battery MITSUBISHI LANCER EVOLUTION 2007 Service Owner's Manual

ENGINE -On-vehicle Service11A-12
12. Install the ignition coils and spark plugs.
13. Use the MUT-IIto erase the self-diagnosis codes or
disconnect the battery cable from the battery ( - ) terminal
for 10 seconds or more and then reconnect the cable.
NOTE
This will erase the diagnosis code resulting from the crank
angle sensor connector being disconnected.
MANIFOLD VACUUM CHECK
1. Set the vehicle to the pre-inspection condition.
2. Turn the ignition switch to the “LOCK” (OFF) position.
3. Set the engine tachometer or connect the MUT-II.
4. Check that the idle speed is within the standard value.
NOTE
When using the MUT-II, select the code No.22.
5. Connect the three-way union joint to the vacuum hose
between the fuel pressure control valve and the air intake
plenum, and connect a vacuum gauge.
6. Check the manifold vacuum at idle.
Limit: 58 kPa
7. Turn the ignition switch to the “LOCK” (OFF) position.
8. Remove the vacuum gauge and install the vacuum hose
in its original location.
9. Remove the engine tachometer or the MUT-II.
LASH ADJUSTER CHECK
If an abnormal noise (knocking) that seems to be coming
from the lash adjuster is heard after starting the engine and
does not stop, carry out the following check.
NOTE
(1) The abnormal noise which is caused by a problem
with the lash adjusters is generated after the engine
is started, and will vary according to the engine speed.
However, this noise is not related to the actual engine
load.
Because of this, if the noise does not occur
immediately after the engine is started, if it does not
change in accordance with the engine speed, or if
it changes in accordance with the engine load, the
source of the noise is not the lash adjusters.
Vacuum gauge
Fuel pressure
control valve

ENGINE -Cylinder Head Gasket11A-28
CYLINDER HEAD GASKET
REMOVAL AND INSTALLATION
Caution
If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to contact
the parts or tools to the caliper because the paint of caliper will be scratched.
Pre-removal and Post-installation Operation
DFuel Outflow Preventive Operation (Refer to GROUP 13A - On-vehicle Service.)
DFuel Leak Check
DStrut Tower Bar Removal and Installation (Refer to GROUP 42.)
DUnder Cover Removal and Installation (Refer to GROUP 51 - Front Bumper.)
DDrive Belt Tension Check (Refer to P.11A-7.)
DAccelerator Cable Adjustment (Refer to GROUP 17 - On-vehicle Service.)
DDrainage and Refilling Engine Oil (Refer to GROUP 12 - On-vehicle Service.)
DDrainage and Refilling of Engine Coolant (Refer to GROUP 14 - On-vehicle Service.)
DAir Cleaner Assembly Removal and Installation (Refer to GROUP 15.)
DAir Hose E, Air Pipe C, Air hose D Removal and Installation (Refer to GROUP 15 - Intercooler.)
DBattery Removal and Installation
DCenter Cover Removal and Installation (Refer to P.11A-17.)
DAccelerator Cable Removal and Installation (Refer to GROUP 17.)
DRadiator Removal and Installation (Refer to GROUP 14.)
DSecondary Air Control Valve Bracket Removal and Installation (Refer to GROUP 15 - Secondary Air Supply System.)
DCrossmember Bar Removal and Installation (Refer to GROUP32 - Engine Roll Stopper, Centermember.)
DFront Exhaust Pipe Removal and Installation (Refer to GROUP 15.)
DStarter Removal and Installation (Refer to GROUP 16.)
DTiming Belt Removal and Installation (Refer to P.11A-34.)

ENGINE -Timing Belt and Timing Belt B11A-37

(1) Connect the special tool (MB991668) to the MUT-II.
(2) Connect the special tool (MB991704) to the MUT-II
and the battery.
(3) Rotate the crankshaft clockwise for two rounds to
position No.1 cylinder at compression TDC and check
that timing marks of each sprocket are aligned with
each other.
(4) Select “Belt Tension Measurement” from the menu
screen of the MUT-II.
(5) Hold the special tool (MB991668) to the middle of
the belt between sprockets (at the place indicated
by the arrow) as shown in the illustration about 10
- 20 mm away from the rear surface of the belt and
so that it is perpendicular to the belt (within an angle
of±15_).
(6) Gently tap the middle of the belt between sprockets
(the place indicated by the arrow) with your finger
as shown in the illustration and check that the vibration
frequency of the belt is within the standard value.
Caution
1) If strong gusts of wind blow against the
microphone or if there are any loud sources
of noise nearby, the values measured by the
microphone may not correspond to actual
values.
2) If the microphone is touching the belt while
the measurement is being made, the values
measured by the microphone may not
correspond to actual values.

Apply a force of approx.100N to the middle (arrow part)
of pulley shown in the figure, and check that the deflection
is within the standard value.
3. If it is outside the standard value, re-adjust belt tension.
MB991668
10 - 20 mm
15_
15_
Gently tap with
your finger
Deflection
Approx.
100 N

ENGINE -Engine Assembly11A-43
ENGINE ASSEMBLY
REMOVAL AND INSTALLATION
Caution
1. If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to
contact the parts or tools to the caliper because the paint of caliper will be scratched.
2. Tightening sections indicated in the mark (*) should be finally tightened with engine weight
applied on the body after lightly tightening.
Pre-removal and Post-installation Operation
DFuel Outflow Preventive Operation (Refer to GROUP 13A - On-vehicle Service.)
DFuel Leak Check
DRemoval and Installation of Hood (Refer to GROUP 42.)
DRemoval and Installation of Strut Tower Bar (Refer to GROUP 42.)
DRemoval and Installation of Under Cover (Refer to GROUP 51 - Front Bumper.)
DRemoval and Installation of Side Cover.
DDrive Belt Tension Check (Refer to P.11A - 7.)
DAccelerator Cable Adjustment (Refer to GROUP 17 - On-vehicle Service.)
DDrainage and Refilling Engine Oil(Refer to GROUP 12 - On-vehicle Service.)
DDrainage and Refilling of Engine Coolant (Refer to GROUP 14 - On-vehicle Service.)
DAir Cleaner Removal and Installation (Refer to GROUP 15)
DRemoval and Installation of Air Pipe C, Air Pipe B and Air Hose A (Refer to GROUP 15 - Intercooler.)
DBattery and Battery Tray Removal and Installation
DRemoval and Installation of Center Cover (Refer to P.11A - 17.)
DRemoval and Installation of Accelerator Cable (Refer to GROUP 17.)
DRemoval and Installation of Radiator (Refer to GROUP 14.)
DRemoval and Installation of Crossmember Bar (Refer to GROUP 32 - Engine Roll Stopper, Centermember.)
DRemoval and Installation of Front Exhaust Pipe (Refer to GROUP 15.)
DRemoval and Installation of Air Outlet Fitting (Refer to GROUP 15 - Exhaust manifold.)

ENGINE OVERHAUL -Special Tools11B-9
SPECIAL TOOLS
ToolNumberNameUse
MD998781Flywheel stopperFixing of flywheel
MD998778Crankshaft
sprocketRemoval of crankshaft sprocket and
crankshaft sprocket B
MB998785Sprocket stopperHolding of counter balance shaft sprocket
MB991704Battery harnessMeasurement of timing belt B tension
(Use together with MUT-II.)
MB991502MUT-IIsub
assemblyMeasurement of timing belt B tension
(Use together with MB991704 and
MB991668.)
MB991668Belt tension meter
setMeasurement of timing belt B tension
(Use together with MUT-II.)
MD998767Tension pulley
socket wrenchOperation of tensioner pulley during adjust-
ment of timing belt tension
MD998738Set screwHolding of tensioner arm and auto tensioner
during installation of timing belt
MD998713Camshaft oil seal
installerInstallation of camshaft oil seal

ENGINE OVERHAUL -Timing Belt11B-18
3. Confirm that the tensioner B centre and bolt centre are
positioned as shown in the illustration.
4. Apply tension on the timing belt by lifting tensioner B
in the direction of the arrow with a finger, and tension
the tension side until it is “tight”. Fix tensioner B in this
state by tightening the bolt.
NOTE
Make sure that the tensioner B shaft does not rotate
when tightening the bolt. If the shaft rotates, the timing
belt becomes too tense.
5. Connect the special tool (MB991704) to MUT-IIand the
battery.
6. Connect the special tool (MB991668) to MUT-II.
7. Rotate the crankshaft clockwise two turns, and align each
timing mark.
8. Select “Belt Tension Measurement” from the MUT-IImenu
screen.
9. Separate the special tool (MB991668) 10 to 20 mm from
the centre back between the sprockets (shown with an
arrow), and hold so that it is vertical (inclination within
±15_) in respect to the belt.
10. Lightly tap the section shown with an arrow with fingers,
and measure the belt vibration frequency. If the results
are deviated from the standard value, loosen the bolt,
tension the belt again, and then measure the vibration
frequency again. Repeat this step until the standard value
is attained. Tighten the bolt when the standard value
is attained.
Standard value:
ItemWhen
checkWhen
adjustedWhen
replaced
Vibration frequency Hz52 - 9276 - 9276 - 92
Deflection
(Reference value) mm5-105-75-7
Tensioner
B centre
Installation
bolt centre
Timing
belt B
Belt tension side
Tensioner
B
MB991668
15_ 15_
10 - 20 mm

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-26
Code No. P0135 Oxygen sensor heater (front) systemProbable cause
Inspection Range
DThe engine coolant temperature is approximately more than 20_C.
DThe oxygen sensor heater (front) is ON.
DThe engine speed is more than 50 r/min.
DA/C relay: OFF, radiator fan: OFF
DThe battery voltage is 11 - 16 V.
Evaluation Conditions
DThe oxygen sensor heater (front) current is less than 0.2 A or more than 3.5
A for 4 seconds.DOxygen sensor heater (front) malfunction
DOxygen sensor heater (front) circuit disconnection,
short-circuit, or connector contact defect
DEngine-ECU malfunction
OK
Intermittent malfunction
(Refer to GROUP 00 - Points to Note
for Intermittent Malfunctions.)
OK
Check the trouble symptom.NGReplace the engine-ECU.
OK
Check the harness between the
oxygen sensor (front) and
engine-ECU.
DCheck for damage of the earth
wire.NG
repair
OK
Check the harness between the
oxygen sensor (front) and engine
control relay.
DCheck for damage of the power
cable.NG
Repair
OK
Check the following connector:
C-118NG
Repair
OK
Replace the engine-ECU.NG
OK
Check the harness between the
oxygen sensor (front) and
engine-ECU.
DCheck for disconnection and
short-circuit of the earth wire.Repair
OK
Measure at the C-118 engine-ECU
connector.
DMeasure the engine-ECU terminal
voltage.
DIgnition switch: ON
DVoltage between terminal No. 60
and earth.
OK:System voltageNGCheck the following connector:
C-118NG
Repair
OK
Check and repair the harness between
the oxygen sensor (front) and engine
control relay.
DCheck the power cable for
disconnection and short-circuit.
OK
Measure at the B-34 oxygen sensor
(front) connector.
DDisconnect the connector, and
measure at the harness.
DIgnition switch: ON
DVoltage between terminal No. 1
and earth
OK:System voltageNGCheck the following connector:
B-11XNG
Repair
OK
Measure at the B-34 oxygen sensor
(front) connector.
DDisconnect the connector, and
measure at the sensor.
DResistance between terminal No.
1 and terminal No. 3.
OK:4.5 - 8.0ΩNGReplace the oxygen sensor (front).
Check the following connector:
B-34NG
Repair

MPI -Troubleshooting13A-29
Code No. P0141 Oxygen sensor heater (rear) systemProbable cause
Inspection Range
DThe engine coolant water temperature is approximately more than 20_C.
DThe oxygen sensor heater (rear) is ON.
DThe engine speed is more than 50 r/min.
DA/C relay: OFF, radiator fan: OFF
DThe battery voltage is 11 - 16 V.
Evaluation Conditions
DThe oxygen sensor heater (rear) current is less than 0.2 A or more than 3.5
A for 4 seconds.DOxygen sensor heater (rear) malfunction
DOxygen sensor heater (rear) circuit disconnection,
short-circuit, or connector contact defect
DEngine-ECU malfunction
OK
Intermittent malfunction
(Refer to GROUP 00 - Points to Note
for Intermittent Malfunctions.)
OK
Check the trouble symptom.NGReplace the engine-ECU.
OK
Check the harness between the
oxygen sensor (rear) and engine-ECU.
DCheck for damage of the earth
wire.NG
Repair
OK
Check the harness between the
oxygen sensor (rear) and engine
control relay.
DCheck for damage of the power
cable.NG
Repair
OK
Check the following connector:
B-11X, C-108NG
Repair
OK
Replace the engine-ECU.NG
OK
Check the harness between the
oxygen sensor (rear) and engine-ECU.
DCheck for disconnection and
short-circuit of the earth wire.Repair
OK
Measure at the C-118 engine-ECU
connector.
DMeasure the engine-ECU terminal
voltage.
DIgnition switch: ON
DVoltage between terminal No. 54
and earth.
OK:System voltageNGCheck the following connector:
C-118NG
Repair
OK
Check and repair the harness between
the oxygen sensor (rear) and engine
control relay.
DCheck the power cable for
disconnection and short-circuit.
OK
Measure at the D-22 oxygen sensor
(rear) connector.
DDisconnect the connector, and
measure at the harness.
DIgnition switch: ON
DVoltage between terminal No. 3
and earth
OK:System voltageNGCheck the following connector:
B-11XNG
Repair
OK
Measure at the D-22 oxygen sensor
(rear) connector.
DDisconnect the connector, and
measure at the sensor.
DResistance between terminal No.
3 and terminal No. 4.
OK:11 - 1 8ΩNGReplace the oxygen sensor (rear).
Check the following connector:
D-22NG
Repair

MPI -Troubleshooting13A-39
Code No. P0403 EGR control solenoid valve systemProbable cause
Inspection Range
DThe battery voltage is 10 V or more.
Evaluation Conditions
DSolenoid coil’s surge voltage (battery voltage +2 V) is not detected when EGR
control solenoid valve is turned OFF from ON.DEGR control solenoid valve malfunction
DEGR control solenoid valve circuit disconnection,
short-circuit, or connector contact defect
DEngine-ECU malfunction
OK
To the next page
OK
Check the harness between the EGR
control solenoid valve and
engine-ECU.
DCheck for damage of the output
cable.NG
Repair
OK
Check the following connector:
C-126NG
Repair
OK
Check and repair the harness between
the EGR control solenoid valve and
engine-ECU.
DCheck for disconnection and
short-circuit of the output cable.
OK
Measure at the C-126 engine-ECU
connector.
DDisconnect the connector to
measure at the harness side
DIgnition switch: ON
DVoltage between terminal No. 6 and
earth
OK:System voltageNGCheck the following connectors:
B-14, C-126NG
Repair
OK
Check and repair the harness between
the EGR control solenoid valve and
engine control relay.
DCheck for disconnection and
short-circuit of the power cable.
OK
Measure at the B-112 EGR control
solenoid valve connector.
DDisconnect the connector to
measure at the harness side.
DIgnition switch: ON
DVoltage between terminal No. 1 and
earth
OK:System voltageNGCheck the following connectors:
B-11X, B-14NG
Repair
OK
Measure at the B-112 EGR control so-
lenoid valve connector.
DDisconnect the connector to
measure at the solenoid valve side.
DResistance between terminal No. 1
and terminal No. 2
OK:29 - 35Ω(at 20_C)NGReplace the EGR control solenoid
valve.
NG
Check the following connector:
B-112NG
Repair
MUT-IIActuator test
DNo.10: EGR control solenoid valve
OK:Operation sound is heard,
and there is vibration.OKIntermittent malfunction
(Refer to GROUP 00 - Points to Note
for Intermittent Malfunctions.)