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. Please bear in mind that vehicle specifications may change and that future models may not be the same. [. . . ] 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. 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. OK NG NG Repair Inspect the harness between the NG MAP sensor and the engine ECU. 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. OK MUT-II/III service data · No. 95: MAP sensor (Ref: P13A-24) NG OK Go on to the next page Replace the engine ECU OK NG NG Repair Temporary malfunction (Ref Section 00: Dealing with temporary malfunctions) Repair Repair Temporary malfunction (Ref Section 00: Dealing with temporary malfunctions) 13A-8 Continued from the previous page OK NG Measurements taken at the B-135 MAP sensor connector · Connect the test harness (MB991348) to the connector and measure at the pick-up harness component. · Ignition switch: ON · Voltage across earth at 2 OK: 4. 9~5. 1V OK Measurements taken at the B-135 MAP sensor connector · Connect the test harness (MB991348) to the connector and measure at the pick-up harness component. · Ignition switch: ON · Voltage across earth at 1 OK: altitude 0m 1. 2~1. 8V altitude 600m 1. 1~1. 7V altitude 1200m 1. 0~1. 6V altitude 1800m 0. 9~1. 5V OK NG Measurements taken at the C-50 engine ECU connector · Measure engine ECU terminal voltage · Ignition switch: ON · Voltage across earth at 92 OK: altitude 0m 1. 2~1. 8V altitude 600m 1. 1~1. 7V altitude 1200m 1. 0~1. 6V altitude 1800m 0. 9~1. 5V OK NG Check connector C-50 OK OK MUT-II/III service data · No. 95: MAP sensor (Ref: P13A-24) NG Replace the engine ECU NG MPI ­ TROUBLESHOOTING NG Check connector C-50 OK Inspect the harness between the MAP sensor and the engine ECU, repair if necessary. Repair NG Check connector C-50 OK Inspect the harness between the MAP sensor and the engine ECU. OK Replace the MAP sensor NG Repair Repair NG Check connector C-50 OK Inspect the harness between the MAP sensor and the engine ECU, repair if necessary · Check if the output wire has been cut or damaged. Repair Repair Temporary malfunction (Ref Section 00: Dealing with temporary malfunctions) MPI ­ TROUBLESHOOTING 13A-9 Code No. P0340 Exhaust cam position sensor system Probable cause of the malfunction Conditions for inspection · Malfunction of the exhaust cam position · Ignition switch: ON sensor · With engine cranking or running · Broken circuit or short circuit in the exhaust Evaluation conditions cam position sensor circuit, or poor connector · The sensor output voltage does not change for 4 seconds (with no input of contact pulse signals) · Malfunction of engine ECU NG Check connector B-115 OK (1) NG Measurements taken at the B-115 connector of the exhaust cam position sensor · Undo the connector and take measurements using the harness (1) Voltage across earth at 3 (ignition switch: ON) OK: battery voltage (2) Voltage across earth at 2 (2) NG (ignition switch: ON) OK: 4. 9~5. 1V (3) Resistance across earth at 1 OK: Less than 2 NG Check connector B-19X OK Inspect the harness between the exhaust cam position sensor and the engine control relay, repair if necessary · Check if the power supply wire is cut or has short circuited OK Measurements taken at engine ECU connector C-50 · Measurement of voltage at engine ECU terminals · Undo the B-115 exhaust cam position sensor connector · Ignition switch: ON · Voltage across earth at 50 OK: 4. 9~5. 1V NG Check connector C-50 OK Inspect the harness between the exhaust cam position sensor and the engine ECU · Check if the output wire has short circuited OK Check that the problem has been solved NG Replace engine ECU (3) NG Check connector C-49 OK Inspect the harness between the exhaust cam position sensor and the engine ECU · Check if the earth wire is cut or damaged OK OK To next page Check the problem has been solved NG Replace engine ECU NG Repair NG Repair OK Temporary malfunction (Ref Section 00: Dealing with temporary malfunctions) NG Repair NG Repair Check connector C-50 OK NG Repair Inspect the harness between the exhaust cam position sensor and the engine ECU, repair if necessary · Check if the output wire is cut Repair Repair OK Temporary malfunction (Ref Section : Dealing with temporary malfunctions) 13A-10 Continued from the previous page OK NG Measurement of the output wave at the exhaust cam position sensor connector B-115 (using an oscilloscope) · Use test harness (MB991709), connect it to the connector, and take measurements at the pickup harness component · Engine: idling · Voltage across earth at 2 OK: An output wave as described on P. 13A-25 (Main points for oscilloscope testing) is produced, with the maximum value in excess of 4. 8V and the minimum value less than 0. 6V. There should be no noise in the output wave form. MPI ­ TROUBLESHOOTING NG Check connector B-19X OK Inspect the harness between the exhaust cam position sensor and the engine control relay · Check if the power wire is damaged OK Check connector C-49 and C-50 OK Inspect the harness between the exhaust cam position sensor and the engine ECU · Check if the output wire is damaged OK Check the exhaust cam position sensing cylinder OK Check that the problem has been solved NG Replace the exhaust cam position sensor OK Temporary malfunction (Ref Section 00: Dealing with temporary malfunctions) NG NG Repair NG Repair NG Repair Repair Replace the exhaust cam position sensing cylinder OK Check that the problem has been solved NG Replace the engine ECU OK Temporary malfunction (Ref Section 00: Dealing with temporary malfunctions) MPI ­ TROUBLESHOOTING Code No. P1012 Intake cam position sensor system Conditions for inspection · With engine cranking or running Evaluation conditions · Sensor output voltage does not change for 4 seconds (with no input of pulse signals) 13A-11 Probable cause of the malfunction · Malfunction of the intake cam position sensor · Broken circuit or short circuit in the intake cam position sensor circuit, or poor connector contact · Malfunction of engine ECU NG Check connector B-33 OK (1) NG Measurements taken at the B-33 connector of the intake cam position sensor · Undo the connector and take measurements using the harness (1) Voltage across earth at 3 (ignition switch: ON) OK: battery voltage (2) Voltage across earth at 2 (ignition switch: ON) OK: 4. 9~5. 1V (3) Resistance across earth at 1 OK: Less than 2 Check connectors B-19X & C-23 OK Inspect the harness between the intake cam position sensor and the engine control relay, repair if necessary · Check if the power supply wire is cut or has short circuited OK (2) NG Measurements taken at engine ECU connector C-50 · Measurement of voltage at engine ECU terminals · Undo the B-33 intake cam position sensor connector · Ignition switch: ON · Voltage across earth 53 OK: 4. 9~5. 1V NG NG Check connector C-50 OK Inspect the harness between the intake cam position sensor and the engine ECU · Check if the earth wire is cut or damaged OK Check that the problem has been solved NG Replace engine ECU (3) NG Check connector C-49 OK Harness inspection between the intake cam position sensor and the engine ECU · Check if the earth wire is cut or damaged OK OK To next page Check that the problem has been solved NG Replace the engine ECU OK Temporary malfunction (Ref Section 00: Dealing with temporary malfunctions) NG Repair NG Repair NG Repair Repair Check connector C-50 OK NG Repair Inspect the harness between the intake cam position sensor and the engine ECU, repair if necessary · Check if the output wire is cut NG Repair Repair OK Temporary malfunction (Ref Section 00: Dealing with temporary malfunctions) 13A-12 Continued from the previous page OK Measurement of the output wave at the intake cam position sensor connector B-33 (using an oscilloscope) · Use test harness (MB991709), connect it to the connector, and take measurements at the pickup harness component · Engine: idling · Voltage across earth at 2 OK: An output wave as described on P. 13A-25 (Main points for oscilloscope testing) is produced, with the maximum value in excess of 4. 8V and the minimum value less than 0. 6V. NG MPI ­ TROUBLESHOOTING NG Check connectors B-19X & C-23 OK NG Inspect the harness between the intake cam position sensor and the engine control relay · Check if the power wire is damaged OK Check connectors C-49 & C-50 OK Inspect the harness between the intake cam position sensor and the engine ECU · Check if the output wire is damaged OK Check the intake cam position sensing cylinder OK Check that the problem has been solved NG Replace the intake cam position sensor OK Temporary malfunction (Ref Section 00: Dealing with temporary malfunctions) NG Replace the intake cam position sensing cylinder NG Repair NG Repair Repair Repair OK OK Check that the problem has been solved NG Replace engine ECU Temporary malfunction (Ref Section 00: Dealing with temporary malfunctions) MPI ­ TROUBLESHOOTING Code No. P1021 Oil feeder control valve system Conditions for inspection · Oil feeder control valve: OFF Evaluation conditions · Operational terminal voltage of the oil feeder control valve in the ECU is abnormal for 4 seconds · · 13A-13 Probable cause of the malfunction Malfunction of the oil feeder control valve Broken circuit or short circuit in the oil feeder control valve circuit, or poor connector contact Malfunction of engine ECU · NG Check connector B-134 OK NG Inspect the oil feeder control valve by itself (Ref: P13A-30) OK NG A-134 Measurement of the oil feeder control valve · Measure using a harness connected to the connector · Ignition switch: ON · Voltage across earth at 1 OK: battery voltage OK NG Check connectors B-19 & C-23 OK Inspect the harness between the engine control relay and the oil feeder control valve, repair if necessary · Check for damage to the power supply wire OK C-49 Measurement of engine ECU · Undo the connector and measure on the harness side · Ignition switch: ON · Voltage across earth at 32 OK: battery voltage OK NG Check connector C-49 OK NG Inspect the harness between the engine ECU and the oil feeder control valve · Check for damage to the output wire OK OK Check that the problem has been solved NG Replace the engine ECU Temporary malfunction (Ref Section 00: Dealing with temporary malfunctions) Repair Repair NG NG Check connector C-49 OK Inspect the harness between the engine ECU and the oil feeder control valve, repair if necessary · Check if the output wire is cut or has short circuited Repair NG Repair Repair Check connectors B-19X & C-23 OK Inspect the harness between the engine control relay and the oil feeder control valve, repair if necessary · Check if the power supply wire is cut or has short circuited NG Repair Replace the oil feeder control valve Repair 13A-14 MPI ­ TROUBLESHOOTING Probable cause of the malfunction · Malfunction of the atmospheric pressure sensor · Broken circuit or short circuit in the atmospheric pressure sensor circuit, or poor connector contact · Malfunction of engine ECU Code No. P2226 Atmospheric pressure sensor system Conditions for inspection · Ignition switch: ON · Wait for 2 seconds after the ignition switch has been turned on or the engine has started. Evaluation conditions · Output voltage from the sensor is more than 4. 5V (when atmospheric pressure is in excess of 114kPa) for 4 seconds. Or, · Output voltage from the sensor is more than 0. 2V (when atmospheric pressure is less than 5kPa) for 4 seconds. MUT-II/III Service data · No. 25: atmospheric sensor (Ref: P13A-83) * NG Check connector B-08 OK OK Temporary malfunction (Ref Section 00: Dealing with temporary malfunctions) NG Repair (1) NG OK Measurement at C-50 engine ECU connector · Measure the voltage at the engine ECU terminals · Ignition switch: ON · Voltage across earth at 42 OK: 4. 9~5. 1V NG Check connector C-50 OK Inspect the harness between the AFS and the engine ECU · Check if the power supply wire has short circuited OK MUT-II/III Service data · No. 25: atmospheric sensor (Ref: P13A-83) * NG Replace the engine ECU (2) NG Check connector C-49 OK Inspect the harness between the AFS and the engine ECU · Check if the earth wire is cut or damaged OK MUT-II/III Service data · No. 25: atmospheric sensor (Ref: P13A-83) * NG Replace the engine ECU OK Temporary malfunction (Ref Section 00: Dealing with temporary malfunctions) NG Repair NG Repair Check connector C-50 OK NG Repair Measurement at B-08 AFS connector · Undo the connector and measure on the harness side. (1) Voltage across earth at 1 (ignition switch: ON) OK: 4. 9~5. 1V (2) Resistance across earth at 5 OK: Less than 2 NG NG Inspect the harness between the AFS and the engine ECU, repair if necessary · Check if the power supply wire is cut Repair Repair OK Temporary malfunction (Ref Section 00: Dealing with temporary malfunctions) OK Go on to the next page *: Refer to the 03-1 Service Manual for the Lancer Evolution VIII (No. 1036K07) MPI ­ TROUBLESHOOTING Continued from previous page OK (1) NG Measurements taken at B-08 AFS connector · Only connect the test harness (MB991709) to terminals No. 1, No. 2 and No. 5 of the connector and measure at the pick up harness component. · Ignition switch: ON (1) Voltage across earth at 1 (2) NG OK: 4. 9~5. 1V (2) Voltage across earth at 2 OK: altitude 0m 3. 8~4. 2V altitude 600m 3. 5~3. 9V altitude 1200m 3. 3~3. 7V altitude 1800m 3. 0~3. 4V NG Check connectors C-49 & C-50 OK Inspect the harness between AFS and engine ECU, repair if necessary · Check if the power supply wire is damaged NG Check connector C-50 OK NG Inspect the harness between AFS and engine ECU · Check if the output wire has short circuited or is damaged OK Replace the AFS OK Measurement at the C-50 engine ECU connector · Measurement of the terminal voltage of the engine ECU · Ignition switch: ON · Voltage across earth at 51 OK: altitude 0m 3. 8~4. 2V altitude 600m 3. 5~3. 9V altitude 1200m 3. 3~3. 7V altitude 1800m 3. 0~3. 4V OK NG Check connector C-50 OK OK MUT-II/III Service data · No. 25: atmospheric sensor (Ref: P13A-83) * NG Replace the engine ECU Temporary malfunction (Refer to Section 00: Dealing with temporary malfunctions) Repair NG Check connector C-50 NG Inspect the harness between AFS and engine ECU, repair if necessary · Check if the output wire is cut or damaged Repair Repair Repair 13A-15 OK Repair *: Refer to the 03-1 Service Manual for the Lancer Evolution VIII (No. 1036K07) 13A-16 4. Checklist of faults MPI ­ TROUBLESHOOTING Inspection procedure Fault to be checked Engine seems hesitant Acceleration malfunction 11 Engine seems to stumble Engine has a power surge 15 Mis-timed ignition 35 Inter-cooler water spray circuit system 37 No. 2 waste gate solenoid valve system 38 Air temperature sensor system Reference page 13A-16 13A-18 13A-19 13A-21 13A-22 5. Inspection procedure for each type of fault Inspection procedure 11 Engine seems hesitant, acceleration malfunction, engine seems to stumble, engine has a power surge Probable causes of the malfunction Malfunction of the air/fuel mixing control system Malfunction of the ignition system Malfunction of the fuel system Malfunction of the intake system Malfunction of the exhaust gas purification system Failure of compression pressure Malfunction of the turbocharger system Probable causes of the malfunction are noted in the right hand · column. · · · · · · YES MUT-II/III diagnosis code · Is the diagnosis code displayed? [. . . ] Before installing the cover and gasket, put the camshaft to the No. 1 top dead centre position, and check that the vanes of the respective sensing cylinders are located in the positions shown in the diagram. Vane Vane (large) Vane 20 Exhaust side 4G6 ­ ROCKER ARM / CAMSHAFT Intake side 2. Ensure that the cutaways in the intake side cover and the tabs on the gasket are aligned with the positions shown in the diagram, and tighten at the specified torque of 14 ±1 N-m. The exhaust side cover and gasket do not have a specified installation direction. Comment : The cover and gasket do not have distinct front and rear sides. No cutaway No installation direction Tab Tab Cutaway Cutaway * A * * * * * * * * * 4G6 ­ OIL PUMP / SUMP Oil Pump / Oil Pan Removal and Installation 21 Apply engine oil to all sliding parts before installing. Removal Sequence 1. [. . . ]