engine MITSUBISHI LANCER EVOLUTION IX 2005 Repair Manual

13A-28MPI – TROUBLESHOOTING
Standard waveform
2 engine revolutions (1 camshaft revolution)
crank angle
sensor output
waveform
exhaust cam
position sensor
output waveform(cam reset angle)
(cam most advanced angle)
(phase-
angle)

•The intake cam position sensor detects the position of the inlet camshaft. The notch located on the intake side of the
camshaft creates 4 output pulses for each revolution of the camshaft.
•When the time difference between the rise and fall of the output waveform from the crank angle sensor and the rise and fall
of the output waveform from the intake cam position sensor is long the cam is at the reset angle, when the time difference is
short the cam is at the most advanced angle.
Note
When the cam is at the most advanced angle, the rise and fall of the output waveform from the intake cam position sensor
should be at an advancing angle of about 60°.

•As engine revolutions approach 2500r/min, check that the time difference (T) between the rise and fall of the output
waveform from the crank angle sensor, and the rise and fall of the output waveform from the intake cam position sensor, gets
shorter.

•Example 1
Waveform characteristics
Arectangular waveform is produced even though the
engine has not been started.
Cause of the problem
Sensor interface fault

13A-29MPI – TROUBLESHOOTING, ON-VEHICLE SERVICING
•Example 2
Waveform characteristics
The waveform is displaced to the left or the right.
Cause of the problem
The timing belt is loose
There is an abnormality in the fuel pump camshaft
On-vehicle servicing
1. Adjusting standard engine revolutions
when idling
The standard engine revolutions when idling have been
changed. All other servicing requirements are the same as
before.
Standard engine revolutions when idling: 800 ± 50 r/min
NameCodeNameCode
Intake cam position sensorCOil feeder control valveA
Air temperature sensorBManifold absolute pressure sensorB
Exhaust cam position sensorC
2. Layout diagram for MPI system components
air temp. sensor side
connector
air temp.
sensor
3. Inspection of the air temperature sensor
(1) Disconnect the air temperature sensor connector.
(2) Measure the resistance across the terminals of the air
temperature sensor connector.
Standard values:
13~18 kΩ (when at -20 ºC)
5.1~6.9 kΩ (when at 0 ºC)
2.0~3.0 kΩ (when at 20 ºC)
0.9~1.5 kΩ (when at 40 ºC)
0.40~0.78 kΩ (when at 60 ºC)
0.23~0.42 kΩ (when at 80 ºC)

ENGINE COOLING – GENERAL
14-1
SECTION 14
ENGINE COOLING
CONTENTS
General........................................................1
Water pump ................................................2Water hose and pipe ..................................3
General
The following servicing guidelines for the water pump and the water hose and pipe have been prepared for vehicles which use
the 4G63-MIVEC-T/C engine. Other servicing guidelines remain unchanged.

ENGINE COOLING – WATER PUMP14-2
Water pump
Removal and fitting
Jobs to be completed before removal and after fitting
•Draining and refilling of the coolant
•Removal and refitting of the timing belt (Ref Section 11)
Removal procedure
1. Alternator bracket
2. Water pump
3. Water pump gasket
4. O-ring
Fitting guidelines



A 
Fitting the O-ring
Fit the O-ring into the O-ring groove at the end of the water inlet
pipe, and insert it into the water pump after moistening with water
the places where the O-ring will make contact with the water pump.
Caution
Ensure that absolutely no engine oil, or other type of grease,
gets onto the O-ring.
Positions for fitting different sized bolts
Nominal diameter and nominal length (mm)



A 
water pump
O-ring
water inlet pipe

ENGINE COOLING – WATER HOSE AND PIPE
14-3
Water hose and pipe
Removal and fitting
Jobs to be completed before removal and after fitting
•Removal and refitting of the valence
•Draining and refilling of the water coolant
•Removal and refitting of the air cleaner ASSY
•Removal and refitting of the air by-pass valve ASSY, the air by-pass hose, air hoses D and E, and air pipe C
•Removal and refitting of the secondary air control valve (Ref Section 15: Secondary air control system)
Removal procedure
1. Connection to the radiator upper hose
2. Connection to the radiator lower hose
3. Water temperature gauge unit connector
4. Water temperature sensor connector
5. Water hose
6. Bracket
7. Water outlet fitting and thermostat case
ASSY
8. Thermostat case gasket
9. Connection to the knock sensor harness
clamp
10. O-ring
11. Water hose12. Water hose
13. Connection to the heater hose
14. Water hose
15. Water inlet pipe
16. O-ring
17. Turbocharger water feed pipe
18. Gasket
•Turbocharger ASSY
19. Turbocharger water return pipe
20. Gasket
 
A






B 
 
A






B 



A 




A 



A 

ENGINE COOLING – WATER HOSE AND PIPE14-4
Removal guidelines
 
A


Removing the radiator upper hose and the radiator
lower hose
Mark the radiator hose and the hose clamp with indicator marks
and then remove the radiator hose.
Fitting guidelines



A 
Fitting the O-ring and the water inlet pipe
Fit the O-ring into the groove at the end of the water inlet pipe, and
insert it after moistening with water the places where the O-ring and
the water inlet pipe will be in contact.
Caution
Ensure that absolutely no engine oil, or other type of grease,
gets onto the O-ring.



B 
Connecting the radiator lower hose and the radiator
upper hose
1. Insert the hose as far as the protrusion on the water inlet pipe
and the water outlet fitting.
2. Match up the indicator marks on the radiator hose and the hose
clamp, and fit the radiator hose.
indicator marks
water pump and
thermostat case
O-ring
water inlet pipe
protrusion
water inlet pipe and
water outlet pipe fittingindicator marks

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

INTAKE & EXHAUST – SECONDARY AIR CONTROL SYSTEM, INLET MANIFOLD15-5
Fitting guidelines



A 
Fitting the gasket
Fit the gasket so that the protruding part points in the direction
shown in the diagram.
Inlet manifold
Removal and fitting
Jobs to be completed before removal and
after fitting
•Take measures to prevent fuel leaking (only
before removal)
•Removal and refitting of the valence (Ref
Section 15: Front bumper)
•Draining and refilling the coolant
•Removal and refitting of the air duct•Removal and refitting of the strut tower bar
•Removal and refitting of the throttle body
•Removal and refitting of the secondary air
control valve (Ref P15-4)
•Removal and refitting of the cross member bar
•Removal and refitting of the front exhaust pipe
protruding
part
(engine oil)
(engine oil)

INTAKE & EXHAUST – INLET MANIFOLD
15-7
Removal procedure
24. Knock sensor connector
25. Purge control solenoid valve ASSY
26. Vacuum hose
27. Fuel pressure solenoid valve ASSY
28. PCV hose
•Alternator (Ref Section 16: Alternator)
29. Secondary air control solenoid valve
connector
30. Vacuum tank, ACV solenoid valve,
vacuum hose & pipe ASSY31. Inlet manifold stay
32. Cover
33. Gasket
34. Harness connection
35. Crank angle sensor connector
36. Alternator bracket
37. Inlet manifold
38. Inlet manifold gasket
Removal guidelines
 
A


Removal of the delivery pipe, the injector and the fuel
pressure regulator ASSY
Remove the deliver pipe, with the injector and the fuel pressure
regulator intact.
Caution
When removing the delivery pipe, be careful not to drop the
injector.
Fitting guidelines



A 

Connecting the O-ring and the fuel high pressure hose
1. Apply a small quantity of fresh engine oil to the O-ring, and
insert it into the delivery pipe without damaging the O-ring.
2. Check that the high pressure hose can be turned smoothly. If it
cannot be turned smoothly there is a possibility that it is biting
into the O-ring, so remove the 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.
3. Tighten the mounting bolt to the specified torque.
Tightening torque: 5.0 ± 1.0 N·m

INTAKE & EXHAUST – EXHAUST MANIFOLD & TURBOCHARGER15-8
Exhaust manifold and turbocharger
Removal and fitting
Jobs to be completed before removal and after
fitting
• Removal and refitting of the valence
• Removal and refitting of the radiator
• Removal and refitting of the air intake hose and
air hose A• Removal and refitting of the cross member bar
• Removal and refitting of the front exhaust pipe
• Draining and refilling of the engine oil