2005 MITSUBISHI LANCER EVOLUTION IX checking oil

ENGINE – SPECIAL TOOLS
11 - 3
ToolNumberNameFunction
MD998737Va l ve stem seal
installerValve stem seal installation
MD998713Camshaft oil seal
installerCamshaft oil seal installation
MB991654Cylinder head bolt
wrenchCylinder head bolt removal, installation
MB991367Special spannerHolding the crankshaft sprocket
MB991385Pins
MB991704Battery harnessChecking and adjustment of the tension in the
balancer timing belt (Use in conjunction with VCI
or MUT-II)
MD998738Adjusting boltHolding the tensioner arm or the auto-tensioner
adjuster
MD998767Tensioner pulley
socket wrenchAdjusting the tension of the timing belt

ENGINE – CAMSHAFT, VALVE STEM SEAL
11 - 9
Removal guidelines
 
A


Detaching the radiator upper hose
Align the indicator marks on the radiator upper hose and the hose
clamp, and then detach the radiator upper hose.
 
B


Removing the camshaft sprockets
Grip the hexagonal part of the camshaft with a wrench, loosen the
mounting bolt, and remove the camshaft sprocket.
 
C


Removing the valve spring retainer lock
Compress the valve spring using the special tool for compressing
valve springs (MD998772), and remove the valve spring retainer
lock.
Caution
When removing the valve spring retainer lock, each cylinder
piston should be in the top dead centre position. If pistons are
not in the top dead centre position, valves could fall into the
cylinders.
Fitting guidelines



A 
Fitting the exhaust valve stem seals and the inlet valve
stem seals
1. Inlet valve stem seals and exhaust valve stem seals can be
distinguished by checking the colour of the rubber parts.
2. Apply a small quantity of engine oil to the valve stem seals.
3. Place the valve stem component into the guides, and then insert
a new valve stem seal into the valve stem guide by using the
special tool for installing valve stem seals.
Caution
(1) Valve stem seals cannot be re-used.
(2) Please use the special tool for installing valve stem seals
(MD998737) because oil could leak if the valve stem seals
are not fitted correctly.
Indicator marks
Colour of main
body: greyColour of main
body: grey/green
Inlet sideExhaust side
Valve
Valve guide
Valve stem
seal

ENGINE – TIMING BELT, TIMING BELT B, ENGINE ASSY11-28
5. Using the special wrench for the tensioner pulley socket
(MD998767) or a torque wrench, apply tension torque (3.5 N·m)
to the timing belt in the direction shown in the diagram, and
tighten the mounting bolt for the tensioner pulley to the specified
torque.
Tightening torque: 48 ± 5 N·m
Caution
When tightening the installed bolt, take care that the
tensioner pulley does not turn around with it. If the pulley
does turn around with the bolt, the tension of the belt will
become too strong.
6. Remove the wire or pin which had been inserted when the auto-
tensioner 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.
•Check for fuel dripping.
•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.
•Adjustment of the axle letter cable.
•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 ASSY11-32
 
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).
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.
MZ203830 or MZ203831
slide bracket (HI)

ENGINE – ENGINE ASSY
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) (MZ203830 or MZ203831)>
Install the special mechanical engine hanger (MZ203830
or MZ203831).
(2)
Fit the following parts to the base hanger.
• Slide bracket (HI)
• Foot (standard) (MB991932)
• Joint (90) (MB991930)
Install the special engine hanger (MB991928)



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).engine sideengine side
engine mount stopper
rear of chassis> front of chassis>
MZ203830 or MZ203831
slide bracket (HI)
front of
chassis
joint (90)
(MB991930)
foot (standard) (MB991932)
slide bracket (HI)

MPI – GENERAL
13A-1
SECTION 13A
MPI (Multi-point Fuel Injection)
CONTENTS
General ..................................................................... 2
Servicing standards .................................................3
Special tools ............................................................3
Troubleshooting ......................................................5Servicing the vehicle ............................................29
1. Adjusting specified revolutions when idling.....29
2. MPI system components layout diagram ........29
3. Checking the air temperature sensor..............29
4. Checking the oil feeder control valve..............30
GENERAL
Servicing guidelines have been changed because of the changes listed below.
•Avariable valve timing control system (V.V.T.) has been adopted. Because of this, an oil feeder control valve and an intake
cam position sensor have been added.
•Amanifold absolute pressure (MAP) sensor has been added.
•An air temperature sensor has been added.

MPI – SERVICING STANDARDS, SPECIAL TOOLS
13A-3
Servicing standards
Special tools
ItemStandard level
Revolutions when idling r/min800 ± 50
Air temperature sensor resistance kΩat -20 ºC13~18
at 0 ºC5.1~6.9
at 20 ºC2.0~3.0
at 40 ºC0.9~1.5
at 60 ºC0.40~0.78
at 80 ºC0.23~0.42
Oil feeder control valve resistance (at 20 ºC) Ω6.9~7.9
ToolNumberNameFunction
MB991502MUT-II sub ASSYChecking the MPI system
MB991955
A:MB991824
B:MB991827
C:MB991910
D:MB991911
E:MB991825
F:MB991826MUT-III sub ASSY
A: Vehicle Communication
Interface (V.C.I..)
B: USB cable
C: MUT-III Main harness A
(For vehicles fitted with
CAN)
D: MUT-III Main harness B
(For vehicles not fitted with
CAN)
E: Adaptor
F: Trigger harnessNote
If a MUT-III main harness A is connected to
a vehicle not fitted with CAN, there is a
chance that a pulse signal will be entered
in the simulated vehicle speed line, when
the MUT-III is activated. Therefore, use a
MUT-III main harness B with vehicles not
fitted with CAN.
DO NOT USE

MPI – TROUBLESHOOTING
13A-5
TROUBLESHOOTING
1. Diagnosis Functions
1-1 Engine warning light (Check engine lamp)
Changes have been made to engine warning lights.
Checklist for engine warning lights.
1-2 Checking of freeze frame data
Additions have been made to the freeze frame data tables.
Checklist for data tables
1-3 Failsafe and back-up functions
If one of the diagnosis functions detects that one of the main sensors is malfunctioning, it will ensure that the car can be driven
safely, in accordance with the pre-set control logic.
Engine ECU
Air flow sensor (AFS)
Manifold absolute pressure (MAP) sensor system
Intake air temperature sensor
Throttle position sensor (TPS)
Water temperature sensor
Crank angle sensor
Exhaust cam position sensor
Injector
Ignition coil (with built-in power transistor)
Atmospheric pressure sensor
O
2sensor
O
2sensor heater
Fuel system malfunction
Knock sensor
Intake cam position sensor system
Oil feeder control valve system
Item numberType of data Units/condition
95MAP sensorkPa
Malfunctioning itemControl measures taken when a malfunction occurs
Air temperature sensorRegulation 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 sensorThe oil feeder control valve should be switched "OFF", and the
angle of the cam should be in the reset position.