User manual MITSUBISHI LANCER EVOLUTION IX MANUAL SERVICE SUPPLEMENT

[. . . ] Workshop Manual - Supplement Evolution - IX · Chassis · Engine · Wiring Diagrams · Technical Information LANCER SERVICE MANUAL Supplement LANCER EVOLUTION IX FOREWORD This manual contains details of the main changes to the 2005 model Lancer Evolution IX. Only differences to the current Lancer Evolution VIII MR are included, so please use this manual in conjunction with the related manuals as listed on the following page. Please read this manual carefully so that servicing can be done correctly and quickly, and vehicle performance maintained. This manual is based on the current (March 2005) model. [. . . ] Secondary air control solenoid valve Check valve H 4. Throttle position sensor Vacuum tank By-pass valve Secondary air valve I3. Fuel pressure control solenoid valve I8. Oil feeder control valve Fuel pressure regulator From fuel pump To fuel tank H 8. No. 1 waste gate solenoid valve Catalyst H 5. O2 sensor MPI ­ SERVICING STANDARDS, SPECIAL TOOLS Servicing standards Item Revolutions when idling r/min Air temperature sensor resistance k at -20 ºC at 0 ºC at 20 ºC at 40 ºC at 60 ºC at 80 ºC Oil feeder control valve resistance (at 20 ºC) Standard level 800 ± 50 13~18 5. 1~6. 9 2. 0~3. 0 0. 9~1. 5 0. 40~0. 78 0. 23~0. 42 6. 9~7. 9 13A-3 Special tools Tool Number MB991502 Name MUT-II sub ASSY Function Checking the MPI system MB991955 A:MB991824 B:MB991827 C:MB991910 D:MB991911 E:MB991825 F:MB991826 MUT-III sub ASSY A: Vehicle Communication Interface (V. C. I. . ) B: USB cable C: MUT-III Main harness A (For vehicles fitted with CAN) D: MUT-III Main harness B (For vehicles not fitted with CAN) E: Adaptor F: Trigger harness Note If a MUT-III main harness A is connected to a vehicle not fitted with CAN, there is a chance that a pulse signal will be entered in the simulated vehicle speed line, when the MUT-III is activated. Therefore, use a MUT-III main harness B with vehicles not fitted with CAN. DO NOT USE 13A-4 Tool Number MB991348 MPI- SPECIAL TOOLS Name Test harness Function Inspection using an oscilloscope MB991709 Test harness · Troubleshooting voltage measurement · Inspection using an oscilloscope MB991658 Test harness Inspection using an oscilloscope MD998478 Test harness (3P, triangular) · Troubleshooting voltage measurement · Inspection using an oscilloscope Red coloured harness (for DLI) MB991223 Inspection harness set connector · Pin contact pressure inspection harness · Commercial tester connection probe (for ordinary connectors) Terminal voltage measurement White coloured harness (for LC) MPI ­ TROUBLESHOOTING TROUBLESHOOTING 1. Diagnosis Functions 1-1 Engine warning light (Check engine lamp) Changes have been made to engine warning lights. 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 O2 sensor O2 sensor heater Fuel system malfunction Knock sensor Intake cam position sensor system Oil feeder control valve system 1-2 Checking of freeze frame data Additions have been made to the freeze frame data tables. Checklist for data tables Item number 95 Type of data MAP sensor Units/condition kPa 13A-5 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. Malfunctioning item Air temperature sensor Exhaust cam position sensor Control measures taken when a malfunction occurs Regulation of the intake air temperature at 25ºC. (1) Simultaneous flushing out of all fuel pipes. 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. 1 cylinder has not been detected in the TDC position after the ignition switch has been turned "ON". ) The oil feeder control valve should be switched "OFF", and the angle of the cam should be in the reset position. Intake cam position sensor 13A-6 MPI- TROUBLESHOOTING 2. Diagnosis code classification table Code No. P0105 P0340 P1012 P1021 P2226 Diagnosis item MAP sensor Exhaust cam position sensor system Intake cam position sensor system Oil feeder control valve system Atmospheric pressure system Page 13A-7 13A-9 13A-11 13A-13 13A-14 MPI ­ TROUBLESHOOTING 3. INSPECTION PROCEDURES FOR EACH DIAGNOSIS CODE Code No. P0105 MAP sensor system 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) 13A-7 Probable cause of the malfunction · MAP sensor malfunction · Broken circuit or short circuit in the MAP sensor circuit · Poor connector contact · Engine ECU malfunction MUT-II/III service data · No. 95 atmospheric pressure sensor (Ref: P13A-24) NG Check connector B-135 OK 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: 2 or less OK Temporary malfunction (Ref Section 00: Dealing with temporary malfunctions) NG Repair OK (1) NG 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 NG Check connector C-50 OK Check connector C50 Repair Inspect the harness between the MAP sensor and the engine ECU, repair if necessary. · Check if the power supply wire is cut. OK NG NG Repair Inspect the harness between the NG MAP sensor and the engine ECU. · Check if the power supply has short circuited. OK OK MUT-II/III service data · No. 95: MAP sensor (Ref: P13A-24) NG Replace the engine ECU (2) NG Check connector C-50 OK Inspect the harness between the MAP sensor and the engine ECU. [. . . ] Counterbalance shaft rear bearing, left 22 4G6 ­ PISTONS / CONNECTING RODS Piston / Connecting Rod Removal and Installation Apply engine oil to all sliding parts before installing. Removal Sequence 1. *1 * 6. *1 * *1 * *1 ** A *1 * Connecting rod cap nut Connecting rod cap Connecting rod bearing Piston connecting rod Connecting rod bearing Piston ring No. Bolt 4G6 - PISTONS / CONNECTING RODS Position of crankshaft pin diameter identification marks 23 Installation Service Point A* Installation of bearings on connecting rod 1. When replacing a bearing, connecting rod or crankshaft, choose a bearing of the correct size which corresponds to the external diameter of the crankshaft pin, in accordance with the identification marks on the crankshaft pin and the connecting rod bearing given in the table below. [. . . ]