charging MITSUBISHI LANCER EVOLUTION IX 2005 Workshop Manual

INTAKE & EXHAUST – GENERAL, SERVICING STANDARDS, SPECIAL TOOLS,
ON-VEHICLE SERVICING15-1
SECTION 15
INTAKE & EXHAUST
CONTENTS
General................................................................................1
Servicing standards ..........................................................1
Special tools.......................................................................1
On-vehicle servicing..........................................................1
Turbocharger super charging pressure check ...............1Inter-cooler water spray ....................................................2
Secondary air control system ..........................................4
Inlet manifold .....................................................................5
Exhaust manifold and turbocharger ................................8
General
The following servicing guidelines have been prepared for vehicles which use the 4G63-MIVEC-T/C engine. Other servicing
guidelines remain unchanged.
• Changes to the turbocharger supercharging pressure
• Changes to the inter-cooler water spray hose
• Changes to the secondary air control valve
• Changes to the inlet manifold
• Changes to the exhaust manifold and the turbocharger
Special tools
On-vehicle servicing
Turbocharger supercharging pressure check
The standard value for the turbocharger charging pressure has
been changed. Other servicing guidelines remain unchanged.
Standard value: 97 ~ 157 kPa
ItemStandard value
Turbocharger charging pressure kPa97~157
Servicing standards
ToolNumberNameFunction
MD998770O
2sensor wrenchRemoval and fitting of the O
2
sensor

ENGINE ELECTRICAL – CHARGING SYSTEM
16-1
SECTION 16
ENGINE ELECTRICAL
CONTENTS
Charging system ........................................1
General .................................................................1
Alternator...............................................................1
Ignition system...........................................4
General .................................................................4
Servicing standards...................................4
On-vehicle servicing ..................................4
Checking, cleaning and replacing spark plugs .....4
Cam position sensor .................................4
Charging system
General
The following alternator servicing guidelines have been prepared for vehicles which use the 4G63-MIVEC-T/C engine. Other
servicing guidelines remain unchanged.
Alternator
Removal and fitting
Jobs to be done before removal and after fitting
• Removal and refitting of the valence
• Checking the tension of the drive belt <only after fitting>
• Removal and refitting of the strut tower bar
• Removal and refitting of the front exhaust pipe ASSY
• Adjustment of the accelerator cable <only after fitting>

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

ENGINE ELECTRICAL – CHARGING SYSTEM
16-3
Removal guidelines
 
A



Removing the delivery pipe, the injector, and the fuel
pressure regulator ASSY
Loosen the bolts holding it in place, slightly dislodge all of the
components and make space for the alternator to be removed.
 
B


Removing the drive belt
The following procedures are necessary because a serpentine drive
system with auto-tensioner has been installed.
1. Insert a 12.7sq spinner handle into the auto-tensioner hole, and
turn the auto-tensioner in an anti-clockwise direction until it
reaches the stopper.
2. Align the A hole and the B hole, hold them in place by inserting
an L-shaped hexagonal Allen Key, 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.
 
C


Removing the alternator
Push the whole engine up using a garage jack, and remove the
alternator from above.
AholeB hole
L-shaped
hexagonal
Allen
wrench

3-1
SECTION 3
CIRCUIT DIAGRAMS
CONTENTS
J/B ............................................................3-4
J/C ............................................................3-6
Central Junction....................................3-11
Power Supply ........................................3-18
Starting System ....................................3-23
Ignition ...................................................3-24
Charging ................................................3-26
Engine Control ......................................3-28
Cooling ..................................................3-36
Lighting
Headlights (excl. discharge type).....................3-38
Headlights (discharge type) .............................3-42
Tail lights, position lights, licence plate
lights, lighting monitor report buzzer................3-46
Cabin lights, boot compartment lights,
ignition key cylinder illumination light,
door ajar indicator light ....................................3-50
Fog lamps ........................................................3-54
Headlight levelling system ...............................3-58
Signals
Turn signal lights, hazard warning lights .........3-60
Reversing lights ...............................................3-64
Stop lights ........................................................3-65
Horn .................................................................3-66
Meters
Needle meters..................................................3-68
Remaining fuel warning light, oil pressure
warning light, brake warning light,
seatbelt warning light .......................................3-70
Door Opening / Closing Control
Power windows ................................................3-72
Central door locking
(vehicle without keyless entry) .........................3-78
Central door locking
(vehicle with keyless entry) ..............................3-80
Temperature Control
Heater ..............................................................3-86
Manual air-conditioning ....................................3-90
Fully automatic air-conditioning .......................3-96
Vision / Safety
Windscreen washer / wipers ..........................3-104
Rear washer / wiper .......................................3-108
Demister
(vehicle with heater or manual A/C) ...............3-110
Demister, door mirror heating elements
(vehicle with full auto A/C)..............................3-112
Electric stowable remote control
door mirrors ....................................................3-114
Accessories
Spare audio connectors .................................3-118
Clock ..............................................................3-120
Cigarette lighter, ashtray illumination lamp ....3-121
Cont. on next page

3-18CIRCUIT DIAGRAMS - POWER DISTRIBUTION
Battery
Fusible
links
Charging
Charging •ACD (vehicle
w/out AYC)
•ACD, AYC•Full auto A/C
•Manual A/C
•Cooling
Dedicated
fuses
•Full auto A/C
•Manual A/C
•CoolingEngine control
•Security alarm
•Central door
locking (keyless
entry)
•Turn signal
lights, hazard
lights•Full auto
A/C
•Manual
A/C
•Cooling•ABS
•ACD
(vehicle
w/out AYC)
•ACD, AYC
•Stop lights•Heater
•Full auto
A/C
•Manual
A/C
POWER DISTRIBUTION

CIRCUIT DIAGRAMS - POWER DISTRIBUTION3-20
Power distribution (continued)
Fusible link
Dedicated
fuse
Intercooler
water spray Ignition
switch
•Engine control
•Starting system
Ignition
•ABS
•ACD (vehicle
w/out AYC)
•ACD, AYC
•SRS airbags,
seatbelt pre-
tensioners
•Ignition key
reminder buzzer
•Intercooler water
spray
•Windscreen
washer / wiper
•Warning lights
•Engine control
•Sunroof
•Needle meters
•Charging
•Security alarm
•Central door
locking•Turn signal lights,
hazard lights
•Tail lights, position
lights, licence plate
lights, lighting
monitor warning
buzzer
•Electric stowable
remote control
door mirrors
•Power windows
•Generic spare
connector
•Fog lamps
•Headlights
•Rear washer /
wiper
•Cabin lights, boot
compartment
lights, ignition key
cylinder
illumination light,
door ajar indicator
light •SRS airbags,
seatbelt pre-
tensioners
•Reversing
lights
•Rear washer /
wiper Engine control

CIRCUIT DIAGRAMS - CHARGING3-26
CHARGING
Fusible
link
Engine ECUBattery
Dedicated
fuse
Combination
meter Ignition switch (IG1)
Brake
warning light •Windscreen washer /
wiper
•Engine control
•Needle meters
•Turn signal lights, hazard
lights
•Tail lights, position lights,
licence plate lights, lighting
monitor warning buzzer
•Electric stowable remote
control door mirrors
•Generic spare connector
•Fog lights
•Headlights
•Rear washer / wiper
•Cabin lights, boot
compartment lights,
ignition key cylinder
illumination light, door ajar
indicator light Note:
*
Alternator
Field coil
Starter
coil
IC voltage regulator

CIRCUIT DIAGRAMS - LIGHTING3-39
Ignition
switch (IG2)
•Intercooler
water spray
•Heater
•Full auto
A/C
•Manual A/C
•Full auto A/C
•Manual A/C
•Cooling•ABS
•ACD, AYC
•ACD (vehicle w/out AYC)
•SRS airbags, seatbelt pre-
tensioners
•Intercooler water spray
•Windscreen washer / wiper
•Warning lamps
•Engine control
•Needle meters
•Charging
•Electric stowable remote
control door mirrors
•Generic spare connector
•Cabin lights, boot
compartment lights, ignition
key cylinder illumination
light, door ajar indicator
light Ignition
switch (IG1)
Generic
fuse
J/B
(
)
Dimmer
passing
switch
Column switchWriting
switch
()()
Power
supply

CIRCUIT DIAGRAMS - LIGHTING3-43
Ignition
switch (IG2)Ignition
switch (IG1)
•Intercooler
water spray
•Manual A/C
•Full auto A/C
•Full auto A/C
•Manual A/C
•Cooling
Generic
fuse
J/B
(
)
•ABS
•ACD, AYC
•ACD (vehicle w/out AYC)
•SRS airbags, seatbelt pre-
tensioners
•Intercooler water spray
•Windscreen washer / wiper
•Warning lights
•Engine control
•Needle meters
•Charging
•Electric stowable remote
control door mirrors
•Generic spare connector
•Cabin lights, boot
compartment lights, ignition
key cylinder illumination light,
door ajar indicator light
Dimmer
passing
switch
Column switch
(
)
Lighting
switch()
Power
supply