Mitsubishi Lancer Evolution IV Evolution V Workshop Manual

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WORKSHOP MANUAL

EVOLUTION-IV EVOLUTION-V

Pub. No. S9806CNCP9

General . . . . . . . . . . . . . . . . . . . . . . . .

EVOLUTION-IV EVOLUTION-V

WORKSHOP MANUAL

FOREWORD

This Workshop Manual contains procedures for service mechanics, including removal, disassembly, inspection, adjustment, reassembly and installation. Figures taken from registration documents are given in metric units only. All other figures are given in SI units with metric units in brackets. Use the following manuals in combination with this manual as required.

Engine . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Lubrication . . . . . . . . . . . . .

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Cooling . . . . . . . . . . . . . . . . .

Intake and Exhaust . . . . . . . . . . . .

Engine Electrical . . . . . . . . . . . . . . .

Engine and Emission Control . . . .

Clutch . . . . . . . . . . . . . . . . . . . . . . . . .

Manual Transmission . . . . . . . . . . .

Front Axle . . . . . . . . . . . . . . . . . . . . . .

Rear Axle . . . . . . . . . . . . . . . . . . . . . .

Power Plant Mount . . . . . . . . . . . . . .

11 12 13 14 15 16 17 21 22 26 27 32

TECHNICAL INFORMATION MANUAL

N9806CNCP9

All information, illustrations and product descriptions contained in this manual are current as at the time of publication. We, however, reserve the right to make changes at any time without prior notice or obligation.

July 1998

Front Suspension . . . . . . . . . . . . . . .

Rear Suspension . . . . . . . . . . . . . . .

Service Brakes . . . . . . . . . . . . . . . . .

Parking Brakes . . . . . . . . . . . . . . . . .

Steering . . . . . . . . . . . . . . . . . . . . . . . .

Body . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exterior . . . . . . . . . . . . . . . . . . . . . . . .

Chassis Electrical . . . . . . . . . . . . . .

Electrical Wiring . . . . . . . . . . . . . . . .

33 34 35 36 37 42 51 54

ELECTRICAL

WIRING

CONTENTS

HOW TO READ THE WIRING DIAGRAMS A. . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL WIRING (EVOLUTION-IV) B. . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL WIRING (EVOLUTION-V) C. . . . . . . . . . . . . . . . . . . . . . . .

NOTES

GENERAL

CONTENTS

MODELS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

00-1

00-2

16 valves-intercooler

(4WD-5M/T)

controlled fuel

(4WD-5M/T)

MODELS

GENERAL – Models

Model code

E-CN9A SNDF ’97 RS 4G63 (2,000-DOHC –-W5M51

Class code

SRGF ’97 GSR

Model year

Grade Engine model Transmission

model

turbo)

Model code

GF-CP9A SNDF ’98 EVOLUTION-V RS 4G63 (2,000-DOHC –

Class code

SNGF ’98 EVOLUTION-V

Model year

Grade Engine model Transmission

GSR

model W5M51

valves-intercooler

turbo)

Applicable serial numbers

E-CN9A: CN9A – 0000001 Y GF-CP9A: CP9A – 0000001 Y

Fuel supply system

Electronically

injection (MPI)

Fuel supply system

MPI

ENGINE

CONTENTS

11-1

SERVICE SPECIFICATIONS 2. . . . . . . . . . . . . .

SEALANTS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIAL TOOLS 2. . . . . . . . . . . . . . . . . . . . . . . .

ENGINE ADJUSTMENTS 4. . . . . . . . . . . . . . . . .

1. Drive Belt Tension Check 4. . . . . . . . . . . . . . .

2. Auto Tensioner Check 5. . . . . . . . . . . . . . . . . . .

3. Lash Adjuster Check 5. . . . . . . . . . . . . . . . . . . .

4. Lash Adjuster Replacement 7. . . . . . . . . . . . . .

5. Ignition Timing Check 7. . . . . . . . . . . . . . . . . . .

6. Idle Speed Check and Idle Mixture Check 7

7. Compression Pressure Check 7. . . . . . . . . . . .

8. Manifold Vacuum Check 8. . . . . . . . . . . . . . . . .

CRANKSHAFT PULLEY 9. . . . . . . . . . . . . . . . . .

CAMSHAFT AND CAMSHAFT

OIL SEAL 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OIL PAN 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CRANKSHAFT OIL SEAL 15. . . . . . . . . . . . . .

CYLINDER HEAD GASKET 17. . . . . . . . . . . .

TIMING BELT . . . . . . . . . . . . . . 21. . . .

ENGINE ASSEMBLY 32. . . . . . . . . . . . . . . . . . .

11-2

ENGINE – Service Specifications / Sealants / Special Tools

SERVICE SPECIFICATIONS

Items Standard value Limit Basic ignition timing 5_ BTDC ± 3_ – Ignition timing (at idle) Approx. 5_ BTDC – Idle speed rpm 850 ± 50 – CO contents % 0.6 or less – HC contents ppm 300 or less – Compression pressure kg/cm2 – rpm 11.5 – 250 Min. 9.7 – 250 Compression pressure difference of all cylinders kg/cm Intake manifold vacuum kPa {mmHg} – Min. 55 {410} Cylinder head bolt shank length mm – 99.4

– Max. 1.0

SEALANTS

Items Specified sealants Rocker cover Semi-drying sealant: THREEBOND 1207D [MZ 100168] (containing 150 g) Oil pan Semi-drying sealant: THREEBOND 1207F [MZ 100191] (containing 150 g)

NOTE: Given in [ ] are MITSUBISHI GENUINE PART numbers.

SPECIAL TOOLS

Tool Number Name Use

MD998782 Valve lifter set Replacing the lash adjuster

MB990767 End yoke holder D Holding the crankshaft pulley

D Holding the camshaft sprocket

Tool UseNameNumber

ENGINE – Special Tools

11-3

MD998719 Crankshaft pulley

holder pin

MD998715 Pulley holder pin

MD998713 Camshaft oil seal

installer

MD998727 Oil pan remover Removing the oil pan

D Holding the crankshaft pulley D Holding the camshaft sprocket

Pressfitting the camshaft oil seal

MD998781 Flywheel stopper Securing the flywheel or drive plate

MD998776 Crankshaft rear oil

seal installer

MB990938 Handle

MD998382 Crankshaft front oil

seal installer

Pressfitting the crankshaft rear oil seal

Installing the crankshaft front oil seal

MD998285 Crankshaft front oil

seal guide

11-4

Tool UseNameNumber

ENGINE – Special Tools / Engine Adjustments

MB991654 Cylinder head bolt

wrench

MD998767 Tensioner pulley

socket wrench

Recommended tool MZ203826 by Anzen Jidosha or MZ203827 by Banzai

MD991453 Engine hanger

Engine lifter Supporting the engine assembly during

assembly

Removing and reinstalling the cylinder head bolt

Timing belt tension adjustment

removal and installation of the transmission

ENGINE ADJUSTMENTS

Auto tensioner

Indicator mark

1. DRIVE BELT TENSION CHECK

NOTE Use of the auto tensioner eliminates the need for belt tension adjustment. Check that the indicator mark on the auto tensioner is in the range of A shown. If it is outside the specified range (i.e., in range of B shown), replace the drive belt. (For the removal and installation of the drive belt, refer to P.11-9.)

Good

Tool mounting hole

MAX

MIN

High-pressure chamber

ENGINE – Engine Adjustments

2. AUTO TENSIONER CHECK

(1) Stop the engine from the idle speed and check that the

belt rests within the auto tensioner pulley width.

(2) Remove the drive belt.

(For the removal of the drive belt, refer to P.11-9.)

(3) Fit a spinner handle or similar tool into the tool mounting

hole of the auto tensioner and turn the tensioner clockwise and counterclockwise to ensure that it does not bind.

(4) If step (1) or (3), or both, have been checked abnormally,

replace the auto tensioner.

(5) Reinstall the drive belt.

3. LASH ADJUSTER CHECK

NOTE If an unusual knocking noise can be heard immediately after the engine has started or while it is running and if that is probably attributable to the lash adjuster, make the following checks.

(1) Check the engine oil and add or change oil as necessary.

NOTE (1) If the engine oil level is low, air is taken in through

the oil screen, entering the oil passage.

(2) If the oil level is too high, the cranks agitate oil causing

oil to trap a large amount of air.

(3) Air does not easily separate from a deteriorated oil

that can contain an increased amount of air.

When air trapped in oil for these reasons gets into the high-pressure chamber of the lash adjuster, the air in the high-pressure chamber is compressed to shrink the lash adjuster excessively while the valve is opening, resulting in an unusual noise occurring. This is the same symptom developing when the valve clearance is adjusted to an excessive value. The problem in this case is gone when air is released from the lash adjuster.

(2) Start the engine and carry out several cycles (10 or less)

of mild racing*. If the noise is gone after racing, it indicates that air has been released from the high-pressure chamber of the lash adjuster, restoring the lash adjuster to normal operating conditions. *: Gradually (extending over a 30-sec. period) increase

the engine speed from idle speed to 3,000 r/min and then reduce it down to the idle speed gradually (extending over a 30-sec. period).

11-5

NOTE (1) If the vehicle is parked on a slope for a long time,

the amount of oil in the lash adjuster will decrease, causing air to get into the high-pressure chamber when the engine is started.

(2) After the vehicle has been parked for a long time,

oil drains out of the oil passage and it takes a long time for the oil to reach the lash adjuster. This can cause air to get into the high-pressure chamber.

11-6

ENGINE – Engine Adjustments

Timing belt side

AA B B

ABAB

(3) If the noise is not eliminated by racing, follow these steps

to check the lash adjuster. a. Stop the engine. b. Bring no. 1 cylinder to TDC on the compression stroke. c. Push the rocker arms indicated by arrow A on the

left to see if they go down. d. Slowly turn the crankshaft clockwise 360_. e. Perform the same step as step c for rocker arms

indicated by arrow B.

f. Push the part of the rocker arm which contacts the

top of the lash adjuster. If the rocker arm can be

easily moved down to the bottom, the lash adjuster

is defective, requiring replacement.

When the lash adjuster is replaced, be sure first to

bleed the lash adjuster of air before installation. Then,

perform steps a through e to ensure that no abnormal

symptoms are noted.

NOTE

(1) The leak-down test is an effective means to

accurately determine if the lash adjuster is operational or not.

(2) For the leak-down test and bleeding procedures,

refer to ENGINE WORKSHOP MANUAL. If the rocker arm is felt binding and cannot be pushed downward as you push it, the lash adjuster is operational. Check for other possible causes for the noise.

MD998782

(4) Lash adjuster replacement

Caution From the cylinder from which the lash adjuster is to be removed, turn the crankshaft to lower the piston, as the valve contacts the piston when pushed down. A rocker arm cannot be removed if it is lifted by the cam. If this is the case, turn the crankshaft so that the arm is not lifted.

a. Using the special tool, push the valve downward to

remove the roller rocker arm. b. Remove the lash adjuster from the cylinder head. c. Mount a brandnew lash adjuster which has been bled

of air in the cylinder head. d. Using the special tool, lower the valve and install

the roller rocker arm.

NOTE

To mount the roller rocker arm, first place the pivot

side of the rocker arm on the lash adjuster, then push

down the valve; next, place the slipper side of the

rocker arm on the valve system side.

ENGINE – Engine Adjustments

4. LASH ADJUSTER REPLACEMENT

Refer to (4) of the preceding paragraph.

5. IGNITION TIMING CHECK

Check that ignition timing is at the standard value.

Standard value: approx. 5_BTDC

NOTE Ignition timing is variable within about ±7_, even under normal operating.

11-7

Crank angle sensor connector

6. IDLE SPEED CHECK AND IDLE MIXTURE CHECK

(1) Run the engine at 2,000 to 3,000 r/min for 2 minutes. (2) Check the CO and HC contents at idle.

Standard value

CO contents: 0.6% or less HC contents: 300 ppm or less

7. COMPRESSION PRESSURE CHECK

(1) Before inspection, check that the engine oil, starter and

battery are normal. In addition, set the vehicle to the pre-inspection condition.

(2) Remove all of the spark plugs. (3) Disconnect the crank angle sensor connector.

NOTE Doing this will prevent the engine-ECU from carrying out ignition and fuel injection.

(4) Cover the spark plug hole with a shop towel etc., and

after the engine has been cranked, check that no foreign material is adhering to the shop towel.

Caution (1) Keep away from the spark plug hole when

cranking.

(2) If compression is measured with water, oil, fuel,

etc., that has come from cracks inside the cylinder, these materials will become heated and will gush out from the spark plug hole, which is dangerous.

11-8

Compression gauge

ENGINE – Engine Adjustments

(5) Set compression gauge to one of the spark plug holes. (6) Crank the engine with the throttle valve fully open and

measure the compression pressure.

Standard value

(at engine speed of 250 r/min): 11.5 kg/cm

Limit (at engine speed of 250 r/min): 9.7 kg/cm

(7) Measure the compression pressure for all the cylinders,

and check that the pressure differences of the cylinders are below the limit.

Limit: Max. 1.0 kg/cm

(8) If there is a cylinder with compression or a compression

difference that is outside the limit, pour a small amount of engine oil through the spark plug hole, and repeat the operations in steps (5) through (7). a. If the compression increases after oil is added, the

cause of the malfunction is a worn or damaged piston ring and/or cylinder inner surface.

b. If the compression does not rise after oil is added,

the cause is a burnt or defective valve seat, or pressure is leaking from the gasket.

(9) Connect the crank angle sensor connector. (10)Install the spark plugs. (11)Install the ignition coil and connect the ignition coil

connector.

(12)Erase the diagnosis codes by keeping the battery minus

(–) cable disconnected for more than 10 seconds. NOTE

This will erase the diagnosis code resulting from the crank angle sensor connector being disconnected.

Fuel pressure regulator valve

Vacuum gauge

8. MANIFOLD VACUUM CHECK

(1) Before inspection, set the vehicle to the pre-inspection

condition.

(2) Connect a tachometer connector. (3) Attach a three-way union to the vacuum hose between

the fuel pressure regulator valve and the intake manifold, and connect a vacuum gauge.

(4) Start the engine and check that idle speed is within

standard value.

Standard value: 850 ± 50 r/min

5. Check the manifold vacuum at idling.

Limit: Min. 55 kPa {410 mmHg}

ENGINE – Crankshaft Pulley

CRANKSHAFT PULLEY

REMOVAL AND INSTALLATION

11-9

Pre-removal Operation

D Under Cover Removal

Post-installation Operation

D Drive Belt Tension Adjustment (Refer to P.11-4.) D Under Cover Installation

25 {2.5}

Removal steps

AA" 1. Drive belt

2. Crankshaft pulley

Auto tensioner

Hole in arm

Hole in bracket

Unit: Nm {kgf@m}

REMOVAL SERVICE POINT

AA" DRIVE BELT REMOVAL

(1) Align the hole in the auto tensioner bracket with that

in the arm and insert a screwdriver into the holes.

(2) Remove the drive belt.

Phillips screwdriver

11-10

ENGINE – Camshaft and Camshaft Oil Seal

CAMSHAFT AND CAMSHAFT OIL SEAL

REMOVAL AND INSTALLATION

Pre-removal and Post-installation Operation

(1) Engine Coolant Draining and Refilling (2) Air Hose C Removal and Installation

(Refer to GROUP 15 – Intercooler.)

(3) Spark Plug Cable and Ignition Coil Assembly Removal

and Installation

10 {1.0}

(4) Air Pipe Removal and Installation

(Refer to GROUP 15 – Air Control Valve.)

(5) Timing Belt Removal and Installation

(Refer to P.11-21.)

9 {0.9}

3.4 {0.35}

20 {2.0}

22 {2.2}

12 – 15 {1.2 – 1.5}

Removal steps

1. Breather hose connection

2. PCV hose connection

3. Crank angle sensor bracket connection

4. Control harness connection

5. Rocker cover

6. Radiator upper hose connection

7. Cover

"EA 8. Cam position sensing cylinder

17 16

88 {9.0}

Unit: Nm {kgf@m}

9. Cam position sensor support

10. Semi-circular packing

AA""DA 11. Camshaft sprocket

"CA 12. Camshaft oil seal "BA 13. Front cam cap "BA 14. Rear cam cap "BA 15. Cam cap "AA 16. Camshaft (exhaust side) "AA 17. Camshaft (intake side)

ENGINE – Camshaft and Camshaft Oil Seal

Grease and adhesive application points

11-11

10 mm

φ 3 mm

Semi-drying sealant:

THREEBOND 1207F

10 mm

Semi-drying sealant: THREEBOND 1207D

10 mm

Timing belt side

Lip

Engine oil

MB990767

MD998719

Camshaft sprocket side

Camshaft (exhaust side)

Slit

REMOVAL SERVICE POINT

AA" CAMSHAFT SPROCKET REMOVAL

INSTALLATION SERVICE POINTS

"AA CAMSHAFT INSTALLATION

(1) Apply engine oil to the cams and journals of the camshaft. (2) Mount the camshaft on the cylinder head.

Caution Make sure that the camshaft has a unique orientation for installation, the intake side and exhaust side. The exhaust camshaft has a slit in the rear end face.

11-12

Approx. 12_

Dowel pin

ENGINE – Camshaft and Camshaft Oil Seal

"BA CAM CAP / REAR CAP / FRONT CAM CAP

INSTALLATION

(1) Locate the camshaft dowel pins as illustrated.

Intake side

Exhaust side

(2) Temporarily tighten cam cap in two to three steps, then

torque it to specification.

Tightening torque: 20 Nm {2.0 kgf@m}

"CA CAMSHAFT OIL SEAL INSTALLATION

(1) Apply engine oil to the entire periphery of the oil seal

lip.

(2) Pressfit the oil seal as shown.

ID paint

MD998713

90_

Dowel pin

"DA CAMSHAFT SPROCKET INSTALLATION

As you did during removal, secure the camshaft sprocket with the special tool and tighten bolt to specification.

Tightening torque: 88 Nm {9.0 kgf@m}

"EA CAM POSITION SENSING CYLINDER

Install the cam position sensing cylinder so that the ID paint on the cam position sensing cylinder is 90_ with respect to the camshaft dowel pin as shown.

OIL PAN

REMOVAL AND INSTALLATION

Pre-removal and Post-installation Operation

(1) Under Cover Removal and Installation (2) Front Exhaust Pipe Removal and Installation

(Refer to GROUP 15.)

ENGINE – Oil Pan

(3) Oil Level Gauge Removal and Installation (4) Engine Oil Draining and Supplying

Identification of bolt location

11-13

φ 4 mm

Groove

Semi-drying sealant: THREEBOND 1207D

Bolt hole

9 {0.9}

A: 6 × 8 mm B: 6 × 10 mm

30 {3.1}

39 – 44 {4.0 – 4.5}

"BA 3. Oil return pipe gasket

39 {4.0}

Removal steps

1. Starter

2. Oil return pipe

4. Engine oil cooler return pipe

7 {0.7}

26 {2.6}

5. Bell housing cover

6. Drain plug

"AA 7. Drain plug gasket

AA" 8. Oil pan

Washer assembled bolt 9 {0.9} Flange bolt 10 {1.0}

Unit: Nm {kgf@m}

11-14

ENGINE – Oil Pan

MD998727

Drain plug gasket

MD998727

Printed portion

Oil pan side

REMOVAL SERVICE POINT

AA" OIL PAN REMOVAL

INSTALLATION SERVICE POINTS

"AA DRAIN PLUG GASKET INSTALLATION

Install the drain plug gasket in the direction so that it faces as shown in the illustration.

"BA OIL RETURN PIPE GASKET INSTALLATION

Install the gasket with the printed portion toward the oil pan.

Gasket

ENGINE – Crankshaft Oil Seal

CRANKSHAFT OIL SEAL

REMOVAL AND INSTALLATION

11-15

127 – 137 {13.0 – 14.0}

Crankshaft front oil seal removal steps

D Timing belt and timing belt B

(Refer to P.11-21.)

D Crank angle sensor

(Refer to GROUP 16.)

1. Crankshaft sprocket B

2. Key

"CA 3. Crankshaft front oil seal

Engine oil

Crankshaft rear oil seal removal steps

D Transmission assembly D Clutch cover and disc

AA""BA 4. Flywheel

"AA 5. Crankshaft rear oil seal

Unit: Nm {kgf@m}

11-16

ENGINE – Crankshaft Oil Seal

REMOVAL SERVICE POINT

AA" FLYWHEEL ASSEMBLY REMOVAL

Use the special tool to secure the flywheel assembly and remove the bolts.

MD998781

Crankshaft rear oil seal

MB990938

MB998776

Crankshaft

Oil seal

Crankshaft

INSTALLATION SERVICE POINTS

"AA CRANKSHAFT REAR OIL SEAL INSTALLATION

(1) Apply a small mount of engine oil to the entire

circumference of the oil seal lip.

(2) Install the oil seal with the special tool as far as the

chamfered position of the oil seal case as shown in the illustration.

"BA FLYWHEEL ASSEMBLY INSTALLATION

Use the special tool to hold the flywheel in the same manner as removal, and install the bolt. Tighten the bolts to the specification.

Tightening torque: 127 – 137 Nm {13.0 – 14.0 kgf@m}

"CA CRANKSHAFT FRONT OIL SEAL INSTALLATION

Apply a small amount of engine oil to the entire circumference of the oil seal lip. Pressfit the oil seal until it is flush with the chamfered end of the oil pump case.

MD998382

MD998285 (Lubricate outer circumference with oil)

ENGINE – Cylinder Head Gasket

CYLINDER HEAD GASKET

REMOVAL AND INSTALLATION

11-17

Pre-removal Operation

(1) Fuel Discharge Prevention (2) Engine Oil Removal (3) Strut Tower Bar Removal (4) Timing Belt Removal (Refer to P.11-21.) (5) Thermostat Case Assembly Removal

(Refer to GROUP 14 – Water Hose Pipe.)

(6) Front Exhaust Pipe Removal (Refer to GROUP 15.)

Delivery pipe

O-ring

Engine oil

Post-installation Operation

(1) Front Exhaust Pipe Installation

(Refer to GROUP 15.)

(2) Thermostat Case Assembly Installation

(Refer to GROUP 14 – Water Hose Pipe.) (3) Engine Oil Filling (4) Timing Belt Installation (Refer to P.11-21.) (5) Strut Tower Bar Installation (6) Accelerator Cable Adjustment

10 {1.0}

3 {0.3}

5 {0.5}

9 {0.9}

Removal steps

1. Center cover

2. Accelerator cable connection

3. Ignition coil connector

4. Ignition coil

5. Crank angle sensor connector

6. Crank angle sensor bracket connection

7. Brake booster vacuum hose connection

8. Vacuum hose connection

9. TPS connector

10. ISC motor connector

12 – 15 {1.2 – 1.5}

Unit: Nm {kgf@m}

11. Water hose connection

12. Oxygen sensor connector

13. Injector connector

14. Cam position sensor connector

15. Coolant temperature sensor connector

16. Water temperature gauge unit connector

17. Control harness

"DA 18. Fuel pipe pressure hose connection

19. Fuel return hose connection

20. Oil level gauge guide assembly

11-18

ENGINE – Cylinder Head Gasket

78 → 0 → 20 → +90_ → +90_ {8.0 → 0 → 2.0 → +90_ → +90_}

3.4 {0.35}

22 {2.2}

9 {0.9}

10 mm

30 {3.1}

10 mm

9 {0.9}

Removal steps

21. PCV hose connection

22. Rocker cover

23. Semi-circular packing

24. Starter

25. Oil return pipe

"CA 26. Oil return pipe gasket

27. Vacuum tank/solenoid valve/vacuum hose assembly

30 {3.1}

10 mm10 mm

Semi-drying sealant:

THREEBOND 1207D

28. Intake manifold stay

29. Heater hose connection

30. Alternator brace stay mounting bolt

AA""BA 31. Cylinder head bolt

32. Cylinder head assembly

"AA 33. Cylinder head gasket

Unit: Nm {kgf@m}

MB991654

ENGINE – Cylinder Head Gasket

REMOVAL SERVICE POINT

AA" CYLINDER HEAD BOLT REMOVAL

Loosen the bolts in 2 or 3 steps in order of the numbers shown in the illustration, and remove the cylinder head assembly.

11-19

Intake side

Exhaust side

Washer

Cylinder head

Front of engine

Cylinder head bolt

(Engine oil)

INSTALLATION SERVICE POINTS

"AA CYLINDER HEAD GASKET INSTALLATION

(1) Wipe off all oil and grease from the gasket mounting

surface.

(2) Install so that the shapes of the cylinder head holes match

the shapes of the respective cylinder head gasket holes.

"BA CYLINDER HEAD BOLT INSTALLATION

(1) When installing the cylinder head bolts, the length below

the head of the bolts should be within the limit. If it is outside the limit, replace the bolts.

Limit (A): 99.4 mm

(2) Apply a small amount of engine oil to the thread section

and the washer of the cylinder head bolt.

11-20

MB991654

Intake side

Exhaust side

Front of engine

ENGINE – Cylinder Head Gasket

(3) Tighten the bolts by the following procedure.

Step Operation

1 Tighten to 78 Nm {8.0 kgf@m} in the order shown in the

illustration.

2 Fully loosen in the reverse order of that shown in the

illustration.

3 Tighten to 20 Nm {2.0 kgf@m} in the order shown in the

illustration.

4 Mark the head of the cylinder head bolt and cylinder head

by paint, then tighten 90_ of a turn in the order shown in the illustration.

5 Tighten 90_ of a turn in the order shown in the illustration.

Check that the painted mark of the head bolt is lined up with that of the cylinder head.

Caution (1) Always make a tightening angle just 90_. If it is less

than 90_, the head bolt will be loosened.

(2) If it is more than 90_, remove the head bolt and repeat

the procedure from step 1.

Step 4

90_

Painted mark

Gasket

Step 5

Painted mark

Printed portion

90_

"CA OIL RETURN PIPE GASKET INSTALLATION

Install the gasket with the printed portion toward the oil pan.

"DA HIGH-PRESSURE FUEL HOSE INSTALLATION

(1) Apply a small amount of new engine oil to the O-ring,

then fit the O-ring in the delivery pipe.

Caution Do not let any engine oil get into the delivery pipe.

(2) Check that the high pressure hose turns smoothly.

If the hose does not turn smoothly, the O-ring is probably being clamped. Disconnect the high-pressure fuel hose and check the O-ring for damage. After this, re-install the hose to the delivery pipe and check that the hose turns smoothly.

(3) Tighten the mounting bolts to the specification.

TIMING BELT

REMOVAL AND INSTALLATION

ENGINE – Timing Belt

11-21

11 {1.1}

9 {0.9}

49 {5.0}

118 {12.0}

19 {1.9}

24 {2.4}

45 {4.6}

24 {2.4}

11 {1.1}

49 {5.0}

3.5 {0.35}

11 {1.1}

30 {3.1}

88 {9.0}

48 {4.9}

AA""LA 5. Timing belt

"KA 6. Tensioner pulley "JA 8. Auto tensioner

AB""IA 11. Oil pump sprocket AC""HA 12. Crankshaft bolt AD" 13. Crankshaft sprocket

Removal steps

1. Front upper cover

2. Front center cover

3. Front lower cover

4. Bracket

7. Tensioner arm

9. Idle pulley

10. Crankshaft position sensor

14. Sensing blade

54 {5.5}

9 {0.9}

AE""GA 16. Timing belt B AF""FA 17. Counterbalance shaft sprocket

AG" 19. Crankshaft sprocket B

AH""AA 24. Camshaft sprocket bolt

49 {5.0}

15. Tensioner B

"EA 18. Spacer

20. Crankshaft key

"DA 21. Rocker cover "CA 22. Semi-circular packing "BA 23. Engine support bracket

25. Camshaft sprocket

26. Timing belt rear right cover

27. Timing belt rear left upper cover

28. Timing belt rear left lower cover

Unit: Nm {kgf@m}

11-22

Timing mark

ENGINE – Timing Belt

REMOVAL SERVICE POINTS

AA" TIMING BELT REMOVAL

(1) If the timing belt is to be reused, chalk an arrow mark

on the back surface of the belt so that the belt can be reinstalled in the same direction.

(2) Place the exhaust camshaft sprocket in a position where

the timing mark for No. 1 cylinder is positioned about one tooth before the top dead center of the compression stroke.

Caution The camshaft sprocket on the exhaust side can turn very easily because of the valve spring tension. Use care not to allow your fingers to get caught by the sprocket.

(3) Loosen the lock nut of the tensioner pulley, then remove

the timing belt.

AB" OIL PUMP SPROCKET REMOVAL

(1) Remove the plug on the left side of cylinder block. (2) Insert a screwdriver (shank diameter 8 mm) to block the

counterbalance shaft. (3) Loosen the flange bolt. (4) Remove the oil pump sprocket.

AC" CRANKSHAFT BOLT LOOSENING

AD" CRANKSHAFT SPROCKET REMOVAL

If it is difficult to remove the sprocket, use the special tool.

ENGINE – Timing Belt

AE" TIMING BELT “B” REMOVAL

Make an arrow mark on the back of the timing belt indicating the direction of rotation so it may be reassembled in the same direction if it is to be reused.

6EN1322

AF" COUNTERBALANCE SHAFT SPROCKET

REMOVAL

11-23

AG" CRANKSHAFT SPROCKET “B” REMOVAL

If it is difficult to remove the sprocket, use the special tool.

AH" CAMSHAFT SPROCKET BOLT LOOSENING

Use a wrench to hold the hexagonal part of the camshaft, and then remove the camshaft sprocket mounting bolt.

INSPECTION

TIMING BELT

Replace belt if any of the following conditions exist. (1) Hardening of back rubber.

Back side is glossy without resilience and leaves no indent

when pressed with fingernail.

11-24

ENGINE – Timing Belt

Peeling of canvas

Cracks on rib root

Cracks

Tooth missing

Cracks

Cracks on sides

(2) Cracks on rubber back. (3) Cracks of canvas. (4) Cracks on rib root. (5) Cracks on belt sides.

(6) Abnormal wear of belt sides.

NOTE

The sides are normal if they are sharp as if cut by a

knife.

(7) Abnormal wear on teeth.

Initial stage:

Canvas on load side tooth flank worn (Fluffy canvas fibers, rubber gone and color changed to white, and unclear canvas texture)

Final stage:

Canvas on load side tooth flank worn down and rubber exposed (tooth width reduced)

(8) Missing tooth.

12 mm

98 to 196 N {10 to 20 kgf}

Movement

6EN1033

AUTO TENSIONER

(1) Check the auto tensioner for possible leaks and replace

as necessary. (2) Check the rod end for wear or damage and replace as

necessary. (3) Measure the rod protrusion. If it is out of specification,

replace the auto tensioner.

Standard value: 12 mm

(4) Press the rod with a force of 98 – 196 N {10 – 20 kgf}

and measure its protrusion. If it is out of specification,

replace the auto tensioner.

Standard value: 1 mm or less

ENGINE – Timing Belt

INSTALLATION SERVICE POINTS

"AA CAMSHAFT SPROCKET BOLT TIGHTENING

Using a wrench, hold the camshaft at its hexagon and tighten the bolt to the specification.

Caution Locking the camshaft sprocket with a tool damages the sprocket.

11-25

Apply sealant

"BA ENGINE SUPPORT BRACKET LEFT

INSTALLATION

Coat the bolts illustrated with sealant before tightening.

Specified sealant: THREEBOND 1207F or equivalent

"CA SEALANT APPLICATION ON SEMI-CIRCULAR

PACKING

Apply sealant to the areas indicated in the illustration.

Specified sealant: THREEBOND 1212D or equivalent

10 mm

Semi-circular packing

Apply sealant

10 mm

Cylinder head

11-26

10 mm

ENGINE – Timing Belt

"DA SEALANT APPLICATION ON ROCKER COVER

Apply sealant to the areas indicated in the illustration.

Specified sealant: THREEBOND 1212D or equivalent

10 mm

Apply sealant

10 mm

Apply sealant

Spacer

Chamfer

10 mm

Oil seal

Apply sealant

"EA SPACER INSTALLATION

(1) Apply very thin coat of oil to the outer periphery of the

spacer (oil seal contacting surface). (2) Install the spacer with the chamfered end toward the

oil seal. Mounting in the reverse direction can damage

the oil seal lip.

"FA COUNTERBALANCE SHAFT SPROCKET

INSTALLATION

Timing marks

"GA TIMING BELT “B” INSTALLATION

(1) Align timing marks on the crankshaft sprocket “B” and

counterbalance shaft sprocket with the marks on the front

case respectively. (2) Install the timing belt “B” on the crankshaft sprocket “B”

and counterbalance shaft sprocket. There should be no

slack on the tension side.

ENGINE – Timing Belt

11-27

Tensioner “B”

Center of tensioner pulley

Center of bolt

T ension side of timing belt

Timing belt “B”

(3) Make sure that the relationship between the tensioner

pulley center and the bolt center is as shown in the

illustration.

(4) Move the tensioner “B” in the direction of arrow while

lifting with a finger to give a sufficient tension to the tension

side of timing belt. In this condition, tighten bolt to secure

tensioner “B”. When the bolt is tightened, use care to

prevent shaft from turning together. If shaft is turned

together, belt will be overtensioned.

"HA CRANKSHAFT BOLT TIGHTENING

"IA OIL PUMP SPROCKET INSTALLATION

(1) Block the counterbalance shaft in the same way as at

the disassembly to prevent it from turning. (2) Install the oil pump sprocket. (3) Apply a proper amount of engine oil to the bearing surfaces

of the flange nuts. (4) Tighten the flange nuts to the specified torque.

6EN0564

"JA AUTO TENSIONER INSTALLATION

(1) If the auto tensioner rod is in its fully extended position,

reset it as follows.

a. Clamp the auto-tensioner in the vise with soft jaws.

b. Push in the rod little by little with the vise until the

set hole A in the rod is aligned with the hole B in the cylinder.

6AE0049

11-28

Holes in tensioner pulley

ENGINE – Timing Belt

c. Insert a wire (1.4 mm in diameter) into the set holes.

d. Unclamp the auto tensioner from the vise. (2) Install the auto tensioner. Leave the wire installed in the

auto tensioner until the timing belt is installed.

6AE0050

"KA TENSIONER PULLEY INSTALLATION

Install the tensioner pulley as shown in the illustration.

6EN1323

Timing marks

"LA TIMING BELT INSTALLATION

(1) Place the exhaust side camshaft sprocket in a position

where its timing mark is one tooth offset from the timing

mark on the rocker cover in the counterclockwise direction.

NOTE

Even if the timing marks on the sprocket and the rocker

cover are brought into alignment, the exhaust camshaft

is forced back by the valve spring tension. It is stabilized

at a position one tooth before the timing mark.

(2) Align the timing mark on the intake side camshaft sprocket

with that on the rocker cover.

NOTE

Even if the timing marks on the sprocket and the cover

are brought into alignment, the intake camshaft is forced

to turn one tooth in the clockwise direction by the valve

spring tension and stabilized there.

(3) Place the timing mark on the crankshaft sprocket one

tooth this side from the mated timing mark as in the case

of the camshaft sprocket.

Timing marks

Plug

Screwdriver

ENGINE – Timing Belt

(4) Align the timing mark on the oil pump sprocket with its

mating mark. (5) Remove the plug on the left side of the cylinder block

and insert a Phillips screwdriver (shank diameter 8 mm)

through the hole.

If it can be inserted as deep as 60 mm or more, the

timing marks are correctly aligned. If the inserted depth

is only 20 – 25 mm, turn the oil pump sprocket one turn

and realign timing marks. Then check to ensure that the

screwdriver can be inserted 60 mm or more.

(6) Remove the Phillips screwdriver. Place the oil pump

sprocket in a position where its timing mark is one tooth

offset from the mated timing mark in the counterclockwise

direction.

11-29

6EN1327

(7) Fit the timing belt over the exhaust side camshaft sprocket,

and secure it at the illustrated position using a paper

clip.

(8) Turn the intake side camshaft sprocket as shown to a

position where its timing mark is one tooth offset from

the mated timing mark in the counterclockwise direction.

Then, fit the timing belt over the sprocket and secure

it with a paper clip.

NOTE

The intake camshaft will be turned a little clockwise by

the valve spring tension and stabilized in position even

if the belt is clipped at one tooth offset position.

Timing marks

(9) Check to ensure that the timing marks on the intake

camshaft sprocket side are in alignment when the exhaust

camshaft sprocket is turned clockwise to align the timing

marks.

NOTE

The timing belt span between the intake and exhaust

sprockets will have 17 cogs.

11-30

Camshaft sprocket

Crankshaft sprocket

ENGINE – Timing Belt

(10)Fit the timing belt over the idler pulley, oil pump sprocket

and crankshaft sprocket in this order.

NOTE

Be careful that the belt does not become slack.

Oil pump sprocket

(11)Fit the timing belt over the tensioner pulley.

NOTE

When fitting the timing belt over the tensioner pulley,

turn the intake side camshaft sprocket a little

counterclockwise, as this will facilitate the work.

Crankshaft sprocket

MD998767

(12)Turn the crankshaft pulley a little in the illustrated direction

to pull up the timing belt at the idler pulley side. (13)Check to ensure that the timing marks on the crankshaft

sprocket, oil pump sprocket and exhaust camshaft

sprocket are all offset one tooth from the corresponding

timing marks in the counterclockwise direction.

(14)Using the special tool, turn the tensioner pulley in the

illustrated direction to strain the timing belt. Then, secure

the tensioner temporarily by tightening the retaining bolt

lightly.

NOTE

There must be no slack in the timing belt between the

intake and exhaust camshafts. (15)Turn the crankshaft to align the timing mark with the mark

for No. 1 cylinder top dead center in the compression

stroke. (16)Set the special tool as shown and screw it in up to the

position where the wire inserted in the auto-tensioner

when installing it can be moved lightly.

MD998738

ENGINE – Timing Belt

11-31

MD998767

(17)Loosen the retaining bolt of the tensioner pulley.

Caution

Loosening the retaining bolt can cause the intake

and exhaust camshafts to turn, resulting in slackened

timing belt. Use care that the timing belt does not

come off the sprockets at this time.

(18)Pull up the slack of the timing belt by turning the tensioner

in illustrated direction using the special tool and a torque

wrench (0 – 5 Nm {0 – 0.5 kgf@m}). (19)From this position, turn back the tensioner until the torque

wrench reading becomes 3.5 Nm {0.36 kgf@m}, then

secure it by tightening the retaining bolt. (20)Remove the special tool attached in step (16). (21)Rotate the crankshaft clockwise 2 turns. Then, leave it

intact 15 minutes. (22)Check to see that the wire inserted when installing the

auto-tensioner can be pulled out lightly. If it can be pulled

out lightly, the timing belt is being tensioned properly.

If so, remove the wire. In addition, check that the rod

protrusion from the auto-tensioner meets the standard

value, which is also an indication of properly tensioned

timing belt.

Standard value: 3.8 – 4.5 mm

(23)If the wire cannot be removed with a light force, repeat

steps (16) through (21) until the proper belt tensioner

is obtained.

ENGINE – Engine Assembly

ENGINE ASSEMBLY

REMOVAL AND INSTALLATION

11-32

Pre-removal Operation

(1) Fuel Discharge Prevention (2) Hood Removal (3) Strut Tower Bar Removal (4) Air Hose C Removal

(Refer to GROUP 15 – Intercooler.) (5) Radiator Assembly Removal (Refer to GROUP 14.) (6) Under Cover Removal (7) Front Exhaust Pipe Removal (Refer to GROUP 15.)

Delivery pipe

O-ring

Engine oil

10 – 12 {1.0 – 1.2}

Post-installation Operation

(1) Front Exhaust Pipe Installation

(Refer to GROUP 15.) (2) Under Cover Installation (3) Radiator Assembly Installation

(Refer to GROUP 14.) (4) Accelerator Cable Adjustment (5) Air Hose C Installation

(Refer to GROUP 15 – Intercooler.) (6) Strut Tower Bar Installation (7) Hood Installation

10 – 12 {1.0 – 1.2}

5 {0.5}

3 {0.3}

Removal steps

1. Center cover

2. Accelerator cable

3. Brake booster vacuum hose connection

4. Vacuum hose connection

5. Throttle position sensor connector

6. Idle speed control motor connector

7. Heater hose connection

8. Ignition coil connector

9. Crank angle sensor connector

10. Oxygen sensor connector

11 10

Unit: Nm {kgf@m}

11. Injector connector

12. Cam position sensor connector

13. Coolant temperature sensor connector

14. Coolant temperature gauge unit connector

15. Vacuum pipe/hose assembly

16. Control harness

"CA 17. High-pressure fuel hose connection

18. Fuel return hose connection

11-33

ENGINE – Engine Assembly

39 {4.0}

9 {0.9}

12 {1.2}

57 {5.8}

19. Solenoid valve connector

20. Vacuum tank/solenoid valve/vacuum hose assembly

21. Oil pressure switch connector

22. Alternator connector

D Drive belt tension inspection

(Refer to P.11-4.)

AA" 23. Drive belt AB" 24. A/C compressor AC" 25. Power steering oil pump

D Transmission assembly

98 {10.0}*

Unit: Nm {kgf@m}

26. A/C relay box

27. A/C receiver bracket mounting bolt

28. Oil pressure hose mounting bolt

AC""BA 29. Engine mount bracket AE""AA 30. Engine assembly

Caution Mounting locations marked by * should be provisionally tightened, and then fully tightened after placing the vehicle horizontally and loading the full weight of the engine on the vehicle body.

Hole in arm

Phillips screwdriver

Auto tensioner

Hole in bracket

ENGINE – Engine Assembly

REMOVAL SERVICE POINTS

AA" DRIVE BELT REMOVAL

(1) Align the hole in the auto tensioner bracket with that

in the arm and insert a screwdriver into the holes.

(2) Remove the drive belt.

11-34

MZ203826 or MZ203827

MB991453

AB" POWER STEERING OIL PUMP REMOVAL

Remove the power steering oil pump from the bracket with the hose attached.

NOTE Place the removed power steering oil pump in a place where it will not be a hindrance when removing and installing the engine assembly, and tie it with a cord.

AC" A/C COMPRESSOR REMOVAL

Disconnect the A/C compressor connector and remove the compressor from the compressor bracket with the hose still attached.

NOTE Place the removed A/C compressor where it will not be a hindrance when removing and installing the engine assembly, and tie it with a cord.

AD" ENGINE MOUNT BRACKET REMOVAL

(1) Support the engine with a garage jack. (2) Remove the special tools which was attached when the

transmission assembly was removed.

(3) Hold the engine assembly with a chain block or similar

tool.

(4) Place a garage jack against the engine oil pan with a

piece of wood in between, jack up the engine so that the weight of the engine is no longer being applied to the engine mount bracket, and then remove the engine mount bracket.

11-35

ENGINE – Engine Assembly

AE" ENGINE ASSEMBLY REMOVAL

After checking that all cables, hoses and harness connectors, etc., are disconnected from the engine, lift the chain block slowly to remove the engine assembly upward from the engine compartment.

INSTALLATION SERVICE POINTS

"AA ENGINE ASSEMBLY INSTALLATION

Install the engine assembly, checking that the cables, hoses, and harness connectors are not clamped.

MZ203826 or MZ203827

MB991453

"BA ENGINE MOUNT BRACKET INSTALLATION

(1) Place a garage jack against the engine oil pan with a

piece of wood in between, and install the engine mount

bracket while adjusting the position of the engine. (2) Support the engine with the garage jack. (3) Remove the chain block and support the engine assembly

with the special tools.

"CA HIGH-PRESSURE FUEL HOSE INSTALLATION

(1) Apply a small amount of new engine oil to the O-ring,

then fit the O-ring in the delivery pipe.

Caution

Do not let any engine oil get into the delivery pipe.

(2) Check that the high pressure hose turns smoothly.

If the hose does not turn smoothly, the O-ring is probably

being clamped. Disconnect the high-pressure fuel hose

and check the O-ring for damage. After this, re-install

the hose to the delivery pipe and check that the hose

turns smoothly. (3) Tighten the mounting bolt to the specification.

ENGINE

LUBRICATION

CONTENTS

LUBRICANTS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE OIL COOLER 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12-1

12-2

ENGINE LUBRICATION – Lubricants / Engine Oil Cooler

LUBRICANTS

Items Capacity dm3 {ȏ} Engine oil Quantity in oil filter 0.3 {0.3}

Quantity in oil cooler 0.16 {0.16} Total quantity 5.1 {5.1} Brand DIA QUEEN MOTOR OIL (Grade SG or higher); or engine oil in

a can marked with ILSAC certification.

ENGINE OIL COOLER

REMOVAL AND INSTALLATION

Pre-removal and Post-installation Operation

(1) Engine Oil Removal and Refilling (2) Front Bumper Removal and Installation

(Refer to GROUP 51.)

12 {1.2}

Removal steps

1. Engine oil cooler

"AA 2. Feed hose assembly "AA 3. Return hose assembly

12 {1.2}

29 – 34 {3.0 – 3.5}

12 {1.2}

39 – 44 {4.0 – 4.5}

Unit: Nm {kgf@m}

INSTALLATION SERVICE POINT

"AA FEED HOSE ASSEMBLY / RETURN HOSE

Fit the hose joint positioning tab into the hole in oil cooler to secure the hose assembly in position.

TSB Revision

ASSEMBLY INSTALLATION

FUEL

CONTENTS

13-1

MULTIPOINT INJECTION (MPI) 2. . . . . . .

GENERAL INFORMATION 2. . . . . . . . . . . . . . . .

SERVICE SPECIFICATIONS 3. . . . . . . . . . . . . .

SEALANT 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIAL TOOLS 4. . . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING 6. . . . . . . . . . . . . . . . . . . .

ON-VEHICLE SERVICE 30. . . . . . . . . . . . . . . .

1. Idle Position Switch and Throttle Position

Sensor (TPS) Adjustment 30. . . . . . . . . . . . .

2. Fixed SAS Adjustment 30. . . . . . . . . . . . . . . .

3. Basic Idle Speed Adjustment 30. . . . . . . . . .

4. Fuel Pressure Measurement 30. . . . . . . . . . .

5. MPI System Components Layout 31. . . . . .

6. Intake Air Temperature Sensor Check 32. .

7. Engine Coolant Temperature

Sensor Check 32. . . . . . . . . . . . . . . . . . . . . . . .

8. Oxygen Sensor Check 32. . . . . . . . . . . . . . . .

9. Injector Check 34. . . . . . . . . . . . . . . . . . . . . . .

10. Resistor Check 34. . . . . . . . . . . . . . . . . . . . . . .

11. Fuel Pump Relay No.2 Check 35. . . . . . . . .

12. Fuel Pump Resistor Check 35. . . . . . . . . . . .

INJECTOR 36. . . . . . . . . . . . . . . . . . . . . . . . . . . .

THROTTLE BODY 37. . . . . . . . . . . . . . . . . . . . .

13-2

MPI – General Information

MULTIPOINT INJECTION (MPI)

GENERAL INFORMATION

OMPI System Diagram

L1 Oxygen sensor L2 Air flow sensor L3 Intake air temperature sensor L4 Throttle position sensor L5 Idle switch L6 Camshaft position sensor L7 Crank angle sensor L8 Barometric pressure sensor L9 High temperature sensor L10 Engine coolant temperature sensor L11 Detonation sensor

D Power supply voltage D Ignition switch-IG D Ignition switch-ST D Vehicle speed sensor D A/C switch D Power steering fluid pressure switch D Alternator FR signal

l5 Secondary air

control solenoid valve

Canister

Check valve

Engine ECU

From fuel tank

Throttle position sensor (with a built-in idle switch)

l1 Injector l2 ISC servo l3 Fuel pressure control valve l4 Waste gate solenoid valve l5 Secondary air control solenoid valve

D Control relay D Fuel pump relay D A/C relay D Ignition coil D Exhaust temperature warning lamp D Engine warning lamp D Diagnosis output D Alternator G terminal D Fan motor relay D Tachometer D Fuel pump relay No.2

l2 ISC servo

L4, L5

Secondary air valve

L8 Barometric

pressure sensor

L2 Air flow sensor

Air

Intake air temperature sensor

l4 Waste gate

solenoid valve

L1 Oxygen sensor

Waste gate actuator

To fuel tank

Fuel pressure regulator

From fuel pump

L10 Coolant temperature sensor

L7 Crank angle sensor L1 1 Detonation sensor

Catalytic converter

l3 Fuel pressure

control valve

L6 Camshaft position

sensor

l1 Injector

L9 High temperature

sensor

Given above is the MPI system diagram for EVOLUTION-IV. The MPI system for EVOLUTION-V is different from this in the following point;

D Oxygen sensor with a heater is adopted. D The diagnosis connector power supply circuit is different. D The high temperature sensor is no longer used.

MPI – Service Specifications / Sealant

kPa {kgf/

}

SERVICE SPECIFICATIONS

Items Specifications Basic ignition timing _BTDC 5 ± 3 Basic idle speed rpm 850 ± 50 Throttle position sensor adjusting voltage mV 400 – 1,000 Throttle position sensor resistance kΩ 3.5 – 6.5 ISC servo coil resistance (at 20_C) Ω 28 – 33 Intake air temperature sensor resistance kΩ At 20_C 2.3 – 3.0

At 80_C 0.30 – 0.42

Coolant temperature sensor resistance kΩ At 20_C 2.1 – 2.7

At 80_C 0.26 – 0.36

13-3

Fuel pressure

Injector coil resistance Ω 2 – 3 Amount of injector fuel leak drop/min 1 or less Oxygen sensor output voltage 0.6 – 1.0 Fuel pressure control valve coil resistance (at 20_C) Ω 28 – 36

When vacuum hose is connected 230 {2.35} When vacuum hose is disconnected 289 – 309 {2.95 – 3.15}

SEALANT

Item Specified sealant Coolant temperature sensor Drying sealant: HELMESEAL H-1M [0110513]

NOTE: Given in [ ] are MITSUBISHI GENUINE PART numbers.

13-4

MPI – Special Tools

SPECIAL TOOLS

Tool Number Name Use

MB991348 Test harness set D Measurement of voltage during trouble-

shooting

D Inspection using an oscilloscope

MB991519 Alternator harness

connector

MB991536 TPS check

harness

MD998464 Test harness

(4-pin, square)

MD998463 Test harness

(6-pin, square)

Measurement of voltage during troubleshooting

Adjustment of idle switch and throttle position sensor (TPS)

Inspection of oxygen sensor

D Inspection of idle speed control servo D Inspection using an oscilloscope

MD998478 Test harness

(3-pin, triangle)

MD998706 Injector test set Checking the spray condition of injectors

MD998741 Injector test

adaptor

MB991607 Injector test

harness

D Measurement of voltage during trouble-

shooting

D Inspection using an oscilloscope

Tool UseNameNumber

MD998746 Clip Checking the spray condition of injectors

MD998709 Adaptor hose Measurement of fuel pressure

MD998742 Hose adaptor

MB991637 Fuel pressure

MPI – Special Tools

gauge set

13-5

Red harness

White harness

MB991223 Inspection test

herness set D Pin contact

pressure inspection harness

D Market tester

contact probe (for general connectors)

MB991529 Diagnostic trouble

code check harness

MB991709 Test harness D Measurement of voltage during trouble-

Measurement of terminal voltage

Reading of diagnosis codes

shooting

D Inspection using an oscilloscope

13-6

Engine warning lamp (check engine lamp)

MPI – Troubleshooting

TROUBLESHOOTING

1. DIAGNOSIS FUNCTION

1-1 ENGINE WARNING LAMP (CHECK ENGINE LAMP)

If an abnormality occurs in any of the following items related to the Multipoint Fuel Injection (MPI) system, the engine warning lamp will illuminate. If the lamp remains illuminated or if the lamp illuminates while the engine is running, check the diagnosis code output.

Engine warning lamp inspection items

Engine-ECU Air flow sensor (AFS) Intake air temperature sensor Throttle position sensor (TPS) Engine coolant temperature sensor Crank angle sensor Camshaft position sensor Barometric pressure sensor Detonation sensor Injector Ignition coil, power transister Misfire <Evolution-V only>

1-2 METHOD OF READING AND ERASING DIAGNOSIS

CODES

(1) Use the special tool to earth No.1 terminal (diagnosis

control terminal) of the diagnosis connector.

(2) To check ABS system, remove the valve relay.

NOTE That is because the valve relay is off and the warning lamp remains illuminated if there is a fault in the ABS system.

(3) Turn off the ignition switch. (4) Read out a diagnosis code by observing how the warning

lamp flashes.

Indication of diagnosis code by warning lamp

When the diagnosis code No.24 is output When no diagnosis code is output*

0.5 sec.

1.5 secs. 0.5 sec.

On Off

Pause time 3 secs.

Tens signal

Place division 2 secs.

Units signal

On Off

A03X0113

0.5 sec. <MPI, A/T>

0.25 sec. <ABS>

NOTE *: Even if the ABS system is normal, removing the valve relay causes the diagnosis code No.52 to

be output.

MPI – Troubleshooting

13-7

1-3 ERASING DIAGNOSIS CODES

(1) Turn the ignition switch to OFF. (2) After disconnecting the battery cable from the battery (–) terminal for 10 seconds or more, reconnect

the cable.

(3) After the engine has warmed up, run it at idle for about 15 minutes.

1-4 FAIL-SAFE FUNCTION REFERENCE TABLE

When the main sensor malfunctions are detected by the diagnosis function, the vehicle is controlled by means of the pre-set control logic to maintain safe conditions for driving.

Malfunctioning item Control contents during malfunction Air flow sensor (AFS) (1) Uses the throttle position sensor signal and engine speed signal (crank angle sensor

signal) to take reading of the basic injector drive time and basic ignition timing from the pre-set mapping.

(2) Fixes the ISC servo in the appointed position so idle control is not performed.

Intake air temperature sensor

Throttle position sensor (TPS)

Engine coolant temperature sensor

Camshaft position sensor

Barometric pressure sensor

Detonation sensor Switches the ignition timing from ignition timing for super petrol to ignition timing for standard

Ignition coil, power transistor

Alternator FR terminal Does not control the output of the alternator according to an electrical load. (works as a

Misfire (Evolution-V only)

Controls as if the intake air temperature is 25_C.

No increase in fuel injection amount during acceleration due to the throttle position sensor signal.

Controls as if the engine coolant temperature is 80_C. (This condition is maintained until the ignition switch is turned off even when the sensor signal returns normal.)

(1) Injects fuel to all cylinders simultaneously for 4 seconds.

(However, after the ignition switch is turned to ON, the No. 1 cylinder top dead centre is not detected at all.)

(2) Lets the fan motor (radiator and condensor) run at high speed. Controls as if the barometric pressure is 101 kPa {760 mmHg}.

petrol. Cuts off the fuel supply to cylinders with an abnormal ignition.

normal alternator) Cuts off the fuel to the misfiring cylinder if a misfire that could damage the catalyst is detected.

13-8

MPI – Troubleshooting

2. INSPECTION CHART FOR DIAGNOSIS CODES

Code No. Diagnosis item Reference page 12 Air flow sensor (AFS) system 13-8 13 Intake air temperature sensor system 13-9 14 Throttle position sensor (TPS) system 13-9 21 Engine coolant temperature sensor system 13-10 22 Crank angle sensor system 13-11 23 Camshaft position sensor system 13-11 24 Vehicle speed sensor system 13-12 25 Barometric pressure sensor system 13-13 31 Detonation sensor system 13-14 41 Injector system 13-14 44 Ignition coil and power transistor unit system 13-15 64 Alternator FR terminal system 13-16

3. INSPECTION PROCEDURE FOR DIAGNOSIS CODES

Code No. 12 Air flow sensor (AFS) system Probable cause

Range of Check D Engine speed is 500 r/min or more. Set conditions D Sensor output frequency is 3 Hz or less for 4 seconds.

Measure at the air flow sensor connector A-25. D Connect the connector. (Use

the test harness: MB991709)

1. Voltage between 3 and earth (Engine: Idling) OK: 2.2–3.2 V

2. Voltage between 7 and earth OK: 0–1 V (Engine: idling)

6–9 V (2,000 r/min)

Replace the engine-ECU.

1. NG Check the air flow sensor circuit.

2. NG Measure at the engine-ECU con-

nector B-59.

D Connect the connector. D Voltage between 19 and earth

(Ignition switch: ON)

OK: 6–9 V

Check the following connector:

B-59

Check trouble symptom.

D Malfunction of the air flow sensor D Improper connector contact, open circuit or

short-circuited harness wire of the air flow sensor

D Malfunction of the engine-ECU

Check the following connector:

A-25

Check trouble symptom.

Repair

Replace the air flow sensor.

Repair

Replace the engine-ECU.

MPI – Troubleshooting

Code No. 13 Intake air temperature sensor system Probable cause

Range of Check

D Ignition switch: ON D Excluding 60 seconds after the ignition switch is turned to ON or immediately

after the engine starts. Set conditions D Sensor output voltage is 4.6 V or more (corresponding to an intake air temperature

of –45_C or less) for 4 seconds. or D Sensor output voltage is 0.2V or less (corresponding to an intake air temperature

of 125_C or more) for 4 seconds.

D Malfunction of the intake air temperature sensor D Improper connector contact, open circuit or

short-circuited harness wire of the intake air temperature sensor circuit

D Malfunction of the engine-ECU

13-9

Check the intake air temperature sensor. (Refer to P.13-32.)

Measure at the air flow sensor connector A-25. D Disconnect the connector, and

measure at the harness side.

D Voltage between 6 and earth

(Ignition switch: ON) OK: 4.5–4.9 V

D Continuity between 5 and earth

OK: Continuity

Check the following connector:

A-25

Check trouble symptom.

Replace air flow sensor.

Check the following connector:

C-62

Check trouble symptom.

Check the harness wire between the engine-ECU and the intake air temperature sensor connector.

Repair

Replace the engine-ECU.

Repair

Code No. 14 Throttle position sensor (TPS) system Probable cause

Range of Check

D Ignition switch: ON D Excluding 60 seconds after the ignition switch is turned to ON or immediately

after the engine starts. Set conditions

D The sensor output voltage is 0.2 V or less for 4 seconds.

D Malfunction of the throttle position sensor D Improper connector contact, open circuit or

short-circuited harness wire of the throttle position sensor circuit

D Improper “ON” state of idle position switch D Short circuit of the idle position switch signal line D Malfunction of the engine-ECU

Check the throttle position sensor.

Measure at the throttle position sensor connector A-16. D Disconnect the connector, and

measure at the harness side.

D Voltage between 1 and earth

(Ignition switch: ON) OK: 4.8–5.2 V

D Continuity between 4 and earth

OK: Continuity

Check the throttle position sensor output circuit.

Replace

Check the following connector:

B-62

Check trouble symptom.

Check the harness wire between the engine-ECU and the throttle position sensor connector.

Replace the engine-ECU.

Repair

13-10

MPI – Troubleshooting

Code No. 21 Engine coolant temperature sensor system Probable cause

Range of Check

D Ignition switch: ON D Excluding 60 seconds after the ignition switch is turned to ON or immediately

after the engine starts. Set conditions D Sensor output voltage is 4.6 V or more (corresponding to an engine coolant

temperature of –45_C or less) for 4 seconds. or D Sensor output voltage is 0.1 V or less (corresponding to an engine coolant

temperature of 140_C or more) for 4 seconds. Range of Check

D Ignition switch: ON D Engine speed is approx. 50 r/min or more

Set conditions D The sensor output voltage increases from 1.6 V or less (corresponding to an

engine coolant temperature of 40_C or more) to 1.6 V or more (corresponding

to an engine coolant temperature of 40_C or less).

D After this, the sensor output voltage is 1.6 V or more for 5 minutes.

D Malfunction of the engine coolant temperature sensor D Improper connector contact, open circuit or

short-circuited harness wire of the engine coolant temperature sensor circuit

D Malfunction of the engine-ECU

Check the engine coolant temperature sensor. (Refer to P.13-32.)

Measure at the engine coolant temperature sensor connector A-38. D Disconnect the connector, and

measure at the harness side.

D Voltage between 1 and earth

(Ignition switch: ON) OK: 4.5–4.9 V

D Continuity between 2 and earth

OK: Continuity

Check the following connector:

A-38

Check trouble symptom.

Replace

Check the following connector:

B-62

Check trouble symptom.

Check the harness wire between the engine-ECU and the engine coolant temperature sensor connector.

Repair

Replace the engine-ECU.

Repair

MPI – Troubleshooting

Code No. 22 Crank angle sensor system Probable cause

Range of Check D Engine is cranking. Set conditions

D Sensor output voltage does not change for 4 seconds (no pulse signal input.)

D Malfunction of the crank angle sensor D Improper connector contact, open circuit or

short-circuited harness wire of the crank angle sensor

D Malfunction of the engine-ECU

13-11

Measure at the crank angle sensor connector A-51.

D Connect the connector. (Use the test harness: MD998478.) D Voltage between 2 (black clip) and earth (Engine: cranking)

OK: 0.4–4.0 V

D Voltage between 2 (black clip) and earth (Engine: idling)

OK: 1.5–2.5 V

Measure at the crank angle sensor connector A-51. D Disconnect the connector, and measure at the harness side.

1. Voltage between 3 and earth (Ignition switch: ON) OK: System voltage

2. Voltage between 2 and earth (Ignition switch: ON) OK: 4.8–5.2 V

3. Continuity between 1 and earth OK: Continuity

Check the following connector: A-51

Check trouble symptom.

Replace the crank angle sensor.

Repair

1. NG

2. NG

3. NG

Replace the engine-ECU.

Check the harness wire between the crank angle sensor and the control relay connector, and repair if necessary.

Check the following connector: B-62

Check trouble symptom.

Check the harness wire between the engine-ECU and the crank angle sensor connector.

Replace the engine-ECU.

Check the harness wire between the crank angle sensor and the earth, and repair if necessary.

Repair

Code No. 23 Camshaft position sensor system Probable cause

Range of Check

D Ignition switch: ON D Engine speed is approx. 50 r/min or more.

Set conditions D Sensor output voltage does not change for 4 seconds (no pulse signal input.)

Measure at the camshaft position sensor connector A-97.

D Connect the connector. D Voltage between 2 and earth (Engine: cranking)

OK: 0.4–3.0 V

D Voltage between 2 and earth (Engine: idling)

OK: 0.5–2.0 V

Measure at the camshaft position sensor connector A-97. D Disconnect the connector, and measure at the harness side.

1. Voltage between 3 and earth (Ignition switch: ON) OK: System voltage

2. Voltage between 2 and earth (Ignition switch: ON) OK: 4.8–5.2 V

3. Continuity between 1 and earth OK: Continuity

Check the following connector: A-97

Check trouble symptom.

Replace the camshaft position sensor.

Repair

1. NG

2. NG

3. NG

D Malfunction of the camshaft position sensor D Improper connector contact, open circuit or

short-circuited harness wire of the camshaft position sensor circuit

D Malfunction of the engine-ECU

Replace the engine-ECU.

Check the harness wire between the camshaft position sensor and the control relay connector, and repair if necessary.

Check the following connector: B-62

Check trouble symptom.

Check the harness wire between the engine-ECU and the camshaft position sensor connector.

Replace the engine-ECU.

Repair

Check the harness wire between the camshaft position sensor and the earth, and repair if necessary.

13-12

MPI – Troubleshooting

Code No. 24 Vehicles speed sensor system Probable cause

Range of check

D Ignition switch: ON D Excluding 60 seconds after the ignition switch is turned to ON or immediately

after the engine starts.

D Idle position switch: OFF D Engine speed is 3,000 r/min or more. D Driving under high engine load conditions.

Set conditions

D Sensor output voltage does not change for 4 seconds (no pulse signal input).

D Malfunction of the vehicle speed sensor D Improper connector contact, open circuit or

short-circuited harness wire of the vehicle speed sensor circuit

D Malfunction of the engine-ECU

Check the vehicle speed sensor. (Refer to GROUP 54 – Combination Meters.)

Measure at the vehicle speed sensor connector A-19. D Disconnect the connector, and measure at the harness side.

1. Voltage between 1 and earth (Ignition switch: ON) OK: System voltage

2. Voltage between 3 and earth (Ignition switch: ON) OK: 4.8 – 5.2 V

3. Continuity between 2 and earth OK: Continuity

Check the following connectors:

A-19, B-62

Check trouble symptom.

Check the harness wire between the engine-ECU and the vehicle speed sensor connector.

Replace the engine-ECU.

Repair

1. NG

2. NG

3. NG

Replace

Check the following connectors:

B-64, B-74, B-76

Check trouble symptom.

Check the harness wire between the vehicle speed sensor and ignition switch connector.

Check the ignition switch. (Refer to GROUP 54 – Ignition Switch.)

Check the following connector:

B-62

Check trouble symptom.

Check the harness wire between the engine-ECU and the vehicle speed sensor connector.

Replace the engine-ECU.

Repair

Check the harness wire between the vehicle speed sensor and the earth, and repair if necessary.

MPI – Troubleshooting

Code No. 25 Barometric pressure sensor system Probable cause

Range of Check

D Ignition switch: ON D Excluding 60 seconds after the ignition switch is turned to ON or immediately

after the engine starts. Set conditions D Sensor output voltage is 4.5 V or more (corresponding to a barometric pressure

of 114 kPa {855 mmHg} or more) for 4 seconds. or D Sensor output voltage is 0.2 V or less (corresponding to a barometric pressure

of 53 kPa {40 mmHg} or less) for 4 seconds.

D Malfunction of the barometric pressure sensor D Improper connector contact, open circuit or

short-circuited harness wire of the barometric pressure sensor circuit

D Malfunction of the engine-ECU

13-13

Measure at the air flow sensor connector A-25. D Connect the connector. (Use

the test harness: MB991709)

D Voltage between 2 and earth

(Ignition switch: ON) OK: 3.7–4.3 V (Altitude: 0 m)

3.2–3.8 V (Altitude: 1,200 m)

Measure at the engine-ECU connector B-62.

D Connect the connector. D Voltage between 85 and earth

(Ignition switch: ON) OK: 3.7–4.3 V (Altitude: 0 m)

3.2–3.8 V (Altitude: 1,200 m)

Check the following connectors:

A-25, B-62

Measure at the air flow sensor connector A-25. D Disconnect the connector , and

measure at the harness side.

D Voltage between 1 and earth

(Ignition switch: ON) OK: 4.8–5.2 V

D Continuity between 5 and earth

OK: Continuity

Check the following connector:

A-25

Check trouble symptom.

Check the harness wire between the engine-ECU and the barometric pressure sensor connector, and repair if necessary.

Repair

Check the following connector:

B-62

Check trouble symptom.

Check the harness wire between the engine-ECU and the barometric pressure sensor connector.

Repair

Replace the engine-ECU.

Check the harness wire between the engine-ECU and the barometric pressure sensor connector.

Replace the air flow sensor.

Repair

Check trouble symptom.

Replace the engine-ECU.

13-14

MPI – Troubleshooting

Code No.31 Detonation sensor system Probable cause

Range of Check

D Ignition switch: ON D Excluding 60 seconds after the ignition switch is turned to ON or immediately

after the engine starts. D Engine speed is approx. 5,000 r/min or more Set conditions The change in the detonation sensor output voltage (detonation sensor peak voltage at each 1/2 revolution of the crankshaft) is less than 0.06 V for 200 times in succession.

D Malfunction of the detonation sensor D Improper connector contact, open circuit or

short-circuited harness wire of the detonation sensor circuit

D Malfunction of the engine-ECU

Measure at the detonation sensor connector A-96. D Disconnect the connector and

measure at the harness side.

D Continuity between 2 and earth

OK: Continuity

Check the harness wire between the detonation sensor and earth, and repair if necessary.

Check the following connector:

B-62

Check trouble symptom.

Check the harness wire between the engine-ECU and the detonation sensor connector.

Repair

Replace the detonation sensor.

Check trouble symptom.

Replace the engine-ECU.

Code No. 41 Injector system Probable cause

Range of Check

D Engine speed is approx. 50 –1,000 r/min D The throttle position sensor output voltage is 1.15 V or less.

Set conditions D Surge voltage of injector coil is not detected for 4 seconds.

Check the injector. (Refer to P.13-34.) Check the resistor. (Refer to P.13-34.)

Measure at the resistor connector A-125. D Disconnect the connector, and

measure at the harness side.

D Voltage between 3 and earth

(Ignition switch: ON) OK: System voltage

Measure at the injector connectors A-53, A-54, A-55, A-56. D Disconnect the connector, and

measure at the harness side.

D Voltage between 1 and earth

(Ignition switch: ON) OK: System voltage

Check the injector control circuit.

Replace

Check the harness wire between the control relay and the resistor connector, and repair if necessary.

Check the following connector:

A-125

Check trouble symptom.

Check the harness wire between the resistor and the injector connector , and repair if necessary.

D Malfunction of the injector D Improper connector contact, open circuit or

short-circuited harness wire of the injector circuit

D Malfunction of the engine-ECU

Repair

MPI – Troubleshooting

Code No. 44 Ignition coil and power transistor unit system Probable cause

Range of Check

D Engine speed is approx. 50 – 4,000 r/min. D Engine is not being cranked.

Set conditions D Abnormal engine speed is detected due to misfiring by crank angle sensor. (One

of two coils fails.)

D Malfunction of the ignition coil D Improper connector contact, open circuit or

short-circuited harness wire of the ignition primary circuit

D Malfunction of the engine-ECU.

13-15

Check the ignition coil. (Refer to Group 16 – Ignition System.)

Measure at the ignition coil connectors A-110, A-111. D Disconnect the connector, and measure at the harness.

1. Voltage between 1 and earth (Ignition switch: ON) OK: System voltage

2. Voltage between 3 and earth (Engine: Cranking) OK: 0.5 – 4.0 V

3. Continuity between 2 and earth OK: Continuity

Check the following connectors:

A-110, A-111

Check trouble symptom.

Check the following items.

D Check the spark plugs and spark plug cables. D Check the compression pressure.

Repair

1. NG

2. NG

3. NG

Replace

Check the following connectors:

B-65, B-76

Check trouble symptom.

Check the harness wire between the ignition coil and ignition switch connector, and repair if necessary.

Check the following connector:

B-59

Check trouble symptom.

Check the harness wire between the engine-ECU and ignition coil connector.

Replace the engine-ECU.

Repair

Check the harness wire between the ignition coil connector and earth, and repair if necessary.

13-16

MPI – Troubleshooting

Code No. 64 Alternator FR Terminal System Probable cause

Range of Check D Engine speed is approximately 50 r/min or more. Set conditions

D Input voltage at the alternator FR terminal is 4.5 V or more for 20 seconds.

D Open circuit in alternator FR terminal circuit D Malfunction of the engine-ECU.

Measure at the alternator connector D Connect the connector.

(Use test harness MB991519.)

D Voltage between 4 (blue clip)

and earth (Engine: Idling) (Radiator fan: Stopped) (Headlamp: OFF → ON) (Brake lamp: OFF → ON) (Rear defogger switch: OFF → ON) OK: Voltage drops by 0.2 to

3.5 V. OK

Replace the engine-ECU.

Measure at the alternator connector A-05. D Disconnect the connector , and

measure at the harness side.

D Voltage between 4 and earth

(Ignition switch: ON) OK: 4.8 – 5.2 V

Check the following connector:

A-05

Check trouble symptom.

Check the harness wire between the engine-ECU and alternator connector.

Replace the alternator.

Check the following connectors:

B-60, A-88

Check trouble symptom.

Check the harness wire between the engine-ECU and alternator connector.

Repair

Replace the engine-ECU.

Repair

MPI – Troubleshooting

13-17

4. PROBLEM SYMPTOMS TABLE

Items Symptom Starting Won’t start The starter is used to crank the engine, but there is no combustion within the

cylinders, and the engine won’t start. Fires up and dies There is combustion within the cylinders, but then the engine soon stalls. Hard starting Engine starts after cranking a while.

Idling stability

Rough idle Hunting

Engine speed doesn’t remain constant and changes at idle.

Usually, a judgement can be based upon the movement of the tachometer

pointer, and the vibration transmitted to the steering wheel, shift lever , body , etc.

This is called rough idle or hunting. Incorrect idle speed The engine doesn’t idle at the usual correct speed. Engine stall

(Die out) Engine stall

(Pass out)

The engine stalls when the accelerator pedal is released, regardless of whether

the vehicles is moving or not.

The engine stalls when the accelerator pedal is depressed or while it is being

used.

Driving Hesitation, Sag “Hesitation” is the delay in response of the vehicle speed (engine speed) that

occurs when the accelerator is depressed in order to accelerate from the speed

at which the vehicle is now traveling, or a temporary drop in vehicle speed

(engine speed) during such acceleration. Serious hesitation is called “sag”.

(Refer to Figure 1.) Poor acceleration Poor acceleration is inability to obtain an acceleration corresponding to the

degree of throttle opening, even though acceleration is smooth, or the inability

to reach maximum speed. Stumble Engine speed increase is delayed when the accelerator pedal is initially

depressed for acceleration. (Refer to Figure 2.) Shock The feeling of a comparatively large impact or vibration when the engine is

accelerated or decelerated. Surge This is repeated forward or rearward surging during constant speed travel or

Knocking A sharp sound like a hammer striking the cylinder walls during driving and which

Stopping Run on

(“Dieseling”)

(Figure 1)

Normal

Vehicle speed

Initial accelerator pedal depression

Hesitation

Time

during variable speed travel.

adversely affects driving.

The condition in which the engine continues to run after the ignition switch is

turned to OFF. Also called “Dieseling”.

(Figure 2)

Vehicle speed

Initial accelerator pedal depression

Sag

Idling

Normal

Stumble

Time

13-18

Air/fuel mixt

The oxygen sensor signal is used to

(Changes)

95_C

OFF

iti

5. SERVICE DATA LIST

<EVOLUTION-IV>

MPI – Troubleshooting

Item No.

11 Oxygen

12 Air flow

13 Intake air

Inspection item

sensor

temperature sensor

Inspection contents Normal condition

Engine: After having been warmed

f decelerating, and is made richer when racing.

Engine: After having been warmed The oxygen sensor signal is used to

check the air/fuel mixture ratio, and control condition is also checked by the ECU.

D Engine coolant temperature: _Engine is idling 17 – 43 Hz D Lamps, electric cooling fan and

all accessories:

D Transmission: Neutral

Ignition switch: ON or with engine running

ure is made leaner when

–

When at 4,000 r/min, engine is suddenly decelerated

When engine is suddenly raced

Engine is idling 400 mV or less

2,500 r/min

2,500 r/min 46 – 86 Hz Engine is raced Frequency increases

When intake air temperature is –20_C

When intake air temperature is 0_C

200 mV or less

600 – 1,000 mV

(Changes) 600 – 1,000 mV

in response to racing –20_C

0_C

When intake air temperature is 20_C

When intake air temperature is 40_C

When intake air temperature is 80_C

14 Throttle

pos

sensor

16 Power

supply voltage

18 Cranking

signal (ignition switch-ST)

NOTE *: When the car is new (distance it travelled is less than 500 km), output frequency of the air flow sensor may

become about 10% higher.

Ignition switch: ON Set to idle position 300 – 1,000 mV

Gradually open Increases in proportion

Open fully 4,500 – 5,500 mV

Ignition switch: ON System voltage

Ignition switch: ON Engine: Stopped OFF

Engine: Cranking ON

20_C

40_C

80_C

to throttle opening angle

MPI – Troubleshooting

(when A/C switch is ON, A/C

13-19

Item No.

21 Engine

22 Crank angle

Inspection item

coolant

emperature

sensor

Inspection contents Normal condition

Ignition switch: ON or with engine running

D Engine: Idling D Idle position switch: ON

When engine coolant temperature is –20_C

When engine coolant temperature is 0_C

When engine coolant temperature is 20_C

When engine coolant temperature is 40_C

When engine coolant temperature is 80_C

When engine coolant temperature is –20_C

When engine coolant temperature is 0_C

When engine coolant temperature is 20_C

When engine coolant temperature is 40_C

–20_C

0_C

20_C

40_C

80_C

1,300 – 1,500 rpm

1,150 – 1,350 rpm

25 Barometric

pressure sensor

26 Idle position

switch

27 Power

steering fluid pressure switch

28 A/C switch Engine: Idling

Ignition switch: ON At altitude of 0 m 101 kPa

Ignition switch: ON (Check by operating accelerator

pedal repeatedly.)

Engine: Idling Steering wheel stationary OFF

compressor should be operating.)

When engine coolant temperature is 80_C

At altitude of 600 m 95 kPa At altitude of 1,200 m 88 kPa At altitude of 1,800 m 81 kPa Throttle valve: Set to idle

position Throttle valve: Slightly open OFF*

Steering wheel turning ON

A/C switch: OFF OFF A/C switch: ON ON

750 – 950 rpm

13-20

dri

95_C

OFF

D Timing lamp is set. (The timing

motor

D Lamps, electric cooling fan and

D Engine: Idling

MPI – Troubleshooting

Item No.

41 Injector

44 Ignition

45 ISC

item

drive time*

Injector

ve time

advance

(stepper) position *

Normal conditionInspection contentsInspection

Engine: Cranking When engine coolant temper-

D Engine coolant temperature: _Engine is idling 1.2 – 2.4 ms

D Lamps, electric cooling fan and D Transmission: Neutral

D Engine: After having been

D Engine coolant temperature:

D Transmission: Neutral D Idle position switch: ON

–

all accessories:

warmed up lamp is set in order to check

actual ignition timing.)

80 – 90_C

all accessories: OFF

ature is 0_C (injection is carried out for all cylinders simultaneously)

When engine coolant temperature is 20_C

When engine coolant temperature is 80_C

2,500 r/min 1.0 – 2.2 ms When engine is suddenly

raced Engine is idling 3 – 13_BTDC

2,500 r/min 24 – 44_BTDC

A/C switch: OFF 2 – 25 steps

A/C switch: OFF → ON Increases by 10 – 70

27 – 41 ms

14 – 22 ms

3.9 – 5.9 ms

Increases

steps

(When A/C switch is ON, A/C compressor should be operating.)

49 A/C relay Engine: After having been warmed

up/Engine is idling

NOTE *1: The idle position switch normally turns off when the voltage of the throttle position sensor is 50 – 100 mV

higher than the voltage at the idle position. If the idle position switch turns back on after the throttle valve is opened, the idle position switch and the throttle position sensor need to be adjusted.

*2: The injector drive time represents the time when the cranking speed is at 250 r/min or below when the power

supply voltage is 11 V.

*3: In a new vehicle [driven approximately 500 km or less], the injector drive time is sometimes 10% longer than

the standard time.

*4: In a new vehicle [driven approximately 500 km or less], the step of the stepper motor is sometimes 30 steps

greater than the standard value.

A/C switch: OFF Increases by 5 – 50

steps

A/C switch: OFF OFF (Compressor

clutch is not operating)

A/C switch: ON ON (Compressor

clutch is operating)

MPI – Troubleshooting

*180

95_C

OFF

dri

95_C

OFF

advance

warmed up

<EVOLUTION-V>

Descriptions other than those given below are the same as for the EVOLUTION-IV.

13-21

Item No.

12 Air flow

41 Injector

44 Ignition

Inspection item

sensor

drive time*

Injector

ve time

Inspection contents Normal condition

D Engine coolant temperature: _Engine is idling 12 – 38 Hz

–

D Lamps, electric cooling fan and

all accessories:

D Transmission: Neutral

Engine: Cranking*

D Engine coolant temperature: _Engine is idling 0.9 – 2.1 ms

D Lamps, electric cooling fan and D Transmission: Neutral

D Engine: After having been

–

all accessories:

2,500 r/min 36 – 76 Hz Engine is raced Frequency increases

in response to racing

When engine coolant temperature is 0_C

When engine coolant temperature is 20_C

When engine coolant temperature is 80_C

2,500 r/min 0.7 – 1.9 ms When engine is suddenly

raced Engine is idling 0 – 13_BTDC

27 – 40 ms

14.5 – 21.7 ms

3.8 – 5.6 ms

Increases

D Timing lamp is set.

NOTE *1: In a new vehicle (driven approximately 500 km or less), the air flow sensor output frequency is sometimes

10 % higher than the standard frequency.

*2: The injector drive time represents the time when the cranking speed is at 250 r/min or below when the power

supply voltage is 11 V.

*3: In a new vehicle (driven approximately 500 km or less), the injector drive time is sometimes 10 % longer than

the standard time.

2,500 r/min 24 – 44_BTDC

13-22

htly f

6. ENGINE-ECU INSPECTION

6-1 TERMINAL VOLTAGES Engine ECU connector

MPI – Troubleshooting

Terminal No.

1 No.1 injector While engine is idling after having been warmed up, 14 No.2 injector 2 No.3 injector 15 No.4 injector 3 Fuel pressure control

4 Stepper motor coil (A1) Engine: Immediately after engine has been startedfChanges repeatedly 17 Stepper motor coil (A2) 5 Stepper motor coil (B1) 18 Stepper motor coil (B2) 6 Secondary air control

8 Fuel pump relay Ignition switch: ON Battery voltage

Check item Check condition (Engine condition) Normal condition

Momentarily drops

rom 11 – 14 V.

to battery voltage.

valve

solenoid valve

suddenly depress the accelerator pedal. slig

Ignition switch: ON Battery voltage Engine: Cranking to idling (within about two minutes) 0 – 3 V to battery

voltage

or warming up

Ignition switch: ON Battery voltage

rom battery voltage to

0 – 6 V and from 0 – 6

Engine: Idling 0 – 3 V

10 Power transistor unit

(A)

23 Power transistor unit

(B)

11 Wastegate solenoid

valve

12 Power supply Ignition switch: ON Battery voltage 25 19 Air flow sensor reset

signa

20 Fan motor relay (HI) Fan not operating (coolant temperature: 90_C or

Engine speed: 3,000 r/min 0.3 – 3.0 V

Ignition switch: ON Battery voltage Engine: At idle after having been warmed up (when

premium gasoline is used)

Engine: Idling 0 – 1 V Engine speed: 3,000 r/min 6 – 9 V

below) Fan at high speed (coolant temperature: 105_C or

above)

0 – 3 V

Battery voltage

0 – 3 V

MPI – Troubleshooting

(Evoluti

)

13-23

Terminal No.

21 Fan motor relay (LOW) Fan not operating (coolant temperature: 90_C or

below) Fan at low speed (coolant temperature: 90 – 100_C) 0 – 3 V

22 A/C relay D Engine: Idling

D A/C switch: OFF to ON (Compressor is being

driven.)

33 Alternator G terminal D Engine: Warm, idle (radiator fan: OFF)

D Headlamp: OFF to ON D Brake lamp: OFF to ON D Rear defogger switch: OFF to ON

36 Engine warning lamp Ignition switch: OFF → ON 0 – 3 V → Battery

37 Power steering fluid

pressure switch

Engine: Idling after warming up

When steering wheel is stationary

When steering wheel is turned

Normal conditionCheck condition (Engine condition)Check item

Battery voltage

Battery voltage, or 6 V or more instantaneously to 0 – 3 V

Voltage rises by 0.2 –

3.5 V.

voltage (After several seconds have elapsed)

Battery voltage

0 – 3 V

38 Control relay Ignition switch: OFF Battery voltage

Ignition switch: ON 0 – 3 V

39 Fuel pump relay No.2 While engine is idling, suddenly depress the

accelerator pedal.

40 Exhaust temperature

warning lamp

41 Alternator FR terminal D Engine: Warm, idle (radiator fan: OFF)

45 A/C switch Engine: Idle speed Turn the A/C switch OFF 0 – 3 V

60 Oxygen sensor heater

on-V only

71 Ignition switch-ST Engine: Cranking 8 V or more

Ignition switch: OFF to ON 0 – 3 V to battery

D Headlamp: OFF to ON D Brake lamp: OFF to ON D Rear defogger switch: OFF to ON

Turn the A/C switch ON (A/C compressor is oper-

ating) Engine: Idling 0 – 3 V Engine speed: 5,000 r/min Battery voltage

Momentarily rises slightly from 0 to 3 V.

voltage (After several seconds have elapsed)

Voltage drops by 0.2 –

3.5 V.

Battery voltage

13-24

MPI – Troubleshooting

Terminal No.

72 Intake air temperature

sensor

76 Oxygen sensor Engine: Running at 2,000 r/min after having been

80 Backup power supply Ignition switch: OFF Battery voltage 81 Sensor impressed

voltage 82 Ignition switch-IG Ignition switch: ON Battery voltage 83 Engine coolant

temperature sensor

Ignition switch: ON When intake air tempera-

ture is 0_C When intake air tempera-

ture is 20_C When intake air tempera-

ture is 40_C When intake air tempera-

ture is 80_C

warmed up (Check using a digital type voltmeter)

Ignition switch: ON 4.5 – 5.5 V

Ignition switch: ON When engine coolant

temperature is 0_C

Normal conditionCheck condition (Engine condition)Check item

3.2 – 3.8 V

2.3 – 2.9 V

1.5 – 2.1 V

0.4 – 1.0 V

0 ↔ 0.8 V (Changes repeatedly)

3.2 – 3.8 V

When engine coolant temperature is 20_C

When engine coolant temperature is 40_C

When engine coolant temperature is 80_C

84 Throttle position sensor Ignition switch: ON Set throttle valve to idle

position Fully open throttle valve 4.5 – 5.5 V

85 Barometric pressure

sensor

86 Vehicle speed sensor D Ignition switch: ON

87 Idle position switch Ignition switch: ON Set throttle valve to idle

88 Camshaft position

sensor

Ignition switch: ON When altitude is 0 m 3.7 – 4.3 V

When altitude is 1,200 m 3.2 – 3.8 V

D Move the vehicle slowly forward

position Slightly open throttle

valve Engine: Cranking 0.4 – 3.0 V Engine: Idle speed 0.5 – 2.0 V

2.3 – 2.9 V

1.3 – 1.9 V

0.3 – 0.9 V

0.3 – 1.0 V

0 ↔ 5 V (Changes repeatedly)

0 – 1 V

4 V or more

89 Crank angle sensor Engine: Cranking 0.4 – 4.0 V

Engine: Idle speed 1.5 – 2.5 V

90 Air flow sensor Engine: Idle speed 2.2 – 3.2 V

Engine speed: 2,500 r/min

MPI – Troubleshooting

6-2 RESISTANCE AND CONTINUITY BETWEEN HARNESS SIDE CONNECTORS AND

TERMINALS

Engine-ECU Harness Side Connector Terminal Arrangement

Terminal No. Inspection item Normal condition (Check condition) 1 – 12 No.1 injector 2 – 3 Ω (At 20_C) 14 – 12 No.2 injector 2 – 12 No.3 injector 15 – 12 No.4 injector 3 – 12 Fuel pressure control valve 28 – 36 Ω (At 20_C)

13-25

4 – 12 Stepper motor coil (A1) 28 – 33 Ω (At 20_C) 17 – 12 Stepper motor coil (A2) 5 – 12 Stepper motor coil (B1) 18 – 12 Stepper motor coil (B2) 6 – 12 Secondary air control solenoid valve 28 – 36 Ω (At 20_C) 11 – 12 Wastegate solenoid valve 62 – 74 Ω (At 20_C) 13 – Body earth Engine-ECU earth Continuity established (0 Ω) 26 – Body earth 60 – 12 Oxygen sensor heater (EVOLUTION-V

only)

72 – 92 Intake air temperature sensor 5.3 – 6.7 kΩ (When intake air temperature is 0_C)

74 – 77 High temperature sensor 3 Ω or less

11 – 18 Ω (at 20_C)

2.3 – 3.0 kΩ (When intake air temperature is 20_C)

1.0 – 1.5 kΩ (When intake air temperature is 40_C)

0.30 – 0.42 kΩ (When intake air temperature is 80_C)

83 – 92 Engine coolant temperature sensor 5.1 – 6.5 kΩ (When coolant temperature is 0_C)

2.1 – 2.7 kΩ (When coolant temperature is 20_C)

0.9 – 1.3 kΩ (When coolant temperature is 40_C)

0.26 – 0.36 kΩ (When coolant temperature is 80_C)

87 – 92 Idle position switch Continuity established (when throttle valve is at idle

position) No continuity (when throttle valve is slightly open)

91 – Body earth – Continuity established

13-26

MPI – Troubleshooting

7. INSPECTION PROCEDURE USING OSCILLOSCOPE

7-1 AIR FLOW SENSOR (AFS)

Observing waveforms displayed on the oscilloscope allows you to visually identify possible unusual disturbances in waveform that could temporarily occur in the air flow sensor output.

Oscilloscope

(1) Disconnect the air flow sensor connector and connect

the special tool (Test Harness: MB991709) to it. (Ensure that all terminals are connected.)

(2) Connect the oscilloscope probe to terminal no. 3 of air

flow sensor connector. NOTE

If the engine ECU connector is used, connect the oscilloscope probe to terminal no. 90.

(3) Perform the same steps from here on as with the 4G9

engine.

7-2 CAMSHAFT POSITION SENSOR AND CRANK

ANGLE SENSOR

Perform the same steps as with the conventional 4G9 engine for the inspection.

7-3 INJECTOR

Observing waveforms displayed on the oscilloscope allows you to visually check the conditions of injector drive signals actually output from the engine ECU.

Injector Control Signal (Oscilloscope 1) <Measurement procedure>

(1) Disconnect the injector connector and connect the special

tool (Test Harness: MB991348) to the circuit. (Ensure that the terminals on both the power supply and engine ECU sides are connected.)

(2) Connect the oscilloscope probe to terminal no. 2 of injector

connector. NOTE

If the engine ECU connector is used for the measurement, take measurements at each of the following terminals. Connect the oscilloscope probe to terminal no. 1 when the waveform is observed with no. 1 cylinder, to terminal no. 14 when the waveform is observed with no. 2 cylinder, to terminal no. 2 when the waveform is observed with no. 3 cylinder, and to terminal no. 15 when the waveform is observed with no. 4 cylinder.

MPI – Troubleshooting

13-27

Point B

Injector drive time

Point A

Solenoid counter emf (approx. 7 × 10 V)

Power supply voltage

Observation conditions

Probe selector switch × 10 AC-GND-DC DC VOLTS/DIV. 1 V TIME/DIV. 0.5 ms Misc. – Engine speed Idle

The power supply voltage is being normally applied and, when a signal is received from the engine ECU, the voltage drops to around 0 V for the period of time equivalent to its drive signal. When the signal from the engine ECU turns OFF, the counter emf of the coil causes a voltage peak to develop, thus resuming the power supply voltage.

Injector drive time:

The fuel injection time as determined by the engine ECU according to the output values of sensors including AFS. Injector drive time = effective injection time + invalid injection time (Invalid injection time: corrects operation time lag caused by a power supply voltage drop)

Solenoid coil counter emf:

When the signal from the engine ECU turns OFF, counter emf occurs in the injector coil (approx. 65 to 75 V).

Power supply voltage:

The power supply voltage is being applied in the absence of a signal from the engine ECU. If this voltage is low, it extends the invalid injection time and, thus, the drive time.

<Waveform observation points> Point A: Strength of solenoid coil counter emf

Solenoid coil counter emf is low or zero. Injector solenoid shorting

Point B: Injector drive time When the engine is suddenly raced, the drive time temporarily

extends by a wide margin and soon returns to the normal drive time corresponding to the engine speed.

At idle During racing

13-28

MPI – Troubleshooting

Injector Power Supply Voltage (Oscilloscope 2) <Measurement procedure>

(1) Disconnect the resistor connector and connect the special

tool (Harness Connector: MD998463) to the circuit.

(2) Connect the oscilloscope probe to resistor connector

terminal (1) (special tool red clip) when the waveform is observed with no. 1 cylinder, to terminal (4) (black clip) when the waveform is observed with no. 2 cylinder, to terminal (5) (green clip) when the waveform is observed with no. 3 cylinder, and to terminal (6) (yellow clip) when the waveform is observed with no. 4 cylinder.

(3) For the power supply voltage, observe the waveform of

the injector control signal at the same time. (Refer to P.13-26 for the injector control signal measurement procedure.)

<Standard waveform> Observation conditions

Injector power supply voltage waveform Injector control signal Probe selector switch × 1 × 10 AC-GND-DC AC DC VOLTS/DIV. 5 V 1 V TIME/DIV. 0.5 ms Misc. To be timed with injector control signal Engine speed Idle (850 rpm)

Plunger in fully opened position

Point B

Injector power supply voltage waveform (oscilloscope 2)

Point A

Injector control signal waveform (oscilloscope 1)

Fuel injection time

Time

MPI – Troubleshooting

13-29

The injector power supply voltage waveform shows a voltage drop caused by resistance of the resistor. As the amount of current increases, voltage gradually decreases and a spike occurs at the plunger fully opened position due to counter emf.

<Waveform observation points> Point A: Voltage drop during fuel injection time (Refer to abnormal waveform example 1.)

Difference from standard waveform Possible cause Voltage drop during fuel injection time is small (there

should normally be a voltage drop of about 10 V).

Resistance of resistor is too small. Resistance of injector is too large.

Point B: Spike when plunger is fully open (Refer to abnormal waveform example 2.)

Difference from standard waveform Possible cause No spike when plunger is fully open Plunger inoperative

D Example 1

Abnormal waveform

[Cause of problem]

Resistance of the resistor is too small.

[Waveform characteristics]

Normal waveform

Small voltage drop

D Example 2

[Cause of problem]

Plunger is inoperative.

[Waveform characteristics]

No spike when plunger is fully open.

7-4 IGNITION COIL

Perform the same steps as with the conventional 4G9 engine for the inspection.

13-30

MPI – On-vehicle Service

ON-VEHICLE SERVICE

1. IDLE POSITION SWITCH AND THROTTLE POSITION SENSOR (TPS) ADJUSTMENT

The thickness of the feeler gauge inserted between the fixed SAS and throttle lever should be 0.45 mm.

2. FIXED SAS ADJUSTMENT

<EVOLUTION-IV>

Turn down one turn after the fixed SAS has touched the throttle lever.

<EVOLUTION-V>

Turn down 1-1/4 turns after the fixed SAS has touched the throttle lever.

3. BASIC IDLE SPEED ADJUSTMENT

The basic idle speed should be 850 ± 50 rpm.

4. FUEL PRESSURE MEASUREMENT

The fuel pressure gauge should be installed at the location shown on the left.

MPI – On-vehicle Service

13-31

5. MPI SYSTEM COMPONENTS LAYOUT

Name Symbol Name Symbol A/C switch Q Exhaust temperature warning lamp S A/C relay H Fuel pressure control valve A Air flow sensor (with a built-in intake air temperature

sensor and barometric pressure sensor)

Camshaft position sensor M ISC servo D Control relay and fuel pump relay P Oxygen sensor K Coolant temperature sensor E Power steering fluid pressure switch I Crank angle sensor J Secondary air control solenoid valve N Detonation sensor C Throttle position sensor (with a built-in idle switch) D Diagnosis connector R Engine ECU O Vehicle speed sensor T Engine warning lamp S Wastegate solenoid valve G

F Ignition coil and power transistor unit L

Injector B

13-32

MPI – On-vehicle Service

Equipment sideconnector

Air flow sensor

Intake air temperature sensor

6. INTAKE AIR TEMPERATURE SENSOR CHECK

1. Disconnect the air flow sensor connector.

2. Measure resistance between terminals 5 and 6.

Standard value:

2.3 – 3.0 kΩ (at 20_C)

0.30 – 0.42 kΩ (at 80_C)

3. Measure resistance while heating the sensor using a hair drier.

Normal condition:

Temperature (_C) Resistance (kΩ) Higher Smaller

4. If the value deviates from the standard value or the resistance remains unchanged, replace the air flow sensor assembly.

Engine coolant temperature sensor

Oxygen sensor equipment side connector

Oxygen sensor connector

Oxygen sensor

7. ENGINE COOLANT TEMPERATURE SENSOR CHECK

The engine coolant temperature sensor is located as shown on the left.

Standard value:

2.1 – 2.7 kΩ (at 20_C)

0.26 – 0.36 kΩ (at 80_C)

8. OXYGEN SENSOR CHECK

<EVOLUTION-IV>

The sensor connector is located as shown on the left.

<EVOLUTION-V>

(1) Disconnect the oxygen sensor connector and connect

the special tool (Test Harness: MD998464) to the oxygen sensor connector.

White clip

Blue clip

Red clip

Black clip

MD998464

Red clip

MD998464

Blue clip

MPI – On-vehicle Service

(2) Check that there is continuity (11 to 18 Ω at 20_C) across

terminal no. 1 (special tool red clip) and terminal no. 3 (special tool blue clip) of the oxygen sensor connector.

(3) If there is no continuity, replace the oxygen sensor.

(4) Run the engine until the engine coolant temperature

exceeds 80_C.

(5) Using jumper wires, connect oxygen sensor terminal no.

1 (special tool red clip) and terminal no. 3 (special tool blue clip) to battery (+) and (–) terminal, respectively.

Caution Make sure of the correct connections: if a wrong connection is made, a broken oxygen sensor results.

(6) Connect a digital voltmeter between terminal no. 2 (special

tool black clip) and terminal no. 4 (special tool white clip).

(7) Race the engine repeatedly to measure the oxygen sensor

output voltage.

Standard value:

13-33

Engine Oxygen sensor

output voltage

When engine is raced

0.6 – 1.0 V When engine racing is

NOTE

repeated to enrich air-fuel ratio, an operational oxygen sensor should output a voltage of 0.6 to 1.0 V.

NOTE Use the same procedures to remove and install the oxygen sensor.

13-34

5.5 to 6.5 (at 20_C)

MPI – On-vehicle Service

9. INJECTOR CHECK

Injection Condition Check

(1) Release the residual pressure from the fuel pipe line to

prevent fuel from flowing out.

(2) Remove the injector. (3) Set up the special tools (Injector Test Set, Adapter, Fuel

Pressure Regulator, and Clip) as illustrated below.

(4) From here on, use the same procedure as with the

conventional 4G9 engine for the check.

Main hose

MB991607

Battery

MD998741

Return hose

Fuel Pressure Regulator: MD1 16395

MD998706

Clip: MD998746

Injector

Resistor

10. RESISTOR CHECK

(1) Disconnect the resistor connector. (2) Measure resistance across terminals as detailed below.

Standard value

Measurement terminals Resistance (Ω)

1 – 3 4 – 3

5 – 3 6 – 3

Fuel pump relay No.2

MPI – On-vehicle Service

11. FUEL PUMP RELAY NO.2 CHECK

(1) Remove fuel pump relay No.2.

(2) Using jumper wires, connect fuel pump relay No.2 terminal

(3) to battery (+) terminal, and terminal (1) to battery (–) terminal, respectively.

(3) Connecting and disconnecting the jumper wire on the

battery (–) terminal end, check for continuity across terminal (2) and terminal (5), and across terminal (4) and terminal (5), of fuel pump relay No.2.

13-35

Jumper wire Continuity across

terminals (2) and (5) Connected No Yes Disconnected Yes No

(4) If the continuity is checked abnormally, replace fuel pump

relay No.2.

Continuity across terminals (4) and (5)

12. FUEL PUMP RESISTOR CHECK

(1) Disconnect the fuel pump resistor connector.

Fuel pump resistor

(2) Measure resistance across the terminals.

Standard value: 0.6 – 0.9 Ω

(3) If the measurement falls outside the specified range,

replace the fuel pump resistor.

13-36 INJECTOR

REMOVAL AND INSTALLATION

MPI – Injector

Pre-removal Operation

(1) Fuel Discharge Prevention (2) Air Hose D Removal

(Refer to GROUP15 – Intercooler.)

10 – 13 {1.0 – 1.3}

Post-installation Operation

(1) Air Hose D Installation

(Refer to GROUP15 – Intercooler.)

(2) Fuel Leakage Check

3, 6

O-ring

Removal steps

1. Injector connector

2. PCV hose connection

AA" 3. High-pressure fuel hose connection

4. Fuel return hose connection

5. Vacuum hose connector

AA" 6. Fuel pressure regulator

Engine oil

9 {0.9}

Unit: Nm {kgf@m}

7. Fuel return pipe

AA" 8. Delivery pipe

9. Insulator

10. Insulator

AA""AA 11. Injector

12. Grommet

THROTTLE BODY

REMOVAL AND INSTALLATION

MPI – Throttle Body

13-37

Pre-removal Operation

(1) Engine Coolant Draining (2) Air Hose D Removal

(Refer to GROUP 15 – Intercooler.)

(3) Strut Tower Bar Removal

19 {1.9}

Post-installation Operation

(1) Strut Tower Bar Installation (2) Air Hose D Installation

(Refer to GROUP 15 – Intercooler.) (3) Engine Coolant Supplying (4) Accelerator Cable Adjustment

5 {0.5}

Removal steps

1. Accelerator cable connection

2. Throttle position sensor connector

3. Idle speed control servo connector

4. Vacuum hose connection

Unit: Nm {kgf@m}

5. Water hose connection

6. Throttle body

"AA 7. Throttle body gasket

INSTALLATION SERVICE POINT

"AA THROTTLE BODY GASKET INSTALLATION

Place the gasket so that the projecting part is positioned as shown in the illustration, and then install it between the intake manifold and the throttle body.

Towards front of vehicle

ENGINE

COOLING

CONTENTS

14-1

SERVICE SPECIFICATIONS 2. . . . . . . . . . . . . .

LUBRICANT 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ON-VEHICLE SERVICE 2. . . . . . . . . . . . . . . . . .

Coolant Replacement 2. . . . . . . . . . . . . . . . . . . . . .

THERMOSTAT 3. . . . . . . . . . . . . . . . . . . . . . . . . . .

WATER PUMP 5. . . . . . . . . . . . . . . . . . . . . . . . . . .

WATER HOSE AND WATER PIPE 6. . . . . . . .

RADIATOR 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14-2

ENGINE COOLING – Service Specifications / Lubricant / On-vehicle Service

SERVICE SPECIFICATIONS

Items Standard value Thermostat valve opening temperature _C When open 76.5 ± 1.5

When fully open 90

Thermostat lift mm 8.5 or more

LUBRICANT

Items Brand Quantity dm3 {ȏ} Coolant capacity (in condenser tank) MITSUBISHI GENUINE DIA QUEEN SUPER

LONG LIFE COOLANT

ON-VEHICLE SERVICE

COOLANT REPLACEMENT CYLINDER BLOCK DRAIN PLUG

44 {4.5}

6 {6}

Drying sealant: HELMESEAL H-1M

RADIATOR CAP VALVE OPENING PRESSURE CHECK

On EVOLUTION-V, the radiator cap valve opening pressure must be as shown below.

Standard value: 93 – 123 kPa {0.95 – 1.25 kgf/cm2} Limit: 83 kPa {0.85 kgf/cm

Unit: Nm {kgf@m}

}

ENGINE COOLING – Thermostat

THERMOSTAT

REMOVAL AND INSTALLATION

Pre-removal and Post-installation Operation

D Engine Coolant Draining and Supplying

(Refer to P.14-2.)

D Air Intake Hose Assembly Removal and Installation

(Refer to GROUP 15 – Intercooler.)

14-3

Removal steps

AA""BA 1. Radiator lower hose connection

2. Control wiring harness connection

3. Water inlet fitting

"AA 4. Thermostat

13 {1.3}

Unit: Nm {kgf@m}

REMOVAL SERVICE POINT

AA" RADIATOR LOWER HOSE DISCONNECTION

After making mating marks on the radiator hose and the hose clamp, disconnect the radiator hose.

14-4

ENGINE COOLING – Thermostat

Rubber ring

Jiggle valve

INSTALLATION SERVICE POINTS

"AA THERMOSTAT INSTALLATION

(1) Install the thermostat so that the jiggle valve is facing

straight up.

Caution Make absolutely sure that no oil is adhering to the rubber ring of the thermostat. If the rubber ring is damaged, replace the thermostat.

(2) When assembling the thermostat, be careful not to fold

over or scratch the rubber ring.

"BA RADIATOR LOWER HOSE CONNECTION

(1) Insert each hose as far as the projection of the water

inlet fitting.

(2) Align the mating marks on the radiator hose and hose

clamp, and then connect the radiator hose.

INSPECTION

THERMOSTAT CHECK

(1) Immerse the thermostat in water, and heat the water while

stirring. Check the thermostat valve opening temperature.

V alve lift

Standard value: 76.5 ± 1.5_C

(2) Check that the amount of valve lift is at the standard

value when the water is at the full-opening temperature.

Standard value:

Full-opening temperature: 90_C Amount of valve lift: 8.5 mm or more

NOTE Measure the valve height when the thermostat is fully closed, calculate the valve lift by subtracting this measurement from the valve height when the thermostat is fully open.

ENGINE COOLING – Water Pump

WATER PUMP

REMOVAL AND INSTALLATION

Pre-removal and Post-installation Operation

D Engine Coolant Draining and Supplying

(Refer to P.14-2.)

22 {2.2}

14-5

D Timing Belt and Timing Belt B Removal and Installation

(Refer to GROUP 11.)

24 {2.4}

12 – 15 {1.2 – 1.5}

Removal steps

1. Alternator brace

2. Water pump

3. Water pump gasket

"AA 4. O-ring

Unit: Nm {kgf@m}

Bolt specifications

8 × 70

8 × 14

8 × 24

8 × 22

Screw diameter × length mm

Water pump

O-ring

Water inlet pipe

INSTALLATION SERVICE POINT

"AA O-RING INSTALLATION

Fit the O-ring in the O-ring groove in the water inlet pipe, and coat the outer circumference of the O-ring or the inside surface of the water pump with water before inserting the pipe.

14-6

ENGINE COOLING – Water Hose and Water Pipe

WATER HOSE AND WATER PIPE

REMOVAL AND INSTALLATION

Pre-removal and Post-installation Operation

(1) Coolant Draining and Refilling (Refer to P.14-2.) (2) Air Hose C Removal and Installation

(Refer to GROUP 15 – INTERCOOLER.)

(3) Air Control Valve Bracket Removal and Installation

(Refer to GROUP 15 – AIR CONTROL VALVE.)

24 {2.4}

41 {4.2}

10 {1.0}

13 {1.3}

48 {4.9}

24 {2.4}

13 {1.3}

41 {4.2}

10 {1.0}

Removal steps

AA""CA 1. Radiator upper hose connection AA""CA 2. Radiator lower hose connection

3. Water hose

4. Water hose

5. Water inlet fitting

"BA 6. Thermostat case assembly

7. Water hose

8. Water hose

Unit: Nm {kgf@m}

"AA 10. O-ring "AA 12. O-ring

f3mm

Semi-drying sealant:

THREEBOND 1207F

9. Heater hose connection

11. Water inlet pipe D Turbocharger (Refer to GROUP 15.)

13. Water pipe assembly A

14. Water pipe assembly B

ENGINE COOLING – Radiator

RADIATOR

REMOVAL AND INSTALLATION

Pre-removal and Post-installation Operation

D Engine Coolant Draining and Supplying (Refer to

P.14-2.)

12 {1.2}

14-7

12 {1.2}

Radiator removal steps

1. Drain plug

2. Radiator cap

3. Overflow hose

4. Reserve tank

5. Reserve tank bracket

AA""AA 6. Radiator upper hose AA""AA 7. Radiator lower hose

8. Radiator assembly

9. Lower insulator

10. Radiator fan motor assembly

Unit: Nm {kgf@m}

Radiator fan motor removal steps

1. Drain plug

2. Radiator cap

AA""AA 6. Radiator upper hose

D Air intake hose

(Refer to GROUP15 – Intercooler.)

10. Radiator fan motor assembly

11. Fan

12. Radiator fan motor

13. Shroud

14-8

ENGINE COOLING – Radiator

REMOVAL SERVICE POINTS

AA" RADIATOR UPPER HOSE / RADIATOR LOWER

HOSE DISCONNECTION

After making mating marks on the radiator hose and the hose clamp, disconnect the radiator hose.

INSTALLATION SERVICE POINT

"AA RADIATOR LOWER HOSE / RADIATOR UPPER

HOSE CONNECTION

(1) Insert each hose as far as the projection of the water

inlet or outlet fitting.

(2) Align the mating marks on the radiator hose and hose

clamp, and then connect the radiator hose.

Caution Fit the clamp on the hose at the same position as before.

Radiator fan motor relay LO

INSPECTION

1. RADIATOR FAN MOTOR CHECK

Apply the battery voltage across connector terminals 1 and 2, and terminals 3 and 4, of the radiator fan motor and check, at that time, that the radiator fan turns.

2. POWER RELAY CONTINUITY CHECK

Battery voltage Terminal number

1 3 4 5 When deenergized When energized

ENGINE COOLING – Radiator

14-9

Radiator fan motor relay HI

Battery voltage Terminal number

1 2 3 4 When deenergized When energized

INTAKE AND

EXHAUST

CONTENTS

15-1

SERVICE SPECIFICATIONS 2. . . . . . . . . . . . . .

SPECIAL TOOL 2. . . . . . . . . . . . . . . . . . . . . . . . .

ON-VEHICLE SERVICE 2. . . . . . . . . . . . . . . . . .

1. Turbocharger Boost Pressure Check 2. . . .

2. Boost Pressure Control System Check 3. .

3. Wastegate Actuator Check 4. . . . . . . . . . . . .

4. Wastegate Solenoid Valve Check 4. . . . . . .

5. Air Bypass Valve Check 4. . . . . . . . . . . . . . .

6. Secondary Air Control System Check 5. . .

7. Secondary Air Control Solenoid Valve

Check 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8. Secondary Air Valve Check 6. . . . . . . . . . . .

9. Vacuum Tank Check 6. . . . . . . . . . . . . . . . . . .

INTERCOOLER 7. . . . . . . . . . . . . . . . . . . . . . . . . .

AIR CONTROL VALVE 8. . . . . . . . . . . . . . . . . . .

INTAKE MANIFOLD 9. . . . . . . . . . . . . . . . . . . . . .

EXHAUST MANIFOLD AND

TURBOCHARGER 11. . . . . . . . . . . . . . . . . . . . . .

EXHAUST PIPE AND MUFFLER 14. . . . . . . .

15-2

INTAKE AND EXHAUST –

Service Specifications / Special Tool / On-vehicle Service

SERVICE SPECIFICATIONS

Items Standard value Limit Turbocharger boost pressure kPa {kg/cm2} 53 – 87 {0.54 – 0.89} – Wastegate actuator activation pressure kPa {kg/cm2} Approx. 100 {1.02} – Wastegate solenoid valve coil resistance (at 20_C) Ω 62 – 74 – Air bypass valve activation pressure kPa {mmHg} Approx. 53 {400} – Secondary air control solenoid valve coil resistance (at 20_C) Ω 28 – 36 – Intake manifold and exhaust manifold mounting surface distortion

Within 0.15 0.20

SPECIAL TOOL

Tool Number Name Application

MB998770 Oxygen sensor

wrench

Wastegate solenoid valve

ON-VEHICLE SERVICE

1. TURBOCHARGER BOOST PRESSURE

Blank plug

CHECK

Removal and installation of oxygen sensor

Caution Carry out driving tests in a location where full-throttle acceleration is possible with utmost safety. Two persons should be in the vehicle during the test, the assistant in the front passenger seat reading the pressure gauge.

(1) Disconnect the hose (black) from the boost pressure

control solenoid valve and fit the pressure gauge to this hose. After the hose (black) has been disconnected, fit a blank plug to the solenoid valve nipple.

(2) Drive at full-throttle acceleration in second gear and

measure the boost pressure when the engine speed exceeds about 3,000 r/min.

Standard value:

53 – 87 kPa {0.54 – 0.89 kg/cm 59 – 84 kPa {0.61 – 0.86 kg/cm

} <EVOLUTION-IV>

} <EVOLUTION-V>

INTAKE AND EXHAUST – On-vehicle Service

(igniti

ON)

(3) If the boost pressure is lower than the standard value,

check for following which are probably the cause:

D Wastegate actuator inoperative D Boost pressure leak D Turbocharger defective

(4) If the boost pressure is higher than the standard value,

boost pressure control is probably faulty. Make the following checks:

D Wastegate actuator inoperative D Wastegate valve inoperative D Wastegate actuator rubber hose disconnected or

cracked

15-3

Wastegate solenoid valve

2. BOOST PRESSURE CONTROL SYSTEM CHECK

(1) Disconnect the hose (black) from the wastegate solenoid

valve and connect a three-way joint between the hose and solenoid valve.

(2) Connect a hand vacuum pump to the three-way joint.

(3) Disconnect the hose (black) from the intake pipe nipple

connected to the turbocharger compressor housing and fit a blank plug to this nipple.

(4) Disconnect the negative cable from the battery, keep it

disconnected for 10 sec. or more, and then reconnect it back again.

(5) Block and unblock the end of the vacuum hose (black)

with a finger to apply vacuum and check for the vacuum condition.

Engine condition Hose (black) end Normally Stationary

on switch:

Unblocked Vacuum leaks. Blocked Vacuum retained.

Idling after warmup Vacuum leaks.

NOTE If the vacuum condition is faulty, the wastegate actuator, wastegate solenoid valve, or hose is probably defective.

15-4

INTAKE AND EXHAUST – On-vehicle Service

3. WASTEGATE ACTUATOR CHECK

(1) Connect a hand pump (pressure type) to the nipple. (2) Gradually increase the pressure being applied to check

for the pressure at which the wastegate actuator rod starts moving (approx. 1 mm stroke).

Standard value: Approx. 100 kPa {1.02 kg/cm2} Caution

Do not apply a pressure more than 120 kPa {1.23 kg/cm damaged.

(3) If the pressure drastically deviates from the standard

value, check the actuator or wastegate valve and, if necessary, replace the actuator or turbocharger assembly.

} to prevent the diaphragm from being

4. WASTEGATE SOLENOID VALVE CHECK

4-1 OPERATION CHECK

(1) Connect a hand vacuum pump to nipple A of the solenoid

valve.

(2) Using jumper wires, connect the solenoid valve terminal

to battery terminals.

(3) Disconnecting and reconnecting the jumper wire on the

(–) terminal side, apply vacuum to check for airtightness.

Jumper wire Nipple B condition Normally Connected Open Vacuum leaks.

Plugged Vacuum retained.

Disconnected Open Vacuum retained.

4-2 COIL RESISTANCE CHECK

Measure the resistance across solenoid valve terminals.

Standard value: 62 – 74 Ω (at 20_C)

5. AIR BYPASS VALVE CHECK

(1) Remove the air bypass valve. (2) Connect a hand vacuum pump to the air bypass valve

nipple.

(3) Apply a vacuum of approx. 45 kPa {340 mmHg} and

check that the valve is airtight.

(4) Increase the vacuum and check for valve operation.

Vacuum Valve operation Approx. 53 kPa {400 mmHg} Starts moving

Secondary air control solenoid valve

INTAKE AND EXHAUST – On-vehicle Service

6. SECONDARY AIR CONTROL SYSTEM CHECK

(1) Start the engine and let it run at idle speed. (2) Short-circuit the no. 6 terminal of the engine ECU

connector using a jumper wire and check at this time that the secondary air valve lifts. At this time, the engine ECU connector should be connected.

7. SECONDARY AIR CONTROL SOLENOID VALVE CHECK

7-1 OPERATION CHECK

(1) Disconnect the vacuum hose (white stripe, yellow stripe)

from the solenoid valve.

(2) Disconnect the harness connector.

15-5

Battery

(3) Connect a hand vacuum pump to nipple A of the solenoid

valve.

(4) Using jumper wires, connect the solenoid valve terminal

to battery terminals.

(5) Disconnecting and reconnecting the jumper wire on the

(–) terminal side, apply vacuum to check for airtightness.

Jumper wire Nipple B condition Normally Connected Open Vacuum leaks.

Plugged Vacuum retained.

Disconnected Open Vacuum leaks.

7-2 COIL RESISTANCE CHECK

Measure the resistance across solenoid valve terminals.

Standard value: 28 – 36 Ω (at 20_C)

15-6

INTAKE AND EXHAUST – On-vehicle Service

8. SECONDARY AIR VALVE CHECK

(1) Remove the secondary air valve. (2) Connect a hand vacuum pump to the secondary air valve

nipple.

(3) Apply a vacuum of 67 kPa {500 mmHg} and check that

the vacuum is retained.

(4) Blow air from side (A) and side (B) of the secondary

air valve to check for air passage.

Vacuum Air blowing direction Air passage 0 kPa

(vacuum not applied) 40 kPa {300 mmHg}

or more

(A) → (B) No

(A) → (B) Yes (B) → (A) No

9. VACUUM TANK CHECK

(1) Connect a hand vacuum pump to nipple A of the vacuum

tank. Applying a vacuum of 67 kPa {500 mmHg}, check that the vacuum is retained.

(2) Connect a hand vacuum pump to nipple B of the vacuum

tank.

(3) Apply a vacuum of 67 kPa {500 mmHg] with nipple A

plugged with a finger. Check that the vacuum leaks when the finger is then released.

INTAKE AND EXHAUST – Intercooler

INTERCOOLER

REMOVAL AND INSTALLATION

Pre-removal and Post-installation Operation

D Front Bumper Removal and Installation

(Refer to GROUP 51.)

Hose clamp tightening torque

6 {0.6}

15-7

10 – 13 {1.0 – 1.3}

11 10

Removal steps

1. Vacuum hose connection

2. Air bypass valve assembly

3. Breather hose connection

4. Vacuum hose connection

5. Air intake hose assembly

"AA 6. Air bypass hose

7. Air hose connection

"AA 8. Air hose D

10 – 13 {1.0 – 1.3}

"AA 9. Air hose C "AA 10. Air hose A

"AA 12. Air hose B "AA 14. Air hose B

Unit: Nm {kgf@m}

11. Air pipe A

13. Intercooler assembly

15. Air pipe B

16. Air pipe bracket

10 – 13 {1.0 – 1.3}

INSTALLATION SERVICE POINT

"AA AIR HOSE B / AIR HOSE A / AIR HOSE C / AIR

HOSE D / AIR BYPASS HOSE INSTALLATION

Align the alignment mark (white paint) on each hose with the protrusion on each pipe.

15-8

INTAKE AND EXHAUST – Air Control Valve

AIR CONTROL VALVE

REMOVAL AND INSTALLATION

10 – 12 {1.0 – 1.2}

4 {0.4}

22 {2.2}

10 – 12 {1.0 – 1.2}

24 {2.4}

12 – 15 {1.2 – 1.5}

49 {5.0}

24 {2.4}

Removal steps

1. Control harness connection

2. Vacuum pipe hose assembly

3. Air pipe assembly

"AA 4. Gasket

22 {2.2}

35 {3.6}

Unit: Nm {kgf@m}

5. Air hose

6. Air control valve

7. Engine hanger

8. Air control valve bracket

Protrusion

INSTALLATION SERVICE POINT

"AA GASKET INSTALLATION

Install the gasket so that its protrusion is located as shown.

INTAKE AND EXHAUST – Intake Manifold

INTAKE MANIFOLD

REMOVAL AND INSTALLATION

15-9

Pre-removal Operation

(1) Fuel Discharge Prevention (2) Throttle Body Removal (Refer to GROUP 13.) (3) Front Exhaust Pipe Removal (Refer to P.15-14.) (4) Air Control V alve Bracket Removal (Refer to P.15-8.) (5) Strut Tower Bar Removal

10 – 13 {1.0 – 1.3}

Post-installation Operation

(1) Strut Tower Bar Installation (2) Air Control Valve Bracket Installation

(Refer to P.15-8.) (3) Front Exhaust Pipe Installation (Refer to P.15-14.) (4) Throttle Body Installation (Refer to GROUP 13.)

3 {0.3}

10 – 12 {1.0 – 1.2}

35 {3.6}

20 {2.0}

9 {0.9}

Removal steps

1. Center cover

2. Ignition coil connector connection

3. Oxygen sensor connector connection

4. Crank angle sensor connector connection

5. Injector connector connection

6. PCV hose

7. Vacuum hose connection

8. Brake booster vacuum hose connection

9. Vacuum tank, solenoid valve, and vacuum hose assembly

35 {3.6}

30 {3.1}

20 {2.0}

12 – 15 {1.2 – 1.5}

22 {2.2}

O-ring

Unit: Nm {kgf@m}

10. Intake manifold stay

11. Oil level gauge guide assembly

12. Vacuum hose and pipe mounting bolt

13. Fuel return hose connection

"AA 14. Fuel high pressure hose connection

AA" 15. Delivery pipe, injector, and pres-

sure regulator assembly

16. Insulator

17. Insulator

18. Alternator brace stay

19. Intake manifold

20. Intake manifold gasket

Engine oil

15-10

High-pressure fuel hose

Delivery pipe

O-ring

INTAKE AND EXHAUST – Intake Manifold

REMOVAL SERVICE POINT

AA" DELIVERY PIPE, INJECTOR AND PRESSURE

REGULATOR REMOVAL

Remove the delivery pipe with the injectors and pressure regulator attached to it.

Caution Care must be taken, when removing the delivery pipe, not to drop the injector.

INSTALLATION SERVICE POINT

"AA HIGH-PRESSURE FUEL HOSE INSTALLATION

(1) When connecting the high-pressure fuel hose to the

delivery pipe, apply a small amount of new engine oil to the O-ring and then insert the high-pressure fuel hose, being careful not to damage the O-ring.

Caution Be careful not to let any engine oil get into the delivery pipe.

(2) Check to be sure that the high pressure hose turns

smoothly. If it does not turn smoothly, the O-ring may be trapped. Remove the high-pressure fuel hose to check for damaged O-ring and then re-insert it into the delivery pipe and check once again.

(3) Tighten the mounting bolts to the specification.

INSPECTION

INTAKE MANIFOLD CHECK

(1) Check the intake manifold for damage or cracking and

replace it if defective.

(2) Using a straight edge and feeler gauge, check for distortion

of the cylinder head installation surface.

Standard value: 0.15 mm or less Limit: 0.2 mm

INTAKE AND EXHAUST – Exhaust Manifold and Turbocharger

EXHAUST MANIFOLD AND TURBOCHARGER

REMOVAL AND INSTALLATION

15-11

Pre-removal and Post-installation Operation

(1) Radiator Removal and Installation

(Refer to GROUP 14.)

(2) Air Intake Hose and Air Hose A Removal and

Installation (Refer to P.15-7.)

(3) Front Exhaust Pipe Removal and Installation

(Refer to P.15-14.)

12 – 15 {1.2 – 1.5}

49 {5.0}

29 {3.0}

49 – 59 {5.0 – 6.0}

(4) Air Pipe Assembly Removal and Installation

(Refer to P.15-8.)

(5) Engine Oil Removal and Refilling

54 – 64 {5.5 – 6.5}

49 {5.0}

27 – 32 {2.7 – 3.3}

17 {1.7}

10 – 12 {1.0 – 1.2}

10 {1.0}

54 – 64 {5.5 – 6.5}

Removal steps

1. Exhaust manifold heat protector

AA" 2. Oxygen sensor

3. Turbocharger heat protector

4. Water pipe assembly A connection

5. Water hose connection

AB" 6. Oil pipe

7. Starter

8. Oil return pipe

"CA 9. Oil return pipe gasket

10. Vacuum hose connection

8 9

9 {0.9}

17 – 20 {1.7 – 2.0}

"BA 12. Air outlet fitting gasket

"AA 15. Turbocharger

42 {4.2}

187

30 {3.1}

Unit: Nm {kgf@m}

11. Air outlet fitting

13. Turbocharger gasket

14. Turbocharger assembly

16. Exhaust fitting gasket

17. Exhaust fitting

18. Water pipe hose assembly

19. Exhaust manifold

20. Exhaust manifold gasket

10 {1.0}

Mitsubishi Lancer Evolution IV Evolution V Workshop Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

GENERAL

MODELS

ENGINE

SERVICE SPECIFICATIONS

SEALANTS

SPECIAL TOOLS

ENGINE ADJUSTMENTS

1. DRIVE BELT TENSION CHECK

2. AUTO TENSIONER CHECK

3. LASH ADJUSTER CHECK

4. LASH ADJUSTER REPLACEMENT

5. IGNITION TIMING CHECK

6. IDLE SPEED CHECK AND IDLE MIXTURE CHECK

7. COMPRESSION PRESSURE CHECK

8. MANIFOLD VACUUM CHECK

CRANKSHAFT PULLEY

CAMSHAFT AND CAMSHAFT OIL SEAL

OIL PAN

CRANKSHAFT OIL SEAL

CYLINDER HEAD GASKET

TIMING BELT

ENGINE ASSEMBLY

LUBRICANTS

ENGINE OIL COOLER

FUEL

MULTIPOINT INJECTION (MPI)

GENERAL INFORMATION

SERVICE SPECIFICATIONS

SEALANT

SPECIAL TOOLS

TROUBLESHOOTING

ON-VEHICLE SERVICE

1. IDLE POSITION SWITCH AND THROTTLE POSITION SENSOR (TPS) ADJUSTMENT

2. FIXED SAS ADJUSTMENT

3. BASIC IDLE SPEED ADJUSTMENT

4. FUEL PRESSURE MEASUREMENT

5. MPI SYSTEM COMPONENTS LAYOUT

6. INTAKE AIR TEMPERATURE SENSOR CHECK

7. ENGINE COOLANT TEMPERATURE SENSOR CHECK

8. OXYGEN SENSOR CHECK

9. INJECTOR CHECK

10. RESISTOR CHECK

11. FUEL PUMP RELAY NO.2 CHECK

12. FUEL PUMP RESISTOR CHECK

MPI – Injector

THROTTLE BODY

SERVICE SPECIFICATIONS

LUBRICANT

ON-VEHICLE SERVICE

THERMOSTAT

WATER PUMP

WATER HOSE AND WATER PIPE

RADIATOR

SERVICE SPECIFICATIONS

SPECIAL TOOL

ON-VEHICLE SERVICE

2. BOOST PRESSURE CONTROL SYSTEM CHECK

3. WASTEGATE ACTUATOR CHECK

4. WASTEGATE SOLENOID VALVE CHECK

5. AIR BYPASS VALVE CHECK

6. SECONDARY AIR CONTROL SYSTEM CHECK

7. SECONDARY AIR CONTROL SOLENOID VALVE CHECK

8. SECONDARY AIR VALVE CHECK

9. VACUUM TANK CHECK

INTERCOOLER

AIR CONTROL VALVE

INTAKE MANIFOLD

EXHAUST MANIFOLD AND TURBOCHARGER