to pair MITSUBISHI LANCER EVOLUTION 2007 Service Owner's Guide

GENERAL -Supplemental Restraint System (SRS)00-23
SRS-ECU
Terminal No.Destination of harnessCorrective action
7Instrument panel wiring harness→EarthRepair or replace each wiring
harness
8Instrument panel wiring harness→Combination meter
(SRS warning lamp)
harness
9, 10Instrument panel wiring harness→Front passenger’s air bag
module
11 , 1 2Instrument panel wiring harness→Clock spring→Driver’s air bag
module)Repair or replace the dash wiring
harness. Replace clock spring.
13Instrument panel wiring harness→Junction block (fuse No.3)Repair or replace each wiring
harness
16Instrument panel wiring harness→Junction block (fuse No.2)
harness.
20Instrument panel wiring harness→Diagnosis connector
29, 30Floor wiring harnessàDriver’s seat belt pre-tensioner
27, 28Floor wiring harnessàFront passenger’s seat belt pre-tensioner
6. Inspection of the SRS-ECU harness connector should be carried out by the following procedure.
Insert the special tool (probe, MB991222, in the harness set) into the connector from harness side
(rear side), and connect the tester to this probe. If any tool than specified is used, damage to the
harness and other components will result. Furthermore, measurement should not be carried out by
touching the probe directly against the terminals from the front of the connector. The terminals are
plated to increase their conductivity, so that if they are touched directly by the probe, the plating
may break, which will cause drops in reliability.
MB991222 SRS-ECU harness connector
SRS-ECU harness connector (rear view)
7. SRS components and seat belt with pre-tensioner should not be subjected to hart, so remove the
SRS-ECU, driver’s and front passenger’s air bag modules, clock spring, and seat belt with pre-tensioner
before drying or baking the vehicle after painting.
DSRS - ECU, air bag module, clock spring : 93Æ
or more
DSeat belt with pre-tensioner : 90Æ
or more
8. Whenever you finish servicing the SRS, check warning lamp operation to make sure that the system
functions properly. (Refer to P.52B-6.)
9. Make certain that the ignition switch is LOCK (OFF) position when the MUT-IIis connected or
disconnected.
10. If you have any questions about the SRS, please contact your local distributor.
NOTE
SERIOUS INJURY CAN RESULT FROM UNINTENDED AIR BAG DEPLOYMENT, SO USE ONLY
THE PROCEDURES AND EQUIPMENT SPECIFIED IN THIS MANUAL.

ENGINE OVERHAUL -Crankshaft and Cylinder Block11B-68
INSPECTION
1. CRANKSHAFT OIL CLEARANCE (PLASTIC GAUGE
METHOD)
The oil clearance can be measured easily by using the
“plastic gauge”.
Use the following steps to use the “plastic gauge”.
(1) Wipe off all oil from the crankshaft’s outer diameter
and bearing’s inner diameter.
(2) Assemble the crankshaft.
(3) Set a plastic gauge as long as the bearing width
on the journal shaft so that straightly aligned with
the shaft centre.
(4) Carefully install the beam bearing cap, and tighten
the bolt at the specified torque 25±2N•m+90_
to 100_.
(5) Remove the bolt, and carefully remove the beam
bearing cap.
(6) Measure the width of the crushed plastic gauge (at
the section crushed the most) with the scale printed
on the plastic gauge bag.
Standard value: 0.03 - 0.04 mm
Limit value: 0.1 mm
2. CYLINDER BLOCK
(1) Visually check for the presence of scratches, rusting,
or corrosion, and using flaw detection agent, etc.,
check for cracks. If any faults are found, repair or
replace the part.
(2) Using a straight edge and thickness gauge, measure
the flatness of the cylinder block’s upper surface.
Make sure that no gasket pieces, etc., are adhered
to the upper surface of the cylinder block when
measuring.
Standard value: 0.05 mm
Limit value: 0.1 mm
(3) Check for the presence of scratches or seizure on
the cylinder wall. If any faults are found, repair (over
size) or replace the part.
(4) Using a cylinder gauge, measure the inner diameter
and cylindricity of the cylinder. If greatly worn, repair
the cylinder to the over size, and replace the piston
ring.
Standard value: 85.0 mm
Cylindricity: 0.01 mm
Plastic gauge
12 mm

MPI -TroubleshootingMPI -Troubleshooting13A-10
Code No. Diagnosis item
P0443Purge control solenoid valve system
P0500Vehicle speed sensor system
P0505Idle speed control system
P0551Power steering fluid pressure switch
P1104Waste gate solenoid valve system
P1105Fuel pressure control solenoid valve system
NOTE
If the engine warning lamp illuminates because of a malfunction of the engine-ECU, communication between
MUT-IIand the engine-ECU is impossible. In this case, the diagnosis code cannot be read.
METHOD OF READING AND ERASING DIAGNOSIS
CODES
Refer to GROUP 00 - How to Use Troubleshooting/Inspection
Service Points.
INSPECTION USING MUT-IIDATA LIST AND ACTUATOR
TESTING
1. Carry out inspection by means of the data list and the
actuator test function. If there is an abnormality, check
and repair the chassis harnesses and components.
2. After repairing, re-check using the MUT-IIand check that
the abnormal input and output have returned to normal
as a result of the repairs.
3. Erase the diagnosis code memory.
4. Remove the MUT-II, and then start the engine again and
carry out a road test to confirm that the problem has
disappeared.

MPI -Troubleshooting13A-13
DIAGNOSTIC TROUBLE CODE INSPECTION PROCEDURE
Code No. P0100 Air flow sensor systemProbable cause
Inspection Range
DEngine speed: More than 500 r/min
Evaluation Conditions
DThe sensor output frequency is less than 3 Hz for 4 seconds.DAir flow sensor malfunction
DAir flow sensor 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
MUT-IIData list
DNo. 12 Air flow sensor
(Refer to P.13A-102.)NGReplace engine-ECU.
OK
To the next pageOK
Check the harness between the air
flow sensor and engine-ECU.
DCheck for ground wire
disconnection and damage.NG
Repair
(3) NGCheck the following connector:
C-115NG
Repair
OK
Check the harness between the air
flow sensor and engine control relay.
DCheck for power cable
disconnection and short-circuit.
(2) NGCheck the following connector:
B-11XNG
OK
Intermittent malfunction
(Refer to GROUP 00 - Points to Note
for Intermittent Malfunctions.)
OK
MUT-IIData list
DNo. 12 Air flow sensor
(Refer to P.13A-102.)NGReplace engine-ECU.
OK
Check the harness between the air
flow sensor and engine-ECU.
DCheck for short-circuit of the
output wire.NG
Repair
NG
Check the following connector:
C-115NG
Repair
OK
Check and repair the harness between
the air flow sensor and engine-ECU.
DCheck for disconnection of the
output wire.NG
Repair
OK
Measure at the B-31 air flow sensor
connector.
DDisconnect the connector to
measure at the harness side
(1) Voltage between terminal No. 3
and earth
(Ignition switch: ON)
OK:4.9 - 5.1 V
(2) Voltage between terminal No. 4
and earth
(Ignition switch: ON)
OK:System voltage
(3) Resistance between terminal No.
5 and earth
OK:Less than 2Ω(1) NGMeasure at the C-115 engine-ECU
connector.
DMeasure the voltage of the
engine-ECU terminal.
DIgnition switch: ON
DVoltage between terminal No. 90
and earth.
OK:4.9 - 5.1 VOKCheck the following connector:
C-115
NG
Check the following connector:
B-31NG
Repair
MUT-IIData list
DNo. 12 Air flow sensor
(Refer to P.13A-102.)OKIntermittent malfunction
(Refer to GROUP 00 - Points to Note
for Intermittent Malfunctions.)
Repair

MPI -Troubleshooting13A-14
OK
Check the harness between the air
flow sensor and engine-ECU.
DCheck for damage of the output
wire.
DCheck for damage of the earth
wire.NG
OK
Check the harness between the air
flow sensor and engine control relay.
DCheck for damage of the power
cable.Repair NG
NG
Check the following connectors:
B-11X, C-115Repair OK
Check the trouble symptom.End
OK
Intermittent malfunction
(Refer to GROUP 00 - Points to Note
for Intermittent Malfunctions.)
OK
MUT-IIData list
DNo. 12 Air flow sensor
(Refer to P.13A-102.)NGReplace engine-ECU.
Replace the air flow sensor.
OK
Intermittent malfunction
(Refer to GROUP 00 - Points to Note
for Intermittent Malfunctions.)
OK
Measure the output waveform at the
B-31 air flow sensor connector (using
an analyzer).
DUsing the test harness
(MB991709), connect the
connector, and measure at the
pickup harness.
DEngine: Idle
DVoltage between terminal No. 3
and earth.
OK:Output the waveform as
shown on P.13A-112 (in-
spection procedure by ana-
lyzer), and check that there
is noise in the output wave-
form.NG
OK
MUT-IIData list
DNo. 12 Air flow sensor
(Refer to P.13A-102.)NGReplace engine-ECU.
OK
Check the harness between air flow
sensor and engine-ECU.
DCheck for disconnection and
damage of the reset signal wire.NG
Repair
OK
Measure at the B-31 air flow sensor
connector.
DUsing the test harness
(MB991709), connect the
connector, and measure at the
pickup harness.
DVoltage between terminal No. 7
and earth.
OK:Engine: idle
0-1V
Engine: 3,000 r/min
6-9VNGCheck the following connector:
C-126NGRepair
OK
Replace the air flow sensor.
OK
Check the harness between the air
flow sensor and engine-ECU.
DCheck for short-circuit of the
reset signal wire.NG
Repair
OK
Measure at the B-31 air flow sensor
connector.
DUsing the test harness
(MB991709), connect the
connector, and measure at the
pickup.
DIgnition switch: ON
DVoltage between terminal No. 7
and earth.
OK:7-8VNGCheck the following connector:
C-126NGRepair
From the previous page

MPI -Troubleshooting13A-15
Code No. P0105 Barometric pressure sensor systemProbable cause
Inspection Range
D2 seconds after the ignition switch is set to the “ON” position, or after the
completion of start of engine.
Evaluation Conditions
DThe sensor output voltage is more than 4.5 V for 4 seconds (Equivalent to
air pressure of more than 114 kPa)
or
DThe sensor output voltage is less than 0.2 V for 4 seconds (Equivalent to air
pressure of less than 5 kPa)DBarometric pressure sensor malfunction
DBarometric pressure sensor circuit disconnection,
short-circuit, or connector contact defect
DEngine-ECU malfunction
OK
To the next page
OK
Intermittent malfunction
(Refer to GROUP 00 - Points to Note
for Intermittent Malfunctions.)
OK
MUT-IIData list
DNo. 25 Barometric pressure
sensor (Refer to P.13A-103.)NGReplace engine-ECU.
OK
Check the harness between the air
flow sensor and engine-ECU.
DCheck the earth wire for
disconnection and damage.NG
Repair
(2) NGCheck the following connector:
C-115NG
Repair
OK
Intermittent malfunction
(Refer to GROUP 00 - Points to Note
for Intermittent Malfunctions.)
OK
MUT-IIData list
DNo. 25 Barometric pressure
sensor (Refer to P.13A-103.)NGReplace engine-ECU.
OK
Check the harness between the air
flow sensor and engine-ECU.
DCheck for short-circuit of the
power cable.NG
Repair
NG
Check the following connector:
C-115NG
Repair
OK
Check and repair the harness between
the air flow sensor and engine-ECU.
DCheck for disconnection of the
power cable.NG
Repair
OK
Measure at the B-31 air flow sensor
connector.
DDisconnect the connector to
measure at the harness side
(1) Voltage between terminal No. 1
and earth
(Ignition switch: ON)
OK:4.9 - 5.1 V
(2) Resistance between terminal No.
5 and earth.
OK:Less than 2Ω(1) NGMeasure at the C-115 engine-ECU
connector.
DMeasure the engine-ECU terminal
voltage.
DIgnition switch: ON
DVoltage between terminal No. 81
and earth
OK:4.9 - 5.1 VOKCheck the following connector:
C-115
NG
Check the following connector:
B-31NG
Repair
MUT-IIData list
DNo. 25 Barometric pressure
sensor (Refer to P.13A-103.)OKIntermittent malfunction
(Refer to GROUP 00 - Points to Note
for Intermittent Malfunctions.)

MPI -Troubleshooting13A-16
OK
Intermittent malfunction
(Refer to GROUP 00 - Points to Note
for Intermittent Malfunctions.)
OK
MUT-IIData list
DNo. 25 Barometric pressure
sensor (Refer to P.13A-103.)NGReplace engine-ECU.
OK
Check the following connector:
C-115NG
Repair
OK
Check and repair the harness between
the air flow sensor and engine-ECU.
DCheck for disconnection and
damage of the output wire.
OK
Measure at the C-115 engine-ECU
connector.
DMeasure the engine-ECU terminal
voltage.
DIgnition switch: ON
DVoltage between terminal No. 85
and earth.
OK:High 0 m 3.8 - 4.2 V
High 600 m 3.5 - 3.9 V
High 1,200 m 3.3 - 3.7 V
High 1,800 m 3.0 - 3.4 VNGCheck the following connector:
C-115NGRepair
OK
Replace the air flow sensor.
OK
Check the harness between the air
flow sensor and engine-ECU.
DCheck for short-circuit and
damage of the output wire.NG
Repair
(3) NGCheck the following connector:
C-115NG
Repair
OK
Check and repair the harness between
the air flow sensor and engine-ECU.
DCheck for damage of the power
cable.
DCheck for damage of the earth
wire.
OK
Measure at the B-31 air flow sensor
connector.
DUsing the test harness
(MB991709), connect only
connector terminals No. 1, No. 2,
and No. 5, and measure at the
pickup harness.
DIgnition switch: ON
(1) Voltage between terminal No. 1
and earth
OK:4.9 - 5.1 V
(2) Voltage between terminal No. 5
and earth
OK:Less than 0.5 V
(3) Voltage from No. 2 to earth
OK:High 0 m 3.8 - 4.2 V
High 600 m 3.5 - 3.9 V
High 1,200 m 3.3 - 3.7 V
High 1,800 m 3.0 - 3.4 V(1), (2) NGCheck the following connectors:
C-115NGRepair
From the previous page
Code No. P0110 Intake air temperature sensor systemProbable cause
Inspection Range
DAfter setting the ignition switch to the “ON” position, or after 2 seconds from
completion of start.
Evaluation Conditions
DThe sensor output voltage is more than 4.6 V for 4 seconds (Equivalent to intake
air temperature less than - 40_C)
or
DThe sensor output voltage is less than 0.2 V for 4 seconds (Equivalent to intake
air temperature of more than 120_C)DIntake air temperature sensor malfunction
DIntake air temperature sensor circuit disconnection,
short-circuit, or connector contact defect
DEngine-ECU malfunction

MPI -Troubleshooting13A-17
OK
Check the intake air temperature
sensor alone. (Refer to P.13A-132.)NGReplace the intake air temperature
sensor.
OK
Intermittent malfunction
(Refer to GROUP 00 - Points to Note
for Intermittent Malfunctions.)
OK
To the next page
OK
Intermittent malfunction
(Refer to GROUP 00 - Points to Note
for Intermittent Malfunctions.)
OK
MUT-IIData list
DNo. 13 intake air temperature
sensor
OK:Ambient temperature (More
or less the same as air
temperature)NGReplace engine-ECU.
OK
Check the harness between the air
flow sensor and engine-ECU.
DCheck for short-circuit of the
output wire.NG
Repair
OK
Check and repair the harness between
the air flow sensor and engine-ECU.
DCheck for disconnection of the
output wire.NG
Repair
NG
Check the following connector:
C-115NG
Repair
(2) NGMeasure at the C-115 engine-ECU
connector.
DMeasure the engine-ECU terminal
voltage.
DDisconnect the B-31 air flow
sensor connector.
DIgnition switch: ON
DVoltage between terminal No. 72
and earth.
OK:4.5 - 4.9 VOKCheck the following connector:
C-115
OK
MUT-IIData list
DNo. 13 Intake air temperature
sensor
OK:Ambient temperature (More
or less the same as the air
temperature)NGReplace the engine-ECU.
OK
Check the harness between the air
flow sensor and engine-ECU.
DCheck for disconnection and
damage of the earth wire.NG
Repair
OK
Measure at the B-31 air flow sensor
connector.
DDisconnect the connector to
measure at the harness side
(1) Resistance between terminal No.
5 and earth
OK:Less than 2Ω
(2) Voltage between terminal No. 6
and earth
(Ignition switch: ON)
OK:4.5 - 4.9 V(1) NGCheck the following connector:
C-115NGRepair
NG
Check the following connector:
B-31NG
Repair
MUT-IIData list
DNo. 13 Intake air temperature
sensor
OK:Ambient temperature (More
or less the same as the air
temperature)OKIntermittent malfunction
(Refer to GROUP 00 - Points to Note
for Intermittent Malfunctions.)

MPI -Troubleshooting13A-18
OK
Intermittent malfunction
(Refer to GROUP 00 - Points to Note
for Intermittent Malfunctions.)
OK
MUT-IIData list
DNo. 13 intake air temperature
sensor
OK:Ambient temperature (More
or less the same as the air
temperature)NGReplace engine-ECU.
OK
Check and repair the harness between
the air flow sensor and engine-ECU.
DCheck for damage of the output
wire.
DCheck for damage of the earth
wire.
OK
Measure at the B-31 air flow sensor
connector.
DUsing the test harness
(MB991709), connecting only
connector terminals No. 5 and
No. 6, and measure at the
pickup harness.
DIgnition switch: ON
DVoltage between terminal No. 6
and earth.
OK:Ambient temperature - 20_C
3.8 - 4.4 V
Ambient temperature 0_C
3.2 - 3.8 V
Ambient temperature 20_C
2.3 - 2.9 V
Ambient temperature 40_C
1.5 - 2.1 V
Ambient temperature 60_C
0.8 - 1.4 V
Ambient temperature 80_C
0.4 - 1.0 VNGCheck the following connectors:
C-115NGRepair
From the previous page

MPI -Troubleshooting13A-19
Code No. P0115 Engine coolant temperature sensor
systemProbable cause
Inspection Range
DAfter setting the ignition switch to the “ON” position, or 2 seconds after
completion of engine start.
Evaluation Conditions
DWhen the sensor output voltage is more than 4.6 V for 4 seconds
(Equivalent to water temperature of less than - 45_C)
or
DWhen the sensor output voltage is less than 0.1 V for 4 seconds (Equivalent
to water temperature of more than 140_C)DEngine coolant temperature sensor malfunction
DEngine coolant temperature sensor circuit
disconnection and short-circuit or connector contact
defect
DEngine-ECU malfunction
Inspection Range
DIgnition switch: ON
DThe engine speed is approximately 50 r/min or more.
Evaluation Conditions
DFrom less than 1.6 V (Equivalent to water temperature of more than 40_C),
the sensor output voltage rises to more than 1.6 V (Equivalent to water
temperature of less than 40_C)
DThe sensor output voltage is more than 1.6 V for 5 minutes
OK
To the next page
OK
Measure at the B-118 engine coolant
temperature sensor connector.
DDisconnect the connector and
measure at the sensor side.
DResistance between terminals No.
1 and No. 2
OK:Water temperature - 20_C
14 - 17 kΩ
Water temperature 0_C
5.1 - 6.5 kΩ
Water temperature 20_C
2.1 - 2.7 kΩ
Water temperature 40_C
0.9 - 1.3 kΩ
Water temperature 60_C
0.48 - 0.68 kΩ
Water temperature 80_C
0.26 - 0.36 kΩNGReplace the engine coolant
temperature sensor.
NG
Check the following connector:
B-118NG
Repair
MUT-IIData list
DNo. 21 Engine coolant
temperature sensor
OK:When cool, more or less
the same as the ambient
temperature (air tempera-
ture) When warm
80 - 120_COKIntermittent malfunction
(Refer to GROUP 00 - Points to Note
for Intermittent Malfunctions.)