coil MITSUBISHI LANCER EVOLUTION IX 2005 Workshop Manual

ENGINE – CAMSHAFT, VALVE STEM SEAL
11 - 5



O 



O 
Removal procedure
1. Oil feeder control valve connector
2. Oil feeder control valve
3. O-ring
4. Breather hose
• Secondary air control valve
(refer to Section 15-2: Secondary Air
Control System)
5. Centre cover
• Ignition coil
6. O
2sensor connector
7. Crank angle sensor connector8. Connection of the control harness
9. Vacuum hose
10. PCV hose
11.Connection of the radiator upper hose
12. Camshaft position sensor connector
(exhaust side)
13. Camshaft position sensor connector
(inlet side)
14. Connection of the earth cable
15. Rocker cover ASSY
16. Spark plug hole gasket
17. Rocker cover gasket
 
A






N 



M 

ENGINE – CYLINDER HEAD GASKET
11-15
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 sensor connector
10. Injector connector
11.Exhaust camshaft position sensor
connector12. Inlet camshaft position sensor
connector
13. Water temperature gauge unit
connector
14. Joint control harness and transmission
harness
15. Water temperature sensor connector
16. Secondary air control solenoid valve
connector
17. Vacuum tank, solenoid valve, vacuum
pipe and hose assembly
18. Brake booster vacuum hose connection
19. Oil level gauge and guide assembly
20. O-ring
21. Purge hose connection
(engine oil)

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

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-17MPI – TROUBLESHOOTING
*: Refer to the 01-1 Service Manual for the Lancer Evolution VIII (No.1036K02)
*: Refer to the 03-1 Service Manual for the Lancer Evolution VIII (No.1036K07)
Repair
Repair
Repair
Repair
Repair
Repair
Continued from previous page
Replace the spark plug wire
Replace the spark plug
Replace the ignition coil
Inspection procedure 33: Inspection of the No.1 waste
gate solenoid valve (Ref: P13A-78) *2
Inspection procedure 37: Inspection of the No.2 waste
gate solenoid valve (Ref: P13A-21)
Inspection procedure 31: Inspection of the fuel control
solenoid valve (Ref: P13A-76) *2
Inspection procedure 38: Inspection of the air
temperature sensor (Ref: P13A-22)
Check the spark plug wire (Ref: Section 16: Ignition
apparatus)
Check the spark plug (Ref: Section 16: Ignition
apparatus)
Check connectors B-123 & B-119
Check the ignition coil (Ref: Section 16: Ignition
Apparatus)
Inspect the harness and the connectors between each
cylinder’s ignition coil and the body earth, and between
the engine ECU and the ignition coil. Check for cut or
short circuited wires, or other damage.
MUT-II/III Actuator test
•No.12: Waste gate solenoid valve (Ref: P13A-87)*2
Check the supercharge pressure of the turbo charger
(Ref: Section 15: Intake/Exhaust car servicing)
Check the supercharge pressure control system (Ref:
Section 15: Intake/Exhaust car servicing)
MUT-II/III Actuator test
•No.09: Fuel pressure control solenoid valve (Ref:
P13A-87)
Check the fuel pressure (Ref: P13D-109)
Check the compression pressure (Ref: Section 11:
Engine tuning)
If the intake hose and the inlet manifold are damaged
check the air intake and repair as necessary.
Measurements taken at B-108 air temperature sensor
connector
•Using the test harness (MB991658), connect it to only
connectors No.1 and No.2 and measure at the pick-
up harness component.
•Ignition switch: ON
•Voltage across earth at 1
OK:surrounding temperature -20ºC 3.8~4.4V
surrounding temperature 0ºC 3.2~3.8V
surrounding temperature 20ºC 2.3~2.9V
surrounding temperature 40ºC 1.5~2.1V
surrounding temperature 60ºC 0.8~1.4V
surrounding temperature 80ºC 0.4~1.0V
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
NG
NG
NG
NG
NG
NG
NG
NG
NG
NG
NG

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)

MPI – ON-VEHICLE SERVICING13A-30
(3) Remove the air temperature sensor
(4) Use a hair dryer to increase the temperature and measure the
resistance.
Normal conditions:
air temp. sensor
Temperature (ºC)Resistance (kΩ)
Temperature increasesResistance decreases
(5) If the resistance deviates from the standard values, or if it does
not change, replace the air temperature sensor.
(6) Tighten the air temperature sensor to the specified torque.
Tightening torque: 14 ± N·m
4. Inspection of the oil feeder control valve
Checking the operation of the valve
(1) Disconnect the oil feeder control valve connector.
(2) Apply battery voltage across the terminals of the connector on
the oil feeder control valve side, and check that the sound of the
oil feeder control valve operating can be heard.
Caution
There is a chance that the coil may be damaged, so apply
the voltage in as short a time as possible.
Resistance across the terminals
(1) Remove the oil feeder control valve connector.
(2) Measure the resistance across the terminals of the connector on
the oil feeder control valve side.
Standard value: 6.9~7.9 kΩ (when at 20 ºC)
(3) If the resistance deviates from the standard value, replace the oil
feeder control valve.oil feeder control
valve connector
oil feeder control valve

INTAKE & EXHAUST – INLET MANIFOLD15-6
Removal procedure
1. Centre cover
2. Ignition coil connector
3. O
2sensor connector
4. Oil feeder control valve connector
5. Crank angle sensor connector
6. Injector connector
7. Air temperature sensor connector
8. Manifold absolute pressure sensor
connector
9. Purge control solenoid valve connector
10. Knock sensor connector
11.Fuel pressure solenoid valve connector12. Vacuum hose connection
13. Vacuum hose connection
14. Fuel return hose connection
15. Fuel high pressure hose connection
16. O-ring
17. Delivery pipe, injector and fuel pressure
regulator ASSY
18. Insulator
19. Insulator
20. Oil level gauge & guide ASSY
21. O-ring
22. Brake booster vacuum hose connection
23. Purge hose connection



A 



A 


A

FRONT SUSPENSION – GENERAL, SPECIAL TOOLS, STRUT ASSY
33-1
SECTION 33
FRONT SUSPENSION
CONTENTS
General........................................................1
Special tools ...............................................1Strut ASSY ..................................................1
General
The guidelines for the dismantling and assembly of the front suspension have been changed due to changes made to the
shape of the Bilstein shock absorbers.
Special tools
ToolNumberNameFunction
A: MB991237
B: MB991238A. Spring compressor body
B. Arm setDismantling and assembling
the strut ASSY
MB991680
A: MB991681
B: MB991682Wrench set
A. Wrench
B. Socket
Strut ASSY
Dismantling guidelines
 
A


Removal of the self-locking nut
1. Use the following special tools to compress the coil spring.
• Spring compressor body (MB991237)
• Arm set (MB991238)
Caution
(1) In order to completely compress the coil spring, ensure that
the special tool is fixed when at its greatest possible
extension and that it is fixed evenly to the coil spring.
(2) Do not use an impact wrench, because there is a danger
that the special tool may be damaged.