust car servicing)
Check the supercharge pressure control system (Ref:
Section 15: Intake/Exhaust car servicing)
MUT-II/III Actuator test
•No.09: Fuel pressure control solenoid valve (Ref:
P13A-87)
Check the fuel pressure (Ref: P13D-109)
Check the compression pressure (Ref: Section 11:
Engine tuning)
If the intake hose and the inlet manifold are damaged
check the air intake and repair as necessary.
Measurements taken at B-108 air temperature sensor
connector
•Using the test harness (MB991658), connect it to only
connectors No.1 and No.2 and measure at the pick-
up harness component.
•Ignition switch: ON
•Voltage across earth at 1
OK:surrounding temperature -20ºC 3.8~4.4V
surrounding temperature 0ºC 3.2~3.8V
surrounding temperature 20ºC 2.3~2.9V
surrounding temperature 40ºC 1.5~2.1V
surrounding temperature 60ºC 0.8~1.4V
surrounding temperature 80ºC 0.4~1.0V
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
NG
NG
NG
NG
NG
NG
NG
NG
NG
NG
NG

13A-22MPI – TROUBLESHOOTING
Inspect the air temperature
sensor on its own (Ref: P13A-29)
Check connectorB-34
Measure at the air temperature
sensor connector B-34
•Undo the connector and
measure on the harness side
(1) Resistance across earth at 2
OK:Less than 2Ω
(2) Voltage across earth at 1
(Ignition switch: ON)
OK:4.9~5.1V
Go on to the next page
Replace the air temperature
sensor
Temporary malfunction (Ref
Section 00: Dealing with
temporary malfunctions)
Measure at the engine ECU
connector C-51
•Measure the voltage at the
engine ECU terminal
•Ignition switch: ON
•Voltage across earth at 96
OK:4.5~4.9V
Replace the engine ECU
Check that the problem has been
solved
Inspect the harness between the
air temperature sensor and the
engine ECU
•Check if the earth wire is cut
or damaged
Check connector:C-50
Inspect the harness between the
air temperature sensor and the
engine ECU and repair it if
necessary.
•Check if the output wire is cut
Check connector:C-51
Temporary malfunction (Ref
Section 00: Dealing with
temporary malfunctions)
Check connector:C-51
Check that the problem has been
solved
Replace the engine ECU
Inspect the harness between the
air temperature sensor and the
engine ECU and repair it if
necessary.
•Check if the output wire is cut
OKNG
(1) NG
(2) NG
NG
OK
OK
NG
NG
NG
OK
NG
OK
OK
OK
NG
NG
NG
NG
NG
OK
Repair
Repair
Repair
Repair
Repair
Air temperature sensor systemProbable causes of the malfunction
The air temperature sensor controls the temperature inside the inlet
manifold, and compensates for any burning of fuel.•Malfunction of the air temperature sensor.
•Circuit break, short circuit or a faulty connection in
the air temperature sensor circuit.
•Malfunction of the engine ECU.
Inspection procedure 38
OKNGRepair

13A-29MPI – TROUBLESHOOTING, ON-VEHICLE SERVICING
•Example 2
Waveform characteristics
The waveform is displaced to the left or the right.
Cause of the problem
The timing belt is loose
There is an abnormality in the fuel pump camshaft
On-vehicle servicing
1. Adjusting standard engine revolutions
when idling
The standard engine revolutions when idling have been
changed. All other servicing requirements are the same as
before.
Standard engine revolutions when idling: 800 ± 50 r/min
NameCodeNameCode
Intake cam position sensorCOil feeder control valveA
Air temperature sensorBManifold absolute pressure sensorB
Exhaust cam position sensorC
2. Layout diagram for MPI system components
air temp. sensor side
connector
air temp.
sensor
3. Inspection of the air temperature sensor
(1) Disconnect the air temperature sensor connector.
(2) Measure the resistance across the terminals of the air
temperature sensor connector.
Standard values:
13~18 kΩ (when at -20 ºC)
5.1~6.9 kΩ (when at 0 ºC)
2.0~3.0 kΩ (when at 20 ºC)
0.9~1.5 kΩ (when at 40 ºC)
0.40~0.78 kΩ (when at 60 ºC)
0.23~0.42 kΩ (when at 80 ºC)

INTAKE & EXHAUST – SECONDARY AIR CONTROL SYSTEM, INLET MANIFOLD15-5
Fitting guidelines



A 
Fitting the gasket
Fit the gasket so that the protruding part points in the direction
shown in the diagram.
Inlet manifold
Removal and fitting
Jobs to be completed before removal and
after fitting
•Take measures to prevent fuel leaking (only
before removal)
•Removal and refitting of the valence (Ref
Section 15: Front bumper)
•Draining and refilling the coolant
•Removal and refitting of the air duct•Removal and refitting of the strut tower bar
•Removal and refitting of the throttle body
•Removal and refitting of the secondary air
control valve (Ref P15-4)
•Removal and refitting of the cross member bar
•Removal and refitting of the front exhaust pipe
protruding
part
(engine oil)
(engine oil)

INTAKE & EXHAUST – INLET MANIFOLD15-6
Removal procedure
1. Centre cover
2. Ignition coil connector
3. O
2sensor connector
4. Oil feeder control valve connector
5. Crank angle sensor connector
6. Injector connector
7. Air temperature sensor connector
8. Manifold absolute pressure sensor
connector
9. Purge control solenoid valve connector
10. Knock sensor connector
11.Fuel pressure solenoid valve connector12. Vacuum hose connection
13. Vacuum hose connection
14. Fuel return hose connection
15. Fuel high pressure hose connection
16. O-ring
17. Delivery pipe, injector and fuel pressure
regulator ASSY
18. Insulator
19. Insulator
20. Oil level gauge & guide ASSY
21. O-ring
22. Brake booster vacuum hose connection
23. Purge hose connection



A 



A 


A

INTAKE & EXHAUST – INLET MANIFOLD
15-7
Removal procedure
24. Knock sensor connector
25. Purge control solenoid valve ASSY
26. Vacuum hose
27. Fuel pressure solenoid valve ASSY
28. PCV hose
•Alternator (Ref Section 16: Alternator)
29. Secondary air control solenoid valve
connector
30. Vacuum tank, ACV solenoid valve,
vacuum hose & pipe ASSY31. Inlet manifold stay
32. Cover
33. Gasket
34. Harness connection
35. Crank angle sensor connector
36. Alternator bracket
37. Inlet manifold
38. Inlet manifold gasket
Removal guidelines
 
A


Removal of the delivery pipe, the injector and the fuel
pressure regulator ASSY
Remove the deliver pipe, with the injector and the fuel pressure
regulator intact.
Caution
When removing the delivery pipe, be careful not to drop the
injector.
Fitting guidelines



A 

Connecting the O-ring and the fuel high pressure hose
1. Apply a small quantity of fresh engine oil to the O-ring, and
insert it into the delivery pipe without damaging the O-ring.
2. Check that the high pressure hose can be turned smoothly. If it
cannot be turned smoothly there is a possibility that it is biting
into the O-ring, so remove the high pressure hose and check for
any damage to the O-ring. If the O-ring is undamaged, reinsert it
into the delivery pipe and check once more whether the hose
can be turned smoothly.
3. Tighten the mounting bolt to the specified torque.
Tightening torque: 5.0 ± 1.0 N·m

ENGINE ELECTRICAL – CHARGING SYSTEM16-2
Removal procedure
1. Injector connector
2. Accelerator cable connection
3. Delivery pipe, injector, and fuel pressure
regulator ASSY
4. Insulator
5. Insulator
6. Fuel pressure solenoid valve connector
7. Fuel pressure solenoid valve ASSY
8. Knock sensor connector
9. Purge control solenoid valve connector10. Purge control solenoid valve ASSY
11.Oil level gauge and guide ASSY
12. O-ring
13. Drive belt
14. Alternator connector and terminal
• Engine mount
15. Alternator
16. Water pump pulley
17. O
2sensor connector
18. Alternator bracket
(engine oil)
 
A



B


 
C