engine MITSUBISHI LANCER EVOLUTION IX 2005 Owner's Guide

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.
•Check for fuel dripping.
•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.
•Adjustment of the axle letter cable.
•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.

ENGINE – ENGINE ASSY
11-29
Removal procedure
1. Ignition coil connector
2. O
2sensor connector
3. Oil feeder control valve connector
4. Crank angle sensor connector
5. Manifold absolute pressure sensor
connector
6. Fuel pressure solenoid valve connector
7. Knock sensor connector
8. Purge control solenoid valve connector
9. Throttle position connector
10. Injector connector11.Exhaust cam position sensor connector
12. Inlet cam position sensor connector
13. Water temperature gauge unit connector
14. Joint control harness and transmission
harness
15. Water temperature sensor connector
16. Alternator connector and terminal
17. Secondary air control solenoid valve
connector
18. Engine oil pressure switch connector
19. Drive belt
 
A

ENGINE – ENGINE ASSY11-30
Caution
Parts marked * should be temporarily tightened, and then tightened properly when the full weight of the engine is
being supported by the chassis.
20. Vacuum tank, solenoid valve, vacuum
pipe and hose ASSY
21. Brake booster vacuum hose connection
22. Purge hose connection
23. Power steering oil pressure switch
connector
24. Heat protector
25. Power steering oil pump
26. A/C compressor connector

27. A/C compressor A/C>28. Heater hose connection
29. Fuel return hose connection
30. Fuel high pressure hose connection
31. O-ring
•Transfer ASSY, transmission ASSY
32. Engine mount bracket & stopper ASSY
33. Engine ASSY
 
B


 
B






D 



D 
 
C






C 
 
D






B 
 
E






A 
(engine oil)

ENGINE – ENGINE ASSY
11-31
Removal guidelines
 
A


Removing the drive belt
The following operations are necessary because the engine uses a
serpentine drive system with auto-tensioner.
1. Insert a 12.7sq spinner handle into the auto-tensioner tool hole,
and turn the auto-tensioner in an anti-clockwise direction before
it reaches the stopper.
2. Align hole A and hole B, insert an L-shaped hexagonal Allen
Key, to hold the position, 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.
 
B


Removing the power steering oil pump and the A/C
compressor
1. Remove the power steering oil pump and the A/C compressor
from the bracket with the hoses intact.
2. Secure the removed power steering oil pump and the removed
A/C compressor with string, and put them somewhere where
they will not hinder the removal or fitting of the engine ASSY.
 
C



Removing the transfer ASSY and the transmission
ASSY
1. In order to prepare the special mechanical engine hanger
(MZ203830, MZ203831 or MB991928), the radiator support
upper insulator mounting bolts should be tightened on the
chassis (2 places).
2. Remove the transfer ASSY and the transmission ASSY.
AholeB hole
L-shaped
hex-
agonal
Allen
wrench

ENGINE – ENGINE ASSY11-32
 
D


Removing the engine mount bracket & stopper ASSY
1. Support the engine using a garage jack.
2. Remove the special mechanical engine hanger (MZ203830,
MZ203831 or MB991928).
3. Hold the engine ASSY using a chain block.
4. Support the engine oil pan component with the garage jack
through the engine block, so that the weight of the engine is not
taken by the engine mount bracket.
5. Loosen the nuts and bolts and remove the engine mount bracket
and stopper ASSY.
 
E


Removing the engine ASSY
After checking that all of the cables, hoses and harness connectors
etc have been disconnected, slowly hoist the engine using a chain
block and remove the engine from the engine compartment.
Fitting guidelines



A 
Fitting the engine ASSY
Install the engine whilst checking that cables, hoses and harness
connectors etc will not be squashed beneath it.
MZ203830 or MZ203831
slide bracket (HI)

ENGINE – ENGINE ASSY
11-33



B 
Fitting the engine mount bracket & stopper ASSY
1. Support the engine oil pan component with the garage jack
through the engine block, and fit the engine mount bracket &
stopper ASSY whilst checking the position of the engine. Fix the
engine mount stopper so that the arrow points in the direction
shown in the diagram.
2. Support the engine ASSY with a garage jack.
3. Remove the chain block.
4. In the same way as when it was removed, hold the engine
ASSY with the special tool.
(1) (MZ203830 or MZ203831)>
Install the special mechanical engine hanger (MZ203830
or MZ203831).
(2)
Fit the following parts to the base hanger.
• Slide bracket (HI)
• Foot (standard) (MB991932)
• Joint (90) (MB991930)
Install the special engine hanger (MB991928)



C 
Fitting the transfer ASSY and the transmission ASSY
1. Fit the transfer ASSY and the transmission ASSY.
2. Remove the radiator support upper insulator mounting bolts from
the chassis (2 places).engine sideengine side
engine mount stopper
rear of chassis> front of chassis>
MZ203830 or MZ203831
slide bracket (HI)
front of
chassis
joint (90)
(MB991930)
foot (standard) (MB991932)
slide bracket (HI)

ENGINE – ENGINE ASSY11-34
 
D


Fitting the O-ring and the fuel high pressure hose
1. Apply a little fresh engine oil to the O-ring.
Caution
Ensure that no engine oil gets inside the deliver pipe.
2. Without damaging the O-ring, fit the fuel high pressure hose to
the delivery pipe by twisting it from left to right. Ensure that the
hose is twisted smoothly.
3. If the hose cannot be twisted smoothly, there is a possibility that
it may be biting into the O-ring, so remove the fuel high pressure
hose, and check for any damage to the O-ring. If the O-ring is
undamaged, reinsert it into the delivery pipe and check once
more whether the hose can be turned smoothly.
4. Tighten the mounting bolts for the fuel high pressure hose, to
the specified torque.
Tightening torque: 5.0 ± 1.0 N•m.

MPI – GENERAL13A-2
MPI system diagram
Engine ECU
H1. O
2 sensor
H2. Air flow sensor
H3. Intake air temp.
sensor
H4. Throttle position
sensor
H5. Intake Cam position
sensor
H6. Exhaust Cam
position sensor
H7. Crank angle
sensor
H8. Atmospheric
pressure sensor
H9. Water temp.
sensor
H10. Knock sensor
H11. Manifold absolute
pressure (MAP)
sensor
H12. Air temp. sensor• Power supply
• Ignition switch IG
• Ignition switch ST
• Vehicle speed
sensor
• A/C switch
• A/C load signal
• Power steering
fluid pressure switch
• Alternator FR signal
• Inter-cooler water spray
switch (auto)
•Inter-cooler water spray
switch (manual)I1. Injector
I2. ISC servo (Stepper
motor)
I3. Fuel pressure
control solenoid valve
I4. No. 1 Waste gate
solenoid valve
I5. No. 2 Waste gate
solenoid valve
I6. Purge control
solenoid valve
I7. Secondary air
control solenoid valve
I8. Oil feeder control
valve• Engine control relay
• Fuel pump relay 2,3
(ON/OFF)
• Fuel pump relay (HI/LO
switch)
• A/C relay
• Ignition coil
• Fan controller
• Condenser fan relay (HI)
• Condenser fan relay
(LO)
• Engine warning light
• Diagnosis output
terminal
• Alternator G terminal
• Inter-cooler water spray
relay
•Inter-cooler water spray
lamp
• O
2sensor heater
ÈÈ
I 6. Purge control
solenoid valve
I 7. Secondary
air control
solenoid valveCheck
valve
Secondary air
valve
To fuel
tank
H 6. Exhaust cam
position sensor
H 8. Atmospheric
pressure sensor
H 2. Air flow sensor
Intake
Waste gate actuator
I 4. No.1 waste gate
solenoid valve H 3. Intake air
temperature
sensor
I 5. No.2 waste gate
solenoid valve
H 1. O
2sensor
H 5. Intake cam
position sensorCatalyst
H 7. Crank angle sensor
H 10. Knock sensor
H 9. Water temperature sensor
I 1. Injector From fuel
pump
Fuel pressure
regulatorI 8. Oil feeder control
valve I 3. Fuel pressure
control solenoid
valve
Vacuum
tank
I 2. ISC servoH 11. MAP sensor
H 12. Air temperature sensor
H 4. Throttle
position
sensor
From fuel tank
Canister
By-pass valve

MPI – TROUBLESHOOTING
13A-5
TROUBLESHOOTING
1. Diagnosis Functions
1-1 Engine warning light (Check engine lamp)
Changes have been made to engine warning lights.
Checklist for engine warning lights.
1-2 Checking of freeze frame data
Additions have been made to the freeze frame data tables.
Checklist for data tables
1-3 Failsafe and back-up functions
If one of the diagnosis functions detects that one of the main sensors is malfunctioning, it will ensure that the car can be driven
safely, in accordance with the pre-set control logic.
Engine ECU
Air flow sensor (AFS)
Manifold absolute pressure (MAP) sensor system
Intake air temperature sensor
Throttle position sensor (TPS)
Water temperature sensor
Crank angle sensor
Exhaust cam position sensor
Injector
Ignition coil (with built-in power transistor)
Atmospheric pressure sensor
O
2sensor
O
2sensor heater
Fuel system malfunction
Knock sensor
Intake cam position sensor system
Oil feeder control valve system
Item numberType of data Units/condition
95MAP sensorkPa
Malfunctioning itemControl measures taken when a malfunction occurs
Air temperature sensorRegulation of the intake air temperature at 25ºC.
Exhaust cam position sensor(1) Simultaneous flushing out of all fuel pipes.
(But only if the No. 1 cylinder has not been detected in the
TDC position after the ignition switch has been turned "ON".)
(2) Cutting off the fuel 4 seconds after the malfunction has been
detected.
(But only if the No. 1 cylinder has not been detected in the
TDC position after the ignition switch has been turned "ON".)
Intake cam position sensorThe oil feeder control valve should be switched "OFF", and the
angle of the cam should be in the reset position.

13A-7MPI – TROUBLESHOOTING
3. INSPECTION PROCEDURES FOR EACH DIAGNOSIS CODE
MUT-II/III service data
•No.95 atmospheric pressure
sensor
(Ref: P13A-24)
Go on to the next page
Measurements taken at
C-50 engine ECU connector
•Measure engine ECU terminal
voltage
•Ignition switch: ON
•Voltage across earth at 42
OK:4.9~5.1V
Check connectorC-50
Inspect the harness between the
MAP sensor and the engine ECU.
•Check if the power supply has
short circuited.
MUT-II/III service data
• No.95: MAP sensor
(Ref: P13A-24)
Replace the engine ECU
Check connectorC-50
Inspect the harness between the
MAP sensor and the engine ECU.
•Check if earth wire is cut or
damaged.
MUT-II/III service data
•No.95: MAP sensor
(Ref: P13A-24)
Replace the engine ECU
Check connectorC50
Inspect the harness between the
MAP sensor and the engine ECU,
repair if necessary.
•Check if the power supply wire is
cut.
Temporary malfunction (Ref
Section 00: Dealing with
temporary malfunctions)
Measurements taken at the B-135
MAP sensor connector
•Undo the connector, and take
measurements using the
harness
(1) Voltage across earth at 3
(ignition switch: ON)
OK: 4.9~5.1V
(2) Resistance across earth at 2
OK: 2Ω or less
Temporary malfunction (Ref
Section 00: Dealing with
temporary malfunctions)
Check connectorB-135
NG
(2) NG (1) NGOK
NG
OK
OK
Temporary malfunction (Ref
Section 00: Dealing with
temporary malfunctions)
NG
OK
NG
OK
OK
NGOK
NG
OK
NG
Repair
NG
OK
OK
NG
NG
OK
Repair
Repair
Repair
Repair
Repair
Code No. P0105 MAP sensor systemProbable cause of the malfunction
Conditions for the inspection
• Ignition switch: ON
• Wait for 2 seconds after the ignition switch has been turned on or the
engine has started.
Evaluation conditions
• Sensor output voltage is 4.6V or more for 4 seconds (when atmospheric
pressure is more than 313 kPa)
• Sensor output voltage is 0.2V or less for 4 seconds (when atmospheric
pressure is more than 14 kPa)• MAP sensor malfunction
• Broken circuit or short circuit in the MAP
sensor circuit
• Poor connector contact
• Engine ECU malfunction