Mitsubishi Lancer Evolution 2005 User Manual

LANCER
Evolution - IX
Chassis
Engine
Wiring Diagrams
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. Please bear in mind that vehicle specifications may change and that future models may not be the same. Please note that all the units shown in this manual follow the internationally recognized SI unit system, and that the used previously are not shown alongside the SI units. (Nevertheless, please take care because units in reference documents may be shown in the units which were previously used).
March 2005
MITSUBISHI MOTOR CORPORATION
This manual is printed on recycled paper
Any opinions, requests or questions concerning this manual, should be written on the ‘Servicing Comments Form’ at the end of the manual, and sent to us by fax.
CONTENTS
General ........................................................
Engine .........................................................
Fuel ..............................................................
Engine Cooling ...........................................
Intake and Exhaust ....................................
Engine Electrical ........................................
Rear axle .....................................................
Wheels and tyres........................................
Front suspension ...............................................Body
00
11
13
14
15
16
27
31
33
Body.......................................................................
Exterior........................................................
Interior and SRS Airbag.............................N
Chassis Electrical.........................................
42
51
52
54
Related materials
*Indicates where the new model manual was published with the service manual in a single volume.
WARNING REGARDING THE SERVICING OF VEHICLES FITTED WITH SRS AIR BAGS AND SEATBELTS WITH PRE­TENSIONERS Warning
1. Improper servicing or maintenance of any SRS air bag or pre-tensioner fitted seatbelt component, or related parts, could cause serious injury through the SRS air bag or pre-tensioner fitted seatbelt being activated unintentionally or accidentally.
2. The SRS-ECU, the driver’s side air bag module, the passenger side air bag module, the pre-tensioner fitted seatbelts and the clock spring, should be removed if there is a chance of them being affected by heat during painting work.
• 93ºC and above: the SRS-ECU, the driver’s air bag module, the passenger’s air bag module and the clock spring
should be removed.
• 90ºC and above: the pre-tensioner fitted seatbelts should be removed.
3. Servicing and maintenance of any SRS air bag or pre-tensioner fitted seatbelt components, or related parts, must be performed by an authorized Mitsubishi dealer.
4. Servicing and maintenance of any SRS air bag or pre-tensioner fitted seatbelt components, or related parts, must only be undertaken after this service manual (specifically Section 52B-SRS air bags) has been carefully studied.
Title No. Issue
date
New model manuals Body edition service manual
• Lancer Sedia 1036K30 2000/5 • Lancer Sedia 1036K50 2000/5
• Lancer Sedia 1036K31 2000/7 • Lancer Sedia (supplement) 1036K51 2000/7
• Lancer Evolution VII 1036K32 2001/1 • Lancer Evolution VII 1036K52 2001/5
• Lancer Sedia 1036K33 2001/5 (supplement)
• Lancer Sedia 1036K34 2001/5 • Lancer Sedia (supplement) 1036K53 2001/10
• Lancer Evolution VII 1036K35 2002/1 • Lancer Evolution VII_MR 1036K54 2004/2
• Lancer Sedia 1036K36 2002/5 (supplement)
• Lancer Evolution VII 1036K37 2003/1
• Lancer 1036K38 2003/2
• Lancer 1036K39 2003/12 Electrical wiring service manual
• Lancer Evolution VII_MR 1036K40 2004/2 • Lancer Evolution IX 1036K82 2005/3
• Lancer* 1036K41 2004/3
• Lancer 1036K42 2005/1
• Lancer Evolution IX 1036K43 2005/3
Service manuals Engine service manual
• Lancer Sedia 1036K00 2000/5 • 4G6 engine 1039G46 2001/1
• Lancer Sedia (supplement) 1036K01 2000/7 • 4G6 engine (supplement) 1039G63 2003/1
• Lancer Evolution VII 1036K02 2001/1 • 4G6 engine (supplement) 1039G71 2003/3
(supplement)
• Lancer Sedia (supplement) 1036K03 2001/5
• Lancer Sedia (supplement)
• Lancer Evolution VII 1036K05 2002/1 Transmission service manuals
(supplement) • W5M51 manual transmission 1039M17 2001/1
• Lancer Sedia (supplement) 1036K06 2002/5 • W5M51 manual transmission 1039M22 2003/1
• Lancer Evolution VII 1036K07 2003/1 (supplement)
(supplement) • WGMAA manual transmission 1039M23 2003/1
• Lancer Sedia (supplement) 1036K08 2003/2
• Lancer Sedia (supplement) 1036K09 2003/12
• Lancer Evolution VII MR 1036K10 2004/2
• Lancer* 1036K41 2004/3
• Lancer 1036K11 2005/1
1036K04 2001/10
Title No. Issue
date
SECTION 54A
CHASSIS ELECTRICAL
CONTENTS
Number plate lamp ....................................1
Number plate lamp
Due to changes made to the licence plate lamp, servicing guidelines have been changed to be the same as for the ’03 model Lancer. Other servicing guidelines remain unchanged.
<Notes>
CHASSIS ELECTRICAL – LICENCE PLATE LAMP
SRS AIRBAG – GENERAL
54A-1 52B-1
SECTION 52B
SRS AIRBAG
CONTENTS
General........................................................1
General
A caution label for the airbag has been added on the inside of the bonnet. Other servicing guidelines remain unchanged.
Warning/caution label
bonnet
<Notes>
EXTERIOR – GENERAL
51-1
SECTION 51
EXTERIOR
CONTENTS
General........................................................1
Front bumper..............................................2
Front bumper.......................................................2
Rear bumper...............................................4
Rear bumper ........................................................4
Markings .....................................................6
General
Servicing guidelines have been changed in conjunction with the changes or additions listed below. Other servicing guidelines remain unchanged.
• Changes made to the shape and component of the front bumper.
• Changes made to the shape and component of the rear bumper.
• Changes made to the method for affixing the front 3-diamonds badge.
• Changes made to the position for affixing the LANCER badge and the EVOLUTION badge.
EXTERIOR – FRONT BUMPER
51-2
Front bumper
Front bumper
Removal and fitting
Removal procedure
1. Side valence
2. Centre valence
3. valence centre bracket
4. Front valence
5. Clip for attaching the splash shield
Inter-cooler water spray hose connection (Ref Section 15)
6. Front bumper ASSY
7. Front bumper stay
Cross section through A-A
clip
clip
Cross section through B-B
Cross section through C-C
cap
bumper
EXTERIOR – FRONT BUMPER
51-3
Dismantling and assembly
Dismantling procedure
1. Front 3-diamonds badge
2. Front bumper nut
3. Front number plate garnish
4. Front bumper cover A
5. Front bumper cover B
6. Air dam skirt panel
7. Front bumper centre net
8. Front bumper lower plate
9. Front bumper upper plate
10. Front bumper upper support
11. Air intake cover
12. Front bumper net
13. Bumper side net (LH)
14. Oil cooler duct
15. Bumper side net (RH)
Inter-cooler water spray hose and nozzle (Ref Section 15)
16. Front bumper side plate
17. Front bumper upper reinforcement
18. Front bumper facing
Note: The main points for dismantling and assembly remain unchanged.
Cross section through A-A
hook
Cross section through B-B
clip
!!A"" ""A!!
EXTERIOR – FRONT BUMPER, REAR BUMPER
51-4
Rear bumper
Rear bumper Removal and fitting
Jobs to be completed before removal and after fitting
• Removal and refitting of the rear combination lamp
• Removal and refitting of the rear end trim
• Removal and refitting of the boot area side trim lid
Removal procedure
1. Screw for attaching the splash shield
2. Rear bumper bracket
3. Rear bumper ASSY
4. Rear number plate bracket
Cross section through A-A
clip
splash shield
EXTERIOR – REAR BUMPER
51-5
Dismantling and assembly
Dismantling procedure
1. Number plate lamp bracket
Number plate lamp ASSY
2. Rear bumper reinforcement
3. Rear bumper side plate
4. Rear bumper facing support, side reinforcement
5. Rear bumper valence
6. Rear bumper facing
Note: The main points for dismantling and assembly remain unchanged.
!!A"" ""A!!
!!A"" ""A!!
EXTERIOR – MARKINGS
51-6
Markings
Removal and affixing
1. Front 3-diamonds badge (Ref P.51- 3) 2. LANCER badge
3. EVOLUTION badge
Guidelines for affixing markings
""A!!
Affixing markings
1. Positioning
2. Guidelines for affixing
(1) Using white spirit, remove any grease from the place where the
badges will be affixed.
(2) Remove the protective paper from the back of the badges, and
affix them in the designated places.
Caution
1) Perform this job in an ambient temperature of 20~38ºC, and in a dust free location.
2) If the job is being performed in an ambient temperature of less than 20ºC, warm up the badges, and the area of the body onto which they will be affixed, to a temperature of 20~38ºC.
3) Ensure that air bubbles are not trapped in the adhesive tape when the badges are affixed.
""A!! ""A!!
2. LANCER badge 3. EVOLUTION badge
edge of boot lid
BODY – GENERAL, WINDOW GLASS CHANNEL, DOOR-OPENING WEATHER STRIP
42-1
SECTION 42
BODY
CONTENTS
General........................................................1 Window glass channel, door-opening
weather strip <GT, GSR>...........................1
General
Servicing guidelines have been amended in conjunction with the changes listed below. Other servicing guidelines remain unchanged. <GT, GSR>
Addition of front door opening inner lower weather strip
Addition of front and rear door opening inner weather strip
Window glass channel, door-opening weather strip <GT, GSR>
Removal and fitting
<front door>
<rear door>
Note
: position of clips
Cross section A – A
front door trim
clip
Removal of the front door opening inner lower weather strip
1. Front door opening inner lower weather strip
Procedure for removing the front door opening inner weather strip
Front scuff plate
Cowl side trim
Lower centre pillar trim
2. Front door opening inner weather strip
Procedure for removing the rear door opening inner weather strip
Rear scuff plate
Lower centre pillar trim
3. Rear door opening inner weather strip
<Notes>
FRONT SUSPENSION – GENERAL, SPECIAL TOOLS, STRUT ASSY
33-1
SECTION 33
FRONT SUSPENSION
CONTENTS
General........................................................1
Special tools...............................................1
Strut 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
Tool Number Name Function
A: MB991237 B: MB991238
A. Spring compressor body B. Arm set
Dismantling and assembling the strut ASSY
MB991680
A: MB991681 B: MB991682
Wrench 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.
FRONT SUSPENSION – STRUT ASSY
33-2
pipe
2. Use the following tools to loosen the self-locking nut.
•Wrench (MB991681)
Socket (MB991682)
Caution Do not use an impact wrench when loosening the self­locking nut, because there is a danger that the lock nut on the piston rod inside the strut, may work loose.
Assembly guidelines
""A!!
Fitting the self-locking nut
1. Check that the bearing has completely slotted in.
2. When the coil spring has been compressed using the special tool, provisionally tighten the self-locking nut.
Caution Do not use an impact wrench because there is a danger that the special tool may be damaged.
3. Align the holes in the lower spring plate and the upper spring plate of the strut ASSY. Note This operation can be easily performed by using a pipe to align the holes.
4. Line up the two ends of the coil spring with the slots in the spring plate, and loosen the special tool.
5. Use the following special tools to tighten the self-locking nut to the specified tightening torque.
•Wrench (MB991681)
Socket (MB991682)
Tightening torque: 60 ± 10 N·m
Caution Do not use an impact wrench when loosening the self­locking nut, because there is a danger that the lock nut on the piston rod inside the strut, may work loose.
TYRES AND WHEELS – GENERAL, ON-VEHICLE SERVICING
31-1
SECTION 31
WHEELS AND TYRES
CONTENTS
General........................................................1
On-vehicle servicing..................................1
Removal of emergency puncture repairing agent....1
Disposal of emergency puncture repairing agent ....2
General
The following servicing guidelines have been prepared now that vehicles are supplied with an emergency puncture repair kit.
On-vehicle servicing
Removal of emergency puncture repairing agent
When repairing or replacing a tyre which has been treated using the puncture repair kit, remove the emergency puncture repairing agent (henceforth, repairing agent) from the tyre, in accordance with the guidelines below.
Note When removing the repairing agent, a container (the empty bottle which contained the repairing agent), and the insertion hose and the extraction hose from the emergency puncture repair kit, are needed.
Caution
1. Carry out the operation in a well-ventilated, airy place.
2. Take appropriate measures in order to prevent repairing agent; getting onto the skin, being inhaled, coming into contact with clothing, or getting into the eyes.
3. After the job has been completed, wash hands and face thoroughly.
1. Remove the wheel from the vehicle, and remove the air from the tyre.
2. Cut away the rubber part of the valve using a cutter-knife.
3. Attach the injection hose to the empty repairing agent bottle, and then attach the extraction hose onto the injection hose.
empty bottle of repairing agent
injection
hose
extraction
hose
valve
TYRES AND WHEELS – ON-VEHICLE SERVICING
31-2
4. Put the tyre on a raised surface and tilt it to an angle. Insert the extraction hose through the hole made by removing the valve, so that the tip of the hose is submerged in the repairing agent.
5. Hold the bottle so that it is, as far as possible, below the tyre, and suck the repairing agent out of the tyre by squeezing the bottle by hand. Repeat this operation 2 or 3 times, so that as much of the repairing agent as possible is removed.
6. After the repairing agent has been extracted, remove the tyre from the wheel. Remove any repairing agent stuck onto the tyre, and if the place from which air is escaping can be identified, carry out a normal repair procedure. If the place from which air is escaping cannot be identified, replace the tyre.
Disposal of emergency puncture repairing agent
Dispose of the repairing agent extracted from the tyre, and any unused agent which has exceeded its use-by date, in the same way that used oil is discarded. Note The use-by date is printed on the bottle of repairing agent (about 3 years from the date of purchase)
Caution The repairing agent includes propylene glycol which must be handled as industrial waste.
extraction hose
raised surface
repairing agent
extraction hose
injection hose
bottle
REAR AXLE – GENERAL, DIFFERENTIAL CARRIER <VEHICLES WITH AN AYC SYSTEM>
27B-1
SECTION 27B
REAR AXLE
CONTENTS
General........................................................1 Differential carrier <vehicles with an
AYC system> ..............................................1
General
The tightening torque for the flare nut which joins the fuel pressure unit hose ASSY and the differential carrier ASSY, has been changed. Other servicing guidelines remain unchanged.
Differential carrier <vehicles with an AYC system>
Removal and fitting
Note *1: When the screw is dry. *2: When the screw is lubricated.
NEW
OLD
fuel pressure unit hose ASSY
differential carrier ASSY
<Notes>
ENGINE ELECTRICAL – CHARGING SYSTEM
16-1
SECTION 16
ENGINE ELECTRICAL
CONTENTS
Charging system........................................1
General .................................................................1
Alternator...............................................................1
Ignition system...........................................4
General .................................................................4
Servicing standards...................................4
On-vehicle servicing..................................4
Checking, cleaning and replacing spark plugs .....4
Cam position sensor .................................4
Charging system
General
The following alternator servicing guidelines have been prepared for vehicles which use the 4G63-MIVEC-T/C engine. Other servicing guidelines remain unchanged.
Alternator Removal and fitting
Jobs to be done before removal and after fitting
• Removal and refitting of the valence
• Checking the tension of the drive belt <only after fitting>
• Removal and refitting of the strut tower bar
• Removal and refitting of the front exhaust pipe ASSY
• Adjustment of the accelerator cable <only after fitting>
ENGINE ELECTRICAL – CHARGING SYSTEM
16-2
Removal procedure
1. Injector connector
2. Accelerator cable connection
3. Delivery pipe, injector, and fuel pressure regulator ASSY
4. Insulator
5. Insulator
6. Fuel pressure solenoid valve connector
7. Fuel pressure solenoid valve ASSY
8. Knock sensor connector
9. Purge control solenoid valve connector
10. Purge control solenoid valve ASSY
11. Oil level gauge and guide ASSY
12. O-ring
13. Drive belt
14. Alternator connector and terminal
• Engine mount
15. Alternator
16. Water pump pulley
17. O2sensor connector
18. Alternator bracket
(engine oil)
!!A""
!!B""
!!C""
ENGINE ELECTRICAL – CHARGING SYSTEM
16-3
Removal guidelines
!!A""
Removing the delivery pipe, the injector, and the fuel
pressure regulator ASSY
Loosen the bolts holding it in place, slightly dislodge all of the components and make space for the alternator to be removed.
!!B""
Removing the drive belt
The following procedures are necessary because a serpentine drive system with auto-tensioner has been installed.
1. Insert a 12.7sq spinner handle into the auto-tensioner hole, and turn the auto-tensioner in an anti-clockwise direction until it reaches the stopper.
2. Align the A hole and the B hole, hold them in place by inserting an L-shaped hexagonal Allen Key, 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.
!!C""
Removing the alternator
Push the whole engine up using a garage jack, and remove the alternator from above.
A hole
B hole
L-shaped hexagonal Allen wrench
ENGINE ELECTRICAL – IGNITION SYSTEM
16-4
Ignition system
General
The following servicing guidelines for spark plugs and the cam position sensor have been prepared for vehicles which use the 4G63-MIVEC-T/C engine. Other servicing guidelines remain unchanged.
Servicing standards
On-vehicle servicing
Checking cleaning and replacing spark plugs
The standard value and the upper limit for plug caps, has been changed in conjunction with the changes made to the spark plugs. Other servicing guidelines remain unchanged.
Standard values and upper limits
Cam position sensor
Removal and fitting
Removal procedure <Exhaust side>
1. Cam position sensor connector
2. Cam position sensor
3. O-ring
Removal procedure <Inlet side>
4. Cam position sensor connector
5. Cam position sensor
6. O-ring
Item Standard Value Upper Limit Spark plug cap mm 0.5~0.6 0.75
Manufacturer Model Standard Value mm Upper Limit mm
NGK ILFR7H 0.5~0.6 0.75
INTAKE & EXHAUST – GENERAL, SERVICING STANDARDS, SPECIAL TOOLS,
ON-VEHICLE SERVICING
15-1
SECTION 15
INTAKE & EXHAUST
CONTENTS
General................................................................................1
Servicing standards ..........................................................1
Special tools.......................................................................1
On-vehicle servicing..........................................................1
Turbocharger super charging pressure check ...............1
Inter-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
Item Standard value
Turbocharger charging pressure kPa 97~157
Servicing standards
Tool Number Name Function
MD998770 O2sensor wrench Removal and fitting of the O
2
sensor
INTAKE & EXHAUST INTER-COOLER WATER SPRAY
15-2
Inter-cooler water spray
Removal and fitting
<Water spray nozzle, hose and washer tank>
Procedure for removing the water spray nozzle and the hose
1. Water spray hose connection
• Front bumper ASSY (Ref: Section 51)
• Tape (for fitting the water spray hose ASSY)
2. Water spray nozzle ASSY
3. Water spray hose ASSY
4. Clamp
5. Water spray nozzle (top)
6. Water spray nozzle bracket
7. Water spray nozzle (bottom)
8. Water spray hose
9. Three-way joint
10. Washer valve
•Tape (for attaching clip)
11. Clip
12. Pad
Procedure for removing the washer tank
1. Water spray hose connection
13. Water spray motor connector
14. Washer tank
15. Water spray hose
16. Washer valve
17. Water spray motor
18. Packing
19. Bracket
!!A""
!!A""
INTAKE & EXHAUST INTER-COOLER WATER SPRAY
15-3
Fitting guidelines
!!A""
Fitting the water spray hose ASSY and fixing tape (for securing the water spray hose ASSY)
1. After fitting the water spray hose, the three-way joint and the washer valve, affix pads, clips and tape at the positions shown in the water spray hose diagram.
2. Fit the water spray hose ASSY to the front bumper using the water spray hose ASSY clip.
3. Affix tape as shown in the diagram, so that the water spray hose ASSY does not slip.
View of the inside of the front bumper
tape
three-way joint
pads
tape
washer valve
clip
tape
clip
three-way joint
pad
clip
washer valve
tape
clip
tape
clip
clip
water spray hose ASSY
water spray nozzle brackets
tape
INTAKE & EXHAUST – SECONDARY AIR CONTROL SYSTEM
15-4
Secondary air control system
Removal and fitting
Jobs to be completed before removal and after fitting
• Removal and refitting of the air duct
• Removal and refitting of the strut tower bar
Removal procedure
1. Control harness connection
2. Heat protector
3. Vacuum hose connection
• Air pipe C
4. Vacuum pipe
5. Harness bracket
6. Air hose
7. Air pipe ASSY
8. Gasket
9. Gasket
10. Secondary air control valve
11. Harness bracket
air pipe C
!!A""
INTAKE & EXHAUST – SECONDARY AIR CONTROL SYSTEM, INLET MANIFOLD
15-5
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
15-6
Removal procedure
1. Centre cover
2. Ignition coil connector
3. O2sensor 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 connector
12. 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!!
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 ASSY
31. 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 & TURBOCHARGER
15-8
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
INTAKE & EXHAUST – EXHAUST MANIFOLD
15-9
Removal procedure
1. Exhaust manifold heat protector
2. Air pipe ASSY connection
3. O2sensor
4. Turbocharger heat protector
5. Turbocharger water feed pipe connection
6. Gasket
7. Water hose connection
8. Oil feed pipe
9. Gasket
10. Starter
11. Oil return pipe
12. Oil return pipe gasket (turbocharger side)
13. Oil return pipe gasket (oil pan side)
14. Vacuum hose connection
15. Air outlet fitting
16. Air outlet fitting gasket
17. Exhaust fitting bracket
18. Turbocharger and exhaust fitting ASSY
19. Turbocharger ASSY
20. Exhaust fitting gasket
21. Exhaust fitting
22. Turbocharger gasket
23. Turbocharger water return pipe
24. Gasket
25. Exhaust manifold
26. Exhaust manifold gasket
Removal guidelines
""A!!
Removing the O2sensor
After removing the O2sensor connector and the clamp, use the
special O2 sensor wrench (MD998770) to remove the O2sensor.
""B!!
Removing the oil feed pipe Caution After removing the oil feed pipe, ensure that there is no foreign matter in the oil access hole on the turbocharger.
Fitting guidelines
!!A""
Fitting the turbocharger ASSY
1. Clean away any grease clogging the connection between the oil
pipe and the water pipe, and any grease clogging the eyebolts and the inside of the pipes.
2. If there is any carbon in the oil access on the turbocharger
ASSY, clean it or blow it away.
Caution Ensure that no foreign matter gets inside the turbocharger ASSY.
""A!!
""B!!
!!D"" !!C""
!!B""
!!A""
O2sensor
INTAKE & EXHAUST – EXHAUST MANIFOLD
15-10
!!B""
Fitting the air outlet fitting gasket
Fit the gasket so that the protruding part is in the position located in the diagram.
!!C""
Fitting the oil return pipe gasket (oil pan side)
Fit so that the printed side of the gasket is on the oil pan side.
!!D""
Fitting the oil return pipe gasket (turbocharger side)
Fit so that the printed side of the gasket is on the turbocharger side.
turbocharger
protruding part
view “A”
view “A”
print
print
gasket
gasket
3. Apply some fresh engine oil via the fitting hole for the oil feed pipe in the turbocharger ASSY.
ENGINE COOLING – GENERAL
14-1
SECTION 14
ENGINE COOLING
CONTENTS
General........................................................1
Water pump ................................................2
Water 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 PUMP
14-2
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 hose
12. 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 PIPE
14-4
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 fitting
indicator marks
MPI – GENERAL
13A-1
SECTION 13A
MPI (Multi-point Fuel Injection)
CONTENTS
General..................................................................... 2
Servicing standards .................................................3
Special tools ............................................................3
Troubleshooting ......................................................5
Servicing the vehicle ............................................29
1. Adjusting specified revolutions when idling.....29
2. MPI system components layout diagram........29
3. Checking the air temperature sensor..............29
4. Checking the oil feeder control valve..............30
GENERAL
Servicing guidelines have been changed because of the changes listed below.
•Avariable valve timing control system (V.V.T.) has been adopted. Because of this, an oil feeder control valve and an intake cam position sensor have been added.
•Amanifold absolute pressure (MAP) sensor has been added.
• An air temperature sensor has been added.
MPI – GENERAL
13A-2
MPI system diagram
Engine ECU
H 1. O2 sensor H 2. Air flow sensor
H 3. Intake air temp.
sensor
H 4. Throttle position
sensor
H 5. Intake Cam position
sensor
H 6. Exhaust Cam
position sensor
H 7. Crank angle
sensor
H 8. Atmospheric
pressure sensor
H 9. Water temp.
sensor
H 10. Knock sensor H 11 . Manifold absolute
pressure (MAP) sensor
H 12. 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
• O2sensor heater
È
È
I 6. Purge control
solenoid valve
I 7. Secondary
air control solenoid valve
Check 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. O2sensor
H 5. Intake cam
position sensor
Catalyst
H 7. Crank angle sensor
H 10. Knock sensor
H 9. Water temperature sensor
I 1. Injector
From fuel pump
Fuel pressure regulator
I 8. Oil feeder control
valve
I 3. Fuel pressure
control solenoid valve
Vacuum tank
I 2. ISC servo
H 11 . MAP sensor
H 12. Air temperature sensor
H 4. Throttle
position sensor
From fuel tank
Canister
By-pass valve
MPI – SERVICING STANDARDS, SPECIAL TOOLS
13A-3
Servicing standards
Special tools
Item Standard level
Revolutions when idling r/min 800 ± 50
Air temperature sensor resistance k at -20 ºC 13~18
at 0 ºC 5.1~6.9
at 20 ºC 2.0~3.0
at 40 ºC 0.9~1.5
at 60 ºC 0.40~0.78
at 80 ºC 0.23~0.42
Oil feeder control valve resistance (at 20 ºC) 6.9~7.9
Tool Number Name Function
MB991502 MUT-II sub ASSY 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
MPI- SPECIAL TOOLS
13A-4
Tool Number Name Function
MB991348 Test harness 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
MB991223 Inspection harness set connector
• Pin contact pressure inspection harness
• Commercial tester connection probe (for ordinary connectors)
Terminal voltage measurement
Red coloured harness (for DLI)
White coloured harness (for LC)
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
O2sensor
O2sensor heater
Fuel system malfunction
Knock sensor
Intake cam position sensor system
Oil feeder control valve system
Item number Type of data Units/condition
95 MAP sensor kPa
Malfunctioning item Control measures taken when a malfunction occurs
Air temperature sensor Regulation 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 sensor The oil feeder control valve should be switched "OFF", and the
angle of the cam should be in the reset position.
MPI- TROUBLESHOOTING
13A-6
Code No. Diagnosis item Page
P0105 MAP sensor 13A-7
P0340 Exhaust cam position sensor system 13A-9
P1012 Intake cam position sensor system 13A-11
P1021 Oil feeder control valve system 13A-13
P2226 Atmospheric pressure system 13A-14
2. Diagnosis code classification table
13A-7
MPI – 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 connector C-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 connector C-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 connector C50
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: 2Ωor less
Temporary malfunction (Ref Section 00: Dealing with temporary malfunctions)
Check connector B-135
NG
(2) NG
(1) NG
OK
NG
OK
OK
Temporary malfunction (Ref Section 00: Dealing with temporary malfunctions)
NG
OK
NG
OK
OK
NG
OK
NG
OK
NG
Repair
NG
OK
OK
NG
NG
OK
Repair
Repair
Repair
Repair
Repair
Code No. P0105 MAP sensor system Probable 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
13A-8
MPI – TROUBLESHOOTING
Continued from the previous page
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
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
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
MUT-II/III service data
• No.95: MAP sensor
(Ref: P13A-24)
Replace the engine ECU
Check connector C-50
Check connector C-50
Inspect the harness between the MAP sensor and the engine ECU, repair if necessary.
• Check for damage to the power supply wire.
Check connector C-50
Inspect the harness between the MAP sensor and the engine ECU.
• Check if the output wire has short circuited.
Replace the MAP sensor
Check connector C-50
Inspect the harness between the MAP sensor and the engine ECU, repair if necessary
• Check if the output wire has been cut or damaged.
Temporary malfunction (Ref Section 00: Dealing with temporary malfunctions)
OK
OK
OK
OK
OK
NG
Repair
OK
OK
OK
OK
NG
NG
NG
NG
NG
OK
NG
Repair
NG
NG
Repair
Repair
Repair
13A-9
MPI – TROUBLESHOOTING
Check connector B-115
To next page
Check connector B-19X
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
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
Inspect the harness between the exhaust cam position sensor and the engine ECU
• Check if the output wire has short circuited
Check that the problem has been solved
Check connector C-50
Check connector C-50
Inspect the harness between the exhaust cam position sensor and the engine ECU, repair if necessary
• Check if the output wire is cut
Temporary malfunction (Ref Section : Dealing with temporary malfunctions)
Temporary malfunction (Ref Section 00: Dealing with temporary malfunctions)
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
(ignition switch: ON) OK: 4.9~5.1V
(3) Resistance across earth at 1
OK: Less than 2
NG
Repair
Repair
OK
NG
OK
OK
NG
OK
NG
NG
OK
NG
NG
NG
OK
Inspect the harness between the exhaust cam position sensor and the engine ECU
• Check if the earth wire is cut or damaged
Check connector C-49
OK
OK
Replace engine ECU
NG
Check the problem has been solved
Replace engine ECU
NG
OK
(1) NG
(2) NG
(3) NG
OK
OK
Repair
Repair
Repair
Repair
Repair
Code No.P0340 Exhaust cam position sensor system Probable cause of the malfunction
Conditions for inspection
• Ignition switch: ON
•With engine cranking or running Evaluation conditions
• The sensor output voltage does not change for 4 seconds (with no input of pulse signals)
•Malfunction of the exhaust cam position sensor
• Broken circuit or short circuit in the exhaust cam position sensor circuit, or poor connector contact
• Malfunction of engine ECU
13A-10
MPI – TROUBLESHOOTING
Continued from the previous page
Replace the engine ECU
Check connector B-19X
Inspect the harness between the exhaust cam position sensor and the engine control relay
• Check if the power wire is damaged
Check the exhaust cam position sensing cylinder
Check connector C-49 and C-50
Check that the problem has been solved
Inspect the harness between the exhaust cam position sensor and the engine ECU
• Check if the output wire is damaged
Temporary malfunction (Ref Section 00: Dealing with temporary malfunctions)
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.
Check that the problem has been solved
OK
OK
NG
NG
OK
OK
OK
Replace the exhaust cam position sensor
NG
OK
Replace the exhaust cam position sensing cylinder
Temporary malfunction (Ref Section 00: Dealing with temporary malfunctions)
OK
OK
Repair
Repair
NG
NG
Repair
NG
Repair
NG
NG
OK
13A-11
MPI – TROUBLESHOOTING
Check connector B-33
To next page
Check connectors B-19X & C-23
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
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
Check connector C-50
Check connector C-49
Inspect the harness between the intake cam position sensor and the engine ECU
• Check if the earth wire is cut or damaged
Harness inspection between the intake cam position sensor and the engine ECU
• Check if the earth wire is cut or damaged
Replace the engine ECU
Replace engine ECU
Check that the problem has been solved
Check that the problem has been solved
Check connector C-50
Inspect the harness between the intake cam position sensor and the engine ECU, repair if necessary
Check if the output wire is cut
Temporary malfunction (Ref Section 00: Dealing with temporary malfunctions)
Temporary malfunction (Ref Section 00: Dealing with temporary malfunctions)
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
Code No.P1012 Intake cam position sensor system Probable cause of the malfunction
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)
• 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
OK
OK
NG
(1) NG
(2) NG
(3) NG
OK
NG
NG
OK
OK
OK
NG
NG
NG
OK
NG
OK
OK
NG
NG
OK
OK
NG
Repair
Repair
Repair
Repair
Repair
Repair
Repair
13A-12
MPI – TROUBLESHOOTING
Continued from the previous page
Check connectors B-19X & C-23
Check the intake cam position sensing cylinder
Check that the problem has been solved
Replace the intake cam position sensor
Temporary malfunction (Ref Section 00: Dealing with temporary malfunctions)
Replace the intake cam position sensing cylinder
Temporary malfunction (Ref Section 00: Dealing with temporary malfunctions)
Inspect the harness between the intake cam position sensor and the engine ECU
• Check if the output wire is damaged
Inspect the harness between the intake cam position sensor and the engine control relay
• Check if the power wire is damaged
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. There should be no noise in the output wave form.
Replace engine ECU
Check that the problem has been solved
Check connectors C-49 & C-50
OK
OK
OK
NG
NG
OK
OK
OK
OK
OK
NG
NG
Repair
NG
Repair
NG
Repair
NG
NG
OK
Repair
13A-13
MPI – TROUBLESHOOTING
Replace the engine ECU
Check connectors B-19X & C-23
Check connector B-134
Check connectors B-19 & C-23
Check connector C-49
Check that the problem has been solved
Inspect the oil feeder control valve by itself (Ref: P13A-30)
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
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
Check connector C-49
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
Temporary malfunction (Ref Section 00: Dealing with temporary malfunctions)
Replace the oil feeder control valve
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
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
Inspect the harness between the engine ECU and the oil feeder control valve
• Check for damage to the output wire
OK
NG
OK
OK
OK
OK
OK
OK
OK
OK
NG
NG
NG
NG
NG
NG
NG
NG
NG
NG
OK
OK
Repair
Repair
Repair
Repair
Repair
Repair
Repair
Code No.P1021 Oil feeder control valve system Probable cause of the malfunction
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
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
13A-14
MPI – TROUBLESHOOTING
MUT-II/III Service data
• No.25: atmospheric sensor (Ref: P13A-83) *
Temporary malfunction (Ref Section 00: Dealing with temporary malfunctions)
Check connector C-50
Check connector C-50
Check connector C-49
Check connector B-08
Go on to the next page
Inspect the harness between the AFS and the engine ECU
• Check if the power supply wire has short circuited
Temporary malfunction (Ref Section 00: Dealing with temporary malfunctions)
Temporary malfunction (Ref Section 00: Dealing with temporary malfunctions)
Inspect the harness between the AFS and the engine ECU, repair if necessary
• Check if the power supply wire is cut
MUT-II/III Service data
• No.25: atmospheric sensor (Ref: P13A-83) *
Inspect the harness between the AFS and the engine ECU
• Check if the earth wire is cut or damaged
MUT-II/III Service data
• No.25: atmospheric sensor (Ref: P13A-83) *
Replace the engine ECU
Replace the engine ECU
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
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
*: Refer to the 03-1 Service Manual for the Lancer Evolution VIII (No.1036K07)
Code No.P2226 Atmospheric pressure sensor system Probable cause of the malfunction
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.
• 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
NG
OK
OK
NG
(1) NG
(2) NG
OK
Repair
Repair
Repair
Repair
OK
NG
OK
OK
NG
OK
OK
NG
OK
OK
NG
NG
NG
NG
OK
NG
Repair
Repair
13A-15
MPI – TROUBLESHOOTING
Continued from previous page
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
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
*: Refer to the 03-1 Service Manual for the Lancer Evolution VIII (No.1036K07)
Replace the AFS
Check connector C-50
Replace the engine ECU
Inspect the harness between AFS and engine ECU, repair if necessary
• Check if the output wire is cut or damaged
Temporary malfunction (Refer to Section 00: Dealing with temporary malfunctions)
Check connectors C-49 & C-50
Inspect the harness between AFS and engine ECU
• Check if the output wire has short circuited or is damaged
Inspect the harness between AFS and engine ECU, repair if necessary
• Check if the power supply wire is damaged
MUT-II/III Service data
• No.25: atmospheric sensor (Ref: P13A-83) *
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
Check connector C-50
Check connector C-50
OK
OK
OK
OK
OK
NG
(1) NG
(2) NG
NG
NG
OK
NG
NG
NG
OK
OK
OK
NG
Repair
Repair
Repair
Repair
Repair
13A-16
MPI – TROUBLESHOOTING
Check the purge control solenoid valve (Refer to Section 17: Checking the exhaust gas purification system)
MUT-II/III Service data
No.11 O2sensor (Ref: P13A-83)*
Refer to the diagnosis code classification table (P13A-6)
MUT-II/III diagnosis code
Is the diagnosis code displayed?
Check the timing of ignition (Ref Section 11, Engine tuning)
Check the sound made by the injector (using a soundscope)
Check the crank angle sensor and the fitting of the timing belt cover
If there is abnormality in the exhaust gases and code Nos. P0201~P0204 are recorded, check the injector system
If abnormal sensor data is recorded, carry out inspections for each diagnosis code in order (Ref: P13A-6)
Replace the purge control solenoid valve
Code No.P0130: O2sensor system inspection (Ref:
P13A-16)*
Go on to next page.
MUT-II/III Service data
No.13: Intake air temperature sensor
No.14: TPS
No.21: Water temperature sensor
No.25: Atmospheric pressure sensor
No.95: MAP sensor
(Ref: P13A-24) <Reference> Proceed to OK if all service data levels are normal. Proceed via NG even if only one of the service data levels is abnormal.
*: Refer to the 03-1 Service Manual for the Lancer Evolution VIII (No.1036K07)
NO
OK
OK
OK
OK
OK
YES
NG
NG
NG
NG
Inspection procedure Fault to be checked Reference page
11
Engine seems hesitant
13A-16
Acceleration malfunction
Engine seems to stumble
Engine has a power surge
15 Mis-timed ignition 13A-18
35 Inter-cooler water spray circuit system 13A-19
37 No.2 waste gate solenoid valve system 13A-21
38 Air temperature sensor system 13A-22
Engine seems hesitant, acceleration malfunction, engine seems to stumble, engine has a power surge
Probable causes of the malfunction
Probable causes of the malfunction are noted in the right hand column.
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
5. Inspection procedure for each type of fault
Inspection procedure 11
4. Checklist of faults
13A-17
MPI – 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 pick­up 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-18
MPI – TROUBLESHOOTING
Measure the output wave from the crank angle sensor and the cam position sensor (using an oscilloscope).
Engine: idling <Crank angle sensor>
Measure the output wave at the crank angle sensor connector B-122
Connect test harness (MB998478), to the connector, and take measurements at the pick-up harness component
•Voltage across earth at 2
<Exhaust cam position sensor>
Measure the output wave at the exhaust cam position sensor connector B-115
Connect test harness (MB991709), to the connector and take measurements at the pick-up harness component
•Voltage across earth at 2 OK: The output wave timing
from both sensors is as shown on P13A-25 (Main points for oscilloscope testing).
Check that the problem has been solved
Temporary malfunction (Ref Section 00: Dealing with temporary malfunctions)
Replace the engine ECU
NO
OK
NG
OK
NG
NG
NG
Repair
Miss-timed ignition Probable causes of the malfunction
Probable causes of the malfunction are noted in the right hand column.
Malfunction of the crank angle sensor
Malfunction of the exhaust cam position sensor
Malfunction of the timing belt
Malfunction of the engine ECU
Inspection procedure 15
Refer to the diagnosis code classification table (P13A-6)
MUT-II/III Diagnosis code
Is the diagnosis code displayed?
YES
Repair
Replace the crank angle sensor pane
Match up the timing marks on the timing belt
Replace the exhaust cam position sensing cylinder
Temporary malfunction (Ref Section 00: Dealing with temporary malfunctions)
Check the exhaust cam position sensing cylinder
Check the fitting of the crank angle sensor and the exhaust cam position sensor
Check the timing marks on the timing belt
Check the crank angle sensor pane
Replace the crank angle sensor
Check that the problem has been solved
Replace the exhaust cam position sensor
Check that the problem has been solved
Replace the engine ECU
OK
OK
OK
NG
OK
NG
NG
NG
OK
OK
13A-19
MPI – TROUBLESHOOTING
Check the operation of the inter­cooler water spray
Ignition switch: ON
Inter-cooler water spray switch (manual): ON OK: Inter-cooler water spray
operates
Check the operation of the inter-
cooler water spray
Undo the engine ECU connector C-50, and earth terminal 56.
Ignition switch: ON OK: Inter-cooler water spray
operates
Check connector: C-220
Check the inter-cooler water spray relay (Refer to Section 15: Intake/Exhaust)
Go on to the next page
Measure at the inter-cooler water spray switch connector D-32
Undo the connector and measure on the harness side
Ignition switch: ON
•Voltage across earth at 5
OK: battery voltage
Check connectors: C-22 & C-50
Check connector: D-32
Inspect the harness between the engine ECU and the inter-cooler water spray switch
Check if the signal wire is cut or has short circuited
Replace the engine ECU
Check connectors: C-22 & C-50
Measure at the inter-cooler water spray switch connector D-32
Undo the connector and measure on the harness side
Ignition switch: ON
•Voltage across earth at 3 & 5 OK: battery voltage
Replace the inter-cooler water spray relayReplace engine ECU
Check the inter-cooler water spray switch (Ref Section 15: Intake/Exhaust)
Inspect the harness between the inter-cooler water spray switch and the engine ECU
Check if the signal wire is damaged
Temporary malfunction (Ref Section 00: Dealing with temporary malfunctions)
Check connector: D-32
Check the inter-cooler water spray switch (Ref Section 15: Intake/Exhaust)
Check connector: C-107
Replace the inter-cooler water spray relayInspect the harness between the inter-cooler water spray switch and earth
Check if the earth wire is cut or damaged
Inspect the harness between the inter-cooler water spray switch and the engine ECU, repair if necessary
Check if the signal wire is damaged
Inspect the harness between the engine ECU and the inter-cooler water spray switch
Check if the signal wire is cut or has short circuited
OK
NG
NG
OK
NG
NG
OK
OK
OK
OK
NG
OK
OK
NG
NG
Repair
Inspection procedure 35
Inter-cooler water spray circuit system Probable causes of the malfunction
If the inter-cooler water spray switch (manual) is turned ON, the inter-cooler water spray manual ‘ON’ signal will be input in the engine ECU. When this signal is received, the engine ECU will turn the inter-cooler water spray relay ON, and will start the inter-cooler water spray motor. Water will be sprayed into the inter-cooler to cool intake air, and filling efficiency will improve.
If the inter-cooler water spray switch (auto) is turned ON, the inter-cooler water spray auto ‘ON’ signal will be input in the engine ECU. When this signal is received the engine ECU will intermittently run at a high load, it will turn the inter-cooler water spray relay ON, and it will start the inter-cooler water spray motor. Water will be sprayed into the inter-cooler to cool intake air, and filling efficiency will improve.
Malfunction of the inter-cooler water spray switch.
Malfunction of the inter-cooler water spray relay.
Malfunction of the inter-cooler water spray motor.
Circuit break, short circuit or a faulty connection in the inter-cooler water spray relay circuit.
Circuit break, short circuit or a faulty connection in the inter-cooler water spray switch circuit.
•Malfunction of the ignition switch.
Malfunction of the engine ECU.
Replace the engine ECU
OK
NG
Repair
OK
NG
Repair
OK
NG
Repair
OK
NG
Repair
OK
NG
Repair
OK
NG
Repair
OK
NG
Repair
OK
NG
Repair
OK
NG
Repair
OK
NG
Repair
Repair
13A-20
MPI – TROUBLESHOOTING
Measure at the inter-cooler water spray relay connector C-220
• Undo the connector, and measure on the harness side
•Voltage across earth 3 and 1 (ignition switch: ON) OK: battery voltage
Measure at the engine ECU connector C-50
• Undo the connector, and measure on the harness side
•Voltage across earth 56 (ignition switch: ON)
OK: battery voltage
Check connector: C-31
Inspect the harness between the inter-cooler water spray relay and the inter-cooler water spray motor
• Check if the power supply wire is cut, has short circuited, or is damaged
Inspect the harness between the inter-cooler water spray motor and earth
• Check if the earth wire is cut, or damaged
Check connectors C-209, C-210, C-201 and C-208
Inspect the harness between the inter-cooler water spray relay and the ignition switch
• Check if the power supply wire is damaged
Check connectors C-22 & C-50
Inspect the harness between the inter-cooler water spray relay and the engine ECU
•Check if the signal wire is damaged
Check connector: A-34
Replace the engine ECU
Check the inter-cooler water spray motor (Ref Section 15: Intake/Exhaust)
Check connectors C-209, C-210, C-201 and C-208
Inspect the harness between the inter-cooler water spray relay and the ignition switch
Check if the power supply wire is cut or has short circuited
Continued from the previous page
Check the ignition switch (Ref to Section 54)
Check connectors C-22 and C-208
Inspect the harness between the inter-cooler water spray relay and the engine ECU
Check if the signal wire is cut or has short circuited
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
NG
NG
NG
NG
NG
NG
NG
NG
NG
NG
NG
NG
NG
NG
Repair
Repair
Repair
Repair
Repair
Repair
Repair
Repair
Repair
Repair
Repair
Repair
13A-21
MPI – TROUBLESHOOTING
Check connector: B-32
Replace the No 2. waste gate solenoid valve
Check connector: B-19X
Measure at the waste gate solenoid valve connector B-32
Undo the connector and measure on the solenoid valve side
Resistance between 1-2 OK: 29~35Ω(when at 20ºC)
Measure at the waste gate solenoid valve connector B-32
Undo the connector and measure on the harness side
Ignition switch: ON
•Voltage across earth at 63 OK: battery voltage
Measure at the engine ECU connector C-50
Measure the voltage at the engine ECU terminal
Ignition switch: ON
•Voltage across earth at 63
OK: battery voltage
Check connector: C-50
Inspect the harness between the No.2 waste gate solenoid valve and the engine ECU
• Check if the output wire is
damaged
Inspect the harness between the No.2 waste gate solenoid valve and the engine control relay
• Check if the power supply wire
is damaged
Replace the engine ECU
Inspect the harness between the No.2 waste gate solenoid valve and the engine control relay, and repair if necessary
• Check if the power supply wire is cut or has short circuited
Check connector: C-50
Inspect the harness between the No.2 waste gate solenoid valve and the engine ECU
• Check if the output wire is cut or has short circuited
Replace the engine ECU
NG
OK
OK
OK
OK
OK
NG
NG
NG
NG
Repair
Repair
OK
OK
NG
NG
OK
Repair
NG
Repair
Repair
No.2 waste gate solenoid valve system Probable causes of the malfunction
The No.2 waste gate solenoid valve controls the supercharge pressure introduced to the waste gate actuator in the turbocharger.
Malfunction of the No.2 waste gate solenoid valve.
Circuit break, short circuit or a faulty connection in the No.2 waste gate solenoid valve circuit.
Malfunction of the engine ECU.
OK
NG
Repair
OK
NG
Repair
Inspection procedure 37
13A-22
MPI – TROUBLESHOOTING
Inspect the air temperature sensor on its own (Ref: P13A-29)
Check connector B-34
Measure at the air temperature sensor connector B-34
Undo the connector and measure on the harness side
(1) Resistance across earth at 2
OK: Less than 2
(2) Voltage across earth at 1
(Ignition switch: ON) OK: 4.9~5.1V
Go on to the next page
Replace the air temperature sensor
Temporary malfunction (Ref Section 00: Dealing with temporary malfunctions)
Measure at the engine ECU connector C-51
Measure the voltage at the engine ECU terminal
Ignition switch: ON
•Voltage across earth at 96 OK: 4.5~4.9V
Replace the engine ECU
Check that the problem has been solved
Inspect the harness between the air temperature sensor and the engine ECU
Check if the earth wire is cut or damaged
Check connector: C-50
Inspect the harness between the air temperature sensor and the engine ECU and repair it if necessary.
Check if the output wire is cut
Check connector: C-51
Temporary malfunction (Ref Section 00: Dealing with temporary malfunctions)
Check connector: C-51
Check that the problem has been solved
Replace the engine ECU
Inspect the harness between the air temperature sensor and the engine ECU and repair it if necessary.
Check if the output wire is cut
OK
NG
(1) NG
(2) NG
NG
OK
OK
NG
NG
NG
OK
NG
OK
OK
OK
NG
NG
NG
NG
NG
OK
Repair
Repair
Repair
Repair
Repair
Air temperature sensor system Probable causes of the malfunction
The air temperature sensor controls the temperature inside the inlet manifold, and compensates for any burning of fuel.
Malfunction of the air temperature sensor.
Circuit break, short circuit or a faulty connection in the air temperature sensor circuit.
Malfunction of the engine ECU.
Inspection procedure 38
OK
NG
Repair
13A-23
MPI – TROUBLESHOOTING
Continued from the previous page
Measure at the air temperature sensor connector B-34
Connect the test harness (MB991658), to the connector 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
Check that the problem has been solved
Replace the engine ECU
Inspect the harness between the air temperature sensor and the engine ECU and repair it if necessary.
Check if the earth wire is damaged
Check connector: C-51
Temporary malfunction (Ref Section 00: Dealing with temporary malfunctions)
OK
OK
OK
NG
NG
OK
NG
Repair
13A-24
MPI – TROUBLESHOOTING
13A-23
6. Service data table
7. Engine ECU checks
7-1 Terminal voltage table
13A-25
MPI – TROUBLESHOOTING
13A-24
7-2 Table showing resistance and continuity across the terminals of harness side connectors
8. Checks using an oscilloscope
Sensor output signals and actuator drive signals can be checked visually by taking waveform measurements using an oscilloscope.
crank angle sensor connector
exhaust cam position sensor connector
oscilloscope
8.1 Exhaust cam position sensor and the crank angle sensor <Measurement method>
(1) Disconnect the exhaust cam position sensor connector, and
connect the special test harness (MB991709) in its place.
(2) Disconnect the crank angle sensor connector, and connect
the special test harness (MB998478) in its place.
(3) Connect the No.2 terminal of the exhaust cam position
sensor connector and the No.2 terminal (the black coloured clip on the special tool) of the crank angle sensor connector, to the probes for each channel on the oscilloscope. Note When measuring at the engine ECU connector, connect the probes for each channel on the oscilloscope to No.50 terminal (exhaust cam position sensor), and to No.43 terminal (crank angle sensor).
13A-26
MPI – TROUBLESHOOTING
<Standard waveforms>
Observation conditions
Exhaust cam position sensor Crank angle sensor
Probe switch X1 x1
AC-GND-DC DC DC
TIME/DIV. 10ms 10 ms
VOLTS/DIV. 2V 2V
Other - -
Engine Idling
2 engine revolutions (1 camshaft revolution)
crank angle sensor output waveform
exhaust cam position sensor output waveform
Standard waveform
<Explanation of waveforms>
• The exhaust cam position sensor detects the compression top dead centre for each cylinder, and by simultaneous observation of these and other controlling signals, it is possible to distinguish between the cylinders.
• The crank angle sensor detects the crank angle for each cylinder. There is an output of 4 evenly spaced crank angle sensor HIGH signals for every 2 revolutions of the engine. Therefore, by measuring the cycle time (seconds), engine revolution speed can calculated according to the following formula:
Engine revolution speed = 2/4T (seconds) x 60 = 30/T (seconds)
<Waveform observation points>
• Check that the cycle time gets shorter as the engine revolution speed increases.
13A-27
MPI – TROUBLESHOOTING
<Examples of abnormal waveforms>
Example 1
Waveform characteristics
A rectangular waveform is produced even though the engine has not been started.
Cause of the problem
Sensor interface fault
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 sensor disc.
8-2 Intake cam position sensor <Measurement method>
(1) Disconnect the intake cam position sensor connector and
connect the special test harness (MB991709) in its place. (All terminals should be connected).
(2) Connect the oscilloscope probe to the No.2 terminal of the
intake cam position sensor connector. Note When measuring at the engine ECU connector, connect the No.53 terminal (intake cam position sensor) to the oscilloscope probe.
(3) When checking the output signal of the intake cam position
sensor, observe the output signal of the crank angle sensor at the same time.
crank angle sensor connector
intake cam position sensor connector
oscilloscope
<Standard waveforms>
Observation conditions
Intake cam position sensor Crank angle sensor
Probe switch X1 x1
AC-GND-DC DC DC
TIME/DIV. 10ms 10 ms
VOLTS/DIV. 2V 2V
Other - -
Engine Idling
13A-28
MPI – 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)
(phase­angle)
<Explanation of waveforms>
• 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°.
<Waveform observation points>
• 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.
<Examples of abnormal waveforms>
Example 1
Waveform characteristics
A rectangular waveform is produced even though the engine has not been started.
Cause of the problem
Sensor interface fault
13A-29
MPI – 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
Name Code Name Code Intake cam position sensor C Oil feeder control valve A Air temperature sensor B Manifold absolute pressure sensor B Exhaust cam position sensor C
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 SERVICING
13A-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 increases Resistance 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
ENGINE – GENERAL, SERVICING STANDARDS, SEALANTS
11-1
SECTION 11
ENGINE
CONTENTS
General
The following servicing guidelines have been prepared for vehicles which use the 4G63-MIVEC-T/C engine. Other servicing guidelines remain unchanged.
Servicing standards
General .......................................................1
Servicing standards .................................1
Sealants .....................................................1
Special tools ..............................................2
Engine tuning .............................................4
1. Checking of revolutions when idling ................4
2. Checking compression pressure.......................4
Camshaft, valve stem seals .....................4
Cylinder head gaskets.............................14
Timing belt, timing belt B........................20
Engine ASSY ............................................28
Sealants
Note The code inside the brackets ( ) is the actual product number.
ENGINE – SPECIAL TOOLS
11-2
Special tools
Tool Number Name Function
MB991502 MUT-II Sub
ASSY
Checking and adjusting the tension in timing belt B
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.
MB991955 A: MB991824 B: MB991827 C: MB991910 D: MB991911 E: MB991825 F: MB991826
MUT-III Sub ASSY A: Vehicle
Communication
Interface (VCI) 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
MB991668 A: MB991969 B: MB991670
Belt tension meter set A: Tension meter
cartridge B: Mic ASSY
• Checking the tension in the drive belt. (Use in conjunction with VCI)
• Checking the tension in the balancer timing belt. Adjusting (Use in conjunction with VCI)
MD998772 Valve spring
compressor
Compression of the valve spring.
DO NOT USE
ENGINE – SPECIAL TOOLS
11-3
Tool Number Name Function
MD998737 Val ve stem seal
installer
Valve stem seal installation
MD998713 Camshaft oil seal
installer
Camshaft oil seal installation
MB991654 Cylinder head bolt
wrench
Cylinder head bolt removal, installation
MB991367 Special spanner Holding the crankshaft sprocket
MB991385 Pins
MB991704 Battery harness Checking and adjustment of the tension in the
balancer timing belt (Use in conjunction with VCI or MUT-II)
MD998738 Adjusting bolt Holding the tensioner arm or the auto-tensioner
adjuster
MD998767 Tensioner pulley
socket wrench
Adjusting the tension of the timing belt
ENGINE – SPECIAL TOOLS, ENGINE TUNING, CAMSHAFT, VALVE STEM SEAL
11-4
Engine tuning
1. Checking revolutions when the engine is idling
The standard revolutions for when the engine is idling have been changed. Other servicing guidelines remain unchanged.
Standard revolutions: 800 ± 50 r/min
2. Checking compression pressure
The standard for compression pressure and the limit for compression pressure have been changed. Other servicing
guidelines remain unchanged.
Standard compression pressure: 1000 kPa – 250 r/min Compression pressure limit: 650 kPa – 250r/min
Camshaft, valve stem seal
Removal and fitting Caution
1. If Brembo brake callipers are being used take care that they are not scratched by other components or tools because there is a chance that the paint might peel off. In addition, if any brake fluid gets on the callipers, it should be wiped off immediately.
2. Parts marked with * should be removed and then fitted for each cylinder in turn.
Jobs to be completed before removal and after fitting
• Removal and refitting of the undercover (Ref Section 51: Front bumper)
• Checking the tension of the drive belt (only after fitting)
• Draining and refilling of the coolant
• Removal and refitting of the air duct
• Removal and refitting of air pipe C
• Removal and refitting of the timing belt (refer to P11-20)
Tool Number Name Function
MB991454 Engine hanger
balancer
Holding the engine assembly while the transmission assembly is removed/installed
Recommended tools MZ203830 panzai or MZ203831 safe vehicle handling
Mechanical engine hanger
MB991928 A: MB991929 B: MB991930 C: MB991931 D: MB991932 E: MB991933 F: MB991934
Engine hanger A: joint (50) x2 B: joint (90) x2 C: joint (140) x2 D: Foot (standard) x4 E: Foot (short) x4 F: Chain and hook
ASSY
Slide bracket (HI)
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. O2sensor connector
7. Crank angle sensor connector
8. 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 – CAMSHAFT, VALVE STEM SEAL
11-6
18. Camshaft position sensor support cover
19. Camshaft position sensor support cover gasket
20. Camshaft position sensing cylinder (exhaust side)
21. Camshaft position sensor support
22. Camshaft position sensor support cover
23. Camshaft position sensor support cover gasket
24. Camshaft position sensing cylinder (inlet side)
25. Camshaft position sensor support
26. Camshaft sprocket (exhaust side)
27. Camshaft oil seal
28. Camshaft bearing cap front
29. Camshaft bearing cap rear left
30. Camshaft bearing cap No. 2
31. Camshaft bearing cap No. 5
32. Camshaft bearing cap No. 3
33. Camshaft bearing cap No. 4
34. Exhaust camshaft
35. Camshaft sprocket cap
36. Washer
37. Camshaft sprocket (inlet side)
38. Camshaft oil seal
39. Camshaft bearing cap front
40. Camshaft bearing cap rear right
41. Camshaft bearing cap No. 2
42. Camshaft bearing cap No. 5
43. Camshaft bearing cap No. 3
44. Camshaft bearing cap No. 4
45. Inlet camshaft
During assembly, apply engine oil to all sliding parts.
!!F"" !!F"" !!F"" !!F""
!!E""
""B!! !!H""
!!G""
!!F"" !!F"" !!F"" !!F"" !!F"" !!F""
!!E""
!!L""
!!J""
!!K""
!!J""
""B!! !!I""
!!G""
!!F"" !!F""
ENGINE – CAMSHAFT, VALVE STEM SEAL
11-7
46. Rocker arm
47. Rush adjuster
48. Oil delivery body
49. Spark plug
50. Valve spring retainer lock
51. Valve spring retainer
52. Valve spring
53. Inlet valve stem seal
54. Exhaust valve stem seal
!!D""
""C!! !!C""
!!B"" !!A"" !!A""
ENGINE – CAMSHAFT, VALVE STEM SEAL
11A-8
Locations for the application of lubricant and seals
<View from A>
Semi-dry sealant: Three bond 1207D
(around the lip):
Engine oil
Semi-dry sealant: Three bond 1207F
Semi-dry sealant: Three bond 1207F
<Viewed looking down onto the cylinder head>
Semi-dry sealant: Three bond 1207D
ENGINE – CAMSHAFT, VALVE STEM SEAL
11-9
Removal guidelines
""A!!
Detaching the radiator upper hose
Align the indicator marks on the radiator upper hose and the hose clamp, and then detach the radiator upper hose.
""B!!
Removing the camshaft sprockets
Grip the hexagonal part of the camshaft with a wrench, loosen the mounting bolt, and remove the camshaft sprocket.
""C!!
Removing the valve spring retainer lock
Compress the valve spring using the special tool for compressing valve springs (MD998772), and remove the valve spring retainer lock.
Caution When removing the valve spring retainer lock, each cylinder piston should be in the top dead centre position. If pistons are not in the top dead centre position, valves could fall into the cylinders.
Fitting guidelines
!!A""
Fitting the exhaust valve stem seals and the inlet valve
stem seals
1. Inlet valve stem seals and exhaust valve stem seals can be distinguished by checking the colour of the rubber parts.
2. Apply a small quantity of engine oil to the valve stem seals.
3. Place the valve stem component into the guides, and then insert a new valve stem seal into the valve stem guide by using the special tool for installing valve stem seals.
Caution (1) Valve stem seals cannot be re-used. (2) Please use the special tool for installing valve stem seals
(MD998737) because oil could leak if the valve stem seals are not fitted correctly.
Indicator marks
Colour of main
body: grey
Colour of main
body: grey/green
Inlet side Exhaust side
Valve
Valve guide
Valve stem seal
ENGINE – CAMSHAFT, VALVE STEM SEAL
11-10
!!B""
Fitting the valve spring
Fit the valve spring so that the end of the valve spring which has the smaller radius is on the rocker arm side.
!!C""
Fitting the valve spring retainer lock
In the same way as when the valve spring retainer lock was removed, compress the valve spring using the special tool for compressing valve springs (MD998772), and fit the valve spring retainer lock.
!!D""
Fitting the rush adjuster Caution If a rush adjuster is being reused, it must be washed and inspected before fitting. (Ref: Engine Service Manual)
!!E""
Fitting the camshaft
1. Remove any sealant from the cylinder head.
2. Apply engine oil to the camshaft cams and journals.
3. Fit the camshaft to the cylinder head.
Caution Ensure that the inlet and exhaust sides are not the wrong way round.
!!F""
Fitting the camshaft bearing cap No.4, the camshaft bearing cap No.3, the camshaft bearing cap No.5, the camshaft bearing cap No.2, the rear camshaft bearing cap, and the front camshaft bearing cap
1. Set the camshaft dowel pins in the position shown in the
diagram.
Rocker arm side
Front of engine
<inlet side>
<exhaust side>
slit
slit
Approx. 4°
dowel pins
inlet side
exhaust side
ENGINE – CAMSHAFT, VALVE STEM SEAL
11-11
2. Because camshaft bearing caps Nos. 2~5 are the same shape,
check the identification marks on them so that the bearing cap number and the inlet and exhaust sides are not mistaken. Then fit them in the direction shown in the diagram.
Identification marks (stamped on the front bearing cap, and on bearing cap Nos. 2~5).
I: inlet side E: exhaust side
3. Apply sealant at the 8 places shown in the diagram of the top
view of the cylinder head.
Semi-dry sealant: Three bond 1207D
4. Fit the rear camshaft bearing cap in the direction indicated by
the front mark.
5. In just the same way as for bearing caps Nos. 2~5, check the
identification marks on the front camshaft bearing cap so that the exhaust side and the inlet side are not mistaken.
6. Tighten the bearing cap mounting bolts gradually, 2~3 turns at a
time, to the specified torque.
Tightening torque: 20 ± 1 N•m
7. Check that the rocker arm has been fitted correctly.
Note Completely wipe away any sealant that has been squeezed out.
!!G""
Fitting the camshaft oil seal
1. Apply engine oil around the entire circumference of the oil seal
lip.
2. Insert the oil seal using the special tool for installing the
camshaft oil seal (MD998713), as shown in the diagram.
Front of engine
bearing cap No.
mark indicating inlet side or exhaust side
Front of engine
<Inlet side>
Front
of
engine
Front
of
engine
front mark
<Exhaust side>
front mark
camshaft oil seal
(engine oil)
ENGINE – CAMSHAFT, VALVE STEM SEAL
11-12
!!H""
Fitting the camshaft sprocket (inlet side)
1. Apply engine oil to the edges of the camshaft, and to the parts
of the camshaft sprocket which will make contact with the camshaft.
2. Match up the camshaft dowel pins with the dowel pin holes in
the camshaft sprocket, and fit the camshaft into the camshaft sprocket.
3. Hold the hexagonal part of the camshaft with a wrench, and
check that the camshaft sprocket cannot be twisted. Note This operation is necessary because it is impossible to check by looking whether the camshaft dowel pins are inserted into the dowel pin holes in the camshaft sprocket.
4. Apply engine oil to the screw thread and the underside of the
camshaft sprocket mounting bolt, and in the same way as when the camshaft sprocket was removed, hold the camshaft in place using a wrench and tighten the bolt to the specified torque.
Tightening torque: 65 ± 5 N•m
!!I""
Fitting the camshaft sprocket (exhaust side)
In the same way as when the camshaft sprocket was removed, hold the hexagonal part of the camshaft with a wrench and tighten the bolt to the specified torque.
Tightening torque: 89 ± 9 N•m
!!J""
Fitting the camshaft position sensor support
1. Remove any sealant from the camshaft position sensor support.
2. As shown in the diagram, apply sealant to the flange of the
camshaft position sensor support, and then fit it to the cylinder head.
Semi-dry sealant: Three bond 1207F
3. Tighten the mounting bolts for the camshaft position sensor
support to the specified torque.
Tightening torque: 14 ± 1 N•m
Front of engine
(engine oil)
(engine oil)
camshaft sprocket
camshaft sprocket
Front of engine
<Exhaust side>
<Inlet side>
ENGINE – CAMSHAFT, VALVE STEM SEAL
11-13
!!K""
Fitting the camshaft position sensing cylinder (inlet
side)
1. Set the inlet camshaft dowel pin in the position shown in the
diagram (No.1 cylinder compression top dead centre).
2. Tighten the mounting bolts for the camshaft position sensing
cylinder to the specified torque.
Tightening torque: 22 ± 4 N•m
!!L""
Fitting the camshaft position sensing cylinder (exhaust
side)
1. Set the exhaust camshaft dowel pin in the position shown in the
diagram (No.1 cylinder compression top dead centre). Note Under pressure from the exhaust valve spring, it will turn slightly in an anti-clockwise direction.
2. As shown in the diagram, fit the pane (small) of the camshaft
position sensing cylinder (exhaust side) so that it is in a position approximately 45° to the exhaust camshaft dowel pin.
3. Tighten the mounting bolts for the camshaft position sensing
cylinder to the specified torque.
Tightening torque: 22 ± 4 N•m
!!M""
Fitting the locker cover assembly
1. Apply sealant to the 8 places on the rocker cover gasket as
shown in the diagram.
Semi-dry sealant: Three bond 1207D
2. Fit the rocker cover assembly onto the cylinder head.
!!N""
Connecting the radiator upper hose
1. Insert the radiator upper hose as far as the protrusion on the
water outlet fitting.
2. Match up the indicator marks on the radiator upper hose and the
hose clamp, in order to fit the radiator upper hose.
<Intake side>
dowel pin
pane
pane (small)
dowel pin
approx. 45º
pane (large)
Front of engine
Protrusion
water outlet fitting
indicator marks
ENGINE – CAMSHAFT, VALVE STEM SEAL, CYLINDER HEAD GASKET
11-14
!!O""
Fitting the O-ring/oil feeder control valve Caution
1. Do not re-use O-rings.
2. When fitting O-rings, first wind some non-adhesive tape
(seal tape etc) around the oil channel of the oil feeder control valve, in order to prevent damage to the O-ring. If the O-ring touches the oil it could start an oil leak.
1. Apply engine oil to the O-ring on the oil feeder control valve.
2. Fit the oil feeder control valve to the cylinder head.
3. Tighten the mounting bolts for the oil feeder control valve to the
specified torque.
Tightening torque: 11 ± 1 N•m
Cylinder head gasket
Removal and fitting
Jobs to be completed before removal and after fitting
Measures to prevent fuel leaking. <Only before removal>
Check for fuel dripping. <Only after fitting>
Removal and refitting of the strut tower bar.
•Removal and refitting of the valence. (Ref Section 51: Front bumper)
Check the tension of the drive belt. <Only after fitting>
Adjustment of the axle letter cable. <Only after fitting>
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.
•Removal and refitting of the timing belt. (Ref P11-20)
Tape
ENGINE – CYLINDER HEAD GASKET
11-15
Removal procedure
1. Ignition coil connector
2. O2sensor 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 connector
12. 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 – CYLINDER HEAD GASKET
11-16
22. Alternator bracket connection
23. Inlet manifold stay
24. Eye bolt
25. Gasket
26. Eye bolt
27. Gasket
28. Oil feeder control valve pipe
29. Filter
30. Oil pipe joint
31. Gasket
32. Oil return pipe gasket
33. Oil return pipe
34. Oil return pipe gasket
35. Oil return pipe gasket
36. Exhaust fitting bracket
•Water outlet fitting and thermostat case assembly (Refer to Section 14: Water hose pipe)
37. Water hose connection
38. Heater hose connection
39. Fuel return hose connection
40. Fuel high pressure hose connection
41. O-ring
42. Cylinder head bolt
43. Cylinder head assembly
44. Cylinder head gasket
(when
cool)
(engine oil)
(engine oil)
!!E""
!!D""
!!C"" !!C""
""A!! !!B""
!!A""
ENGINE – CYLINDER HEAD GASKET
11-17
Removal guidelines
!!A""
Removing the cylinder head bolts
Use the special wrench for cylinder head bolts (MB991654) to turn the bolts 2~3 times in order to loosen them, before removing them in the numerical order as shown in the diagram.
Fitting guidelines
!!A""
Fitting the cylinder head gasket
1. Remove the gaskets which have been stuck onto the surface of the gasket.
Caution Do not allow any foreign matter to get into the channels for coolant or oil, or into the cylinder.
2. Fit the cylinder head gasket to the cylinder head, so that the holes in the cylinder head gasket match up with the holes in the cylinder head.
!!B""
Fitting the cylinder head bolts
1. Check that the length of the body of cylinder head bolts is less than the maximum permitted. If the length is in excess of the maximum permitted, replace the bolt with a brand new one.
Maximum length (A): 99.4mm
2. Apply a small amount of engine oil to the screw thread of the bolt, and to the washer.
Front of engine
(engine oil)
ENGINE – CYLINDER HEAD GASKET
11-18
3. Use the special wrench for cylinder head bolts (MB991654) to (loosely) tighten the bolts in the following order.
(1) In the order shown in the diagram, tighten the bolts to
78 ± 2 N•m.
(2) In reverse order to that shown in the diagram, completely loosen
the bolts.
(3) In the order shown in the diagram, tighten the bolts to
20 ± 2 N•m.
(4) Make a paint mark on the top of the cylinder head bolt, and on
the cylinder head, and tighten them to 90° as shown in the diagram.
(5) Tighten the bolts to 90° as shown in the diagram, and check that
the paint mark on the top of the cylinder head bolt and the paint mark on the cylinder head are in line.
Caution
1) If a bolt is tightened to an angle of less than 90° it has not been tightened sufficiently.
2) If the angle of tightening exceeds the regulation level, remove the bolt and start again from procedure number (1).
!!C""
Fitting the O-ring/fuel high pressure hose
1. Apply a little fresh engine oil to the O-ring.
Caution Ensure that engine oil does not get inside the delivery pipe.
2. Without damaging the O-ring, twist the fuel high pressure hose to fit it to the delivery pipe, making sure that it 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.
Front of engine
Procedure number (4) Procedure number (5)
paint mark
paint mark
ENGINE – CYLINDER HEAD GASKET
11-19
!!D""
Fitting the oil return pipe gasket
Replace the gasket with a new one, and fit it to the protruded part shown in the diagram. Note: For the oil return pipe gasket on the turbocharger side, there is no direction for slotting it in.
!!E""
Fitting the eyebolts Caution When tightening the eyebolts, hold the oil pipe joint in place with a spanner so that it does not turn round as the eyebolts are tightened.
Protrusion
ENGINE – TIMING BELT, TIMING BELT B
11-20
TIMING BELT, TIMING BELT B
Removal and fitting
Caution If Brembo brake callipers are being used take care that they are not scratched by other components or tools because there is a chance that the paint might peel off. In addition, if any brake fluid gets on the callipers, it should be wiped off immediately.
Jobs to be completed before removal and after fitting
•Removal and refitting of the valence. (Ref Section 51: Front bumper)
Removal and refitting of the LH side cover.
Checking and adjustment of the tension of the drive belt. <Only after fitting>
Removal and refitting of the crankshaft pulley.
Removal and refitting of the cross member bar.
•Removal and refitting of the front exhaust pipe.
Removal procedure
1. Pressure hose connection
2. Timing belt front upper cover
3. Water pump pulley
4. Idler pulley
5. Drive belt auto-tensioner
6. Timing belt front lower cover
Remove the engine mount bracket
Adjust the tension of the timing belt <Only after fitting>
7. Timing belt
8. Tensioner pulley
9. Tensioner arm
10. Auto-tensioner
!!G""
""A!! !!F""
!!E""
!!D""
ENGINE – TIMING BELT, TIMING BELT B
11-21
10. Power steering oil pressure switch connector
11. Heat protector
12. Power steering oil pump ASSY
13. Power steering oil pump bracket
14. Idler pulley
15. Crank angle sensor
16. Crankshaft sprocket
17. Crankshaft sensing blade
Adjust the tension of the timing belt B <Only after fitting>
18. Timing belt B tensioner
19. Timing belt B
Removal guidelines
""A!!
Removing the timing belt
1. Turn the crankshaft in a clockwise direction, and match up all the timing marks until the No.1 cylinder is in the compressor top dead centre position.
Caution Turn the crankshaft in the normal way.
2. Remove the rubber plug from the rear cover of the timing belt, and prepare the special tool for adjusting bolts (MD998738).
""C!! !!C""
!!C"" !!B""
!!A""
""D!! !!A""
""B!!
(engine oil)
Timing marks
Timing belt valence
ENGINE – TIMING BELT, TIMING BELT B
11-22
3. Twist the special tool for adjusting bolts (MD998738) by hand until it touches the tensioner arm.
Caution The special tool for adjusting bolts (MD998738) can be slowly twisted at a rate of about 30° per second but if it is suddenly twisted the auto-tensioner rod cannot be easily withdrawn, and this may lead to problems with twisting and the possibility that the special tool for adjusting bolts (MD998738) may become bent.
4. Twist the special tool for adjusting bolts (MD998738) a little, and align the auto-tensioner rod with setting hole A, and the tensioner cylinder with setting hole B.
5. Insert a wire or a pin into the aligned holes.
6. Remove the special tool for adjusting bolts (MD998738), and then loosen the bolt for fitting the timing belt tensioner, and remove the timing belt.
Caution If a timing belt is being re-used, check and make a note of the direction of the arrows indicating the rotational direction (clockwise direction) on the back of the belt.
""B!!
Removing the power steering oil pump ASSY
Remove the power steering oil pump ASSY from its bracket, with the hose intact. Note Secure the removed power steering oil pump ASSY with string, and put it somewhere where it will not hinder the removal or fitting of the timing belt.
""C!!
Removing the crankshaft sprocket
1. Hold the crankshaft sprocket in place using the special spanner (MB991367) and the special pin (MB991385).
2. Remove the crankshaft sprocket.
timing belt tensioner
arm
bolt for fitting the timing belt
tensioner
wire or pin
Crankshaft sprocket
ENGINE – TIMING BELT, TIMING BELT B
11-23
""D!!
Removing timing belt B
Caution If planning to re-use a timing belt B, 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.
Fitting guidelines
!!A""
Fitting timing belt B and the timing belt B tensioner
1. Check that the timing marks for the crankshaft sprocket and the balancer shaft sprocket are aligned.
2. Fit timing belt B onto the crankshaft sprocket and the balancer shaft sprocket. Ensure that the side of the belt under tension is not slack.
3. As a temporary step, fit the timing belt B tensioner pulley so that its centre is to the upper left of the centre of the mounting bolt, and so that the flange of the pulley is facing towards the front of the engine.
4. Adjust the tension of timing belt B.
!!B""
Adjusting the tension of timing belt B
1. Hold the timing belt B tensioner between fingertips and in the direction of the arrows, apply tension torque (3.0 ± 0.4 N·m) to timing belt B until the side of the belt under tension becomes taught. In this condition, tighten the mounting bolt to the specified torque, and fit the tensioner.
Tightening torque: 19 ± 3 N·m Caution When tightening the mounting bolt, ensure that the tensioner does not turn round with it. If the tensioner turns with the mounting bolt, it could cause the tension in the belt to become too high.
timing marks
balancer shaft sprocket
crankshaft sprocket
side of belt under tension
timing marks
centre of the pulley
centre of the mounting bolt
ENGINE – TIMING BELT, TIMING BELT B
11-24
2. <Measuring the amount of give>
(1) As shown in the diagram, apply a force of about 100N to the
middle of the belt between the sprockets (indicated by the arrow), and check that the amount of give is as specified.
Specified values:
<when adjusted> 5~7mm <when replaced> 5~7mm
(2) If the specified values are not met, readjust the tension of the
belt.
3. <When using MUT-II/III>
(1) Connect the special belt tension meter set (MB991668) to the
MUT-II/III.
(2) Connect the special battery harness (MB991704) to the MUT-
II/III, and also connect it to the batteries.
(3) Give the crankshaft two turns in a clockwise direction, and check
that the No.1 cylinder is in the top dead centre position, and that the timing marks on each sprocket are aligned.
(4) Select the “belt tension measurement” option from the display
on the MUT-II/III.
(5) As shown in the diagram hold the special belt tension meter set
(MB991668) in the middle of the belt between the sprockets (indicated by the arrow), 10~20mm away from the outer side of the belt and vertically to the belt (not leaning more than ±15° away from vertical).
(6) As shown in the diagram, lightly pull the middle of the belt
between the sprockets (indicated by the arrow) using fingertips and check that the vibration frequency of the belt is within the limits specified.
Specified values: 76 ~ 92 Hz Caution (1) The meter may give an incorrect reading if the
microphone is affected by a strong wind, or if there are loud noises nearby, while testing is taking place.
(2) The meter may give an incorrect reading if testing is
performed while the microphone is touching the belt.
(7) If the specified values are not met, readjust the tension of the
belt.
approx. 100 N
amount of give
pull lightly with fingertips
ENGINE – TIMING BELT, TIMING BELT B
11-25
!!C""
Fitting the crankshaft sensing blade and the
crankshaft sprocket
1. Clean, and remove any grease from the crankshaft sensing blade, the crankshaft sprocket, and the surface of the crankshaft to which the crankshaft sprocket will be fitted.
2. Fit the crankshaft sensing blade and the crankshaft sprocket in the direction shown in the diagram.
3. Clean the screw hole in the crankshaft.
4. Place the washer with the larger surface side in the direction as shown in the diagram, and fit it to the crankshaft bolt.
5. Apply a small quantity of engine oil to the top and to the screw thread parts of the crankshaft bolt.
6. In the same way as when it was removed, hold the crankshaft sprocket using the special tool, and tighten the crankshaft bolt to the specified torque.
Tightening torque: 167 N·m
!!D""
Fitting the auto-tensioner
1. If the auto-tensioner rod remains in an extended state, install it using the following procedure. (1) Using a press or a vice, slowly compress the auto-
tensioner rod and align the rod with setting hole A and the tensioner cylinder with setting hole B.
Caution If the speed of compression is too fast, there is a chance that the rod may break, so carry out this operation slowly.
(2) Insert a wire or pin into the aligned holes.
Note If a brand new or a replacement auto-tensioner is being used, use a pin to set the auto-tensioner in place.
2. Fit the auto-tensioner into the engine and tighten the mounting bolt to the specified torque. Do not remove the wire or pin until the tension of the timing belt has been adjusted.
Tightening torque: 23 ± 3 N·m
!!E""
Fitting the tensioner pulley
As a temporary step, fit the tensioner pulley as shown in the diagram.
Front of engine
washer
crankshaft sprocket
clean here
crankshaft
crankshaft bolt
crankshaft sensing blade
remove grease
wire or pin
tensioner pulley holes
ENGINE – TIMING BELT, TIMING BELT B
11-26
!!F""
Fitting the timing belt
1. Check that all the timing marks for the camshaft sprocket, the crankshaft sprocket and the oil pump sprocket are aligned.
2. After the timing marks for the oil pump sprocket have been aligned, remove the plug from the cylinder block and insert a posidrive (+) with a diameter of 8 mm into the plug hole. Check that more than 60 mm of the shaft of the screwdriver can be inserted. If the screwdriver strikes the balancer shaft and can only be inserted to a depth of 20 ~ 25 mm, turn the sprocket one complete turn, realign the timing marks, and check that more than 60 mm of the screwdriver can be inserted. Do not remove the screwdriver until the timing belt has been fitted.
3. Install the timing belt in accordance with the following guidelines so that the side that is under tension does not get slack. (1) Fit the timing belt around the crankshaft sprocket first, then
the oil pump sprocket and then fit it around the idler pulley.
(2) Fit the timing belt around the camshaft sprocket (exhaust
side) and hold it in place with a paper clip at the position shown in the diagram.
timing marks
camshaft sprocket (inlet side)
timing marks
crankshaft sprocket
camshaft sprocket (exhaust side)
timing marks
oil pump sprocket
plug
more than 60 mm
screwdriver
balancer shaft
camshaft sprocket (inlet side)
tensioner pulley
crankshaft sprocket
camshaft sprocket (exhaust side)
idler pulley
oil pump sprocket
paper clip
ENGINE – TIMING BELT, TIMING BELT B
11-27
(3) Use a wrench to align the timing marks on the rocker cover and
the camshaft sprocket, and whilst doing so, fit the timing belt around the camshaft sprocket (inlet side) and hold it in place with a paper clip at the position shown in the diagram.
(4) Fit the timing belt around the tensioner pulley. (5) Remove the two paper clips.
Caution After the timing belt has been installed, apply some force in an anti-clockwise direction to the camshaft sprocket and check once more that all the timing marks are in the correct position when the side of the belt under tension is taught.
4. Using the special wrench for the tensioner pulley socket (MD998767), tense the timing belt by turning the tensioner pulley in the direction shown in the diagram, and temporarily tighten the mounting bolt for the tensioner pulley.
5. Check that all the timing marks are aligned.
6. Remove the screwdriver, and replace the plug.
7. Adjust the tension of the timing belt.
!!G""
Adjusting the tension of the timing belt
1. Remove the rubber plug from the rear cover of the timing belt and put the special adjusting bolt (MD998738) in position. Slowly twist the adjusting bolt a little at a time, so that the wire or pin inserted when fitting the auto-tensioner, only moves a little.
Caution There is a possibility that the wire or pin inserted in the auto-tensioner may break if the adjusting bolt is twisted with a spanner or a similar tool, so it must be twisted by hand.
2. Turn the crankshaft a quarter turn in an anti-clockwise direction.
3. Turn the crankshaft in a clockwise direction, realign all the timing marks and set the No.1 cylinder in the top dead centre position.
4. Loosen the mounting bolt for the tensioner pulley which had been temporarily tightened.
paper clips
ENGINE – TIMING BELT, TIMING BELT B, ENGINE ASSY
11-28
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 auto­tensioner 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. <Only before removal>
Check for fuel dripping. <Only after fitting>
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. <Only after fitting>
Adjustment of the axle letter cable. <Only after fitting>
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. O2sensor 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 connector
11. 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 ASSY
11-30
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 <For cars fitted with A/C>
27. A/C compressor <For cars fitted with 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)
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