alternator MITSUBISHI LANCER EVOLUTION 2007 Service User Guide

11B-1
ENGINE
OVERHAUL
CONTENTS
GENERAL DESCRIPTION 2...................
SPECIFICATIONS 3..........................
Service Specifications 3.........................
Machining Standards 5.........................
Tightening Torque 5............................
Sealants 8.....................................
Form-In-Place Gasket 8........................
SPECIAL TOOLS 9...........................
ALTERNATOR AND IGNITION SYSTEM 12....
TIMING BELT 13.............................
FUEL SYSTEM 26............................SECONDARY AIR SYSTEM AND INTAKE
MANIFOLD 28...............................
EXHAUST MANIFOLD 30.....................
WATER PUMP AND WATER HOSE 32........
ROCKER ARMS AND CAMSHAFT 34.........
CYLINDER HEAD AND VALVE 40.............
OIL PUMP AND OIL PAN 47.................
PISTON AND CONNECTING ROD 56..........
CRANKSHAFT AND CYLINDER BLOCK 64....

ENGINE OVERHAUL -General Description11B-2
GENERAL DESCRIPTION
LIST OF MODELS
Vehicle nameVehicle modelEngine modelDisplacement mLSpecifications
LANCER Evolution VIICT9A4G63 - 72000DOHC 16 valve T/C
SPECIFICATIONS
ItemsSpecifications
Bore×stroke mm85×88
Total displacement mL1,997
Combustion chamber shapePentroof type
Number of cylinders4
Valve mechanismTypeDOHC
Intake valve2
Exhaust valve2
Lash adjusterHydraulic type
Rocker armRoller follower type
Compression ratio8.8
Fuel injection deviceElectronic control MPI
Ignition device typeElectronic control type 2-coil
Alternator typeAlternating current type (IC regulator built in)
Starter motor typeDeceleration drive

ENGINE OVERHAUL -Specifications11B-4
Unit: mm
Items
Standard valueLimited value
Oil pump, oil pan
Oil pump
Side clearance
Drive gear
Driven gear
0.08 - 0.14
0.06 - 0.12-
-
Piston, connecting rod
Piston
Press-in load N
Piston ring
Clearance between ring and ring groove
No. 1 ring
No. 2 ring
Closed gap
No. 1 ring
No. 2 ring
Oil
Connecting rod
Large end thrust clearance
Crankshaft
Pin section oil clearance
7,355 - 17,162
0.03 - 0.07
0.02 - 0.06
0.20 - 0.30
0.35 - 0.50
0.10 - 0.40
0.10 - 0.25
0.03 - 0.05-
0.1
0.1
0.8
0.8
1.0
0.4
0.1
Crankshaft, cylinder block
Crankshaft
End play
Journal section oil clearance
Cylinder block
Upper surface strain
Upper surface grinding limit (in combination with combined cylinder head)
Cylinder bore
Cylindricity
Clearance between piston and cylinder
0.05 - 0.25
0.03 - 0.04
0.05
-
85.0
0.01 or less
0.02 - 0.040.4
0.1
0.1
0.2
-
-
-
Turbocharger
Waste gate actuator operation pressure100 kPa-
Alternator
Alternator
Rotor coil resistanceΩ
Brush protrusion length
3-5
--
2
Starter motor
Starter motor
Deviation on commutator periphery
Commutator outer diameter
Undercut depth
0.05
29.4
0.50.1
28.8
0.2

ENGINE OVERHAUL -Specifications11B-5
MACHINING STANDARDS
Unit: mm
Items
Standard valueLimited value
Cylinder head, valve
Cylinder head
Oversize valve guide hole diameter
0.05 O.S.
0.25 O.S.
0.50 O.S.
Oversize valve seat hole diameter
Intake
0.3 O.S.
0.6 O.S.
Exhaust
0.3 O.S.
0.6 O.S.
12.05 - 12.07
12.25 - 12.27
12.50 - 12.52
35.30 - 35.33
35.60 - 35.63
33.30 - 33.33
33.60 - 33.63-
-
-
-
-
-
-
TIGHTENING TORQUE
ItemsTightening torque N·m
Alternator, ignition system
Oil level gauge guide bolt13±1
Water pump pulley bolt8.8±1.0
Alternator brace bolt (flange)23±3
Alternator brace bolt (washer)22±4
Alternator nut44±10
Crankshaft pulley bolt25±4
Center cover bolt3±0.5
Ignition coil bolt10±2
Spark plug25±5
Connector bracket bolt8.8±1.0
Timing belt
Timing belt cover bolt (flange)11±1
Timing belt cover bolt (washer)9±1
Power steering pump bracket bolt49±9
Tensioner pulley bolt49±6
Tensioner arm bolt21±4
Auto tensioner bolt23±3
Idler pulley bolt35±6
Crank angle sensor bolt8.8±1.0
Oil pump sprocket nut54±5
Crankshaft bolt162±5
Tensioner B bolt19±3
Counter balance shaft sprocket bolt46±3
Rocker cover bolt3.5±0.5
Engine support bracket bolt49±5

ENGINE OVERHAUL -Alternator and Ignition System11B-12
ALTERNATOR AND IGNITION SYSTEM
REMOVAL AND INSTALLATION
1
13±1N•m
2
3
13
4
7
6
5
89
10
1211
22±4N•m8.8±1.0 N•m
25±5N•m 3±0.5 N•m
10±2N•m
8.8±1.0 N•m
23±3N•m
25±4N•m44±10 N•m
Removal steps
1. Oil level gauge
2. O-ring
3. Oil level gauge guide
4. O-ring
5. Water pump pulley
6. Alternator brace
7. Alternator8. Crankshaft pulley
9. Center cover
10. Spark plug cable
11. Ignition coil
12. Spark plug
13. Connector bracket

ENGINE OVERHAUL -Secondary Air System and Intake Manifold11B-28
SECONDARY AIR SYSTEM AND INTAKE MANIFOLD
REMOVAL AND INSTALLATION
1
11±1N•m
23 4 5
6
7
8
9
10 1112
13
11±1N•m24±3N•m
14±1N•m
31±3N•m5±1N•m
20±2N•m
22±4N•m
36±6N•m23±4N•m
14±1N•m
36±6N•m
36±6N•m22±4N•m
49±5N•m
Removal steps
1. Exhaust manifold heat protector
2. Vacuum hose and pipe
"DA3. Air pipe assembly
4. Air control valve gasket
5. Air control valve assembly
6. Engine hanger
"CA7. Air control valve bracket"BA8. Manifold differential pressure (MDP)
sensor
9. O-ring
"AA10. Intake manifold stay
11. Alternator brace stay
12. Intake manifold
13. Intake manifold gasket

MPI -General Information13A-5
MULTI-POINT FUEL INJECTION SYSTEM DIAGRAM
L1 Oxygen sensor (front)
L2 Oxygen sensor (rear)
L3 Air flow sensor
L4 Intake air temperature sensor
L5 Throttle position sensor
L6 Camshaft position sensor
L7 Crank angle sensor
L8 Barometric pressure sensor
L9 Engine coolant temperature sensor
L10 Detonation sensor
Engine-ECU
l1 Injector
l2 Idle speed control servo
l3 Fuel pressure control solenoid valve
l4 Waste gate solenoid valve
l5 EGR control solenoid valve
l6 Purge control solenoid valve
l7 Secondary air control solenoid valve
DPower supply
DIgnition switch IG
DIgnition switch ST
DVehicle speed sensor
DA/C switch
DA/C load signal
DTachometer
DPower steering fluid pressure switch
DAlternator FR terminal
DDiagnosis control terminal
DIntercooler water spray switch (automatic)
DIntercooler water spray switch (manual)DEngine control relay
DFuel pump relay 2, 3
DA/C relay
DIgnition coil
DFan controller
DCondenser fan relay (HI)
DCondenser fan relay (LOW)
DEngine warning lamp
DDiagnosis output
DAlternator G terminal
DIntercooler water spray relay
DIntercooler water spray lamp
L1 Oxygen
sensor
(front)
L4 Intake air
temperature
sensorL5 Throttle
position
sensor
L6 Camshaft
position sensorl1 Injector l2 Idle
speed
control
servo
l6 Purge
control
solenoid
valve
Three-way
catalytic converter Canister
Air
inletVacuum
tank
Fuel
pressure
reguratorFrom
fuel tank
To fuel tank
PCV valveFrom
fuel pump
Waste gate
actuatorL2 Oxygen sensor (rear) Check
valveBy-pass
valve
l5 EGR control
solenoid valve
l4 Waste gate
solenoid valve L8 Barometric
pressure
sensor
L3 Air flow
sensorl7 Secondary
air control
solenoid
valve
Secondary
air valvel3 Fuel pressure
control
solenoid valve
EGR
valve
L9 Engine coolant
temperature sensor
L7 Crank angle sensor
L10 Detonation sensor

MPI -TroubleshootingMPI -Troubleshooting13A-11
CONFIRMING FREEZE FRAME DATA
When the engine-ECU detects a malfunction and stores a diagnosis code, it also stores a current status
of the engine. This function is called “Freeze frame” data. By analyzing this “Freeze frame” data with
MUT-II, an effective troubleshooting can be performed.
NOTE
If mulfunctions have been detected in multiple systems, engine-ECU stores one malfunction only, which
has been detected first.
Item No.Data itemUnit/StateItem No.Data itemUnit/State
21Engine coolant temperature
sensor_C81Learn value%
22Crank angle sensorr/min82Feedback%
24Vehicle speedkm/h87Engine load%
FAIL-SAFE FUNCTION REFERENCE TABLE
When the main sensor malfunctions are detected by the diagnosis function, the vehicle is controlled
by means of the pre-set control logic to maintain safe conditions for driving.
Malfunctioning itemControl contents during malfunction
Air flow sensor1. Uses the throttle position sensor signal and engine speed signal (crank angle sensor
signal) to take reading of the basic injector drive time and basic ignition timing from
the pre-set mapping.
2. Fixes the idle speed control servo in the appointed position so idle control is not
performed.
Intake air temperature
sensorControls as if the intake air temperature is 25_C.
Throttle position
sensorNo increase in fuel injection amount during acceleration due to the throttle position sensor
signal.
Engine coolant
temperature sensor1. Controls as if the engine coolant temperature is 80_C.
(Even after sensor signal is correctly recovered, continues until the ignition switch
is set to the “LOCK” (OFF) position.)
2. Rotates radiator fan and condenser fan at high speed.
Camshaft position
sensor1. Inject all fuel cylinders simultaneously. (However, when the No.1 cylinder top dead
centre is not detected at all after the ignition switch is turned to “ON” position.)
2. Shuts off fuel supply after 4 seconds have passed since a failure was detected.
(However, when the No.1 cylinder top dead centre is not detected at all after the
ignition switch is turned to “ON” position.)
Barometric pressure
sensorControls as if the barometric pressure is 101 kPa.
Detonation sensorSwitches the ignition timing from ignition timing for super petrol to ignition timing for standard
petrol.
Alternator FR terminalDoes not control the output of the alternator according to an electrical load. (works as a
normal alternator)

MPI -Troubleshooting13A-12
INSPECTION CHART FOR DIAGNOSIS CODES
Code No.Diagnosis itemReference page
P0100Air flow sensor system13A-13
P0105Barometric pressure sensor system13A-15
P0110Intake air temprature sensor system13A-16
P0115Engine coolant temperature sensor system13A-19
P0120Throttle position sensor system13A-21
P0130Oxygen sensor (front) system13A-24
P0135Oxygen sensor heater (front) system13A-26
P0136Oxygen sensor (rear) system13A-27
P0141Oxygen sensor heater (rear) system13A-29
P0201No.1 injector system13A-30
P0202No.2 injector system13A-31
P0203No.3 injector system13A-32
P0204No.4 injector system13A-33
P0325Detonation sensor system13A-34
P0335Crank angle sensor system13A-35
P0340Camshaft position sensor system13A-37
P0403EGR control solenoid valve system13A-39
P0443Purge control solenoid valve system13A-41
P0500Vehicle speed sensor system13A-43
P0505Idle speed control system13A-44
P0551Power steering fluid pressure switch system13A-46
P1104Waste gate solenoid valve system13A-47
P1105Fuel pressure control valve system13A-48
P1500Alternator FR terminal system13A-49
P1603Battery backup line malfunction13A-50
P1610Immobilizer system13A-51

MPI -Troubleshooting13A-49
Code No. P1500 Alternator FR terminal systemProbable cause
Inspection Range
DEngine speed: More than 50 r/min
Evaluation Conditions
DThe input voltage from the alternator FR terminal is between 4.8 V and 5.2 V
or is the battery voltage for 20 seconds.DOpen circuit in the alternator FR terminal circuit
DMalfunction of engine-ECU
OK
Intermittent Malfunction
(Refer to GROUP 00 - Points to
Note for Intermittent Malfunction.)
OK
Check the trouble symptoms.NGReplace the engine-ECU.
OK
Intermittent Malfunction
(Refer to GROUP 00 - Points to
Note for Intermittent Malfunction.)
OK
Check the trouble symptoms.NGReplace the alternator. NG
OK
Check the harness between the middle
connector and engine-ECU.
DCheck for damage of the output
wire.Repair NG
OK
Check the harness between the
alternator and middle connector.
DCheck for damage of the output
wire.Repair
OK
Measure at the B-14 middle
connector.
DUsing the test harness
(MB991658), connect the
connector and measure at the
pickup harness.
DEngine: Idling (After warm-up)
DRadiator fan: OFF
DVoltage between terminal No. 5
and earth.
OK:The voltage drops when
the headlamp is turned
from OFF to ON.NGCheck the following connector:
B-22NG
Repair
OK
Replace the alternator.NG
OK
Check the harness between the
alternator and middle connector.
DCheck for short circuit of the
output wire.Repair
OK
Measure at the B-14 middle
connector.
DUsing the test harness
(MB991658), connect the
connector and measure at the
pickup harness.
DIgnition switch: ON
DVoltage between terminal No.5
and earth.
OK:5-6VNGCheck the following connector:
B-22NG
Repair
OK
Intermittent Malfunction
(Refer to GROUP 00 - Points to
Note for Intermittent Malfunction.)
OK
Check the trouble symptoms.NGReplace the engine-ECU. NG
OK
Check the harness between the
middle connector and engine-ECU.
DCheck for short circuit of the
output wire.Repair
OK
Measure at the B-14 middle
connector.
DDisconnect the connector to
measure at the female connector
side.
DIgnition switch: ON
DVoltage between terminal No.5
and earth.
OK:4.9 - 5.1 VNGCheck the following connector:
C-122NG
Repair
Check the following connector:
B-14NG
Repair