2005 MITSUBISHI LANCER EVOLUTION IX service

13A-17MPI – TROUBLESHOOTING
*: Refer to the 01-1 Service Manual for the Lancer Evolution VIII (No.1036K02)
*: Refer to the 03-1 Service Manual for the Lancer Evolution VIII (No.1036K07)
Repair
Repair
Repair
Repair
Repair
Repair
Continued from previous page
Replace the spark plug wire
Replace the spark plug
Replace the ignition coil
Inspection procedure 33: Inspection of the No.1 waste
gate solenoid valve (Ref: P13A-78) *2
Inspection procedure 37: Inspection of the No.2 waste
gate solenoid valve (Ref: P13A-21)
Inspection procedure 31: Inspection of the fuel control
solenoid valve (Ref: P13A-76) *2
Inspection procedure 38: Inspection of the air
temperature sensor (Ref: P13A-22)
Check the spark plug wire (Ref: Section 16: Ignition
apparatus)
Check the spark plug (Ref: Section 16: Ignition
apparatus)
Check connectors B-123 & B-119
Check the ignition coil (Ref: Section 16: Ignition
Apparatus)
Inspect the harness and the connectors between each
cylinder’s ignition coil and the body earth, and between
the engine ECU and the ignition coil. Check for cut or
short circuited wires, or other damage.
MUT-II/III Actuator test
•No.12: Waste gate solenoid valve (Ref: P13A-87)*2
Check the supercharge pressure of the turbo charger
(Ref: Section 15: Intake/Exhaust car servicing)
Check the supercharge pressure control system (Ref:
Section 15: Intake/Exhaust car servicing)
MUT-II/III Actuator test
•No.09: Fuel pressure control solenoid valve (Ref:
P13A-87)
Check the fuel pressure (Ref: P13D-109)
Check the compression pressure (Ref: Section 11:
Engine tuning)
If the intake hose and the inlet manifold are damaged
check the air intake and repair as necessary.
Measurements taken at B-108 air temperature sensor
connector
•Using the test harness (MB991658), connect it to only
connectors No.1 and No.2 and measure at the 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
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
NG
NG
NG
NG
NG
NG
NG
NG
NG
NG
NG

13A-24MPI – TROUBLESHOOTING
13A-23
6. Service data table
7. Engine ECU checks
7-1 Terminal voltage table

Service Manual
Supplement
Lancer Evolution IX

Service Manual
4G6
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.
CONTENTS
General Information . . . . . . . . . . . . . . . 4
Servicing Specification Values . . . . . . 4
Tightening torques . . . . . . . . . . . . . . . . 5
Sealants . . . . . . . . . . . . . . . . . . . . . . . . . 7
Alternator / Ignition system . . . . . . . . . 8
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
DOHC
ENGINE

2HOW 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
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.
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.
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
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.: Indicates that there is a removal or
disassembly service point
: Indicates that there is an installation or
assembly service point
: Indicates that the removal or disassembly
service point is described in the ’01-14G6
DOHC Engine Service Manual.
: Indicates that the installation or assembly
service point is described in the ’01-14G6
DOHC Engine Service Manual.
: Indicates that the removal or disassembly
service point is described in the ’03-14G6
DOHC Engine Service Manual.
: Indicates that the installation or assembly
service point is described in the ’03-14G6
DOHC Engine Service Manual.

* * 1


* * 2 
*
1
*

* 2
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A

*

* A

94G6 – ALTERNATOR, IGNITION SYSTEM
Removal Service Point
Removal of ignition coil boot
Note :
• 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.
Coupling
section
Air blow hole
White powder coating on
interior part. Do not touchAir blow hole
Upper faceA

*

114G6 – TIMING BELT
9. Connector bracket
10. Rocker cover
11.Rocker cover gasket A
12. Rocker cover gasket B
13. Semi-circular packing
14. Plug cap
15. Timing belt
16. Tensioner pulley
17. Tensioner arm
18. Auto tensioner
19. Idler pulley
20. Crank angle sensor
21. Oil pump sprocket
22. Crankshaft bolt
23. Crankshaft sprocket
24. Crankshaft sensing blade
25. Tensioner B26. Timing belt B
27. Counterbalance shaft sprocket
28. Spacer
29. Crankshaft sprocket B
30. Crankshaft key
31. Engine support bracket
32. V.V.T. sprocket bolt
33. V.V.T. sprocket
34. Camshaft sprocket bolt
35. Camshaft sprocket
36. Timing belt rear right cover
37. Timing belt rear left upper cover
38. Timing belt rear left lower cover
Removal Service Point
Removal of plug cap
Hold hexagonal section of camshaft with wrench, and loosen plug cap.
Removal of V.V.T. sprocket bolt
Hold hexagonal section of camshaft with wrench, and loosen V.V.T.
sprocket bolt.
Installation Service Point
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.
V. V. T.
sprocket
boltV.V.T. sprocket
Camshaft

* A


* B 
B
*
A
*
A
*

* * 1


* * 1


* * 1


* * 1

* * 1

* * 1

* * 1


* * 1 
* 1
* 
* 1
*

* 1
*

* 1
*

* 1
*

* 1
*

* 1
*

* 1
*

* 1
*

* 1
*

* 1
*

* 1
*

* 1
*

* 1
*

* 1
*

* 1
*

* A


* B


* A

144G6 – FUEL SYSTEM
Installation Service Point
Installation of cover
The side of the cover marked “gasket side” should be assembled
facing the inlet manifold.
 A
Gasket
sideCover
Gasket
Inlet manifold