battery MITSUBISHI LANCER EVOLUTION IX 2005 Workshop Manual

ENGINE – SPECIAL TOOLS
11 - 3
ToolNumberNameFunction
MD998737Va l ve stem seal
installerValve stem seal installation
MD998713Camshaft oil seal
installerCamshaft oil seal installation
MB991654Cylinder head bolt
wrenchCylinder head bolt removal, installation
MB991367Special spannerHolding the crankshaft sprocket
MB991385Pins
MB991704Battery harnessChecking and adjustment of the tension in the
balancer timing belt (Use in conjunction with VCI
or MUT-II)
MD998738Adjusting boltHolding the tensioner arm or the auto-tensioner
adjuster
MD998767Tensioner pulley
socket wrenchAdjusting the tension of the timing belt

ENGINE – CAMSHAFT, VALVE STEM SEAL, CYLINDER HEAD GASKET11-14



O 
Fitting the O-ring/oil feeder control valve
Caution
1. Do not re-use O-rings.
2. When fitting O-rings, first wind some non-adhesive tape
(seal tape etc) around the oil channel of the oil feeder
control valve, in order to prevent damage to the O-ring.
If the O-ring touches the oil it could start an oil leak.
1. Apply engine oil to the O-ring on the oil feeder control valve.
2. Fit the oil feeder control valve to the cylinder head.
3. Tighten the mounting bolts for the oil feeder control valve to the
specified torque.
Tightening torque: 11 ± 1 N•m
Cylinder head gasket
Removal and fitting
Jobs to be completed before removal and after fitting
•Measures to prevent fuel leaking. <Only before removal>
•Check for fuel dripping. <Only after fitting>
•Removal and refitting of the strut tower bar.
•Removal and refitting of the valence. (Ref Section 51: Front bumper)
•Check the tension of the drive belt. <Only after fitting>
•Adjustment of the axle letter cable. <Only after fitting>
•Draining and replacing the engine oil.
•Draining and replacing the coolant.
•Removal and refitting of the air cleaner.
•Removal and refitting of air pipe C.
•Removal and refitting of the battery and the battery tray.
•Removal and refitting of the centre cover. (Ref P11-5)
•Removal and refitting of the axle letter cable.
•Removal and refitting of the radiator.
•Removal and refitting of the front exhaust pipe.
•Removal and refitting of the timing belt. (Ref P11-20)
Tape

ENGINE – TIMING BELT, TIMING BELT B11-24
2. <Measuring the amount of give>
(1) As shown in the diagram, apply a force of about 100N to the
middle of the belt between the sprockets (indicated by the
arrow), and check that the amount of give is as specified.
Specified values:
<when adjusted> 5~7mm
<when replaced> 5~7mm
(2) If the specified values are not met, readjust the tension of the
belt.
3. <When using MUT-II/III>
(1) Connect the special belt tension meter set (MB991668) to the
MUT-II/III.
(2) Connect the special battery harness (MB991704) to the MUT-
II/III, and also connect it to the batteries.
(3) Give the crankshaft two turns in a clockwise direction, and check
that the No.1 cylinder is in the top dead centre position, and that
the timing marks on each sprocket are aligned.
(4) Select the “belt tension measurement” option from the display
on the MUT-II/III.
(5) As shown in the diagram hold the special belt tension meter set
(MB991668) in the middle of the belt between the sprockets
(indicated by the arrow), 10~20mm away from the outer side of
the belt and vertically to the belt (not leaning more than ±15°
away from vertical).
(6) As shown in the diagram, lightly pull the middle of the belt
between the sprockets (indicated by the arrow) using fingertips
and check that the vibration frequency of the belt is within the
limits specified.
Specified values: 76 ~ 92 Hz
Caution
(1) The meter may give an incorrect reading if the
microphone is affected by a strong wind, or if there are
loud noises nearby, while testing is taking place.
(2) The meter may give an incorrect reading if testing is
performed while the microphone is touching the belt.
(7) If the specified values are not met, readjust the tension of the
belt.
approx. 100 N
amount of
give
pull lightly with fingertips

ENGINE – TIMING BELT, TIMING BELT B, ENGINE ASSY11-28
5. Using the special wrench for the tensioner pulley socket
(MD998767) or a torque wrench, apply tension torque (3.5 N·m)
to the timing belt in the direction shown in the diagram, and
tighten the mounting bolt for the tensioner pulley to the specified
torque.
Tightening torque: 48 ± 5 N·m
Caution
When tightening the installed bolt, take care that the
tensioner pulley does not turn around with it. If the pulley
does turn around with the bolt, the tension of the belt will
become too strong.
6. Remove the wire or pin which had been inserted when the auto-
tensioner was fitted.
7. Remove by hand the special adjusting bolt (MD998738) which
had been fitted in step 1.
8. Turn the crankshaft two complete turns in a clockwise direction,
and leave it for about 15 minutes.
9. Reinsert the wire or pin which had been removed in step 6, and
check that it can be easily pulled out again.
If the wire or pin can be easily pulled out the tension of the
timing belt is just right, so the wire or pin should be removed
completely. At this point check that the auto-tensioner rod is not
projecting more than the amount specified.
Specified projection (A): 3.8 ~ 4.5 mm
10. If the wire or pin cannot be easily pulled out, repeat steps 1 to 8
until the tension of the timing belt is just right.
11.Recheck that the timing marks on all of the sprockets are in line.
Caution
If the crankshaft bolt is turned in an anti-clockwise
direction, the tightening torque of the crankshaft bolt must
be checked, and if it is loose, it must be retightened.
ENGINE ASSY
Removal and fitting
Jobs to be completed before removal and after fitting
•Measures to prevent fuel leaking. <Only before removal>
•Check for fuel dripping. <Only after fitting>
•Removal and refitting of the bonnet.
•Removal and refitting of the strut tower bar.
•Removal and refitting of the valence. (Ref Section 51: Front bumper)
•Checking the tension of the drive belt. <Only after fitting>
•Adjustment of the axle letter cable. <Only after fitting>
•Draining and replacing the engine oil.
•Draining and replacing the coolant.
•Removal and refitting of the air cleaner.
•Removal and refitting of air pipe C.
•Removal and refitting of the battery and the battery tray.
•Removal and refitting of the centre cover. (Ref P11-5)
•Removal and refitting of the axle letter cable.
•Removal and refitting of the radiator.
•Removal and refitting of the front exhaust pipe.

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-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

13A-13MPI – TROUBLESHOOTING
Replace the engine ECU
Check connectors B-19X & C-23
Check connector B-134
Check connectors B-19 & C-23
Check connector C-49
Check that the problem has been
solved
Inspect the oil feeder control
valve by itself (Ref: P13A-30)
Inspect the harness between the
engine control relay and the oil
feeder control valve, repair if
necessary
•Check for damage to the power
supply wire
Inspect the harness between the
engine control relay and the oil
feeder control valve, repair if
necessary
•Check if the power supply wire
is cut or has short circuited
Check connectorC-49
Inspect the harness between the
engine ECU and the oil feeder
control valve, repair if necessary
•Check if the output wire is cut or
has short circuited
Temporary malfunction (Ref
Section 00: Dealing with
temporary malfunctions)
Replace the oil feeder control
valve
A-134 Measurement of the oil
feeder control valve
•Measure using a harness
connected to the connector
•Ignition switch: ON
•Voltage across earth at 1
OK:battery voltage
C-49 Measurement of engine
ECU
•Undo the connector and
measure on the harness side
•Ignition switch: ON
•Voltage across earth at 32
OK:battery voltage
Inspect the harness between the
engine ECU and the oil feeder
control valve
•Check for damage to the output
wire
OK
NG
OKOK
OK
OK
OK
OK
OK
OK
NG
NG
NG
NG
NG
NG
NG
NG
NG
NG
OK
OK
Repair
Repair
Repair
Repair
Repair
Repair
Repair
Code No.P1021 Oil feeder control valve systemProbable cause of the malfunction
Conditions for inspection
•Oil feeder control valve: OFF
Evaluation conditions
•Operational terminal voltage of the oil feeder control valve in the ECU is
abnormal for 4 seconds•Malfunction of the oil feeder control
valve
•Broken circuit or short circuit in the oil
feeder control valve circuit, or poor
connector contact
•Malfunction of engine ECU

13A-19MPI – TROUBLESHOOTING
Check the operation of the inter-
cooler water spray
•Ignition switch: ON
•Inter-cooler water spray
switch (manual): ON
OK:Inter-cooler water spray
operates
Check the operation of the inter-
cooler water spray
•Undo the engine ECU
connector C-50, and earth
terminal 56.
•Ignition switch: ON
OK:Inter-cooler water spray
operates
Check connector:C-220
Check the inter-cooler water
spray relay (Refer to Section 15:
Intake/Exhaust)
Go on to the next page
Measure at the inter-cooler water
spray switch connector D-32
•Undo the connector and
measure on the harness side
•Ignition switch: ON
•Voltage across earth at 5
OK:battery voltage
Check connectors: C-22 & C-50
Check connector: D-32
Inspect the harness between the
engine ECU and the inter-cooler
water spray switch
•Check if the signal wire is cut
or has short circuited
Replace the engine ECU
Check connectors: C-22 & C-50
Measure at the inter-cooler water
spray switch connector D-32
•Undo the connector and
measure on the harness side
•Ignition switch: ON
•Voltage across earth at 3 & 5
OK:battery voltage
Replace the inter-cooler water
spray relayReplace engine ECU
Check the inter-cooler water
spray switch (Ref Section 15:
Intake/Exhaust)
Inspect the harness between the
inter-cooler water spray switch
and the engine ECU
•Check if the signal wire is
damaged
Temporary malfunction (Ref
Section 00: Dealing with
temporary malfunctions)
Check connector:D-32
Check the inter-cooler water
spray switch
(Ref Section 15: Intake/Exhaust)
Check connector:C-107
Replace the inter-cooler water
spray relayInspect the harness
between the inter-cooler water
spray switch and earth
•Check if the earth wire is cut
or damaged
Inspect the harness between the
inter-cooler water spray switch
and the engine ECU, repair if
necessary
•Check if the signal wire is
damaged
Inspect the harness between the
engine ECU and the inter-cooler
water spray switch
•Check if the signal wire is cut
or has short circuited
OK
NG
NG
OK
NG
NG
OK
OK
OK
OK
NG
OK
OK
NG
NG
Repair
Inspection procedure 35
Inter-cooler water spray circuit systemProbable causes of the malfunction
•If the inter-cooler water spray switch (manual) is turned ON, the inter-cooler
water spray manual ‘ON’ signal will be input in the engine ECU. When this
signal is received, the engine ECU will turn the inter-cooler water spray relay
ON, and will start the inter-cooler water spray motor. Water will be sprayed
into the inter-cooler to cool intake air, and filling efficiency will improve.
•If the inter-cooler water spray switch (auto) is turned ON, the inter-cooler
water spray auto ‘ON’ signal will be input in the engine ECU. When this
signal is received the engine ECU will intermittently run at a high load, it will
turn the inter-cooler water spray relay ON, and it will start the inter-cooler
water spray motor. Water will be sprayed into the inter-cooler to cool intake
air, and filling efficiency will improve.•Malfunction of the inter-cooler water
spray switch.
•Malfunction of the inter-cooler water
spray relay.
•Malfunction of the inter-cooler water
spray motor.
•Circuit break, short circuit or a faulty
connection in the inter-cooler water
spray relay circuit.
•Circuit break, short circuit or a faulty
connection in the inter-cooler water
spray switch circuit.
•Malfunction of the ignition switch.
•Malfunction of the engine ECU.
Replace the engine ECU
OKNGRepair
OKNGRepair
OKNGRepair
OKNGRepair
OKNGRepair
OKNGRepair
OKNGRepair
OKNGRepair
OKNGRepair
OKNGRepair
Repair

13A-20MPI – TROUBLESHOOTING
Measure at the inter-cooler water
spray relay connector C-220
•Undo the connector, and
measure on the harness side
•Voltage across earth 3 and 1
(ignition switch: ON)
OK:battery voltage
Measure at the engine ECU
connector C-50
•Undo the connector, and
measure on the harness side
•Voltage across earth 56
(ignition switch: ON)
OK:battery voltage
Check connector:C-31
Inspect the harness between the
inter-cooler water spray relay and
the inter-cooler water spray motor
•Check if the power supply wire
is cut, has short circuited, or is
damaged
Inspect the harness between the
inter-cooler water spray motor
and earth
•Check if the earth wire is cut, or
damaged
Check connectors C-209,
C-210, C-201 and C-208
Inspect the harness between the
inter-cooler water spray relay and
the ignition switch
•Check if the power supply wire
is damaged
Check connectors C-22 & C-50
Inspect the harness between the
inter-cooler water spray relay and
the engine ECU
•Check if the signal wire is
damaged
Check connector:A-34
Replace the engine ECU
Check the inter-cooler water
spray motor (Ref Section 15:
Intake/Exhaust)
Check connectorsC-209, C-210, C-201 and C-208
Inspect the harness between the inter-cooler water spray
relay and the ignition switch
•Check if the power supply wire is cut or has short circuited
Continued from the previous page
Check the ignition switch (Ref to Section 54)
Check connectorsC-22 and C-208
Inspect the harness between the inter-cooler water spray
relay and the engine ECU
•Check if the signal wire is cut or has short circuited
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
NGNG
NG
NGNG
NG
NG
NG
NG
NG
NG
NG
NG
NG
Repair
Repair
Repair
Repair
Repair
Repair
Repair
Repair
Repair
Repair
Repair
Repair

13A-21MPI – TROUBLESHOOTING
Check connector: B-32
Replace the No 2. waste gate solenoid
valve
Check connector:B-19X
Measure at the waste gate
solenoid valve connector B-32
•Undo the connector and
measure on the solenoid
valve side
•Resistance between 1-2
OK:29~35Ω(when at 20ºC)
Measure at the waste gate
solenoid valve connector B-32
•Undo the connector and
measure on the harness side
•Ignition switch: ON
•Voltage across earth at 63
OK:battery voltage
Measure at the engine ECU
connector C-50
•Measure the voltage at the
engine ECU terminal
•Ignition switch: ON
•Voltage across earth at 63
OK:battery voltage
Check connector:C-50
Inspect the harness between the
No.2 waste gate solenoid valve
and the engine ECU
•Check if the output wire is
damaged
Inspect the harness between the
No.2 waste gate solenoid valve
and the engine control relay
•Check if the power supply wire
is damaged
Replace the engine ECU
Inspect the harness between the No.2
waste gate solenoid valve and the
engine control relay, and repair if
necessary
•Check if the power supply wire is cut
or has short circuited
Check connector:C-50
Inspect the harness between the No.2
waste gate solenoid valve and the
engine ECU
•Check if the output wire is cut or has
short circuited
Replace the engine ECU
NG
OK
OK
OK
OK
OK
NG
NG
NG
NG
Repair
Repair
OK
OK
NG
NG
OK
Repair
NGRepair
Repair
No.2 waste gate solenoid valve systemProbable causes of the malfunction
The No.2 waste gate solenoid valve controls the supercharge pressure
introduced to the waste gate actuator in the turbocharger.•Malfunction of the No.2 waste gate
solenoid valve.
•Circuit break, short circuit or a faulty
connection in the No.2 waste gate
solenoid valve circuit.
•Malfunction of the engine ECU.
OKNGRepair
OKNGRepair
Inspection procedure 37