Mitsubishi Lancer Evolution VIII MR Technical information

Workshop Manual - Supplement
LANCER
Evolution - IX
• Chassis
• Engine
• Wiring Diagrams
• Technical Information
SERVICE MANUAL
Supplement
LANCER
EVOLUTION IX
FOREWORD
This manual contains details of the main changes to the
2005 model Lancer Evolution IX. Only differences to the
current Lancer Evolution VIII MR are included, so please use
this manual in conjunction with the related manuals as listed
on the following page.
Please read this manual carefully so that servicing can be
done correctly and quickly, and vehicle performance
maintained.
This manual is based on the current (March 2005) model.
Please bear in mind that vehicle specifications may change
and that future models may not be the same.
Please note that all the units shown in this manual follow the
internationally recognized SI unit system, and that the used
previously are not shown alongside the SI units.
(Nevertheless, please take care because units in reference
documents may be shown in the units which were previously
used).
CONTENTS
General ........................................................
00
Engine .........................................................
11
Fuel ..............................................................
13
Engine Cooling ...........................................
14
Intake and Exhaust ....................................
15
Engine Electrical ........................................
16
Rear axle .....................................................
27
Wheels and tyres........................................
31
33
Front suspension ...............................................Body
Any opinions, requests or questions concerning this manual,
should be written on the ‘Servicing Comments Form’ at the
end of the manual, and sent to us by fax.
42
Body.......................................................................
Exterior ........................................................
51
Interior and SRS Airbag.............................N
52
Chassis Electrical.........................................
54
March 2005
MITSUBISHI MOTOR CORPORATION
This manual is printed on recycled paper
Related materials
Title
No.
Issue
date
New model manuals
Title
No.
Issue
date
Body edition service manual
• Lancer Sedia
1036K30
2000/5
• Lancer Sedia
1036K50
2000/5
• Lancer Sedia
1036K31
2000/7
• Lancer Sedia (supplement)
1036K51
2000/7
• Lancer Evolution VII
1036K32
2001/1
• Lancer Evolution VII
1036K52
2001/5
• Lancer Sedia
1036K33
2001/5
• Lancer Sedia
1036K34
2001/5
• Lancer Sedia (supplement)
1036K53
2001/10
• Lancer Evolution VII
1036K35
2002/1
• Lancer Evolution VII_MR
1036K54
2004/2
• Lancer Sedia
1036K36
2002/5
• Lancer Evolution VII
1036K37
2003/1
• Lancer
1036K38
2003/2
• Lancer
1036K39
2003/12
Electrical wiring service manual
• Lancer Evolution IX
1036K82
2005/3
1039G46
2001/1
• Lancer Evolution VII_MR
1036K40
2004/2
• Lancer*
1036K41
2004/3
• Lancer
1036K42
2005/1
• Lancer Evolution IX
1036K43
2005/3
Service manuals
(supplement)
(supplement)
Engine service manual
• Lancer Sedia
• Lancer Sedia
(supplement)
1036K00
2000/5
1036K01
2000/7
• 4G6 engine (supplement)
1039G63
2003/1
• Lancer Evolution VII
1036K02
2001/1
• 4G6 engine (supplement)
1039G71
2003/3
(supplement)
• Lancer Sedia
(supplement)
• Lancer Sedia
(supplement)
1036K03
2001/5
1036K04
2001/10
• Lancer Evolution VII
1036K05
2002/1
• W5M51 manual transmission
1039M17
2001/1
• W5M51 manual transmission
1039M22
2003/1
1039M23
2003/1
(supplement)
• Lancer Sedia
(supplement)
1036K06
2002/5
• Lancer Evolution VII
1036K07
2003/1
(supplement)
• Lancer Sedia
(supplement)
• Lancer Sedia
(supplement)
1036K08
2003/2
1036K09
2003/12
• Lancer Evolution VII MR
1036K10
2004/2
• Lancer*
1036K41
2004/3
• Lancer
1036K11
2005/1
• 4G6 engine
Transmission service manuals
(supplement)
• WGMAA manual transmission
*Indicates where the new model manual was published with the service manual in a single volume.
WARNING REGARDING THE SERVICING OF VEHICLES FITTED WITH SRS AIR BAGS AND SEATBELTS WITH PRETENSIONERS
Warning
1. Improper servicing or maintenance of any SRS air bag or pre-tensioner fitted seatbelt component, or related parts,
could cause serious injury through the SRS air bag or pre-tensioner fitted seatbelt being activated unintentionally
or accidentally.
2. The SRS-ECU, the driver’s side air bag module, the passenger side air bag module, the pre-tensioner fitted
seatbelts and the clock spring, should be removed if there is a chance of them being affected by heat during
painting work.
• 93ºC and above: the SRS-ECU, the driver’s air bag module, the passenger’s air bag module and the clock spring
should be removed.
• 90ºC and above: the pre-tensioner fitted seatbelts should be removed.
3. Servicing and maintenance of any SRS air bag or pre-tensioner fitted seatbelt components, or related parts, must
be performed by an authorized Mitsubishi dealer.
4. Servicing and maintenance of any SRS air bag or pre-tensioner fitted seatbelt components, or related parts, must
only be undertaken after this service manual (specifically Section 52B-SRS air bags) has been carefully studied.
GENERAL –TROUBLESHOOTING FOR INSPECTIONS, MODEL LINE-UP,
RELEVANT VEHICLE NUMBERS
00-1
SECTION 00
GENERAL
CONTENTS
Inspection guidelines and
troubleshooting..........................................1
Relevant vehicle numbers ........................1
Model line-up..............................................1
Inspection guidelines and troubleshooting
With the introduction of new settings for the MB992006 (Extra Fine Probe) special tool, the guidelines for inspecting the
connector have been changed. Other servicing guidelines remain unchanged.
Making an inspection with the connector
attached (so the electrical circuit is complete)
<non-waterproof connector>
The test bar should be inserted from the harness side. If the control
unit or the connector is too small, and the test bar cannot be
inserted, do not attempt to force it in. Instead, use the MB992006
(Extra Fine Probe) special tool.
Model line-up
Note
● Indicates a new model, indicates a special model, X indicates a discontinued model.
Relevant vehicle numbers
GH-CT9A: CT9A-0400001 ~
ENGINE – GENERAL, SERVICING STANDARDS, SEALANTS
11-1
SECTION 11
ENGINE
CONTENTS
General .......................................................1
Servicing standards .................................1
Sealants .....................................................1
Special tools ..............................................2
Engine tuning .............................................4
Camshaft, valve stem seals .....................4
Cylinder head gaskets.............................14
Timing belt, timing belt B........................20
Engine ASSY ............................................28
1. Checking of revolutions when idling ................4
2. Checking compression pressure.......................4
General
The following servicing guidelines have been prepared for vehicles which use the 4G63-MIVEC-T/C engine. Other servicing
guidelines remain unchanged.
Servicing standards
Sealants
Note
The code inside the brackets ( ) is the actual product number.
11-2
ENGINE – SPECIAL TOOLS
Special tools
Tool
Number
Name
Function
MB991502
MUT-II Sub
ASSY
Checking and adjusting the tension in
timing belt B
MB991955
A: MB991824
B: MB991827
C: MB991910
D: MB991911
E: MB991825
F: MB991826
DO NOT USE
Note
If a MUT-III main harness A is
connected to a vehicle not fitted with
CAN, there is a chance that a pulse
signal will be entered in the simulated
vehicle speed line, when the MUT-III is
MUT-III Sub ASSY activated. Therefore, use a MUT-III main
harness B with vehicles not fitted with
A: Vehicle
Communication CAN.
Interface (VCI)
B: USB cable
C: MUT-III Main
harness A
(For vehicles
fitted with CAN)
D: MUT-III Main
harness B
(For vehicles
not fitted with
CAN)
E: Adaptor
F: Trigger harness
MB991668
A: MB991969
B: MB991670
Belt tension meter • Checking the tension in the drive belt.
set
(Use in conjunction with VCI)
A: Tension meter • Checking the tension in the balancer
cartridge
timing belt.
B: Mic ASSY
Adjusting (Use in conjunction with VCI)
MD998772
Valve spring
compressor
Compression of the valve spring.
ENGINE – SPECIAL TOOLS
Tool
11-3
Number
Name
Function
MD998737
Valve stem seal
installer
Valve stem seal installation
MD998713
Camshaft oil seal
installer
Camshaft oil seal installation
MB991654
Cylinder head bolt
wrench
Cylinder head bolt removal, installation
MB991367
Special spanner
Holding the crankshaft sprocket
MB991385
Pins
MB991704
Battery harness
Checking and adjustment of the tension in the
balancer timing belt (Use in conjunction with VCI
or MUT-II)
MD998738
Adjusting bolt
Holding the tensioner arm or the auto-tensioner
adjuster
MD998767
Tensioner pulley
socket wrench
Adjusting the tension of the timing belt
11-4
ENGINE – SPECIAL TOOLS, ENGINE TUNING, CAMSHAFT, VALVE STEM SEAL
Tool
Slide bracket (HI)
Number
Name
Function
MB991454
Engine hanger
balancer
Holding the engine assembly while the
transmission assembly is removed/installed
Recommended
tools MZ203830
panzai or
MZ203831 safe
vehicle handling
Mechanical engine
hanger
MB991928
A: MB991929
B: MB991930
C: MB991931
D: MB991932
E: MB991933
F: MB991934
Engine hanger
A: joint (50) x2
B: joint (90) x2
C: joint (140) x2
D: Foot (standard) x4
E: Foot (short) x4
F: Chain and hook
ASSY
Engine tuning
1. Checking revolutions when the engine is
idling
The standard revolutions for when the engine is idling have been
changed. Other servicing guidelines remain unchanged.
Standard revolutions: 800 ± 50 r/min
2. Checking compression pressure
The standard for compression pressure and the limit for
compression pressure have been changed. Other servicing
guidelines remain unchanged.
Standard compression pressure: 1000 kPa – 250 r/min
Compression pressure limit: 650 kPa – 250r/min
Camshaft, valve stem seal
Removal and fitting
Caution
1. If Brembo brake callipers are being used take care that they are not scratched by other components or tools
because there is a chance that the paint might peel off. In addition, if any brake fluid gets on the callipers, it
should be wiped off immediately.
2. Parts marked with * should be removed and then fitted for each cylinder in turn.
Jobs to be completed before removal and after fitting
• Removal and refitting of the undercover (Ref Section 51: Front bumper)
• Checking the tension of the drive belt (only after fitting)
• Draining and refilling of the coolant
• Removal and refitting of the air duct
• Removal and refitting of air pipe C
• Removal and refitting of the timing belt (refer to P11-20)
ENGINE – CAMSHAFT, VALVE STEM SEAL
Removal procedure
1. Oil feeder control valve connector
O
2. Oil feeder control valve
O
3. O-ring
4. Breather hose
• Secondary air control valve
(refer to Section 15-2: Secondary Air
Control System)
5. Centre cover
• Ignition coil
6. O2 sensor connector
7. Crank angle sensor connector
11-5
8. Connection of the control harness
9. Vacuum hose
10. PCV hose
A
N
11. Connection of the radiator upper hose
12. Camshaft position sensor connector
(exhaust side)
13. Camshaft position sensor connector
(inlet side)
14. Connection of the earth cable
M
15. Rocker cover ASSY
16. Spark plug hole gasket
17. Rocker cover gasket
11-6
ENGINE – CAMSHAFT, VALVE STEM SEAL
During assembly, apply
engine oil to all sliding
parts.
L
J
K
J
B
I
G
F
F
18. Camshaft position sensor support cover
19. Camshaft position sensor support cover
gasket
20. Camshaft position sensing cylinder
(exhaust side)
21. Camshaft position sensor support
22. Camshaft position sensor support cover
23. Camshaft position sensor support cover
gasket
24. Camshaft position sensing cylinder (inlet
side)
25. Camshaft position sensor support
26. Camshaft sprocket (exhaust side)
27. Camshaft oil seal
28. Camshaft bearing cap front
29. Camshaft bearing cap rear left
F
F
F
F
E
B
H
G
F
F
F
F
F
F
E
30. Camshaft bearing cap No. 2
31. Camshaft bearing cap No. 5
32. Camshaft bearing cap No. 3
33. Camshaft bearing cap No. 4
34. Exhaust camshaft
35. Camshaft sprocket cap
36. Washer
37. Camshaft sprocket (inlet side)
38. Camshaft oil seal
39. Camshaft bearing cap front
40. Camshaft bearing cap rear right
41. Camshaft bearing cap No. 2
42. Camshaft bearing cap No. 5
43. Camshaft bearing cap No. 3
44. Camshaft bearing cap No. 4
45. Inlet camshaft
ENGINE – CAMSHAFT, VALVE STEM SEAL
46. Rocker arm
D
47. Rush adjuster
48. Oil delivery body
49. Spark plug
C
C
50. Valve spring retainer lock
51. Valve spring retainer
B
52. Valve spring
A
53. Inlet valve stem seal
A
54. Exhaust valve stem seal
11-7
11A-8
ENGINE – CAMSHAFT, VALVE STEM SEAL
Locations for the application of lubricant and seals
<View from A>
Semi-dry sealant: Three bond 1207F
Semi-dry sealant:
Three bond 1207D
(around the lip):
Engine oil
Semi-dry sealant: Three bond 1207F
<Viewed looking down onto the cylinder head>
Semi-dry sealant: Three bond 1207D
ENGINE – CAMSHAFT, VALVE STEM SEAL
11-9
Removal guidelines
A
Detaching the radiator upper hose
Align the indicator marks on the radiator upper hose and the hose
clamp, and then detach the radiator upper hose.
Indicator marks
B
Removing the camshaft sprockets
Grip the hexagonal part of the camshaft with a wrench, loosen the
mounting bolt, and remove the camshaft sprocket.
C
Removing the valve spring retainer lock
Compress the valve spring using the special tool for compressing
valve springs (MD998772), and remove the valve spring retainer
lock.
Caution
When removing the valve spring retainer lock, each cylinder
piston should be in the top dead centre position. If pistons are
not in the top dead centre position, valves could fall into the
cylinders.
Colour of main
body: grey
Colour of main
body: grey/green
Inlet side
Exhaust side
Fitting guidelines
A
Fitting the exhaust valve stem seals and the inlet valve
stem seals
1. Inlet valve stem seals and exhaust valve stem seals can be
distinguished by checking the colour of the rubber parts.
2. Apply a small quantity of engine oil to the valve stem seals.
3. Place the valve stem component into the guides, and then insert
a new valve stem seal into the valve stem guide by using the
special tool for installing valve stem seals.
Caution
(1) Valve stem seals cannot be re-used.
(2) Please use the special tool for installing valve stem seals
(MD998737) because oil could leak if the valve stem seals
are not fitted correctly.
Valve
Valve stem
seal
Valve guide
11-10
ENGINE – CAMSHAFT, VALVE STEM SEAL
B
Fitting the valve spring
Fit the valve spring so that the end of the valve spring which has
the smaller radius is on the rocker arm side.
Rocker arm side
C
Fitting the valve spring retainer lock
In the same way as when the valve spring retainer lock was
removed, compress the valve spring using the special tool for
compressing valve springs (MD998772), and fit the valve spring
retainer lock.
D
Fitting the rush adjuster
Caution
If a rush adjuster is being reused, it must be washed and
inspected before fitting.
(Ref: Engine Service Manual)
Front of engine
<inlet side>
slit
E
Fitting the camshaft
1. Remove any sealant from the cylinder head.
2. Apply engine oil to the camshaft cams and journals.
3. Fit the camshaft to the cylinder head.
Caution
Ensure that the inlet and exhaust sides are not the wrong way
round.
<exhaust side>
slit
F
Fitting the camshaft bearing cap No.4, the camshaft
bearing cap No.3, the camshaft bearing cap No.5, the
camshaft bearing cap No.2, the rear camshaft bearing
cap, and the front camshaft bearing cap
1. Set the camshaft dowel pins in the position shown in the
diagram.
Approx. 4°
dowel pins
inlet side
exhaust side
ENGINE – CAMSHAFT, VALVE STEM SEAL
11-11
2. Because camshaft bearing caps Nos. 2~5 are the same shape,
check the identification marks on them so that the bearing cap
number and the inlet and exhaust sides are not mistaken. Then
fit them in the direction shown in the diagram.
bearing cap No.
Front of
engine
mark indicating
inlet side or
exhaust side
Identification marks (stamped on the front bearing cap, and on
bearing cap Nos. 2~5).
I: inlet side
E: exhaust side
3. Apply sealant at the 8 places shown in the diagram of the top
view of the cylinder head.
Front of engine
Semi-dry sealant: Three bond 1207D
<Inlet side>
front mark
Front
of
engine
4. Fit the rear camshaft bearing cap in the direction indicated by
the front mark.
5. In just the same way as for bearing caps Nos. 2~5, check the
identification marks on the front camshaft bearing cap so that
the exhaust side and the inlet side are not mistaken.
6. Tighten the bearing cap mounting bolts gradually, 2~3 turns at a
time, to the specified torque.
Tightening torque: 20 ± 1 N•m
7. Check that the rocker arm has been fitted correctly.
Note
Completely wipe away any sealant that has been squeezed out.
<Exhaust side>
front mark
Front
of
engine
camshaft oil seal
(engine oil)
G
Fitting the camshaft oil seal
1. Apply engine oil around the entire circumference of the oil seal
lip.
2. Insert the oil seal using the special tool for installing the
camshaft oil seal (MD998713), as shown in the diagram.
11-12
ENGINE – CAMSHAFT, VALVE STEM SEAL
Front of
engine
(engine oil)
camshaft
sprocket
Front of
engine
(engine oil)
H
Fitting the camshaft sprocket (inlet side)
1. Apply engine oil to the edges of the camshaft, and to the parts
of the camshaft sprocket which will make contact with the
camshaft.
2. Match up the camshaft dowel pins with the dowel pin holes in
the camshaft sprocket, and fit the camshaft into the camshaft
sprocket.
3. Hold the hexagonal part of the camshaft with a wrench, and
check that the camshaft sprocket cannot be twisted.
Note
This operation is necessary because it is impossible to check by
looking whether the camshaft dowel pins are inserted into the
dowel pin holes in the camshaft sprocket.
4. Apply engine oil to the screw thread and the underside of the
camshaft sprocket mounting bolt, and in the same way as when
the camshaft sprocket was removed, hold the camshaft in place
using a wrench and tighten the bolt to the specified torque.
Tightening torque: 65 ± 5 N•m
camshaft
sprocket
I
Fitting the camshaft sprocket (exhaust side)
In the same way as when the camshaft sprocket was removed,
hold the hexagonal part of the camshaft with a wrench and
tighten the bolt to the specified torque.
Tightening torque: 89 ± 9 N•m
<Exhaust side>
J
Fitting the camshaft position sensor support
1. Remove any sealant from the camshaft position sensor support.
2. As shown in the diagram, apply sealant to the flange of the
camshaft position sensor support, and then fit it to the cylinder
head.
Semi-dry sealant: Three bond 1207F
3. Tighten the mounting bolts for the camshaft position sensor
support to the specified torque.
Tightening torque: 14 ± 1 N•m
<Inlet side>
ENGINE – CAMSHAFT, VALVE STEM SEAL
<Intake side>
dowel pin
11-13
K
Fitting the camshaft position sensing cylinder (inlet
side)
1. Set the inlet camshaft dowel pin in the position shown in the
diagram (No.1 cylinder compression top dead centre).
2. Tighten the mounting bolts for the camshaft position sensing
cylinder to the specified torque.
Tightening torque: 22 ± 4 N•m
pane
approx. 45º
dowel pin
pane (small)
pane (large)
L
Fitting the camshaft position sensing cylinder (exhaust
side)
1. Set the exhaust camshaft dowel pin in the position shown in the
diagram (No.1 cylinder compression top dead centre).
Note
Under pressure from the exhaust valve spring, it will turn slightly
in an anti-clockwise direction.
2. As shown in the diagram, fit the pane (small) of the camshaft
position sensing cylinder (exhaust side) so that it is in a position
approximately 45° to the exhaust camshaft dowel pin.
3. Tighten the mounting bolts for the camshaft position sensing
cylinder to the specified torque.
Tightening torque: 22 ± 4 N•m
M
Fitting the locker cover assembly
1. Apply sealant to the 8 places on the rocker cover gasket as
shown in the diagram.
Front of engine
Semi-dry sealant: Three bond 1207D
2. Fit the rocker cover assembly onto the cylinder head.
N
Connecting the radiator upper hose
1. Insert the radiator upper hose as far as the protrusion on the
water outlet fitting.
2. Match up the indicator marks on the radiator upper hose and the
hose clamp, in order to fit the radiator upper hose.
Protrusion
water outlet
fitting
indicator marks
11-14
ENGINE – CAMSHAFT, VALVE STEM SEAL, CYLINDER HEAD GASKET
Tape
O
Fitting the O-ring/oil feeder control valve
Caution
1. Do not re-use O-rings.
2. When fitting O-rings, first wind some non-adhesive tape
(seal tape etc) around the oil channel of the oil feeder
control valve, in order to prevent damage to the O-ring.
If the O-ring touches the oil it could start an oil leak.
1. Apply engine oil to the O-ring on the oil feeder control valve.
2. Fit the oil feeder control valve to the cylinder head.
3. Tighten the mounting bolts for the oil feeder control valve to the
specified torque.
Tightening torque: 11 ± 1 N•m
Cylinder head gasket
Removal and fitting
Jobs to be completed before removal and after fitting
• Measures to prevent fuel leaking. <Only before removal>
• Check for fuel dripping. <Only after fitting>
• Removal and refitting of the strut tower bar.
• Removal and refitting of the valence. (Ref Section 51: Front bumper)
• Check the tension of the drive belt. <Only after fitting>
• Adjustment of the axle letter cable. <Only after fitting>
• Draining and replacing the engine oil.
• Draining and replacing the coolant.
• Removal and refitting of the air cleaner.
• Removal and refitting of air pipe C.
• Removal and refitting of the battery and the battery tray.
• Removal and refitting of the centre cover. (Ref P11-5)
• Removal and refitting of the axle letter cable.
• Removal and refitting of the radiator.
• Removal and refitting of the front exhaust pipe.
• Removal and refitting of the timing belt. (Ref P11-20)
ENGINE – CYLINDER HEAD GASKET
11-15
(engine oil)
Removal procedure
1. Ignition coil connector
2. O2 sensor connector
3. Oil feeder control valve connector
4. Crank angle sensor connector
5. Manifold absolute pressure sensor
connector
6. Fuel pressure solenoid valve connector
7. Knock sensor connector
8. Purge control solenoid valve connector
9. Throttle position sensor connector
10. Injector connector
11. Exhaust camshaft position sensor
connector
12. Inlet camshaft position sensor
connector
13. Water temperature gauge unit
connector
14. Joint control harness and transmission
harness
15. Water temperature sensor connector
16. Secondary air control solenoid valve
connector
17. Vacuum tank, solenoid valve, vacuum
pipe and hose assembly
18. Brake booster vacuum hose connection
19. Oil level gauge and guide assembly
20. O-ring
21. Purge hose connection
11-16
ENGINE – CYLINDER HEAD GASKET
(engine oil)
(when
cool)
(engine oil)
22.
23.
E
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
Alternator bracket connection
Inlet manifold stay
Eye bolt
Gasket
Eye bolt
Gasket
Oil feeder control valve pipe
Filter
Oil pipe joint
Gasket
Oil return pipe gasket
Oil return pipe
Oil return pipe gasket
D
35. Oil return pipe gasket
C
C
A
B
A
36. Exhaust fitting bracket
• Water outlet fitting and thermostat case
assembly (Refer to Section 14: Water hose
pipe)
37. Water hose connection
38. Heater hose connection
39. Fuel return hose connection
40. Fuel high pressure hose connection
41. O-ring
42. Cylinder head bolt
43. Cylinder head assembly
44. Cylinder head gasket
ENGINE – CYLINDER HEAD GASKET
11-17
Removal guidelines
A
Removing the cylinder head bolts
Use the special wrench for cylinder head bolts (MB991654) to turn
the bolts 2~3 times in order to loosen them, before removing them
in the numerical order as shown in the diagram.
Front of engine
Fitting guidelines
A
Fitting the cylinder head gasket
1. Remove the gaskets which have been stuck onto the surface of
the gasket.
Caution
Do not allow any foreign matter to get into the channels for
coolant or oil, or into the cylinder.
2. Fit the cylinder head gasket to the cylinder head, so that the
holes in the cylinder head gasket match up with the holes in the
cylinder head.
(engine oil)
B
Fitting the cylinder head bolts
1. Check that the length of the body of cylinder head bolts is less
than the maximum permitted. If the length is in excess of the
maximum permitted, replace the bolt with a brand new one.
Maximum length (A): 99.4mm
2. Apply a small amount of engine oil to the screw thread of the
bolt, and to the washer.
11-18
ENGINE – CYLINDER HEAD GASKET
3. Use the special wrench for cylinder head bolts (MB991654) to
(loosely) tighten the bolts in the following order.
(1) In the order shown in the diagram, tighten the bolts to
78 ± 2 N•m.
(2) In reverse order to that shown in the diagram, completely loosen
the bolts.
(3) In the order shown in the diagram, tighten the bolts to
20 ± 2 N•m.
Front of engine
Procedure number (4)
paint mark
Procedure number (5)
paint mark
(4) Make a paint mark on the top of the cylinder head bolt, and on
the cylinder head, and tighten them to 90° as shown in the
diagram.
(5) Tighten the bolts to 90° as shown in the diagram, and check that
the paint mark on the top of the cylinder head bolt and the paint
mark on the cylinder head are in line.
Caution
1) If a bolt is tightened to an angle of less than 90° it has not
been tightened sufficiently.
2) If the angle of tightening exceeds the regulation level,
remove the bolt and start again from procedure number (1).
C
Fitting the O-ring/fuel high pressure hose
1. Apply a little fresh engine oil to the O-ring.
Caution
Ensure that engine oil does not get inside the delivery pipe.
2. Without damaging the O-ring, twist the fuel high pressure hose
to fit it to the delivery pipe, making sure that it is twisted
smoothly.
3. If the hose cannot be twisted smoothly, there is a possibility that
it may be biting into the O-ring, so remove the fuel high pressure
hose, and check for any damage to the O-ring. If the O-ring is
undamaged, reinsert it into the delivery pipe and check once
more whether the hose can be turned smoothly.
4. Tighten the mounting bolts for the fuel high pressure hose to the
specified torque.
Tightening torque: 5.0 ± 1.0 N•m.
ENGINE – CYLINDER HEAD GASKET
11-19
D
Fitting the oil return pipe gasket
Replace the gasket with a new one, and fit it to the protruded part
shown in the diagram.
Note:
For the oil return pipe gasket on the turbocharger side, there is no
direction for slotting it in.
Protrusion
E
Fitting the eyebolts
Caution
When tightening the eyebolts, hold the oil pipe joint in place
with a spanner so that it does not turn round as the eyebolts
are tightened.
11-20
ENGINE – TIMING BELT, TIMING BELT B
TIMING BELT, TIMING BELT B
Removal and fitting
Caution
If Brembo brake callipers are being used take care that they are not scratched by other
components or tools because there is a chance that the paint might peel off. In
addition, if any brake fluid gets on the callipers, it should be wiped off immediately.
Jobs to be completed before removal and after fitting
• Removal and refitting of the valence. (Ref Section 51: Front bumper)
• Removal and refitting of the LH side cover.
• Checking and adjustment of the tension of the drive belt. <Only after fitting>
• Removal and refitting of the crankshaft pulley.
• Removal and refitting of the cross member bar.
• Removal and refitting of the front exhaust pipe.
Removal procedure
1. Pressure hose connection
2. Timing belt front upper cover
3. Water pump pulley
4. Idler pulley
5. Drive belt auto-tensioner
6. Timing belt front lower cover
•
G
•
A
F
E
D
Remove the engine mount bracket
Adjust the tension of the timing belt
<Only after fitting>
7. Timing belt
8. Tensioner pulley
9. Tensioner arm
10. Auto-tensioner
ENGINE – TIMING BELT, TIMING BELT B
11-21
(engine oil)
B
10.
11.
12.
13.
14.
15.
Power steering oil pressure switch connector
Heat protector
Power steering oil pump ASSY
Power steering oil pump bracket
Idler pulley
Crank angle sensor
C
C
16. Crankshaft sprocket
C
17. Crankshaft sensing blade
B
• Adjust the tension of the timing belt B
<Only after fitting>
A
18. Timing belt B tensioner
D
A
19. Timing belt B
Removal guidelines
A
Removing the timing belt
1. Turn the crankshaft in a clockwise direction, and match up all
the timing marks until the No.1 cylinder is in the compressor top
dead centre position.
Timing marks
Caution
Turn the crankshaft in the normal way.
2. Remove the rubber plug from the rear cover of the timing belt,
and prepare the special tool for adjusting bolts (MD998738).
Timing belt
valence
11-22
ENGINE – TIMING BELT, TIMING BELT B
timing belt tensioner
arm
3. Twist the special tool for adjusting bolts (MD998738) by hand
until it touches the tensioner arm.
Caution
The special tool for adjusting bolts (MD998738) can be
slowly twisted at a rate of about 30° per second but if it is
suddenly twisted the auto-tensioner rod cannot be easily
withdrawn, and this may lead to problems with twisting and
the possibility that the special tool for adjusting bolts
(MD998738) may become bent.
4. Twist the special tool for adjusting bolts (MD998738) a little, and
align the auto-tensioner rod with setting hole A, and the
tensioner cylinder with setting hole B.
bolt for fitting the timing belt
tensioner
wire or pin
5. Insert a wire or a pin into the aligned holes.
6. Remove the special tool for adjusting bolts (MD998738), and
then loosen the bolt for fitting the timing belt tensioner, and
remove the timing belt.
Caution
If a timing belt is being re-used, check and make a note of
the direction of the arrows indicating the rotational
direction (clockwise direction) on the back of the belt.
B
Removing the power steering oil pump ASSY
Remove the power steering oil pump ASSY from its bracket, with
the hose intact.
Note
Secure the removed power steering oil pump ASSY with string, and
put it somewhere where it will not hinder the removal or fitting of the
timing belt.
C
Removing the crankshaft sprocket
1. Hold the crankshaft sprocket in place using the special spanner
(MB991367) and the special pin (MB991385).
2. Remove the crankshaft sprocket.
Crankshaft
sprocket
ENGINE – TIMING BELT, TIMING BELT B
11-23
D
Removing timing belt B
Caution
If planning to re-use a timing belt B, ensure that it will be
refitted the same way round, by marking the back of the belt
with chalk arrows indicating the direction of movement.
Fitting guidelines
timing marks
side of belt
under tension
timing
marks
balancer shaft
sprocket
A
Fitting timing belt B and the timing belt B tensioner
1. Check that the timing marks for the crankshaft sprocket and the
balancer shaft sprocket are aligned.
2. Fit timing belt B onto the crankshaft sprocket and the balancer
shaft sprocket. Ensure that the side of the belt under tension is
not slack.
crankshaft sprocket
centre of the
pulley
3. As a temporary step, fit the timing belt B tensioner pulley so that
its centre is to the upper left of the centre of the mounting bolt,
and so that the flange of the pulley is facing towards the front of
the engine.
4. Adjust the tension of timing belt B.
centre of the
mounting bolt
B
Adjusting the tension of timing belt B
1. Hold the timing belt B tensioner between fingertips and in the
direction of the arrows, apply tension torque (3.0 ± 0.4 N·m) to
timing belt B until the side of the belt under tension becomes
taught. In this condition, tighten the mounting bolt to the
specified torque, and fit the tensioner.
Tightening torque: 19 ± 3 N·m
Caution
When tightening the mounting bolt, ensure that the
tensioner does not turn round with it. If the tensioner turns
with the mounting bolt, it could cause the tension in the belt
to become too high.
11-24
ENGINE – TIMING BELT, TIMING BELT B
approx. 100 N
amount of
give
2. <Measuring the amount of give>
(1) As shown in the diagram, apply a force of about 100N to the
middle of the belt between the sprockets (indicated by the
arrow), and check that the amount of give is as specified.
Specified values:
<when adjusted> 5~7mm
<when replaced> 5~7mm
(2) If the specified values are not met, readjust the tension of the
belt.
3. <When using MUT-II/III>
(1) Connect the special belt tension meter set (MB991668) to the
MUT-II/III.
(2) Connect the special battery harness (MB991704) to the MUTII/III, and also connect it to the batteries.
(3) Give the crankshaft two turns in a clockwise direction, and check
that the No.1 cylinder is in the top dead centre position, and that
the timing marks on each sprocket are aligned.
(4) Select the “belt tension measurement” option from the display
on the MUT-II/III.
pull lightly with fingertips
(5) As shown in the diagram hold the special belt tension meter set
(MB991668) in the middle of the belt between the sprockets
(indicated by the arrow), 10~20mm away from the outer side of
the belt and vertically to the belt (not leaning more than ±15°
away from vertical).
(6) As shown in the diagram, lightly pull the middle of the belt
between the sprockets (indicated by the arrow) using fingertips
and check that the vibration frequency of the belt is within the
limits specified.
Specified values: 76 ~ 92 Hz
Caution
(1) The meter may give an incorrect reading if the
microphone is affected by a strong wind, or if there are
loud noises nearby, while testing is taking place.
(2) The meter may give an incorrect reading if testing is
performed while the microphone is touching the belt.
(7) If the specified values are not met, readjust the tension of the
belt.
ENGINE – TIMING BELT, TIMING BELT B
Front of engine
crankshaft
crankshaft sprocket
clean
here
washer
11-25
C
Fitting the crankshaft sensing blade and the
crankshaft sprocket
1. Clean, and remove any grease from the crankshaft sensing
blade, the crankshaft sprocket, and the surface of the crankshaft
to which the crankshaft sprocket will be fitted.
2. Fit the crankshaft sensing blade and the crankshaft sprocket in
the direction shown in the diagram.
3. Clean the screw hole in the crankshaft.
4. Place the washer with the larger surface side in the direction as
shown in the diagram, and fit it to the crankshaft bolt.
5. Apply a small quantity of engine oil to the top and to the screw
thread parts of the crankshaft bolt.
6. In the same way as when it was removed, hold the crankshaft
sprocket using the special tool, and tighten the crankshaft bolt to
the specified torque.
Tightening torque: 167 N·m
remove
grease
crankshaft bolt
crankshaft
sensing
blade
D
Fitting the auto-tensioner
1. If the auto-tensioner rod remains in an extended state, install it
using the following procedure.
(1) Using a press or a vice, slowly compress the autotensioner rod and align the rod with setting hole A and the
tensioner cylinder with setting hole B.
Caution
If the speed of compression is too fast, there is a
chance that the rod may break, so carry out this
operation slowly.
(2)
wire or pin
Insert a wire or pin into the aligned holes.
Note
If a brand new or a replacement auto-tensioner is being
used, use a pin to set the auto-tensioner in place.
2. Fit the auto-tensioner into the engine and tighten the mounting
bolt to the specified torque. Do not remove the wire or pin until
the tension of the timing belt has been adjusted.
Tightening torque: 23 ± 3 N·m
E
Fitting the tensioner pulley
As a temporary step, fit the tensioner pulley as shown in the
diagram.
tensioner pulley holes
11-26
ENGINE – TIMING BELT, TIMING BELT B
F
Fitting the timing belt
1. Check that all the timing marks for the camshaft sprocket, the
crankshaft sprocket and the oil pump sprocket are aligned.
timing marks
camshaft
sprocket
(exhaust
side)
camshaft
sprocket (inlet
side)
timing
marks
timing
marks
oil pump
sprocket
crankshaft
sprocket
more than
60 mm
plug
screwdriver
2. After the timing marks for the oil pump sprocket have been
aligned, remove the plug from the cylinder block and insert a
posidrive (+) with a diameter of 8 mm into the plug hole. Check
that more than 60 mm of the shaft of the screwdriver can be
inserted. If the screwdriver strikes the balancer shaft and can
only be inserted to a depth of 20 ~ 25 mm, turn the sprocket one
complete turn, realign the timing marks, and check that more
than 60 mm of the screwdriver can be inserted. Do not remove
the screwdriver until the timing belt has been fitted.
balancer shaft
camshaft
sprocket (inlet
side)
camshaft
sprocket
(exhaust side)
tensioner pulley
crankshaft
sprocket
paper
clip
3. Install the timing belt in accordance with the following guidelines
so that the side that is under tension does not get slack.
(1) Fit the timing belt around the crankshaft sprocket first, then
the oil pump sprocket and then fit it around the idler pulley.
idler
pulley
oil pump
sprocket
(2)
Fit the timing belt around the camshaft sprocket (exhaust
side) and hold it in place with a paper clip at the position
shown in the diagram.
ENGINE – TIMING BELT, TIMING BELT B
paper clips
11-27
(3) Use a wrench to align the timing marks on the rocker cover and
the camshaft sprocket, and whilst doing so, fit the timing belt
around the camshaft sprocket (inlet side) and hold it in place
with a paper clip at the position shown in the diagram.
(4) Fit the timing belt around the tensioner pulley.
(5) Remove the two paper clips.
Caution
After the timing belt has been installed, apply some force in
an anti-clockwise direction to the camshaft sprocket and
check once more that all the timing marks are in the correct
position when the side of the belt under tension is taught.
4. Using the special wrench for the tensioner pulley socket
(MD998767), tense the timing belt by turning the tensioner
pulley in the direction shown in the diagram, and temporarily
tighten the mounting bolt for the tensioner pulley.
5. Check that all the timing marks are aligned.
6. Remove the screwdriver, and replace the plug.
7. Adjust the tension of the timing belt.
G
Adjusting the tension of the timing belt
1. Remove the rubber plug from the rear cover of the timing belt
and put the special adjusting bolt (MD998738) in position.
Slowly twist the adjusting bolt a little at a time, so that the wire
or pin inserted when fitting the auto-tensioner, only moves a
little.
Caution
There is a possibility that the wire or pin inserted in the
auto-tensioner may break if the adjusting bolt is twisted
with a spanner or a similar tool, so it must be twisted by
hand.
2. Turn the crankshaft a quarter turn in an anti-clockwise direction.
3. Turn the crankshaft in a clockwise direction, realign all the timing
marks and set the No.1 cylinder in the top dead centre position.
4. Loosen the mounting bolt for the tensioner pulley which had
been temporarily tightened.
11-28
ENGINE – TIMING BELT, TIMING BELT B, ENGINE ASSY
5. Using the special wrench for the tensioner pulley socket
(MD998767) or a torque wrench, apply tension torque (3.5 N·m)
to the timing belt in the direction shown in the diagram, and
tighten the mounting bolt for the tensioner pulley to the specified
torque.
Tightening torque: 48 ± 5 N·m
Caution
When tightening the installed bolt, take care that the
tensioner pulley does not turn around with it. If the pulley
does turn around with the bolt, the tension of the belt will
become too strong.
6. Remove the wire or pin which had been inserted when the autotensioner was fitted.
7. Remove by hand the special adjusting bolt (MD998738) which
had been fitted in step 1.
8. Turn the crankshaft two complete turns in a clockwise direction,
and leave it for about 15 minutes.
9. Reinsert the wire or pin which had been removed in step 6, and
check that it can be easily pulled out again.
If the wire or pin can be easily pulled out the tension of the
timing belt is just right, so the wire or pin should be removed
completely. At this point check that the auto-tensioner rod is not
projecting more than the amount specified.
Specified projection (A): 3.8 ~ 4.5 mm
10. If the wire or pin cannot be easily pulled out, repeat steps 1 to 8
until the tension of the timing belt is just right.
11. Recheck that the timing marks on all of the sprockets are in line.
Caution
If the crankshaft bolt is turned in an anti-clockwise
direction, the tightening torque of the crankshaft bolt must
be checked, and if it is loose, it must be retightened.
ENGINE ASSY
Removal and fitting
Jobs to be completed before removal and after fitting
• Measures to prevent fuel leaking. <Only before removal>
• Check for fuel dripping. <Only after fitting>
• Removal and refitting of the bonnet.
• Removal and refitting of the strut tower bar.
• Removal and refitting of the valence. (Ref Section 51: Front bumper)
• Checking the tension of the drive belt. <Only after fitting>
• Adjustment of the axle letter cable. <Only after fitting>
• Draining and replacing the engine oil.
• Draining and replacing the coolant.
• Removal and refitting of the air cleaner.
• Removal and refitting of air pipe C.
• Removal and refitting of the battery and the battery tray.
• Removal and refitting of the centre cover. (Ref P11-5)
• Removal and refitting of the axle letter cable.
• Removal and refitting of the radiator.
• Removal and refitting of the front exhaust pipe.
ENGINE – ENGINE ASSY
Removal procedure
1. Ignition coil connector
2. O2 sensor connector
3. Oil feeder control valve connector
4. Crank angle sensor connector
5. Manifold absolute pressure sensor
connector
6. Fuel pressure solenoid valve connector
7. Knock sensor connector
8. Purge control solenoid valve connector
9. Throttle position connector
10. Injector connector
A
11-29
11. Exhaust cam position sensor connector
12. Inlet cam position sensor connector
13. Water temperature gauge unit connector
14. Joint control harness and transmission
harness
15. Water temperature sensor connector
16. Alternator connector and terminal
17. Secondary air control solenoid valve
connector
18. Engine oil pressure switch connector
19. Drive belt
11-30
ENGINE – ENGINE ASSY
Caution
Parts marked * should be temporarily tightened, and then tightened properly when the full weight of the engine is
being supported by the chassis.
(engine oil)
B
B
20. Vacuum tank, solenoid valve, vacuum
pipe and hose ASSY
21. Brake booster vacuum hose connection
22. Purge hose connection
23. Power steering oil pressure switch
connector
24. Heat protector
25. Power steering oil pump
26. A/C compressor connector
<For cars fitted with A/C>
27. A/C compressor <For cars fitted with
A/C>
D
D
C
C
D
B
E
A
28. Heater hose connection
29. Fuel return hose connection
30. Fuel high pressure hose connection
31. O-ring
• Transfer ASSY, transmission ASSY
32. Engine mount bracket & stopper ASSY
33. Engine ASSY
ENGINE – ENGINE ASSY
11-31
Removal guidelines
A
Removing the drive belt
The following operations are necessary because the engine uses a
serpentine drive system with auto-tensioner.
1. Insert a 12.7sq spinner handle into the auto-tensioner tool hole,
and turn the auto-tensioner in an anti-clockwise direction before
it reaches the stopper.
2. Align hole A and hole B, insert an L-shaped hexagonal Allen
Key, to hold the position, and remove the drive belt.
B hole
A hole
Caution
If planning to re-use the drive belt, ensure that it will be
refitted the same way round, by marking the back of the belt
with chalk arrows indicating the direction of movement.
L-shaped
hexagonal
Allen
wrench
B
Removing the power steering oil pump and the A/C
compressor
1. Remove the power steering oil pump and the A/C compressor
from the bracket with the hoses intact.
2. Secure the removed power steering oil pump and the removed
A/C compressor with string, and put them somewhere where
they will not hinder the removal or fitting of the engine ASSY.
C
Removing the transfer ASSY and the transmission
ASSY
1. In order to prepare the special mechanical engine hanger
(MZ203830, MZ203831 or MB991928), the radiator support
upper insulator mounting bolts should be tightened on the
chassis (2 places).
2. Remove the transfer ASSY and the transmission ASSY.
11-32
ENGINE – ENGINE ASSY
MZ203830 or MZ203831
D
Removing the engine mount bracket & stopper ASSY
1. Support the engine using a garage jack.
2. Remove the special mechanical engine hanger (MZ203830,
MZ203831 or MB991928).
slide bracket (HI)
3. Hold the engine ASSY using a chain block.
4. Support the engine oil pan component with the garage jack
through the engine block, so that the weight of the engine is not
taken by the engine mount bracket.
5. Loosen the nuts and bolts and remove the engine mount bracket
and stopper ASSY.
E
Removing the engine ASSY
After checking that all of the cables, hoses and harness connectors
etc have been disconnected, slowly hoist the engine using a chain
block and remove the engine from the engine compartment.
Fitting guidelines
A
Fitting the engine ASSY
Install the engine whilst checking that cables, hoses and harness
connectors etc will not be squashed beneath it.
ENGINE – ENGINE ASSY
engine side
engine side
engine mount stopper
<viewed from
rear of chassis>
<viewed from
front of chassis>
MZ203830 or MZ203831
slide bracket (HI)
front of
chassis
11-33
B
Fitting the engine mount bracket & stopper ASSY
1. Support the engine oil pan component with the garage jack
through the engine block, and fit the engine mount bracket &
stopper ASSY whilst checking the position of the engine. Fix the
engine mount stopper so that the arrow points in the direction
shown in the diagram.
2. Support the engine ASSY with a garage jack.
3. Remove the chain block.
4. In the same way as when it was removed, hold the engine
ASSY with the special tool.
(1)
<When using the special mechanical engine hanger
(MZ203830 or MZ203831)>
Install the special mechanical engine hanger (MZ203830
or MZ203831).
(2) <When using the special engine hanger (MB991928)>
Fit the following parts to the base hanger.
• Slide bracket (HI)
• Foot (standard) (MB991932)
• Joint (90) (MB991930)
Install the special engine hanger (MB991928)
joint (90)
(MB991930)
foot (standard) (MB991932)
slide bracket (HI)
C
Fitting the transfer ASSY and the transmission ASSY
1. Fit the transfer ASSY and the transmission ASSY.
2. Remove the radiator support upper insulator mounting bolts from
the chassis (2 places).
11-34
ENGINE – ENGINE ASSY
D
Fitting the O-ring and the fuel high pressure hose
1. Apply a little fresh engine oil to the O-ring.
Caution
Ensure that no engine oil gets inside the deliver pipe.
2. Without damaging the O-ring, fit the fuel high pressure hose to
the delivery pipe by twisting it from left to right. Ensure that the
hose is twisted smoothly.
3. If the hose cannot be twisted smoothly, there is a possibility that
it may be biting into the O-ring, so remove the fuel high pressure
hose, and check for any damage to the O-ring. If the O-ring is
undamaged, reinsert it into the delivery pipe and check once
more whether the hose can be turned smoothly.
4. Tighten the mounting bolts for the fuel high pressure hose, to
the specified torque.
Tightening torque: 5.0 ± 1.0 N•m.
MPI – GENERAL
13A-1
SECTION 13A
MPI (Multi-point Fuel Injection)
CONTENTS
General..................................................................... 2
Servicing standards .................................................3
Special tools ............................................................3
Troubleshooting ......................................................5
Servicing the vehicle ............................................29
1. Adjusting specified revolutions when idling.....29
2. MPI system components layout diagram........29
3. Checking the air temperature sensor..............29
4. Checking the oil feeder control valve..............30
GENERAL
Servicing guidelines have been changed because of the changes listed below.
• A variable valve timing control system (V.V.T.) has been adopted. Because of this, an oil feeder control valve and an intake
cam position sensor have been added.
• A manifold absolute pressure (MAP) sensor has been added.
• An air temperature sensor has been added.
13A-2
MPI – GENERAL
MPI system diagram
H 1. O2 sensor
H 2. Air flow sensor
H 3. Intake air temp.
sensor
H 4. Throttle position
sensor
H 5. Intake Cam position
sensor
H 6. Exhaust Cam
position sensor
H 7. Crank angle
sensor
H 8. Atmospheric
pressure sensor
H 9. Water temp.
sensor
H 10. Knock sensor
H 11. Manifold absolute
pressure (MAP)
sensor
H 12. Air temp. sensor
•
•
•
•
Power supply
Ignition switch IG
Ignition switch ST
Vehicle speed
sensor
• A/C switch
• A/C load signal
• Power steering
fluid pressure switch
• Alternator FR signal
• Inter-cooler water spray
switch (auto)
• Inter-cooler water spray
switch (manual)
È
Engine ECU
I1. Injector
I2. ISC servo (Stepper
motor)
I3. Fuel pressure
control solenoid valve
I4. No. 1 Waste gate
solenoid valve
I5. No. 2 Waste gate
solenoid valve
I6. Purge control
solenoid valve
I7. Secondary air
control solenoid valve
I8. Oil feeder control
valve
È
• Engine control relay
• Fuel pump relay 2,3
(ON/OFF)
• Fuel pump relay (HI/LO
switch)
• A/C relay
• Ignition coil
• Fan controller
• Condenser fan relay (HI)
• Condenser fan relay
(LO)
• Engine warning light
• Diagnosis output
terminal
• Alternator G terminal
• Inter-cooler water spray
relay
• Inter-cooler water spray
lamp
• O2 sensor heater
H 12. Air temperature sensor
H 11. MAP sensor
I6. Purge control
solenoid valve
I2. ISC servo
Canister
From fuel tank
I7. Secondary
air control
solenoid valve
Check
valve
By-pass valve
H 4. Throttle
position
sensor
I3. Fuel pressure
control solenoid
valve
Secondary air
valve
I8. Oil feeder control
valve
Fuel pressure
regulator
To fuel
tank
From fuel
pump
H 6. Exhaust cam
position sensor
H 8. Atmospheric
pressure sensor
H 2. Air flow sensor
Vacuum
tank
H 3. Intake air
temperature
sensor
I1. Injector
Intake
H 9. Water temperature sensor
H 10. Knock sensor
Waste gate actuator
H 7. Crank angle sensor
I4. No.1 waste gate
solenoid valve
Catalyst
H 5. Intake cam
position sensor
I5. No.2 waste gate
solenoid valve
H 1. O2 sensor
MPI – SERVICING STANDARDS, SPECIAL TOOLS
13A-3
Servicing standards
Item
Standard level
Revolutions when idling r/min
800 ± 50
Air temperature sensor resistance kΩ
at -20 ºC
13~18
at 0 ºC
5.1~6.9
at 20 ºC
2.0~3.0
at 40 ºC
0.9~1.5
at 60 ºC
0.40~0.78
at 80 ºC
0.23~0.42
Oil feeder control valve resistance (at 20 ºC) Ω
6.9~7.9
Special tools
Tool
DO NOT USE
Number
Name
Function
MB991502
MUT-II sub ASSY
Checking the MPI system
MB991955
A:MB991824
B:MB991827
C:MB991910
D:MB991911
E:MB991825
F:MB991826
MUT-III sub ASSY
Note
If a MUT-III main harness A is connected to
a vehicle not fitted with CAN, there is a
chance that a pulse signal will be entered
in the simulated vehicle speed line, when
the MUT-III is activated. Therefore, use a
MUT-III main harness B with vehicles not
fitted with CAN.
A: Vehicle Communication
Interface (V.C.I..)
B: USB cable
C: MUT-III Main harness A
(For vehicles fitted with
CAN)
D: MUT-III Main harness B
(For vehicles not fitted with
CAN)
E: Adaptor
F: Trigger harness
13A-4
MPI- SPECIAL TOOLS
Tool
Red coloured harness (for DLI)
White coloured
harness (for LC)
Number
Name
Function
MB991348
Test harness
Inspection using an oscilloscope
MB991709
Test harness
• Troubleshooting voltage measurement
• Inspection using an oscilloscope
MB991658
Test harness
Inspection using an oscilloscope
MD998478
Test harness
(3P, triangular)
• Troubleshooting voltage measurement
• Inspection using an oscilloscope
MB991223
Inspection harness set connector
• Pin contact pressure inspection
harness
• Commercial tester connection
probe (for ordinary connectors)
Terminal voltage measurement
MPI – TROUBLESHOOTING
13A-5
TROUBLESHOOTING
1. Diagnosis Functions
1-1 Engine warning light (Check engine lamp)
Changes have been made to engine warning lights.
Checklist for engine warning lights.
Engine ECU
Air flow sensor (AFS)
Manifold absolute pressure (MAP) sensor system
Intake air temperature sensor
Throttle position sensor (TPS)
Water temperature sensor
Crank angle sensor
Exhaust cam position sensor
Injector
Ignition coil (with built-in power transistor)
Atmospheric pressure sensor
O2 sensor
O2 sensor heater
Fuel system malfunction
Knock sensor
Intake cam position sensor system
Oil feeder control valve system
1-2 Checking of freeze frame data
Additions have been made to the freeze frame data tables.
Checklist for data tables
Item number
Type of data
Units/condition
95
MAP sensor
kPa
1-3 Failsafe and back-up functions
If one of the diagnosis functions detects that one of the main sensors is malfunctioning, it will ensure that the car can be driven
safely, in accordance with the pre-set control logic.
Malfunctioning item
Control measures taken when a malfunction occurs
Air temperature sensor
Regulation of the intake air temperature at 25ºC.
Exhaust cam position sensor
(1) Simultaneous flushing out of all fuel pipes.
(But only if the No. 1 cylinder has not been detected in the
TDC position after the ignition switch has been turned "ON".)
(2) Cutting off the fuel 4 seconds after the malfunction has been
detected.
(But only if the No. 1 cylinder has not been detected in the
TDC position after the ignition switch has been turned "ON".)
Intake cam position sensor
The oil feeder control valve should be switched "OFF", and the
angle of the cam should be in the reset position.
13A-6
MPI- TROUBLESHOOTING
2. Diagnosis code classification table
Code No.
Diagnosis item
Page
P0105
MAP sensor
13A-7
P0340
Exhaust cam position sensor system
13A-9
P1012
Intake cam position sensor system
13A-11
P1021
Oil feeder control valve system
13A-13
P2226
Atmospheric pressure system
13A-14
13A-7
MPI – TROUBLESHOOTING
3. INSPECTION PROCEDURES FOR EACH DIAGNOSIS CODE
Code No. P0105 MAP sensor system
Conditions for the inspection
• Ignition switch: ON
• Wait for 2 seconds after the ignition switch has been turned on or the
engine has started.
Evaluation conditions
• Sensor output voltage is 4.6V or more for 4 seconds (when atmospheric
pressure is more than 313 kPa)
• Sensor output voltage is 0.2V or less for 4 seconds (when atmospheric
pressure is more than 14 kPa)
MUT-II/III service data
• No.95 atmospheric pressure
sensor
(Ref: P13A-24)
Probable cause of the malfunction
• MAP sensor malfunction
• Broken circuit or short circuit in the MAP
sensor circuit
• Poor connector contact
• Engine ECU malfunction
OK
Temporary malfunction (Ref
Section 00: Dealing with
temporary malfunctions)
NG
Check connector B-135
OK
NG
Repair
(1) NG
Measurements taken at
C-50 engine ECU connector
• Measure engine ECU terminal
voltage
• Ignition switch: ON
• Voltage across earth at 42
OK: 4.9~5.1V
NG
Measurements taken at the B-135
MAP sensor connector
• Undo the connector, and take
measurements using the
harness
(1) Voltage across earth at 3
(ignition switch: ON)
OK: 4.9~5.1V
(2) Resistance across earth at 2
OK: 2Ω or less
Check connector C-50
OK
OK
Check connector C50
OK
NG
Repair
Inspect the harness between the
MAP sensor and the engine ECU,
repair if necessary.
• Check if the power supply wire is
cut.
NG
Inspect the harness between the NG
MAP sensor and the engine ECU.
• Check if the power supply has
short circuited.
OK
OK
MUT-II/III service data
• No.95: MAP sensor
(Ref: P13A-24)
Repair
Repair
Temporary malfunction (Ref
Section 00: Dealing with
temporary malfunctions)
NG
Replace the engine ECU
(2) NG
Check connector C-50
NG
Repair
OK
Inspect the harness between the
MAP sensor and the engine ECU.
• Check if earth wire is cut or
damaged.
NG
Repair
OK
MUT-II/III service data
• No.95: MAP sensor
(Ref: P13A-24)
NG
OK
Go on to the next page
Replace the engine ECU
OK
Temporary malfunction (Ref
Section 00: Dealing with
temporary malfunctions)
MPI – TROUBLESHOOTING
13A-8
Continued from the previous page
OK
NG
NG
Check connector C-50
Measurements taken at the B-135
MAP sensor connector
• Connect the test harness
(MB991348) to the connector
and measure at the pick-up
harness component.
• Ignition switch: ON
• Voltage across earth at 2
OK: 4.9~5.1V
Repair
OK
Inspect the harness between the
MAP sensor and the engine ECU,
repair if necessary.
• Check for damage to the power
supply wire.
OK
Measurements taken at the B-135
MAP sensor connector
• Connect the test harness
(MB991348) to the connector
and measure at the pick-up
harness component.
• Ignition switch: ON
• Voltage across earth at 1
OK: altitude 0m
1.2~1.8V
altitude 600m 1.1~1.7V
altitude 1200m 1.0~1.6V
altitude 1800m 0.9~1.5V
NG
NG
Repair
Check connector C-50
OK
Inspect the harness between the
MAP sensor and the engine ECU.
• Check if the output wire has
short circuited.
NG
Repair
OK
Replace the MAP sensor
OK
NG
NG
Check connector C-50
Measurements taken at the C-50
engine ECU connector
• Measure engine ECU terminal
voltage
• Ignition switch: ON
• Voltage across earth at 92
OK: altitude 0m
1.2~1.8V
altitude 600m 1.1~1.7V
altitude 1200m 1.0~1.6V
altitude 1800m 0.9~1.5V
OK
Inspect the harness between the
MAP sensor and the engine ECU,
repair if necessary
• Check if the output wire has
been cut or damaged.
OK
NG
Repair
Check connector C-50
OK
OK
MUT-II/III service data
• No.95: MAP sensor
(Ref: P13A-24)
NG
Replace the engine ECU
Temporary malfunction (Ref
Section 00: Dealing with
temporary malfunctions)
Repair
13A-9
MPI – TROUBLESHOOTING
Code No.P0340 Exhaust cam position sensor system
Probable cause of the malfunction
Conditions for inspection
• Malfunction of the exhaust cam position
• Ignition switch: ON
sensor
• With engine cranking or running
• Broken circuit or short circuit in the exhaust
Evaluation conditions
cam position sensor circuit, or poor connector
• The sensor output voltage does not change for 4 seconds (with no input of contact
pulse signals)
• Malfunction of engine ECU
NG
Repair
Check connector B-115
OK
(1) NG
Measurements taken at the B-115
connector of the exhaust cam
position sensor
• Undo the connector and take
measurements using the
harness
(1) Voltage across earth at 3
(ignition switch: ON)
OK: battery voltage
(2) Voltage across earth at 2
(2) NG
(ignition switch: ON)
OK: 4.9~5.1V
(3) Resistance across earth at 1
OK: Less than 2Ω
NG
Check connector B-19X
Repair
OK
Inspect the harness between the
exhaust cam position sensor and
the engine control relay, repair if
necessary
• Check if the power supply wire
is cut or has short circuited
OK
Check connector C-50
Measurements taken at engine
ECU connector C-50
• Measurement of voltage at
engine ECU terminals
• Undo the B-115 exhaust cam
position sensor connector
• Ignition switch: ON
• Voltage across earth at 50
OK: 4.9~5.1V
NG
OK
Repair
Inspect the harness between the
exhaust cam position sensor and
the engine ECU, repair if
necessary
• Check if the output wire is cut
NG
Repair
Check connector C-50
OK
NG
Inspect the harness between the
exhaust cam position sensor and
the engine ECU
• Check if the output wire has
short circuited
OK
NG
Repair
OK
Temporary malfunction (Ref
Section 00: Dealing with
temporary malfunctions)
Check that the problem has been
solved
NG
Replace engine ECU
(3) NG
NG
Repair
Check connector C-49
OK
Inspect the harness between the
exhaust cam position sensor and
the engine ECU
• Check if the earth wire is cut or
damaged
OK
OK
To next page
Check the problem has been
solved
NG
Replace engine ECU
NG
Repair
OK
Temporary malfunction (Ref
Section : Dealing with temporary
malfunctions)
MPI – TROUBLESHOOTING
13A-10
Continued from the previous page
OK
NG
NG
Measurement of the output wave
at the exhaust cam position
sensor connector B-115 (using an
oscilloscope)
• Use test harness (MB991709),
connect it to the connector, and
take measurements at the pickup harness component
• Engine: idling
• Voltage across earth at 2
OK: An output wave as
described on P.13A-25
(Main points for
oscilloscope testing) is
produced, with the
maximum value in excess
of 4.8V and the minimum
value less than 0.6V.
There should be no noise
in the output wave form.
Repair
Check connector B-19X
OK
NG
Inspect the harness between the
exhaust cam position sensor and
the engine control relay
• Check if the power wire is
damaged
OK
Repair
NG
Repair
Check connector C-49 and C-50
OK
NG
Repair
Inspect the harness between the
exhaust cam position sensor and
the engine ECU
• Check if the output wire is
damaged
OK
NG
Check the exhaust cam position
sensing cylinder
Replace the exhaust cam position
sensing cylinder
OK
Check that the problem has been
solved
NG
Replace the exhaust cam position
sensor
OK
Check that the problem has been
solved
NG
Replace the engine ECU
OK
Temporary malfunction (Ref
Section 00: Dealing with
temporary malfunctions)
OK
Temporary malfunction (Ref
Section 00: Dealing with
temporary malfunctions)
13A-11
MPI – TROUBLESHOOTING
Code No.P1012 Intake cam position sensor system
Probable cause of the malfunction
Conditions for inspection
• With engine cranking or running
Evaluation conditions
• Sensor output voltage does not change for 4 seconds (with no input of
pulse signals)
• Malfunction of the intake cam position sensor
• Broken circuit or short circuit in the intake
cam position sensor circuit, or poor
connector contact
• Malfunction of engine ECU
NG
Check connector B-33
Repair
OK
(1) NG
Measurements taken at the B-33
connector of the intake cam
position sensor
• Undo the connector and take
measurements using the
harness
(1) Voltage across earth at 3
(ignition switch: ON)
OK: battery voltage
(2) Voltage across earth at 2
(ignition switch: ON)
OK: 4.9~5.1V
(3) Resistance across earth at 1
OK: Less than 2Ω
Check connectors B-19X & C-23
NG
Repair
OK
Inspect the harness between the
intake cam position sensor and
the engine control relay, repair if
necessary
• Check if the power supply wire
is cut or has short circuited
OK
(2) NG
Measurements taken at engine
ECU connector C-50
• Measurement of voltage at
engine ECU terminals
• Undo the B-33 intake cam
position sensor connector
• Ignition switch: ON
• Voltage across earth 53
OK: 4.9~5.1V
Check connector C-50
OK
NG
Repair
Inspect the harness between the
intake cam position sensor and
the engine ECU, repair if
necessary
• Check if the output wire is cut
NG
NG
Check connector C-50
Repair
OK
Inspect the harness between the
intake cam position sensor and
the engine ECU
• Check if the earth wire is cut or
damaged
OK
NG
Repair
OK
Check that the problem has been
solved
Temporary malfunction (Ref
Section 00: Dealing with
temporary malfunctions)
NG
Replace engine ECU
NG
(3) NG
Repair
Check connector C-49
OK
NG
Repair
Harness inspection between the
intake cam position sensor and
the engine ECU
• Check if the earth wire is cut or
damaged
OK
OK
To next page
Check that the problem has been
solved
NG
Replace the engine ECU
OK
Temporary malfunction (Ref
Section 00: Dealing with
temporary malfunctions)
MPI – TROUBLESHOOTING
13A-12
Continued from the previous page
OK
NG
Measurement of the output wave
at the intake cam position
sensor connector B-33 (using an
oscilloscope)
• Use test harness (MB991709),
connect it to the connector, and
take measurements at the pickup harness component
• Engine: idling
• Voltage across earth at 2
OK: An output wave as described
on P.13A-25 (Main points for
oscilloscope testing) is
produced, with the maximum
value in excess of 4.8V and
the minimum value less than
0.6V. There should be no
noise in the output wave form.
NG
Check connectors B-19X & C-23
Repair
OK
NG
Inspect the harness between the
intake cam position sensor and
the engine control relay
• Check if the power wire is
damaged
OK
Repair
NG
Repair
Check connectors C-49 & C-50
OK
NG
Repair
Inspect the harness between the
intake cam position sensor and
the engine ECU
• Check if the output wire is
damaged
OK
NG
Replace the intake cam position
sensing cylinder
Check the intake cam position
sensing cylinder
OK
Check that the problem has been
solved
NG
Replace the intake cam position
sensor
OK
OK
Check that the problem has been
solved
NG
Replace engine ECU
Temporary malfunction (Ref
Section 00: Dealing with
temporary malfunctions)
OK
Temporary malfunction (Ref
Section 00: Dealing with
temporary malfunctions)
13A-13
MPI – TROUBLESHOOTING
Code No.P1021 Oil feeder control valve system
Probable cause of the malfunction
Conditions for inspection
• Oil feeder control valve: OFF
Evaluation conditions
• Operational terminal voltage of the oil feeder control valve in the ECU is
abnormal for 4 seconds
•
•
•
Malfunction of the oil feeder control
valve
Broken circuit or short circuit in the oil
feeder control valve circuit, or poor
connector contact
Malfunction of engine ECU
NG
Check connector B-134
Repair
OK
NG
Inspect the oil feeder control
valve by itself (Ref: P13A-30)
Replace the oil feeder control
valve
OK
NG
Check connectors B-19X & C-23
A-134 Measurement of the oil
feeder control valve
• Measure using a harness
connected to the connector
• Ignition switch: ON
• Voltage across earth at 1
OK: battery voltage
NG
Repair
OK
Inspect the harness between the
engine control relay and the oil
feeder control valve, repair if
necessary
• Check if the power supply wire
is cut or has short circuited
OK
NG
Check connectors B-19 & C-23
Repair
OK
Inspect the harness between the
engine control relay and the oil
feeder control valve, repair if
necessary
• Check for damage to the power
supply wire
NG
Repair
OK
C-49 Measurement of engine
ECU
• Undo the connector and
measure on the harness side
• Ignition switch: ON
• Voltage across earth at 32
OK: battery voltage
NG
NG
Check connector C-49
OK
Inspect the harness between the
engine ECU and the oil feeder
control valve, repair if necessary
• Check if the output wire is cut or
has short circuited
OK
NG
Check connector C-49
Repair
OK
NG
Inspect the harness between the
engine ECU and the oil feeder
control valve
• Check for damage to the output
wire
Repair
OK
OK
Check that the problem has been
solved
NG
Replace the engine ECU
Temporary malfunction (Ref
Section 00: Dealing with
temporary malfunctions)
Repair
MPI – TROUBLESHOOTING
13A-14
Code No.P2226 Atmospheric pressure sensor system
Probable cause of the malfunction
Conditions for inspection
• Ignition switch: ON
• Wait for 2 seconds after the ignition switch has been turned on or the
engine has started.
Evaluation conditions
• Output voltage from the sensor is more than 4.5V (when atmospheric
pressure is in excess of 114kPa) for 4 seconds.
Or,
• Output voltage from the sensor is more than 0.2V (when atmospheric
pressure is less than 5kPa) for 4 seconds.
• Malfunction of the atmospheric pressure
sensor
• Broken circuit or short circuit in the
atmospheric pressure sensor circuit, or poor
connector contact
• Malfunction of engine ECU
MUT-II/III Service data
• No.25: atmospheric sensor
(Ref: P13A-83) *
NG
OK
Temporary malfunction (Ref
Section 00: Dealing with
temporary malfunctions)
NG
Repair
Check connector B-08
OK
(1) NG
Measurement at B-08 AFS
connector
• Undo the connector and
measure on the harness side.
(1) Voltage across earth at 1
(ignition switch: ON)
OK: 4.9~5.1V
(2) Resistance across earth at 5
OK: Less than 2Ω
OK
Measurement at C-50 engine
ECU connector
• Measure the voltage at the
engine ECU terminals
• Ignition switch: ON
• Voltage across earth at 42
OK: 4.9~5.1V
NG
Check connector C-50
OK
Inspect the harness between the
AFS and the engine ECU
• Check if the power supply wire
has short circuited
OK
Check connector C-50
OK
NG
NG
Repair
Inspect the harness between the
AFS and the engine ECU, repair
if necessary
• Check if the power supply wire
is cut
Repair
NG
Repair
OK
MUT-II/III Service data
• No.25: atmospheric sensor
(Ref: P13A-83) *
Temporary malfunction (Ref
Section 00: Dealing with
temporary malfunctions)
NG
Replace the engine ECU
(2) NG
NG
Check connector C-49
OK
Repair
NG
Repair
Inspect the harness between the
AFS and the engine ECU
• Check if the earth wire is cut or
damaged
OK
MUT-II/III Service data
• No.25: atmospheric sensor
(Ref: P13A-83) *
NG
Replace the engine ECU
OK
Go on to the next page
*: Refer to the 03-1 Service Manual for the Lancer Evolution VIII (No.1036K07)
OK
Temporary malfunction (Ref
Section 00: Dealing with
temporary malfunctions)
13A-15
MPI – TROUBLESHOOTING
Continued from previous page
OK
(1) NG
Measurements taken at B-08 AFS
connector
• Only connect the test harness
(MB991709) to terminals
No.1, No.2 and No.5 of the
connector and measure at the
pick up harness component.
• Ignition switch: ON
(1) Voltage across earth at 1
(2) NG
OK: 4.9~5.1V
(2) Voltage across earth at 2
OK: altitude 0m 3.8~4.2V
altitude 600m 3.5~3.9V
altitude 1200m 3.3~3.7V
altitude 1800m 3.0~3.4V
NG
Check connectors C-49 & C-50
Repair
OK
Inspect the harness between AFS
and engine ECU, repair if
necessary
• Check if the power supply wire
is damaged
NG
Repair
Check connector C-50
OK
NG
Inspect the harness between AFS
and engine ECU
• Check if the output wire has
short circuited or is damaged
Repair
OK
Replace the AFS
OK
NG
Measurement at the C-50 engine
ECU connector
• Measurement of the terminal
voltage of the engine ECU
• Ignition switch: ON
• Voltage across earth at 51
OK: altitude 0m 3.8~4.2V
altitude 600m 3.5~3.9V
altitude 1200m 3.3~3.7V
altitude 1800m 3.0~3.4V
Check connector C-50
NG
Inspect the harness between AFS
and engine ECU, repair if
necessary
• Check if the output wire is cut or
damaged
OK
NG
Repair
Check connector C-50
OK
OK
MUT-II/III Service data
• No.25: atmospheric sensor
(Ref: P13A-83) *
Temporary malfunction (Refer to
Section 00: Dealing with
temporary malfunctions)
NG
Replace the engine ECU
*: Refer to the 03-1 Service Manual for the Lancer Evolution VIII (No.1036K07)
OK
Repair
MPI – TROUBLESHOOTING
13A-16
4. Checklist of faults
Inspection procedure Fault to be checked
Engine seems hesitant
Acceleration malfunction
11
Engine seems to stumble
Engine has a power surge
15
Mis-timed ignition
35
Inter-cooler water spray circuit system
37
No.2 waste gate solenoid valve system
38
Air temperature sensor system
Reference page
13A-16
13A-18
13A-19
13A-21
13A-22
5. Inspection procedure for each type of fault
Inspection procedure 11
Engine seems hesitant, acceleration malfunction, engine
seems to stumble, engine has a power surge
Probable causes of the malfunction
Probable causes of the malfunction are noted in the right hand •
column.
•
•
•
•
•
•
Malfunction of the air/fuel mixing control system
Malfunction of the ignition system
Malfunction of the fuel system
Malfunction of the intake system
Malfunction of the exhaust gas purification system
Failure of compression pressure
Malfunction of the turbocharger system
YES
Refer to the diagnosis code classification table (P13A-6)
MUT-II/III diagnosis code
• Is the diagnosis code displayed?
NO
NG
Check the crank angle sensor and the fitting of the timing
belt cover
Check the timing of ignition (Ref Section 11, Engine
tuning)
OK
If there is abnormality in the exhaust gases and code
Nos. P0201~P0204 are recorded, check the injector
system
Check the sound made by the injector (using a
soundscope)
OK
MUT-II/III Service data
• No.13: Intake air temperature sensor
• No.14: TPS
• No.21: Water temperature sensor
• No.25: Atmospheric pressure sensor
• No.95: MAP sensor
(Ref: P13A-24)
<Reference>
Proceed to OK if all service data levels are normal.
Proceed via NG even if only one of the service data
levels is abnormal.
NG
If abnormal sensor data is recorded, carry out inspections
for each diagnosis code in order (Ref: P13A-6)
OK
NG
Check the purge control solenoid valve (Refer to Section
17: Checking the exhaust gas purification system)
Replace the purge control solenoid valve
OK
MUT-II/III Service data
•
No.11 O2 sensor (Ref: P13A-83)*
NG
Code No.P0130: O2 sensor system inspection (Ref:
P13A-16)*
OK
Go on to next page.
*: Refer to the 03-1 Service Manual for the Lancer Evolution VIII (No.1036K07)
MPI – TROUBLESHOOTING
13A-17
Continued from previous page
OK
Check the spark plug wire (Ref: Section 16: Ignition
apparatus)
Replace the spark plug wire
OK
Check the spark plug (Ref: Section 16: Ignition
apparatus)
NG
Replace the spark plug
OK
NG
Check connectors B-123 & B-119
Repair
OK
NG
Check the ignition coil (Ref: Section 16: Ignition
Apparatus)
Replace the ignition coil
OK
NG
Inspect the harness and the connectors between each
cylinder’s ignition coil and the body earth, and between
the engine ECU and the ignition coil. Check for cut or
short circuited wires, or other damage.
Repair
OK
NG
MUT-II/III Actuator test
• No.12: Waste gate solenoid valve (Ref: P13A-87)*2
Inspection procedure 33: Inspection of the No.1 waste
gate solenoid valve (Ref: P13A-78) *2
Inspection procedure 37: Inspection of the No.2 waste
gate solenoid valve (Ref: P13A-21)
OK
Check the supercharge pressure of the turbo charger
(Ref: Section 15: Intake/Exhaust car servicing)
NG
Repair
OK
NG
Check the supercharge pressure control system (Ref:
Section 15: Intake/Exhaust car servicing)
Repair
OK
NG
MUT-II/III Actuator test
• No.09: Fuel pressure control solenoid valve (Ref:
P13A-87)
Inspection procedure 31: Inspection of the fuel control
solenoid valve (Ref: P13A-76) *2
OK
NG
Repair
Check the fuel pressure (Ref: P13D-109)
OK
NG
Check the compression pressure (Ref: Section 11:
Engine tuning)
Repair
OK
NG
Measurements taken at B-108 air temperature sensor
connector
• Using the test harness (MB991658), connect it to only
connectors No.1 and No.2 and measure at the pickup harness component.
• Ignition switch: ON
• Voltage across earth at 1
OK: surrounding temperature -20ºC 3.8~4.4V
surrounding temperature 0ºC 3.2~3.8V
surrounding temperature 20ºC 2.3~2.9V
surrounding temperature 40ºC 1.5~2.1V
surrounding temperature 60ºC 0.8~1.4V
surrounding temperature 80ºC 0.4~1.0V
Inspection procedure 38: Inspection of the air
temperature sensor (Ref: P13A-22)
OK
If the intake hose and the inlet manifold are damaged
check the air intake and repair as necessary.
*: Refer to the 01-1 Service Manual for the Lancer Evolution VIII (No.1036K02)
*: Refer to the 03-1 Service Manual for the Lancer Evolution VIII (No.1036K07)
MPI – TROUBLESHOOTING
13A-18
Inspection procedure 15
Miss-timed ignition
Probable causes of the malfunction
Probable causes of the malfunction are noted in the right
hand column.
•
•
•
•
Malfunction
Malfunction
Malfunction
Malfunction
of
of
of
of
the
the
the
the
crank angle sensor
exhaust cam position sensor
timing belt
engine ECU
YES
MUT-II/III Diagnosis code
• Is the diagnosis code displayed?
Refer to the diagnosis code classification table (P13A-6)
NO
OK
Measure the output wave from
the crank angle sensor and the
cam position sensor (using an
oscilloscope).
• Engine: idling
<Crank angle sensor>
• Measure the output wave at
the crank angle sensor
connector B-122
• Connect test harness
(MB998478), to the connector,
and take measurements at the
pick-up harness component
• Voltage across earth at 2
<Exhaust cam position sensor>
• Measure the output wave at
the exhaust cam position
sensor connector B-115
• Connect test harness
(MB991709), to the connector
and take measurements at the
pick-up harness component
• Voltage across earth at 2
OK: The output wave timing
from both sensors is as
shown on P13A-25
(Main points for
oscilloscope testing).
Check that the problem has been
solved
NG
OK
Temporary malfunction (Ref
Section 00: Dealing with
temporary malfunctions)
Replace the engine ECU
NG
NG
Check the fitting of the crank angle sensor and the
exhaust cam position sensor
OK
Check the timing marks on the timing belt
OK
Repair
NG
Match up the timing marks on the timing belt
NG
Replace the crank angle sensor pane
Check the crank angle sensor pane
OK
Check the exhaust cam position sensing cylinder
NG
Replace the exhaust cam position sensing cylinder
OK
Replace the crank angle sensor
Check that the problem has been solved
OK
Repair
NG
Replace the exhaust cam position sensor
Check that the problem has been solved
NG
Replace the engine ECU
OK
Temporary malfunction (Ref Section 00: Dealing with
temporary malfunctions)
13A-19
MPI – TROUBLESHOOTING
Inspection procedure 35
Inter-cooler water spray circuit system
Probable causes of the malfunction
•
•
•
If the inter-cooler water spray switch (manual) is turned ON, the inter-cooler
water spray manual ‘ON’ signal will be input in the engine ECU. When this
signal is received, the engine ECU will turn the inter-cooler water spray relay
ON, and will start the inter-cooler water spray motor. Water will be sprayed
into the inter-cooler to cool intake air, and filling efficiency will improve.
If the inter-cooler water spray switch (auto) is turned ON, the inter-cooler
water spray auto ‘ON’ signal will be input in the engine ECU. When this
signal is received the engine ECU will intermittently run at a high load, it will
turn the inter-cooler water spray relay ON, and it will start the inter-cooler
water spray motor. Water will be sprayed into the inter-cooler to cool intake
air, and filling efficiency will improve.
•
•
•
•
•
•
OK
Check the operation of the intercooler water spray
• Ignition switch: ON
• Inter-cooler water spray
switch (manual): ON
OK: Inter-cooler water spray
operates
OK
Measure at the inter-cooler water
spray switch connector D-32
• Undo the connector and
measure on the harness side
• Ignition switch: ON
• Voltage across earth at 5
OK: battery voltage
NG
Check connector: D-32
Check connectors: C-22 & C-50
NG
OK
Repair
Inspect the harness between the
inter-cooler water spray switch
and the engine ECU
• Check if the signal wire is
damaged
OK
OK
Check the operation of the intercooler water spray
• Undo the engine ECU
connector C-50, and earth
terminal 56.
• Ignition switch: ON
OK: Inter-cooler water spray
operates
Replace the engine ECU
OK
Measure at the inter-cooler water
spray switch connector D-32
• Undo the connector and
measure on the harness side
• Ignition switch: ON
• Voltage across earth at 3 & 5
OK: battery voltage
OK
Inspect the harness between the
engine ECU and the inter-cooler
water spray switch
• Check if the signal wire is cut
or has short circuited
NG
OK
Repair
NG
OK
Check the inter-cooler water
spray relay (Refer to Section 15:
Intake/Exhaust)
OK
Go on to the next page
OK
NG
NG
NG
Replace the engine ECU
Repair
NG
Replace the inter-cooler water
spray relayReplace engine ECU
Repair
Repair
Repair
Temporary malfunction (Ref
Section 00: Dealing with
temporary malfunctions)
OK
Check connector: D-32
NG
OK
Repair
Check the inter-cooler water
spray switch
(Ref Section 15: Intake/Exhaust)
OK
NG
NG
Check connectors: C-22 & C-50
NG
OK
Repair
Check connector: C-220
NG
Check the inter-cooler water
spray switch (Ref Section 15:
Intake/Exhaust)
Inspect the harness between the
engine ECU and the inter-cooler
water spray switch
• Check if the signal wire is cut
or has short circuited
NG
OK
Repair
NG
Malfunction of the inter-cooler water
spray switch.
Malfunction of the inter-cooler water
spray relay.
Malfunction of the inter-cooler water
spray motor.
Circuit break, short circuit or a faulty
connection in the inter-cooler water
spray relay circuit.
Circuit break, short circuit or a faulty
connection in the inter-cooler water
spray switch circuit.
Malfunction of the ignition switch.
Malfunction of the engine ECU.
Repair
Check connector: C-107
OK
NG
Repair
Replace the inter-cooler water
spray relayInspect the harness
between the inter-cooler water
spray switch and earth
• Check if the earth wire is cut
or damaged
OK
NG
Repair
Inspect the harness between the
inter-cooler water spray switch
and the engine ECU, repair if
necessary
• Check if the signal wire is
damaged
MPI – TROUBLESHOOTING
13A-20
Continued from the previous page
OK
NG
Measure at the inter-cooler water
spray relay connector C-220
• Undo the connector, and
measure on the harness side
• Voltage across earth 3 and 1
(ignition switch: ON)
OK: battery voltage
OK
OK
NG
NG
Check connectors C-22 and C-208
OK
Inspect the harness between the inter-cooler water spray
relay and the engine ECU
• Check if the signal wire is cut or has short circuited
NG
Repair
NG
Repair
NG
Repair
Inspect the harness between the
inter-cooler water spray motor
and earth
• Check if the earth wire is cut, or
damaged
OK
NG
Repair
Check connectors C-209,
C-210, C-201 and C-208
OK
NG
Repair
Inspect the harness between the
inter-cooler water spray relay and
the ignition switch
• Check if the power supply wire
is damaged
OK
NG
Check connectors C-22 & C-50
Repair
OK
NG
Inspect the harness between the
inter-cooler water spray relay and
the engine ECU
• Check if the signal wire is
damaged
OK
Repair
NG
Check connector: A-34
OK
Check the inter-cooler water
spray motor (Ref Section 15:
Intake/Exhaust)
OK
Replace the engine ECU
Repair
OK
OK
OK
NG
Check the ignition switch (Ref to Section 54)
Check connector: C-31
Inspect the harness between the
inter-cooler water spray relay and
the inter-cooler water spray motor
• Check if the power supply wire
is cut, has short circuited, or is
damaged
Repair
Inspect the harness between the inter-cooler water spray
relay and the ignition switch
• Check if the power supply wire is cut or has short circuited
OK
Measure at the engine ECU
connector C-50
• Undo the connector, and
measure on the harness side
• Voltage across earth 56
(ignition switch: ON)
OK: battery voltage
NG
Check connectors C-209, C-210, C-201 and C-208
Repair
NG
Repair
Repair
13A-21
MPI – TROUBLESHOOTING
Inspection procedure 37
No.2 waste gate solenoid valve system
Probable causes of the malfunction
The No.2 waste gate solenoid valve controls the supercharge pressure
introduced to the waste gate actuator in the turbocharger.
•
•
•
Malfunction of the No.2 waste gate
solenoid valve.
Circuit break, short circuit or a faulty
connection in the No.2 waste gate
solenoid valve circuit.
Malfunction of the engine ECU.
OK
Repair
Check connector: B-32
NG
NG
Replace the No 2. waste gate solenoid
valve
Measure at the waste gate
solenoid valve connector B-32
• Undo the connector and
measure on the solenoid
valve side
• Resistance between 1-2
OK: 29~35Ω(when at 20ºC)
OK
Measure at the waste gate
solenoid valve connector B-32
• Undo the connector and
measure on the harness side
• Ignition switch: ON
• Voltage across earth at 63
OK: battery voltage
NG
NG
Inspect the harness between the No.2
waste gate solenoid valve and the
engine control relay, and repair if
necessary
• Check if the power supply wire is cut
or has short circuited
OK
NG
Measure at the engine ECU
connector C-50
• Measure the voltage at the
engine ECU terminal
• Ignition switch: ON
• Voltage across earth at 63
OK: battery voltage
NG
NG
Inspect the harness between the No.2
waste gate solenoid valve and the
engine ECU
• Check if the output wire is cut or has
short circuited
OK
Check connector: C-50
NG
Replace the engine ECU
Repair
Inspect the harness between the
No.2 waste gate solenoid valve
and the engine ECU
• Check if the output wire is
damaged
OK
NG
Repair
Inspect the harness between the
No.2 waste gate solenoid valve
and the engine control relay
• Check if the power supply wire
is damaged
OK
Replace the engine ECU
Repair
Check connector: C-50
OK
OK
OK
Repair
Check connector: B-19X
OK
NG
Repair
Repair
MPI – TROUBLESHOOTING
13A-22
Inspection procedure 38
Air temperature sensor system
Probable causes of the malfunction
The air temperature sensor controls the temperature inside the inlet
manifold, and compensates for any burning of fuel.
•
•
•
Malfunction of the air temperature sensor.
Circuit break, short circuit or a faulty connection in
the air temperature sensor circuit.
Malfunction of the engine ECU.
NG
Replace the air temperature
sensor
Inspect the air temperature
sensor on its own (Ref: P13A-29)
OK
NG
Check connector B-34
Repair
OK
(1) NG
Measure at the air temperature
sensor connector B-34
• Undo the connector and
measure on the harness side
(1) Resistance across earth at 2
OK: Less than 2Ω
(2) Voltage across earth at 1
(Ignition switch: ON)
OK: 4.9~5.1V
NG
Check connector: C-50
Repair
OK
NG
Inspect the harness between the
air temperature sensor and the
engine ECU
• Check if the earth wire is cut
or damaged
Repair
OK
OK
Temporary malfunction (Ref
Section 00: Dealing with
temporary malfunctions)
Check that the problem has been
solved
NG
Replace the engine ECU
(2) NG
NG
Check connector: C-51
Measure at the engine ECU
connector C-51
• Measure the voltage at the
engine ECU terminal
• Ignition switch: ON
• Voltage across earth at 96
OK: 4.5~4.9V
OK
NG
NG
Check that the problem has been
solved
NG
Replace the engine ECU
OK
Go on to the next page
Inspect the harness between the
air temperature sensor and the
engine ECU and repair it if
necessary.
• Check if the output wire is cut
NG
Repair
Inspect the harness between the
air temperature sensor and the
engine ECU and repair it if
necessary.
• Check if the output wire is cut
OK
Repair
Repair
Check connector: C-51
NG
NG
OK
Temporary malfunction (Ref
Section 00: Dealing with
temporary malfunctions)
13A-23
MPI – TROUBLESHOOTING
Continued from the previous page
OK
NG
NG
Check connector: C-51
Measure at the air temperature
sensor connector B-34
• Connect the test harness
(MB991658), to the connector
and measure at the pick-up
harness component.
• Ignition switch: ON
• Voltage across earth at 1
OK:
surrounding temperature -20ºC
3.8~4.4V
surrounding temperature 0ºC
3.2~3.8V
surrounding temperature 20ºC
2.3~2.9V
surrounding temperature 40ºC
1.5~2.1V
surrounding temperature 60ºC
0.8~1.4V
surrounding temperature 80ºC
0.4~1.0V
OK
Inspect the harness between the
air temperature sensor and the
engine ECU and repair it if
necessary.
• Check if the earth wire is
damaged
OK
OK
Check that the problem has been
solved
NG
Replace the engine ECU
Temporary malfunction (Ref
Section 00: Dealing with
temporary malfunctions)
Repair
13A-24
6. Service data table
7. Engine ECU checks
7-1 Terminal voltage table
MPI – TROUBLESHOOTING
13A-23
13A-24
MPI – TROUBLESHOOTING
13A-25
7-2 Table showing resistance and continuity across the
terminals of harness side connectors
8. Checks using an oscilloscope
Sensor output signals and actuator drive signals can be
checked visually by taking waveform measurements using an
oscilloscope.
exhaust cam position
sensor connector
crank
angle
sensor
connector
oscilloscope
8.1 Exhaust cam position sensor and the crank angle
sensor
<Measurement method>
(1) Disconnect the exhaust cam position sensor connector, and
connect the special test harness (MB991709) in its place.
(2) Disconnect the crank angle sensor connector, and connect
the special test harness (MB998478) in its place.
(3) Connect the No.2 terminal of the exhaust cam position
sensor connector and the No.2 terminal (the black coloured
clip on the special tool) of the crank angle sensor
connector, to the probes for each channel on the
oscilloscope.
Note
When measuring at the engine ECU connector, connect the
probes for each channel on the oscilloscope to No.50
terminal (exhaust cam position sensor), and to No.43
terminal (crank angle sensor).
MPI – TROUBLESHOOTING
13A-26
<Standard waveforms>
Observation conditions
Exhaust cam position sensor
Crank angle sensor
Probe switch
X1
x1
AC-GND-DC
DC
DC
TIME/DIV.
10ms
10 ms
VOLTS/DIV.
2V
2V
Other
-
-
Engine
Idling
Standard waveform
2 engine revolutions (1 camshaft revolution)
crank angle
sensor
output
waveform
exhaust cam
position sensor
output
waveform
<Explanation of waveforms>
• The exhaust cam position sensor detects the compression top dead centre for each cylinder, and by simultaneous
observation of these and other controlling signals, it is possible to distinguish between the cylinders.
• The crank angle sensor detects the crank angle for each cylinder. There is an output of 4 evenly spaced crank angle sensor
HIGH signals for every 2 revolutions of the engine. Therefore, by measuring the cycle time (seconds), engine revolution
speed can calculated according to the following formula:
Engine revolution speed = 2/4T (seconds) x 60 = 30/T (seconds)
<Waveform observation points>
• Check that the cycle time gets shorter as the engine revolution speed increases.
MPI – TROUBLESHOOTING
13A-27
<Examples of abnormal waveforms>
• Example 1
Waveform characteristics
A rectangular waveform is produced even though the
engine has not been started.
Cause of the problem
Sensor interface fault
•
Example 2
Waveform characteristics
The waveform is displaced to the left or the right.
Cause of the problem
The timing belt is loose.
There is an abnormality in the sensor disc.
oscilloscope
intake cam position
sensor connector
crank
angle
sensor
connector
8-2 Intake cam position sensor
<Measurement method>
(1) Disconnect the intake cam position sensor connector and
connect the special test harness (MB991709) in its place.
(All terminals should be connected).
(2) Connect the oscilloscope probe to the No.2 terminal of the
intake cam position sensor connector.
Note
When measuring at the engine ECU connector, connect the
No.53 terminal (intake cam position sensor) to the
oscilloscope probe.
(3) When checking the output signal of the intake cam position
sensor, observe the output signal of the crank angle sensor
at the same time.
<Standard waveforms>
Observation conditions
Intake cam position sensor
Crank angle sensor
Probe switch
X1
x1
AC-GND-DC
DC
DC
TIME/DIV.
10ms
10 ms
VOLTS/DIV.
2V
2V
Other
-
-
Engine
Idling
13A-28
MPI – TROUBLESHOOTING
Standard waveform
2 engine revolutions (1 camshaft revolution)
(cam reset angle)
(cam most advanced angle)
crank angle
sensor output
waveform
(phaseangle)
exhaust cam
position sensor
output waveform
<Explanation of waveforms>
• The intake cam position sensor detects the position of the inlet camshaft. The notch located on the intake side of the
camshaft creates 4 output pulses for each revolution of the camshaft.
• When the time difference between the rise and fall of the output waveform from the crank angle sensor and the rise and fall
of the output waveform from the intake cam position sensor is long the cam is at the reset angle, when the time difference is
short the cam is at the most advanced angle.
Note
When the cam is at the most advanced angle, the rise and fall of the output waveform from the intake cam position sensor
should be at an advancing angle of about 60°.
<Waveform observation points>
• As engine revolutions approach 2500r/min, check that the time difference (T) between the rise and fall of the output
waveform from the crank angle sensor, and the rise and fall of the output waveform from the intake cam position sensor, gets
shorter.
<Examples of abnormal waveforms>
• Example 1
Waveform characteristics
A rectangular waveform is produced even though the
engine has not been started.
Cause of the problem
Sensor interface fault
MPI – TROUBLESHOOTING, ON-VEHICLE SERVICING
•
13A-29
Example 2
Waveform characteristics
The waveform is displaced to the left or the right.
Cause of the problem
The timing belt is loose
There is an abnormality in the fuel pump camshaft
On-vehicle servicing
1. Adjusting standard engine revolutions
when idling
The standard engine revolutions when idling have been
changed. All other servicing requirements are the same as
before.
Standard engine revolutions when idling: 800 ± 50 r/min
2. Layout diagram for MPI system components
Name
Intake cam position sensor
Air temperature sensor
Exhaust cam position sensor
Code
C
B
C
Name
Oil feeder control valve
Manifold absolute pressure sensor
Code
A
B
3. Inspection of the air temperature sensor
air temp. sensor side
connector
air temp.
sensor
(1) Disconnect the air temperature sensor connector.
(2) Measure the resistance across the terminals of the air
temperature sensor connector.
Standard values:
13~18 kΩ (when at -20 ºC)
5.1~6.9 kΩ (when at 0 ºC)
2.0~3.0 kΩ (when at 20 ºC)
0.9~1.5 kΩ (when at 40 ºC)
0.40~0.78 kΩ (when at 60 ºC)
0.23~0.42 kΩ (when at 80 ºC)
13A-30
MPI – ON-VEHICLE SERVICING
(3) Remove the air temperature sensor
(4) Use a hair dryer to increase the temperature and measure the
resistance.
Normal conditions:
Temperature (ºC)
Resistance (kΩ)
Temperature increases
Resistance decreases
(5) If the resistance deviates from the standard values, or if it does
not change, replace the air temperature sensor.
(6) Tighten the air temperature sensor to the specified torque.
Tightening torque: 14 ± N·m
air temp. sensor
4. Inspection of the oil feeder control valve
oil feeder control
valve connector
Checking the operation of the valve
(1) Disconnect the oil feeder control valve connector.
(2) Apply battery voltage across the terminals of the connector on
the oil feeder control valve side, and check that the sound of the
oil feeder control valve operating can be heard.
oil feeder control valve
Caution
There is a chance that the coil may be damaged, so apply
the voltage in as short a time as possible.
Resistance across the terminals
(1) Remove the oil feeder control valve connector.
(2) Measure the resistance across the terminals of the connector on
the oil feeder control valve side.
Standard value: 6.9~7.9 kΩ (when at 20 ºC)
(3) If the resistance deviates from the standard value, replace the oil
feeder control valve.
ENGINE COOLING – GENERAL
14-1
SECTION 14
ENGINE COOLING
CONTENTS
General........................................................1
Water hose and pipe..................................3
Water pump ................................................2
General
The following servicing guidelines for the water pump and the water hose and pipe have been prepared for vehicles which use
the 4G63-MIVEC-T/C engine. Other servicing guidelines remain unchanged.
14-2
ENGINE COOLING – WATER PUMP
Water pump
Removal and fitting
Jobs to be completed before removal and after fitting
• Draining and refilling of the coolant
• Removal and refitting of the timing belt (Ref Section 11)
Positions for fitting different sized bolts
Nominal diameter and nominal length (mm)
Removal procedure
1. Alternator bracket
2. Water pump
3. Water pump gasket
A
4. O-ring
Fitting guidelines
water pump
O-ring
A
Fitting the O-ring
Fit the O-ring into the O-ring groove at the end of the water inlet
pipe, and insert it into the water pump after moistening with water
the places where the O-ring will make contact with the water pump.
Caution
Ensure that absolutely no engine oil, or other type of grease,
gets onto the O-ring.
water inlet pipe
ENGINE COOLING – WATER HOSE AND PIPE
Water hose and pipe
Removal and fitting
Jobs to be completed before removal and after fitting
• Removal and refitting of the valence
• Draining and refilling of the water coolant
• Removal and refitting of the air cleaner ASSY
• Removal and refitting of the air by-pass valve ASSY, the air by-pass hose, air hoses D and E, and air pipe C
• Removal and refitting of the secondary air control valve (Ref Section 15: Secondary air control system)
Removal procedure
A
B
1. Connection to the radiator upper hose
A
B
2. Connection to the radiator lower hose
3. Water temperature gauge unit connector
4. Water temperature sensor connector
5. Water hose
6. Bracket
7. Water outlet fitting and thermostat case
ASSY
8. Thermostat case gasket
9. Connection to the knock sensor harness
clamp
A
10. O-ring
11. Water hose
12. Water hose
13. Connection to the heater hose
14. Water hose
A
15. Water inlet pipe
A
16. O-ring
17. Turbocharger water feed pipe
18. Gasket
• Turbocharger ASSY
19. Turbocharger water return pipe
20. Gasket
14-3
14-4
ENGINE COOLING – WATER HOSE AND PIPE
Removal guidelines
A
Removing the radiator upper hose and the radiator
lower hose
Mark the radiator hose and the hose clamp with indicator marks
and then remove the radiator hose.
indicator marks
water pump and
thermostat case
Fitting guidelines
A
Fitting the O-ring and the water inlet pipe
Fit the O-ring into the groove at the end of the water inlet pipe, and
insert it after moistening with water the places where the O-ring and
the water inlet pipe will be in contact.
O-ring
Caution
Ensure that absolutely no engine oil, or other type of grease,
gets onto the O-ring.
water inlet pipe
B
Connecting the radiator lower hose and the radiator
upper hose
1. Insert the hose as far as the protrusion on the water inlet pipe
and the water outlet fitting.
2. Match up the indicator marks on the radiator hose and the hose
clamp, and fit the radiator hose.
protrusion
water inlet pipe and
water outlet pipe fitting
indicator marks
INTAKE & EXHAUST – GENERAL, SERVICING STANDARDS, SPECIAL TOOLS,
ON-VEHICLE SERVICING
15-1
SECTION 15
INTAKE & EXHAUST
CONTENTS
General................................................................................1
Servicing standards ..........................................................1
Special tools.......................................................................1
On-vehicle servicing..........................................................1
Turbocharger super charging pressure check ...............1
Inter-cooler water spray ....................................................2
Secondary air control system ..........................................4
Inlet manifold .....................................................................5
Exhaust manifold and turbocharger................................8
General
The following servicing guidelines have been prepared for vehicles which use the 4G63-MIVEC-T/C engine. Other servicing
guidelines remain unchanged.
• Changes to the turbocharger supercharging pressure
• Changes to the inter-cooler water spray hose
• Changes to the secondary air control valve
• Changes to the inlet manifold
• Changes to the exhaust manifold and the turbocharger
Servicing standards
Item
Standard value
Turbocharger charging pressure kPa
97~157
Special tools
Tool
Number
Name
Function
MD998770
O2 sensor wrench
Removal and fitting of the O2
sensor
On-vehicle servicing
Turbocharger supercharging pressure check
The standard value for the turbocharger charging pressure has
been changed. Other servicing guidelines remain unchanged.
Standard value: 97 ~ 157 kPa
15-2
INTAKE & EXHAUST INTER-COOLER WATER SPRAY
Inter-cooler water spray
Removal and fitting
<Water spray nozzle, hose and washer tank>
Procedure for removing the water spray nozzle
and the hose
1. Water spray hose connection
• Front bumper ASSY (Ref: Section 51)
A
• Tape (for fitting the water spray hose ASSY)
2. Water spray nozzle ASSY
A
3. Water spray hose ASSY
4. Clamp
5. Water spray nozzle (top)
6. Water spray nozzle bracket
7. Water spray nozzle (bottom)
8. Water spray hose
9. Three-way joint
10. Washer valve
• Tape (for attaching clip)
11. Clip
12. Pad
Procedure for removing the washer tank
1. Water spray hose connection
13. Water spray motor connector
14. Washer tank
15. Water spray hose
16. Washer valve
17. Water spray motor
18. Packing
19. Bracket
INTAKE & EXHAUST INTER-COOLER WATER SPRAY
15-3
Fitting guidelines
A
Fitting the water spray hose ASSY and fixing tape (for securing the water spray hose ASSY)
1. After fitting the water spray hose, the three-way joint and the washer valve, affix pads, clips and tape at the positions
shown in the water spray hose diagram.
tape
washer valve
clip
three-way joint
pads
three-way joint
washer
valve
tape
clip
clip
tape
2. Fit the water spray hose ASSY to the front bumper using the water spray hose ASSY clip.
3. Affix tape as shown in the diagram, so that the water spray hose ASSY does not slip.
View of the inside of the front bumper
tape
tape
clip
water spray
nozzle brackets
tape
water spray hose ASSY
clip
clip
pad
15-4
INTAKE & EXHAUST – SECONDARY AIR CONTROL SYSTEM
Secondary air control system
Removal and fitting
Jobs to be completed before removal and after fitting
• Removal and refitting of the air duct
• Removal and refitting of the strut tower bar
air pipe C
Removal procedure
1. Control harness connection
2. Heat protector
3. Vacuum hose connection
• Air pipe C
4. Vacuum pipe
5. Harness bracket
6. Air hose
7. Air pipe ASSY
8. Gasket
A
9. Gasket
10. Secondary air control valve
11. Harness bracket
INTAKE & EXHAUST – SECONDARY AIR CONTROL SYSTEM, INLET MANIFOLD
15-5
Fitting guidelines
A
Fitting the gasket
Fit the gasket so that the protruding part points in the direction
shown in the diagram.
protruding
part
Inlet manifold
Removal and fitting
Jobs to be completed before removal and
after fitting
• Take measures to prevent fuel leaking (only
before removal)
• Removal and refitting of the valence (Ref
Section 15: Front bumper)
• Draining and refilling the coolant
• Removal and refitting of the air duct
• Removal and refitting of the
• Removal and refitting of the
• Removal and refitting of the
control valve (Ref P15-4)
• Removal and refitting of the
• Removal and refitting of the
(engine oil)
(engine oil)
strut tower bar
throttle body
secondary air
cross member bar
front exhaust pipe
15-6
INTAKE & EXHAUST – INLET MANIFOLD
Removal procedure
1. Centre cover
2. Ignition coil connector
3. O2 sensor connector
4.
5.
6.
7.
8.
Oil feeder control valve connector
Crank angle sensor connector
Injector connector
Air temperature sensor connector
Manifold absolute pressure sensor
connector
9. Purge control solenoid valve connector
10. Knock sensor connector
11. Fuel pressure solenoid valve connector
A
12. Vacuum hose connection
13. Vacuum hose connection
14. Fuel return hose connection
A
15. Fuel high pressure hose connection
A
16. O-ring
17. Delivery pipe, injector and fuel pressure
regulator ASSY
18. Insulator
19. Insulator
20. Oil level gauge & guide ASSY
21. O-ring
22. Brake booster vacuum hose connection
23. Purge hose connection
INTAKE & EXHAUST – INLET MANIFOLD
Removal procedure
24. Knock sensor connector
25. Purge control solenoid valve ASSY
26. Vacuum hose
27. Fuel pressure solenoid valve ASSY
28. PCV hose
• Alternator (Ref Section 16: Alternator)
29. Secondary air control solenoid valve
connector
30. Vacuum tank, ACV solenoid valve,
vacuum hose & pipe ASSY
15-7
31. Inlet manifold stay
32. Cover
33. Gasket
34. Harness connection
35. Crank angle sensor connector
36. Alternator bracket
37. Inlet manifold
38. Inlet manifold gasket
Removal guidelines
A
Removal of the delivery pipe, the injector and the fuel
pressure regulator ASSY
Remove the deliver pipe, with the injector and the fuel pressure
regulator intact.
Caution
When removing the delivery pipe, be careful not to drop the
injector.
Fitting guidelines
A
Connecting the O-ring and the fuel high pressure hose
1. Apply a small quantity of fresh engine oil to the O-ring, and
insert it into the delivery pipe without damaging the O-ring.
2. Check that the high pressure hose can be turned smoothly. If it
cannot be turned smoothly there is a possibility that it is biting
into the O-ring, so remove the high pressure hose and check for
any damage to the O-ring. If the O-ring is undamaged, reinsert it
into the delivery pipe and check once more whether the hose
can be turned smoothly.
3. Tighten the mounting bolt to the specified torque.
Tightening torque: 5.0 ± 1.0 N·m
15-8
INTAKE & EXHAUST – EXHAUST MANIFOLD & TURBOCHARGER
Exhaust manifold and turbocharger
Removal and fitting
Jobs to be completed before removal and after
fitting
• Removal and refitting of the valence
• Removal and refitting of the radiator
• Removal and refitting of the air intake hose and
air hose A
• Removal and refitting of the cross member bar
• Removal and refitting of the front exhaust pipe
• Draining and refilling of the engine oil
INTAKE & EXHAUST – EXHAUST MANIFOLD
A
Removal procedure
1. Exhaust manifold heat protector
2. Air pipe ASSY connection
3. O2 sensor
4. Turbocharger heat protector
5. Turbocharger water feed pipe connection
6. Gasket
7. Water hose connection
B
8. Oil feed pipe
9. Gasket
10. Starter
11. Oil return pipe
D
12. Oil return pipe gasket (turbocharger side)
C
13. Oil return pipe gasket (oil pan side)
15-9
14. Vacuum hose connection
15. Air outlet fitting
B
16. Air outlet fitting gasket
17. Exhaust fitting bracket
18. Turbocharger and exhaust fitting ASSY
A
19. Turbocharger ASSY
20. Exhaust fitting gasket
21. Exhaust fitting
22. Turbocharger gasket
23. Turbocharger water return pipe
24. Gasket
25. Exhaust manifold
26. Exhaust manifold gasket
Removal guidelines
A
Removing the O2 sensor
After removing the O2 sensor connector and the clamp, use the
special O2 sensor wrench (MD998770) to remove the O2 sensor.
O2 sensor
B
Removing the oil feed pipe
Caution
After removing the oil feed pipe, ensure that there is no foreign
matter in the oil access hole on the turbocharger.
Fitting guidelines
A
Fitting the turbocharger ASSY
1. Clean away any grease clogging the connection between the oil
pipe and the water pipe, and any grease clogging the eyebolts
and the inside of the pipes.
2. If there is any carbon in the oil access on the turbocharger
ASSY, clean it or blow it away.
Caution
Ensure that no foreign matter gets inside the turbocharger
ASSY.
15-10
INTAKE & EXHAUST – EXHAUST MANIFOLD
3. Apply some fresh engine oil via the fitting hole for the oil feed
pipe in the turbocharger ASSY.
turbocharger
protruding part
B
Fitting the air outlet fitting gasket
Fit the gasket so that the protruding part is in the position located in
the diagram.
view “A”
view “A”
print
C
Fitting the oil return pipe gasket (oil pan side)
Fit so that the printed side of the gasket is on the oil pan side.
gasket
print
gasket
D
Fitting the oil return pipe gasket (turbocharger side)
Fit so that the printed side of the gasket is on the turbocharger side.
ENGINE ELECTRICAL – CHARGING SYSTEM
16-1
SECTION 16
ENGINE ELECTRICAL
CONTENTS
Charging system........................................1
General .................................................................1
Alternator...............................................................1
Ignition system...........................................4
Servicing standards...................................4
On-vehicle servicing..................................4
Checking, cleaning and replacing spark plugs .....4
Cam position sensor .................................4
General .................................................................4
Charging system
General
The following alternator servicing guidelines have been prepared for vehicles which use the 4G63-MIVEC-T/C engine. Other
servicing guidelines remain unchanged.
Alternator
Removal and fitting
Jobs to be done before removal and after fitting
• Removal and refitting of the valence
• Checking the tension of the drive belt <only after fitting>
• Removal and refitting of the strut tower bar
• Removal and refitting of the front exhaust pipe ASSY
• Adjustment of the accelerator cable <only after fitting>
16-2
ENGINE ELECTRICAL – CHARGING SYSTEM
(engine oil)
A
Removal procedure
1. Injector connector
2. Accelerator cable connection
3. Delivery pipe, injector, and fuel pressure
regulator ASSY
4. Insulator
5. Insulator
6. Fuel pressure solenoid valve connector
7. Fuel pressure solenoid valve ASSY
8. Knock sensor connector
9. Purge control solenoid valve connector
B
C
10. Purge control solenoid valve ASSY
11. Oil level gauge and guide ASSY
12. O-ring
13. Drive belt
14. Alternator connector and terminal
• Engine mount
15. Alternator
16. Water pump pulley
17. O2 sensor connector
18. Alternator bracket
ENGINE ELECTRICAL – CHARGING SYSTEM
16-3
Removal guidelines
A
Removing the delivery pipe, the injector, and the fuel
pressure regulator ASSY
Loosen the bolts holding it in place, slightly dislodge all of the
components and make space for the alternator to be removed.
B
Removing the drive belt
The following procedures are necessary because a serpentine drive
system with auto-tensioner has been installed.
1. Insert a 12.7sq spinner handle into the auto-tensioner hole, and
turn the auto-tensioner in an anti-clockwise direction until it
reaches the stopper.
2. Align the A hole and the B hole, hold them in place by inserting
an L-shaped hexagonal Allen Key, and remove the drive belt.
B hole
A hole
Caution
If planning to re-use the drive belt, ensure that it will be
refitted the same way round, by marking the back of the belt
with chalk arrows indicating the direction of movement.
L-shaped
hexagonal
Allen
wrench
C
Removing the alternator
Push the whole engine up using a garage jack, and remove the
alternator from above.
16-4
ENGINE ELECTRICAL – IGNITION SYSTEM
Ignition system
General
The following servicing guidelines for spark plugs and the cam position sensor have been prepared for vehicles which use the
4G63-MIVEC-T/C engine. Other servicing guidelines remain unchanged.
Servicing standards
Item
Spark plug cap mm
Standard Value
0.5~0.6
Upper Limit
0.75
On-vehicle servicing
Checking cleaning and replacing spark plugs
The standard value and the upper limit for plug caps, has been changed in conjunction with the changes made to the spark
plugs. Other servicing guidelines remain unchanged.
Standard values and upper limits
Manufacturer
Model
Standard Value mm
Upper Limit mm
NGK
ILFR7H
0.5~0.6
0.75
Cam position sensor
Removal and fitting
Removal procedure <Exhaust side>
1. Cam position sensor connector
2. Cam position sensor
3. O-ring
Removal procedure <Inlet side>
4. Cam position sensor connector
5. Cam position sensor
6. O-ring
REAR AXLE – GENERAL, DIFFERENTIAL CARRIER <VEHICLES WITH AN AYC SYSTEM>
27B-1
SECTION 27B
REAR AXLE
CONTENTS
General........................................................1
Differential carrier <vehicles with an
AYC system> ..............................................1
General
The tightening torque for the flare nut which joins the fuel pressure unit hose ASSY and the differential carrier ASSY, has been
changed. Other servicing guidelines remain unchanged.
Differential carrier <vehicles with an AYC system>
Removal and fitting
NEW
OLD
fuel pressure unit hose ASSY
differential carrier ASSY
Note
*1: When the screw is dry.
*2: When the screw is lubricated.
TYRES AND WHEELS – GENERAL, ON-VEHICLE SERVICING
31-1
SECTION 31
WHEELS AND TYRES
CONTENTS
General........................................................1
Removal of emergency puncture repairing agent....1
On-vehicle servicing..................................1
Disposal of emergency puncture repairing agent ....2
General
The following servicing guidelines have been prepared now that vehicles are supplied with an emergency puncture repair kit.
On-vehicle servicing
Removal of emergency puncture repairing
agent
When repairing or replacing a tyre which has been treated using the
puncture repair kit, remove the emergency puncture repairing agent
(henceforth, repairing agent) from the tyre, in accordance with the
guidelines below.
Note
When removing the repairing agent, a container (the empty bottle
which contained the repairing agent), and the insertion hose and the
extraction hose from the emergency puncture repair kit, are needed.
empty bottle of
repairing agent
extraction
hose
injection
hose
valve
Caution
1. Carry out the operation in a well-ventilated, airy place.
2. Take appropriate measures in order to prevent repairing
agent; getting onto the skin, being inhaled, coming into
contact with clothing, or getting into the eyes.
3. After the job has been completed, wash hands and face
thoroughly.
1. Remove the wheel from the vehicle, and remove the air from the
tyre.
2. Cut away the rubber part of the valve using a cutter-knife.
3. Attach the injection hose to the empty repairing agent bottle, and
then attach the extraction hose onto the injection hose.
31-2
TYRES AND WHEELS – ON-VEHICLE SERVICING
4. Put the tyre on a raised surface and tilt it to an angle. Insert the
extraction hose through the hole made by removing the valve,
so that the tip of the hose is submerged in the repairing agent.
extraction hose
repairing
agent
raised surface
extraction hose
injection hose
bottle
5. Hold the bottle so that it is, as far as possible, below the tyre,
and suck the repairing agent out of the tyre by squeezing the
bottle by hand. Repeat this operation 2 or 3 times, so that as
much of the repairing agent as possible is removed.
6. After the repairing agent has been extracted, remove the tyre
from the wheel. Remove any repairing agent stuck onto the
tyre, and if the place from which air is escaping can be
identified, carry out a normal repair procedure. If the place from
which air is escaping cannot be identified, replace the tyre.
Disposal of emergency puncture repairing
agent
Dispose of the repairing agent extracted from the tyre, and any
unused agent which has exceeded its use-by date, in the same way
that used oil is discarded.
Note
The use-by date is printed on the bottle of repairing agent (about 3
years from the date of purchase)
Caution
The repairing agent includes propylene glycol which must be
handled as industrial waste.
FRONT SUSPENSION – GENERAL, SPECIAL TOOLS, STRUT ASSY 33-1
SECTION 33
FRONT SUSPENSION
CONTENTS
General........................................................1
Strut ASSY ..................................................1
Special tools...............................................1
General
The guidelines for the dismantling and assembly of the front suspension have been changed due to changes made to the
shape of the Bilstein shock absorbers.
Special tools
Tool
Number
A: MB991237
B: MB991238
MB991680
A: MB991681
B: MB991682
Name
Function
A. Spring compressor body
B. Arm set
Dismantling and assembling
the strut ASSY
Wrench set
A. Wrench
B. Socket
Strut ASSY
Dismantling guidelines
A
Removal of the self-locking nut
1. Use the following special tools to compress the coil spring.
• Spring compressor body (MB991237)
• Arm set (MB991238)
Caution
(1) In order to completely compress the coil spring, ensure that
the special tool is fixed when at its greatest possible
extension and that it is fixed evenly to the coil spring.
(2) Do not use an impact wrench, because there is a danger
that the special tool may be damaged.
33-2
FRONT SUSPENSION – STRUT ASSY
2. Use the following tools to loosen the self-locking nut.
• Wrench (MB991681)
• Socket (MB991682)
Caution
Do not use an impact wrench when loosening the selflocking nut, because there is a danger that the lock nut on
the piston rod inside the strut, may work loose.
Assembly guidelines
A
Fitting the self-locking nut
1. Check that the bearing has completely slotted in.
2. When the coil spring has been compressed using the special
tool, provisionally tighten the self-locking nut.
Caution
Do not use an impact wrench because there is a danger that
the special tool may be damaged.
pipe
3. Align the holes in the lower spring plate and the upper spring
plate of the strut ASSY.
Note
This operation can be easily performed by using a pipe to align
the holes.
4. Line up the two ends of the coil spring with the slots in the
spring plate, and loosen the special tool.
5. Use the following special tools to tighten the self-locking nut to
the specified tightening torque.
• Wrench (MB991681)
• Socket (MB991682)
Tightening torque: 60 ± 10 N·m
Caution
Do not use an impact wrench when loosening the selflocking nut, because there is a danger that the lock nut on
the piston rod inside the strut, may work loose.
BODY – GENERAL, WINDOW GLASS CHANNEL, DOOR-OPENING WEATHER STRIP
42-1
SECTION 42
BODY
CONTENTS
General........................................................1
Window glass channel, door-opening
weather strip <GT, GSR>...........................1
General
Servicing guidelines have been amended in conjunction with the changes listed below. Other servicing guidelines remain
unchanged. <GT, GSR>
• Addition of front door opening inner lower weather strip
• Addition of front and rear door opening inner weather strip
Window glass channel, door-opening weather strip
<GT, GSR>
Removal and fitting
<front door>
<rear door>
Cross section A – A
front door trim
clip
Note
: position of clips
Removal of the front door opening inner
lower weather strip
1. Front door opening inner lower weather
strip
Procedure for removing the front door
opening inner weather strip
• Front scuff plate
• Cowl side trim
• Lower centre pillar trim
2. Front door opening inner weather strip
Procedure for removing the rear door
opening inner weather strip
• Rear scuff plate
• Lower centre pillar trim
3. Rear door opening inner weather strip
EXTERIOR – GENERAL
51-1
SECTION 51
EXTERIOR
CONTENTS
General........................................................1
Front bumper..............................................2
Rear bumper...............................................4
Front bumper.......................................................2
Markings .....................................................6
Rear bumper ........................................................4
General
Servicing guidelines have been changed in conjunction with the changes or additions listed below.
Other servicing guidelines remain unchanged.
• Changes made to the shape and component of the front bumper.
• Changes made to the shape and component of the rear bumper.
• Changes made to the method for affixing the front 3-diamonds badge.
• Changes made to the position for affixing the LANCER badge and the EVOLUTION badge.
51-2
EXTERIOR – FRONT BUMPER
Front bumper
Front bumper
Removal and fitting
Cross section through A-A
clip
Cross section through B-B
clip
Cross section through C-C
bumper
cap
Removal procedure
1. Side valence
2. Centre valence
3. valence centre bracket
4. Front valence
5. Clip for attaching the splash shield
•
Inter-cooler water spray hose connection
(Ref Section 15)
6. Front bumper ASSY
7. Front bumper stay
EXTERIOR – FRONT BUMPER
51-3
Dismantling and assembly
Cross section through A-A
hook
Cross section through B-B
clip
Dismantling procedure
1. Front 3-diamonds badge
2. Front bumper nut
3. Front number plate garnish
4. Front bumper cover A
5. Front bumper cover B
6. Air dam skirt panel
7. Front bumper centre net
8. Front bumper lower plate
9. Front bumper upper plate
10. Front bumper upper support
11. Air intake cover
12. Front bumper net
13. Bumper side net (LH)
14. Oil cooler duct
15. Bumper side net (RH)
• Inter-cooler water spray hose and nozzle
(Ref Section 15)
A
A
16. Front bumper side plate
17. Front bumper upper reinforcement
18. Front bumper facing
Note:
The main points for dismantling and assembly remain unchanged.
51-4
EXTERIOR – FRONT BUMPER, REAR BUMPER
Rear bumper
Jobs to be completed before removal and after fitting
• Removal and refitting of the rear combination lamp
• Removal and refitting of the rear end trim
• Removal and refitting of the boot area side trim lid
Rear bumper
Removal and fitting
Cross section
through A-A
clip
splash
shield
Removal procedure
1. Screw for attaching the splash shield
2. Rear bumper bracket
3. Rear bumper ASSY
4. Rear number plate bracket
EXTERIOR – REAR BUMPER
Dismantling and assembly
Dismantling procedure
1. Number plate lamp bracket
• Number plate lamp ASSY
2. Rear bumper reinforcement
A
A
3. Rear bumper side plate
A
A
4. Rear bumper facing support, side
reinforcement
5. Rear bumper valence
6. Rear bumper facing
Note:
The main points for dismantling and assembly remain unchanged.
51-5
51-6
EXTERIOR – MARKINGS
Markings
Removal and affixing
A
2. LANCER badge
A
3. EVOLUTION badge
1. Front 3-diamonds badge (Ref P.51- 3)
Guidelines for affixing markings
A
Affixing markings
1. Positioning
2. LANCER badge
3. EVOLUTION badge
edge of boot lid
2. Guidelines for affixing
(1) Using white spirit, remove any grease from the place where the
badges will be affixed.
(2) Remove the protective paper from the back of the badges, and
affix them in the designated places.
Caution
1) Perform this job in an ambient temperature of 20~38ºC, and
in a dust free location.
2) If the job is being performed in an ambient temperature of
less than 20ºC, warm up the badges, and the area of the
body onto which they will be affixed, to a temperature of
20~38ºC.
3) Ensure that air bubbles are not trapped in the adhesive tape
when the badges are affixed.
CHASSIS ELECTRICAL – LICENCE PLATE LAMP
SRS AIRBAG – GENERAL
SECTION 52B
SRS AIRBAG
CONTENTS
General........................................................1
General
A caution label for the airbag has been added on the inside of the bonnet. Other servicing guidelines remain unchanged.
Warning/caution label
bonnet
SECTION 54A
CHASSIS ELECTRICAL
CONTENTS
Number plate lamp ....................................1
Number plate lamp
Due to changes made to the licence plate lamp, servicing guidelines have
been changed to be the same as for the ’03 model Lancer.
Other servicing guidelines remain unchanged.
54A-1
52B-1
CHASSIS ELECTRICAL – LICENCE PLATE LAMP
SRS AIRBAG – GENERAL
SECTION 52B
SRS AIRBAG
CONTENTS
General........................................................1
General
A caution label for the airbag has been added on the inside of the bonnet. Other servicing guidelines remain unchanged.
Warning/caution label
bonnet
SECTION 54A
CHASSIS ELECTRICAL
CONTENTS
Number plate lamp ....................................1
Number plate lamp
Due to changes made to the licence plate lamp, servicing guidelines have
been changed to be the same as for the ’03 model Lancer.
Other servicing guidelines remain unchanged.
54A-1
52B-1
Service Manual
Supplement
Lancer Evolution IX
Service Manual
CONTENTS
General Information . . . . . . . . . . . . . . . 4
Servicing Specification Values . . . . . . 4
4G6
DOHC
ENGINE
Tightening torques . . . . . . . . . . . . . . . . 5
Sealants . . . . . . . . . . . . . . . . . . . . . . . . . 7
Alternator / Ignition system. . . . . . . . . 8
FOREWORD
This manual contains information about the 4G6
DOHC engine. It only covers those points that are
different from the service manuals listed below.
Therefore, this manual should be used in conjunction
with the following manuals.
• 4G6 DOHC engine Service Manual (No. 1039G46)
• 4G6 DOHC engine Service Manual Supplement
(No.1039G63)
This manual is based on the engine specifications as of
March 2005. Please note that some engine details may
not match those given in this manual due to
subsequent changes in engine specifications. The units
shown in this manual are the standard international
SI units.
(However, conventional units are used for some figures
taken from existing documents)
If you have any opinions, requests or queries regarding
this manual, please write them down on the “Servicing
Comment Form” on the last page, and fax them to us.
March 2005
Mitsubishi Motor Corporation
This manual is printed on recycled paper.
Timing belt . . . . . . . . . . . . . . . . . . . . . 10
Fuel system. . . . . . . . . . . . . . . . . . . . . 13
Secondary air system /
inlet manifold . . . . . . . . . . . . . . . . . . . 15
Exhaust manifold . . . . . . . . . . . . . . . . 16
Water pump / Water hose . . . . . . . . . 17
Rocker arm / Cam shaft . . . . . . . . . . . 18
Oil pump / Sump. . . . . . . . . . . . . . . . . 21
Pistons / Connecting rods. . . . . . . . . 22
Crank shaft / Cylinder block . . . . . . . 25
Turbocharger. . . . . . . . . . . . . . . . . . . . 27
2
HOW TO USE THIS MANUAL
How to Use this Manual
Range of description
This manual explains the service procedure for the engine after it has been removed from the vehicle. For information on
removing the engine from the vehicle, or "on-vehicle" servicing of the engine, please refer to the separate service manual for
the relevant vehicle model.
Understanding the description
Service sequence
(1) A component diagram is provided at the beginning of each section in order to give the reader a clear
understanding of where the various parts are installed.
(2) The numbers in the component diagram indicate the sequence of the service procedure. Tightening torques
are shown and non-reusable parts are indicated where appropriate
Removal sequence: The part numbers correspond to the numbers in the component diagram and indicate
the removal sequence.
Installation sequence: This is only shown if the parts cannot be installed in the reverse order to the removal
sequence.
Disassembly sequence: The numbers of the part names correspond to the symbols in the component
diagram and indicate the disassembly sequence.
Assembly sequence: This is only shown if the parts cannot be re-assembled in the reverse order to the
disassembly sequence.
Types of service points
“Service point” notes are used to give a detailed
description of essential maintenance and service
points, standard values, procedures for using special
tools, and other important information at relevant
points in the service sequence. The different types
of “service point” are shown on the right-hand side.
* A : Indicates that there is a removal or
disassembly service point
A
* : Indicates that there is an installation or
assembly service point
* *1 : Indicates that the removal or disassembly
service point is described in the ’01-14G6
DOHC Engine Service Manual.
*1
* : Indicates that the installation or assembly
service point is described in the ’01-14G6
DOHC Engine Service Manual.
* * 2 : Indicates that the removal or disassembly
service point is described in the ’03-14G6
DOHC Engine Service Manual.
*2
* : Indicates that the installation or assembly
service point is described in the ’03-14G6
DOHC Engine Service Manual.
Symbols for lubricants and sealants
Application points for lubricants and sealants are
indicated by special symbols (shown right) on the
component parts diagram or on the following page.
.............. Grease
.............. Sealant or liquid gasket (FIPG)
.............. Brake fluid
.............. Engine oil
Inspection
The manual only indicates inspection points where special tools or measuring devices are required. It does not mention general
visual checks, part cleaning requirements, and so on, but these must also be carried out as part of the actual service work.
HOW TO USE THIS MANUAL
Page number
Engine type
Title
3
4
4G6 – GENERAL INFORMATION/ SERVICING SPECIFICATIONS
General Information
The 4G63 MIVEC T/C engine fitted in the Lancer Evolution IX incorporates the following changes with respect to the previous
4G63 T/C engine.
• Adoption of variable valve timing control system
• Modification to clearance gap in piston No.2 ring coupling
• Addition of air intake temperature sensor
• Addition of boost sensor
Vehicle Model List
Name
Lancer Evolution IX
Vehicle model
CT9A
Engine type
4G63-7
Exhaust capacity cc
1,997
Specifications
DOHC 16-valve
MIVEC – T/C
Specifications
Item
Bore x stroke
Total displacement cc
Combustion chamber shape
No. of cylinders
Valve mechanism
Type
Intake valves
Exhaust valves
Lash adjuster
Rocker arm
Compression ratio
Fuel injection device
Ignition device
Alternator
Starter motor
Specification
85 x 88
1,997
Pentroof type
4
DOHC
8
8
Hydraulic
Roller follower type
8.8
Electronically controlled MPI
Electronically controlled two-coil type
AC type (with IC regulator)
Deceleration drive
Servicing Specification Values
g
Item
Cylinder head, valves
Valve spring : free height mm
Valve spring : perpendicularity
Pistons, connecting rods
Piston rings : Clearance between ring and ring
groove mm
Piston rings : Closed gap mm
No.1
No.2
No.1
No.2
Oil ring
Standard value
Limit value
50.4
2º or less
49.4
4º
0.03~0.07
0.02~0.06
0.20~0.30
0.30~0.45
0.10~0.40
0.1
0.1
0.8
0.8
1.0
4G6 – TIGHTENING TORQUES
Tightening Torques
Part
Alternator, ignition system
Oil level gauge guide bolt
Water pump pulley bolt
Auto tension bolt (washer)
Auto tension bolt (flange)
Alternator bracket bolt (flange)
Alternator bracket bolt (washer M8 x 22)
Alternator bracket bolt (washer M8 x 32)
Alternator nut
Crankshaft pulley bolt
Centre cover holt
Ignition coil bolt
Spark plug
Timing belt
Timing belt cover bolt (flange)
Timing belt cover bolt (washer)
Power steering pump bracket bolt
Connector bracket bolt
Locker cover bolt
Plug cap
Tensioner pulley bolt
Tensioner arm bolt
Auto tensioner bolt
Idler pulley bolt
Crank angle sensor bolt
Oil pump sprocket nut
Crankshaft holt
Tensioner B bolt
Counterbalance shaft sprocket bolt
Engine support bracket bolt
V.V.T. sprocket bolt
Camshaft sprocket bolt
Fuel system
Throttle body bolt
Cover bolt
Fuel pressure regulator bolt
Delivery pipe and injector bolt
Vacuum hose and pipe bolt
Solenoid valve assembly bolt
Vacuum tank bracket bolt
Secondary air system / Intake manifold
Exhaust manifold heat protector bolt
Air pipe assembly
Tightening Torque Nm
13 ± 1
8.8 ± 1.0
44 ± 10
24 ± 4
24 ± 4
22 ± 4
20 ± 2
44 ± 10
25 ± 4
3.0 ± 0.5
10 ± 2
25 ± 5
11 ± 1
9.0 ± 1.0
49 ± 9
11 ± 1
3.5 ± 0.5
32 ± 2
48 ± 5
21 ± 4
23 ± 3
35 ± 6
8.8 ± 1.0
54 ± 5
167
19 ± 3
45 ± 3
49 ± 5
65 ± 5
88 ± 10
19 ± 3
12 ± 1
8.8 ± 2.0
11 ± 1
11 ± 1
9.0 ± 1.0
9.0 ± 1.0
20 ± 3
5
6
4G6 – TIGHTENING TORQUE
Part
Air pipe assembly bolt (eye bolt)
Air pipe assembly bolt (M6 flange)
Air pipe assembly bolt (M8 flange)
Air pipe assembly bolt (M8 washer)
Air control valve assembly bolt
Engine hanger bolt
Intake air temperature sensor
Boost sensor bolt
Intake manifold stay bolt
Intake manifold bolt (M8)
Intake manifold bolt nut (M10)
Exhaust manifold
Engine hanger bolt
Turbocharger heat protector bolt
Oxygen sensor
Exhaust fitting bracket bolt
Exhaust filling bolt nut
Air outlet fitting bolt
Oil return pipe bolt (flange)
Oil return pipe bolt (washer)
Turbocharger assembly and pipe assembly bolt, nut
Oil pipe bolt (M10 eye bolt)
Oil pipe bolt (M12 eye bolt)
Oil pipe bolt (M12 flange)
Water pipe bolt (flange)
Water pipe bolt (eye bolt)
Exhaust manifold nut (M8)
Exhaust manifold nut (M10)
Water pump / Water hose
Coolant temperature sensor
Coolant temperature gauge unit
Water outlet fitting bolt
Thermostat housing bolt
Water inlet pipe bolt (M6)
Water inlet pipe bolt (M8)
Water pump bolt
Knock sensor
Rocker arm / Camshaft
Cam position sensor bolt
Cover bolt
Cam position sensing cylinder bolt
Cam position sensor support bolt
Bearing cap bolt
Oil delivery body bolt
Tightening Torque
49 ± 5
11 ± 1
24 ± 3
14 ± 1
22 ± 4
19 ± 3
14 ± 1
5.0 ± 1.0
31 ± 3
20 ± 2
36 ± 6
22 ± 3
23 ± 3
44 ± 5
35 ± 6
59 ± 5
19 ± 1
14 ± 1
9.0 ± 1.0
64 ± 5
17 ± 2
31 ± 2
11 ± 1
10 ± 1
42 ± 7
33 ± 6
55 ± 10
29 ± 10
11 ± 1
10 ± 1
23 ± 4
10 ± 1
13 ± 2
14 ± 1
23 ± 2
11 ± 1
10 ± 2
22 ± 4
14 ± 1
20 ± 1
11 ± 1
7
4G6 - TIGHTENING TORQUES
Part
Oil control pump
Check valve
Eye bolt
Oil pipe
Oil pipe joint
Oil pump / Sump
Drain plug
Sump bolt
Oil screen bolt
Baffle plate bolt
Oil pressure switch
Oil cooler bypass valve
Relief plug
Oil filter bracket bolt
Plug cap
Flange bolt
Front case bolt
Oil pump cover bolt
Oil pump cover screw
Piston / Connecting rod
Connecting rod cap nut
Crankshaft / Cylinder block
Flywheel bolt
Rear plate bolt
Bell housing cover bolt (flange)
Bell housing cover bolt (washer)
Rear oil seal case bolt
Beam bearing cap bolt
Check valve
Turbocharger
Waste gate actuator bolt
Tightening Torque
11 ± 1
30 ± 3
42 ± 2
11 ± 1
30 ± 3
39 ± 5
9.0 ± 3.0
19 ± 3
22 ± 4
10 ± 2
54 ± 5
44 ± 5
19 ± 3
23 ± 3
36 ± 3
23 ± 3
17 ± 2
10 ± 2
20 ± 2 _ +90° ~94°
132 ± 5
11 ± 1
10 ± 2
9.0 ± 1.0
11 ± 1
25 ± 2 _ +90° ~ 100°
32 ± 2
12 ± 1
Sealants
Part
Cam position sensor support *
Note : * indicates point where liquid gasket (FIPG) used
Specified Sealant
MZ100191 or equivalent
8
4G6 – ALTERNATOR / IGNITION SYSTEM
Alternator / Ignition System
Removal and Installation
Note :
The ignition coil boot must only be removed from the ignition coil when it is to be replaced.
If removed, always replace with a new part.
Removal sequence
1.
2.
3.
4.
5.
6.
7.
Oil level gauge
O-ring
Oil level gauge guide
O-ring
Water pump pulley
Auto tensioner assembly
Alternator bracket
8. Alternator
9. Crankshaft pulley
10. Centre cover
11. Spark plug cable
12. Ignition coil
A
* 13. Ignition coil boot
14. Spark plug
4G6 – ALTERNATOR, IGNITION SYSTEM
9
Removal Service Point
Air blow hole
Removal of ignition coil boot
A
*
Coupling
section
Note :
Air blow hole
Upper face
White powder coating on
interior part. Do not touch
• If the ignition coil boot is not installed according to the
specifications, then this can lead to various problems, such
as malfunction of the ignition coil, damage to the ignition coil,
leaking of high voltage to external parts, infiltration of water
into the hole, etc.
• The spark plug coupling section of the ignition coil boot is
coated with a white powder. This coating helps to prevent the
boot from welding to the spark plug, and must not be touched
or wiped away.
1. Please check that a spring is fitted inside the new ignition coil
boot.
2. Press the new ignition coil boot firmly onto the ignition coil,
and turn the coupling section 2 or 3 times to seat it correctly
in position, ensuring that there are no gaps.
3. After installation, turn the boot until the air blow hole is
positioned as shown in the diagram.
10
4G6 – TIMING BELT
Timing Belt
Removal and Installation
Note :
NEVER disassemble the V.V.T. sprocket.
Removal Sequence
1. Timing belt front upper cover
2. Timing belt front lower cover
3. Power steering pump bracket
4.
5.
6.
7.
8.
Breather hose
PCV hose
PCV valve
PCV valve gasket
Oil filler cap
11
4G6 – TIMING BELT
9. Connector bracket
*
*1
10. Rocker cover
*1
* 11. Rocker cover gasket A
12. Rocker cover gasket B
*1
* 13. Semi-circular packing
B
* 14. Plug cap
* A
*1
* 15. Timing belt
* *1
*1
* 16. Tensioner pulley
17. Tensioner arm
*1
* 18. Auto tensioner
* *1
*1
* 26. Timing belt B
* *1
*1
* 27. Counterbalance shaft sprocket
*1
* 28. Spacer
* *1
*1
* 29. Crankshaft sprocket B
30. Crankshaft key
*1
* 31. Engine support bracket
A
* 32. V.V.T. sprocket bolt
* B
A
* 33. V.V.T. sprocket
* *1
*1
* 34. Camshaft sprocket bolt
35. Camshaft sprocket
19. Idler pulley
20. Crank angle sensor
* *1
*1
* 21. Oil pump sprocket
* *1
*1
* 22. Crankshaft bolt
* *1
*1
* 23. Crankshaft sprocket
*1
* 24. Crankshaft sensing blade
25. Tensioner B
36. Timing belt rear right cover
37. Timing belt rear left upper cover
38. Timing belt rear left lower cover
Removal Service Point
* A Removal of plug cap
Hold hexagonal section of camshaft with wrench, and loosen plug cap.
* B Removal of V.V.T. sprocket bolt
Hold hexagonal section of camshaft with wrench, and loosen V.V.T.
sprocket bolt.
Installation Service Point
V.V.T. sprocket
V.V.T.
sprocket
bolt
Camshaft
* A Installation of V.V.T. sprocket bolt / V.V.T.
sprocket
1. Apply the minimum suitable coating of engine oil to the following
points:
• Whole circumference of end of camshaft
• Inserted part of V.V.T. sprocket (full circumference; inner
& outer sides)
• Bolt seating of V.V.T. sprocket bolt
2. Install the V.V.T. sprocket.
12
4G6 – TIMING BELT
3. Push the V.V.T. sprocket firmly to the end and, holding the
hexagonal part of the camshaft with a wrench, check that the V.V.T.
sprocket does not rotate.
4. Hold the hexagonal section of the camshaft with a wrench and
tighten the V.V.T. sprocket bolt to the specified torque of 65 ±5 N-m.
5. Hold the hexagonal section of the camshaft with a wrench and
check that the V.V.T. sprocket does not rotate.
Note :
This check shows that the V.V.T. sprocket is locked at the maximum
delay angle by the interior pin.
Installation of plug cap
B
*
Note :
The washer must not be reused.
1. Install the washer on the plug cap.
2. Hold the hexagonal section of the camshaft with a wrench and
tighten the plug cap to the specified torque of 32±2 N-m.
4G6 – FUEL SYSTEM
Fuel System
Removal and Installation
Removal Sequence
1. Throttle body assembly
Throttle body gasket
Cover
4. Gasket
5. Fuel hose
*1
* 6. Fuel pressure regulator
7. O ring
8. Delivery pipe and injector
9. Insulator
10. Fuel return pipe
11. Insulator
*1
* 12. Injector
13. O ring
*1
* 2.
A
* 3.
14. Grommet
15. Delivery pipe
16. Vacuum hose
17. Vacuum hose
18. Vacuum hose
19. Solenoid valve assembly
20. Solenoid valve assembly
21. Vacuum hose and pipe
22. Solenoid valve assembly
23. Vacuum tank bracket
24. Vacuum tank
25. Vacuum hose assembly
26. Vacuum hose and pipe
13
14
4G6 – FUEL SYSTEM
Gasket
side
Installation Service Point
Cover
Gasket
Inlet manifold
A Installation of cover
The side of the cover marked “gasket side” should be assembled
facing the inlet manifold.
4G6 – SECONDARY AIR SYSTEM / INLET MANIFOLD
Secondary Air System / Inlet Manifold
Removal and Installation
Removal Sequence
1. Exhaust manifold heat protector
Air pipe assembly
3. Air control valve gasket
4. Air control valve assembly
5. Engine hanger
*1
* 2.
6. Intake air temperature sensor
Boost sensor
Inlet manifold stay
9. Inlet manifold
10. Inlet manifold gasket
*1
* 7.
*1
* 8.
15
16
4G6 – EXHAUST MANIFOLD
Exhaust Manifold
Removal and Installation
Removal Sequence
1.
2.
3.
4.
5.
6.
7.
*1
* 8.
9.
Engine hanger
Turbocharger heat protector
Oxygen sensor
Exhaust fitting bracket
Exhaust fitting
Exhaust fitting gasket
Air outlet fitting
Air outlet fitting gasket
Oil return pipe
10. Oil return pipe gasket
*1
* 11. Oil return pipe gasket
12. Turbocharger assembly & pipe assembly
*1
*
13. Turbocharger gasket
14. Oil pump
15. Water pipe B
16. Water pipe A
17. Turbocharger assembly
18. Exhaust manifold
19. Exhaust manifold gasket
4G6 – WATER PUMP / WATER HOSE
Water Pump / Water Hose
Removal and Installation
Removal Sequence
1.
2.
3.
4.
*1
* 5.
*1
* 6.
7.
8.
Water hose
Water hose
Water hose
Water hose
Coolant temperature sensor
Coolant temperature gauge unit
Water outlet fitting
Thermostat
9. Thermostat housing
10. Gasket
*1
* 11. Water inlet pipe
*1
* 12. O-ring
13. O-ring
14. Water pump
15. Water pump gasket
16. Knock sensor
17
18
4G6 – ROCKER ARM / CAMSHAFT
Rocker Arm / Camshaft
Removal and Installation
Apply engine oil to all
sliding parts before
installing.
Removal Sequence
1. Cam position sensor
O ring
Cover
Gasket
Cam position sensing cylinder
6. Cam position sensor support
7. Cam position sensor
8. O ring
E
* 9. Cover
E
* 10. Gasket
D
* 11. Cam position sensing cylinder
C
* 12. Cam position sensor support
*1
* 13. Camshaft oil seal
*1
* 14. Bearing cap : rear right
*1
* 15. Bearing cap : rear left
*1
* 16. Bearing cap : front
E
* 2.
E
* 3.
D
* 4.
C
* 5.
*1
* 17. Bearing cap No. 5
*1
* 18. Bearing cap No. 2
*1
* 19. Bearing cap No. 3
*1
* 20. Bearing cap No. 4
*1
* 21. Camshaft
22. Rocker arm
*1
* 23. Lash adjuster
* *1
24. Oil delivery body
25. Oil control valve (OCV)
26. O ring
27. Check valve
* 28. Eye bolt
B
29. Oil pump
A
* 30. OCV filter
31. Oil pump joint
32. Gasket
4G6 – ROCKER ARM / CAMSHAFT
19
Installation Service Point
A
*
Installation of OCV filter
Note :
Before fitting the filter, check that it is clean and is not damaged
or deformed in any way.
B
*
Installation of eye bolt
Note :
The oil pump may be damaged if the oil pipe joint turns with the
eye bolt when it is fitted.
Hold the oil pipe joint in place with a spanner, etc., and then tighten
the eye bolt to the specified torque 42 ±2 N-m.
Eye bolt
Oil pipe joint
Hold with
spanner, etc.
Installation of cam position sensor
C
*
support
1. Wipe away all traces of the old liquid gasket left on the cam
position sensor support and the cylinder head.
2. Apply a 3 mm-thick coat of the liquid gasket to the parts of the
cam position sensor support indicated on the diagram.
Liquid Gasket
Product name : MZ100191 or equivalent
Intake side
Exhaust side
Exhaust side
Intake side
Installation of cam position sensing
D
*
cylinder
Vane
(small)
1. Set the camshaft to the top dead centre for No.1.
2. Install the various vanes of the cam position sensing cylinder at
the positions indicated on the diagram.
Vane
Vane
Vane
Vane
Vane
(large)
Exhaust side
Intake side
Vane
(small)
1. Before installing the cover and gasket, put the camshaft to the
No.1 top dead centre position, and check that the vanes of the
respective sensing cylinders are located in the positions shown in
the diagram.
Vane
Vane
Vane
Vane
(large)
Vane
E
*
Installation of cover / gasket
20
4G6 – ROCKER ARM / CAMSHAFT
Exhaust side
No cutaway
Intake side
No installation direction
Comment :
The cover and gasket do not have distinct front and rear sides.
Tab
Tab
Cutaway
Cutaway
*
A
* *
*
* *
*
*
*
*
2. Ensure that the cutaways in the intake side cover and the tabs on the
gasket are aligned with the positions shown in the diagram, and
tighten at the specified torque of 14 ±1 N-m. The exhaust side cover
and gasket do not have a specified installation direction.
21
4G6 – OIL PUMP / SUMP
Oil Pump / Oil Pan
Removal and Installation
Apply engine oil to all
sliding parts before
installing.
Removal Sequence
1. Drain plug
Drain plug gasket
Oil filter
Oil pan
5. Oil screen
6. Oil screen gasket
7. Baffle plate
*1
* 8. Oil pressure switch
9. Oil cooler bypass valve
10. Relief plug
11. Gasket
12. Relief spring
13. Relief plunger
14. Oil filter bracket
15. Oil filter bracket gasket
* *1
*1
* 16. Plug cap
17. O ring
*1
* 2.
*1
* 3.
* *1
*1
* 4.
*1
* 18. Flange bolt
* *1
*1
* 19. Oil pump case
20. Oil pump case gasket
21. Oil pump cover
*1
* 22. Oil pump driven gear
*1
* 23. Oil pump drive gear
*1
* 24. Crankshaft front oil seal
*1
* 25. Counterbalance shaft oil seal
*1
* 26. Oil pump oil seal
27. Counterbalance
28. Counterbalance
*1
* 29. Counterbalance
* *1
*1
* 30. Counterbalance
* *1
* *1
*1
* 31. Counterbalance
shaft, right
shaft, left
shaft front bearing
shaft rear bearing, right
shaft rear bearing, left
22
4G6 – PISTONS / CONNECTING RODS
Piston / Connecting Rod
Removal and Installation
Apply engine oil to all
sliding parts before
installing.
Removal Sequence
*1
* 1.
*1
* 2.
* *1
* 3.
A
*1
* 4.
A
* 5.
*1
* 6.
Connecting rod cap nut
Connecting rod cap
Connecting rod bearing
Piston connecting rod
Connecting rod bearing
Piston ring No. 1
*1
* 7. Piston ring No. 2
*2
* 8. Oil ring
* *1
*1
* 9. Piston pin
10. Piston
11. Connecting rod
12. Bolt
23
4G6 - PISTONS / CONNECTING RODS
Position of crankshaft pin diameter identification marks
Installation Service Point
A
* Installation of bearings on connecting rod
1. When replacing a bearing, connecting rod or crankshaft,
choose a bearing of the correct size which corresponds to the
external diameter of the crankshaft pin, in accordance with the
identification marks on the crankshaft pin and the connecting
rod bearing given in the table below.
2. The crankshaft identifier is engraved in the position shown in
the diagram.
3. The bearing identifier is engraved or printed at the position
shown in the diagram.
Crankshaft pin
Identification mark
I
II
III
External diameter of
pin (mm)
44.995 – 45.005
44.985 – 44.995
44.980 – 44.985
Connecting rod
bearing
Identification mark
0
1
2
(Selecting a bearing : Example)
If the crankshaft identification mark is I, then choose a bearing
with the identification mark 0.
If it is difficult to make out the crankshaft identifier, measure the
external diameter of the pin and then choose the bearing that
corresponds to that diameter.
4. The selected bearing should be installed in the larger end of
the connecting rod and the cap.
24
4G6 – PISTONS CONNECTING RODS
Inspection
Piston rings
1. Check the clearance between the piston rings and the piston grooves.
If it exceeds the clearance limit value, replace the piston ring, or both
the piston ring and the piston.
Standard values :
No. 1
0.03 – 0.07 mm
No. 2
0.02 – 0.06 mm
Limit value : 0.1 mm
Press with piston
2. Insert the piston ring and the side rail of the oil ring into the cylinder
bore, and press in using the top surface of the piston. After reaching
a right-angle position, measure the opening gaps in the rings using a
thickness gauge.
Remark :
Press the openings of the piston ring and the oil ring side rail with the
piston in the position shown in the diagram, and measure the opening
gaps in this position.
Piston ring
Opening gap
Standard value
No. 1
0.20 – 0.30 mm
No. 2
0.35 – 0.45 mm
Oil ring 0.10 – 0.40 mm
Standard value
No. 1
0.8 mm
No. 2
0.8 mm
Oil ring 1.0 mm
4G6 – CRANKSHAFT / CYLINDER BLOCK
25
Crankshaft / Cylinder Block
Removal and Installation
Bolt with washer : 9.0 ± 1.0 N-m
Flange bolt : 10 ± 2 N-m (supplementary part)
Apply engine oil to all
sliding parts before
installing.
Removal Procedure
1.
2.
3.
4.
*1
* 5.
*1
* 6.
*1
* 7.
*1
* 8.
Flywheel bolt
Flywheel
Rear plate
Bell housing cover
Rear oil seal case
Rear oil seal
Bearing cap bolt
Beam being cap
A
* 9.
Crankshaft bearing lower
10. Crankshaft
A
* 11. Crankshaft bearing upper
*1
* 12. Thrust bearing
13. Check valve
14. Oil jet
15. Cylinder block
26
4G6 – CRANKSHAFT / CYLINDER BLOCK
Position of crankshaft journal diameter identification marks
Installation Service Point
A
* Installation of crankshaft bearings
1. Using the table below, select a bearing of the correct size
corresponding to the diameter of the crankshaft journal.
(Selecting a bearing : Example)
If the identifier on the crankshaft journal is 0, and the identifier on the
cylinder block bearing is 1, then a bearing with identification mark 1
should be chosen.
If the identifier on the crankshaft is difficult to make out, measure the
diameter of the journal and choose the bearing that corresponds to the
measured diameter.
Timing belt
Cylinder block bearing hole diameter
identification mark
Crankshaft journal diameter
Identification mark
Cylinder
bore size
mark
0
Journal
diameter (mm)
56.994~57.000
1
56.988~56.994
2
56.982~56.988
Cylinder
block bearing
Crankshaft
bearing
0
1
2
0
1
2
0
1
2
0
1
2
0
1
2
0
1
2
Position of crankshaft bearing size
identification mark
Identification mark
Groove
Upper bearing
Lower bearing
2. Install grooved bearing on cylinder block side.
3. Install bearing without oil groove on bearing cap side.
4G6 – TURBOCHARGER
Turbocharger
Disassembly and Reassembly
Disassembly Procedure
1.
2.
*1
* 3.
*1
* 4.
*1
* 5.
* *1
* *1
*1
* 6.
7.
*1
* 8.
Snap pin
Waste gate actuator
Cap ring
Turbine housing
Snap ring
Cartridge assembly
Compressor cover
O ring
27