ECU MITSUBISHI LANCER EVOLUTION IX 2005 Workshop Manual

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W
ARNING REGARDING THE SERVICING OF VEHICLES FITTED WITH SRS AIR BAGS AND SEATBELTS WITH PRE-
TENSIONERS
W arning
1. Improper servicing or maintenance of any SRS air bag or pre-tensioner fi\
tted seatbelt component, or related parts, could cause serious injury through the SRS air bag or pre-tensioner fitt\
ed seatbelt being activated unintentionally
or accidentally.
2. The SRS-ECU, the driver’s side air bag module, the passenger side air bag module, the pre-tensio\
ner fitted seatbelts and the clock spring, should be removed if there is a chance o\
f them being affected by heat during
painting work.
• 93ºC and above: the SRS-ECU, the driver’s air bag module, the passenger’s air bag module and the clock spring should be removed.
• 90ºC and above: the pre-tensioner fitted seatbelts should be rem\
oved.
3. Servicing and maintenance of any SRS air bag or pre-tensioner fitted sea\
tbelt components, or related parts, must be performed by an authorized Mitsubishi dealer.
4. Servicing and maintenance of any SRS air bag or pre-tensioner fitted sea\
tbelt components, or related parts, must only be undertaken after this service manual (specifically Section 52B-\
SRS air bags) has been carefully studied.

ENGINE – TIMING BELT, TIMING BELT B11-22
3. Twist the special tool for adjusting bolts (MD998738) by hand
until it touches the tensioner arm.
Caution
The special tool for adjusting bolts (MD998738) can be
slowly twisted at a rate of about 30° per second but if it is
suddenly twisted the auto-tensioner rod cannot be easily
withdrawn, and this may lead to problems with twisting and
the possibility that the special tool for adjusting bolts
(MD998738) may become bent.
4. Twist the special tool for adjusting bolts (MD998738) a little, and
align the auto-tensioner rod with setting hole A, and the
tensioner cylinder with setting hole B.
5. Insert a wire or a pin into the aligned holes.
6. Remove the special tool for adjusting bolts (MD998738), and
then loosen the bolt for fitting the timing belt tensioner, and
remove the timing belt.
Caution
If a timing belt is being re-used, check and make a note of
the direction of the arrows indicating the rotational
direction (clockwise direction) on the back of the belt.
 
B


Removing the power steering oil pump ASSY
Remove the power steering oil pump ASSY from its bracket, with
the hose intact.
Note
Secure the removed power steering oil pump ASSY with string, and
put it somewhere where it will not hinder the removal or fitting of the
timing belt.
 
C


Removing the crankshaft sprocket
1. Hold the crankshaft sprocket in place using the special spanner
(MB991367) and the special pin (MB991385).
2. Remove the crankshaft sprocket.timing belt tensioner
arm
bolt for fitting the timing belt
tensioner
wire or pin
Crankshaft
sprocket

ENGINE – ENGINE ASSY
11-31
Removal guidelines
 
A


Removing the drive belt
The following operations are necessary because the engine uses a
serpentine drive system with auto-tensioner.
1. Insert a 12.7sq spinner handle into the auto-tensioner tool hole,
and turn the auto-tensioner in an anti-clockwise direction before
it reaches the stopper.
2. Align hole A and hole B, insert an L-shaped hexagonal Allen
Key, to hold the position, and remove the drive belt.
Caution
If planning to re-use the drive belt, ensure that it will be
refitted the same way round, by marking the back of the belt
with chalk arrows indicating the direction of movement.
 
B


Removing the power steering oil pump and the A/C
compressor
1. Remove the power steering oil pump and the A/C compressor
from the bracket with the hoses intact.
2. Secure the removed power steering oil pump and the removed
A/C compressor with string, and put them somewhere where
they will not hinder the removal or fitting of the engine ASSY.
 
C



Removing the transfer ASSY and the transmission
ASSY
1. In order to prepare the special mechanical engine hanger
(MZ203830, MZ203831 or MB991928), the radiator support
upper insulator mounting bolts should be tightened on the
chassis (2 places).
2. Remove the transfer ASSY and the transmission ASSY.
AholeB hole
L-shaped
hex-
agonal
Allen
wrench

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-7MPI – TROUBLESHOOTING
3. INSPECTION PROCEDURES FOR EACH DIAGNOSIS CODE
MUT-II/III service data
•No.95 atmospheric pressure
sensor
(Ref: P13A-24)
Go on to the next page
Measurements taken at
C-50 engine ECU connector
•Measure engine ECU terminal
voltage
•Ignition switch: ON
•Voltage across earth at 42
OK:4.9~5.1V
Check connectorC-50
Inspect the harness between the
MAP sensor and the engine ECU.
•Check if the power supply has
short circuited.
MUT-II/III service data
• No.95: MAP sensor
(Ref: P13A-24)
Replace the engine ECU
Check connectorC-50
Inspect the harness between the
MAP sensor and the engine ECU.
•Check if earth wire is cut or
damaged.
MUT-II/III service data
•No.95: MAP sensor
(Ref: P13A-24)
Replace the engine ECU
Check connectorC50
Inspect the harness between the
MAP sensor and the engine ECU,
repair if necessary.
•Check if the power supply wire is
cut.
Temporary malfunction (Ref
Section 00: Dealing with
temporary malfunctions)
Measurements taken at the B-135
MAP sensor connector
•Undo the connector, and take
measurements using the
harness
(1) Voltage across earth at 3
(ignition switch: ON)
OK: 4.9~5.1V
(2) Resistance across earth at 2
OK: 2Ω or less
Temporary malfunction (Ref
Section 00: Dealing with
temporary malfunctions)
Check connectorB-135
NG
(2) NG (1) NGOK
NG
OK
OK
Temporary malfunction (Ref
Section 00: Dealing with
temporary malfunctions)
NG
OK
NG
OK
OK
NGOK
NG
OK
NG
Repair
NG
OK
OK
NG
NG
OK
Repair
Repair
Repair
Repair
Repair
Code No. P0105 MAP sensor systemProbable cause of the malfunction
Conditions for the inspection
• Ignition switch: ON
• Wait for 2 seconds after the ignition switch has been turned on or the
engine has started.
Evaluation conditions
• Sensor output voltage is 4.6V or more for 4 seconds (when atmospheric
pressure is more than 313 kPa)
• Sensor output voltage is 0.2V or less for 4 seconds (when atmospheric
pressure is more than 14 kPa)• MAP sensor malfunction
• Broken circuit or short circuit in the MAP
sensor circuit
• Poor connector contact
• Engine ECU malfunction

13A-8MPI – TROUBLESHOOTING
Continued from the previous page
Measurements taken at the B-135
MAP sensor connector
•Connect the test harness
(MB991348) to the connector
and measure at the pick-up
harness component.
•Ignition switch: ON
•Voltage across earth at 2
OK: 4.9~5.1V
Measurements taken at the B-135
MAP sensor connector
•Connect the test harness
(MB991348) to the connector
and measure at the pick-up
harness component.
•Ignition switch: ON
•Voltage across earth at 1
OK:altitude 0m 1.2~1.8V
altitude 600m 1.1~1.7V
altitude 1200m 1.0~1.6V
altitude 1800m 0.9~1.5V
Measurements taken at the C-50
engine ECU connector
•Measure engine ECU terminal
voltage
•Ignition switch: ON
•Voltage across earth at 92
OK:altitude 0m 1.2~1.8V
altitude 600m 1.1~1.7V
altitude 1200m 1.0~1.6V
altitude 1800m 0.9~1.5V
MUT-II/III service data
•No.95: MAP sensor
(Ref: P13A-24)
Replace the engine ECU
Check connectorC-50
Check connectorC-50
Inspect the harness between the
MAP sensor and the engine ECU,
repair if necessary.
•Check for damage to the power
supply wire.
Check connectorC-50
Inspect the harness between the
MAP sensor and the engine ECU.
•Check if the output wire has
short circuited.
Replace the MAP sensor
Check connectorC-50
Inspect the harness between the
MAP sensor and the engine ECU,
repair if necessary
•Check if the output wire has
been cut or damaged.
Temporary malfunction (Ref
Section 00: Dealing with
temporary malfunctions)
OK
OK
OK
OK
OK
NGRepair
OK
OK
OK
OK
NG
NGNG
NG
NG
OK
NG
Repair
NG
NG
Repair
Repair
Repair

13A-9MPI – TROUBLESHOOTING
Check connector B-115
To next page
Check connectorB-19X
Measurements taken at engine
ECU connector C-50
•Measurement of voltage at
engine ECU terminals
•Undo the B-115 exhaust cam
position sensor connector
•Ignition switch: ON
•Voltage across earth at 50
OK: 4.9~5.1V
Inspect the harness between the
exhaust cam position sensor and
the engine control relay, repair if
necessary
•Check if the power supply wire
is cut or has short circuited
Inspect the harness between the
exhaust cam position sensor and
the engine ECU
•Check if the output wire has
short circuited
Check that the problem has been
solved
Check connectorC-50
Check connectorC-50
Inspect the harness between the
exhaust cam position sensor and
the engine ECU, repair if
necessary
•Check if the output wire is cut
Temporary malfunction (Ref
Section : Dealing with temporary
malfunctions)
Temporary malfunction (Ref
Section 00: Dealing with
temporary malfunctions)
Measurements taken at the B-115
connector of the exhaust cam
position sensor
•Undo the connector and take
measurements using the
harness
(1) Voltage across earth at 3
(ignition switch: ON)
OK:battery voltage
(2) Voltage across earth at 2
(ignition switch: ON)
OK:4.9~5.1V
(3) Resistance across earth at 1
OK:Less than 2Ω
NGRepair
Repair
OK
NG
OK
OK
NG
OK
NG
NG
OK
NGNG
NGOK
Inspect the harness between the
exhaust cam position sensor and
the engine ECU
•Check if the earth wire is cut or
damaged
Check connectorC-49
OK
OK
Replace engine ECU
NG
Check the problem has been
solved
Replace engine ECU
NG
OK
(1) NG
(2) NG
(3) NG
OK
OK
Repair
Repair
Repair
Repair
Repair
Code No.P0340 Exhaust cam position sensor systemProbable cause of the malfunction
Conditions for inspection
•Ignition switch: ON
•With engine cranking or running
Evaluation conditions
•The sensor output voltage does not change for 4 seconds (with no input of
pulse signals)•Malfunction of the exhaust cam position
sensor
•Broken circuit or short circuit in the exhaust
cam position sensor circuit, or poor connector
contact
•Malfunction of engine ECU

13A-10MPI – TROUBLESHOOTING
Continued from the previous page
Replace the engine ECU
Check connectorB-19X
Inspect the harness between the
exhaust cam position sensor and
the engine control relay
•Check if the power wire is
damaged
Check the exhaust cam position
sensing cylinder
Check connectorC-49 and C-50
Check that the problem has been
solved
Inspect the harness between the
exhaust cam position sensor and
the engine ECU
•Check if the output wire is
damaged
Temporary malfunction (Ref
Section 00: Dealing with
temporary malfunctions)
Measurement of the output wave
at the exhaust cam position
sensor connector B-115 (using an
oscilloscope)
•Use test harness (MB991709),
connect it to the connector, and
take measurements at the pick-
up harness component
•Engine: idling
•Voltage across earth at 2
OK: An output wave as
described on P.13A-25
(Main points for
oscilloscope testing) is
produced, with the
maximum value in excess
of 4.8V and the minimum
value less than 0.6V.
There should be no noise
in the output wave form.
Check that the problem has been
solved
OK
OK
NG
NG
OK
OK
OK
Replace the exhaust cam position
sensor
NG
OK
Replace the exhaust cam position
sensing cylinder
Temporary malfunction (Ref
Section 00: Dealing with
temporary malfunctions)
OK
OK
Repair
Repair
NG
NG
Repair NG
Repair NG
NG
OK

13A-11MPI – TROUBLESHOOTING
Check connectorB-33
To next page
Check connectorsB-19X & C-23
Inspect the harness between the
intake cam position sensor and
the engine control relay, repair if
necessary
•Check if the power supply wire
is cut or has short circuited
Measurements taken at engine
ECU connector C-50
•Measurement of voltage at
engine ECU terminals
•Undo the B-33 intake cam
position sensor connector
•Ignition switch: ON
•Voltage across earth 53
OK:4.9~5.1V
Check connectorC-50
Check connectorC-49
Inspect the harness between the
intake cam position sensor and
the engine ECU
•Check if the earth wire is cut or
damaged
Harness inspection between the
intake cam position sensor and
the engine ECU
•Check if the earth wire is cut or
damaged
Replace the engine ECU
Replace engine ECU
Check that the problem has been
solved
Check that the problem has been
solved
Check connector C-50
Inspect the harness between the
intake cam position sensor and
the engine ECU, repair if
necessary
•Check if the output wire is cut
Temporary malfunction (Ref
Section 00: Dealing with
temporary malfunctions)
Temporary malfunction (Ref
Section 00: Dealing with
temporary malfunctions)
Measurements taken at the B-33
connector of the intake cam
position sensor
•Undo the connector and take
measurements using the
harness
(1) Voltage across earth at 3
(ignition switch: ON)
OK:battery voltage
(2) Voltage across earth at 2
(ignition switch: ON)
OK:4.9~5.1V
(3) Resistance across earth at 1
OK:Less than 2Ω
Code No.P1012 Intake cam position sensor systemProbable cause of the malfunction
Conditions for inspection
• With engine cranking or running
Evaluation conditions
• Sensor output voltage does not change for 4 seconds (with no input of
pulse signals)•Malfunction of the intake cam position sensor
•Broken circuit or short circuit in the intake
cam position sensor circuit, or poor
connector contact
•Malfunction of engine ECU
OK
OK
NG
(1) NG
(2) NG
(3) NG
OK
NG
NG
OK
OK
OK
NG
NG
NG
OK
NG
OK OK
NG
NG
OK
OKNG
Repair
Repair
Repair
Repair
Repair
Repair
Repair