MITSUBISHI LANCER EVOLUTION 2007 Service Repair Manual

MANUAL TRANSMISSION - Troubleshooting <ACD>22A-33
Inspection procedure 3
The ACD mode indicator lamp does not light up when the
ignition switch is turned “ON” (engine stop).
Probable cause
The ACD mode indicator lamp circuit or 4WD-ECU may be faulty.DHarness or connector fault
DACD mode indicator lamp assembly fault
D4WD-ECU fault
OK OK OKOK
NG
OK
NG
NG
NG
Check the harness between the ACD mode indicator lamp
assembly and 4WD-ECU.
DCheck for open and damage of the power line.
NG→Repair
Replace the 4WD-ECU.
Measure at 4WD-ECU connector C-43.
DDisconnect the connector and test at the harness side.
DIgnition switch: ON
DBody earth terminals 40, 51, and 52.
OK:The indicator lamp lights up.
Check the trouble symptoms.
Measure at combination meter connector C-01.
DDisconnect the connector and measure at the harness
side.
DIgnition switch: ON
DVoltage between terminal 9 and body earth
OK:System voltageCheck the following connectors:
<L.H. drive vehicles> C-01, C-29, C-213, C-210
<R.H. drive vehicles> C-01, C-213, C-210
NG→Repair
Check the trouble symptoms.
Check the ACD mode indicator lamp assembly.
NG→Replace
Check the harness between the ignition switch and ACD
mode indicator lamp assembly.
DCheck for open circuit or damage of the power line.
NG→Repair
Check the following connectors:
<L.H. drive vehicles> C-43, C-128, C-01
<R.H. drive vehicles> C-43, C-01
NG→Repair
OK
NG
Check the trouble symptoms.
Check the following connector:C-43
NG→Repair

MANUAL TRANSMISSION - Troubleshooting <ACD>22A-34
Inspection procedure 4
More than two ACD mode indicator lamps remain lit even
after the engine starts
Probable cause
The output circuit of the ACD mode indicator lamp may be faulty.DHarness or connector fault
D4WD-ECU fault
DACD mode indicator lamp assembly fault
NOTE
This phenomenon occurs only when communication with the MUT-IIis possible (4WD-ECU power supply
fault) and at the same time, no diagnostic code (no trouble code) is output.
NO
Replace the 4WD-ECU.
Do all the ACD mode indicator lamps go off when 4WD-ECU
connector C-43 is disconnected?
YES
Replace the ACD mode indicator lamp assembly.OK
NG
Check the trouble symptoms.
Check the following connectors:
<L.H. drive vehicles> C-43, C-128, C-01
<R.H. drive vehicles> C-43, C-01
NG→Repair
OK
Check the harness between the ACD mode indicator lamp
assembly and 4WD-ECU.
DCheck for ground and short circuit of output line.
NG→Repair
Inspection procedure 5
ACD does not operate (No diagnosis code)
Probable cause
Insufficient operating oil, oil leakage, faulty operations of the oil pressure unit, and
faulty operations of the ACD transfer may be suspected.DLeakage of transfer oil
DInsufficient transfer oil
DLeakage of oil pressure line
DInsufficient fluid
DHydraulic unit fault
DACD transfer fault
NOTE:
1. This malfunction is restricted to only when no diagnostic code (no trouble code) is output.
2. *: Refer to GROUP 22B.
OK
NG OKNG OKNG
NG
NO
NG
OK
Replenish transfer oil.
Replace the oil pressure unit.
Have foreign particles mixed into the oil pressure line?
YES→Repair
Check the hydraulic pressure (P.22A-43).Perform bleeding (P.22A-42).
Check the fluid (P.22A-41).Check for leakage of the oil pressure line.
NG→Repair
Check the transfer oil (P.22A-40).Check for leakage of the transfer oil.
NG→Repair
Check the trouble symptoms.
Replace the ACD transfer.*OK
Replenish the fluid.
OK
NG
Check the operations of the ACD (P.22A-42).Check the trouble symptoms.

MANUAL TRANSMISSION - Troubleshooting <ACD>22A-35
DATA LIST REFERENCE TABLE
Item
no.Check itemCheck conditionNormal conditions
01Wheel speed sensor
<FR>Execute actual driving.The speed meter dis-
play and MUT-IIdis-
lth02Wheel speed sensor
<FL>
py
play match.
03Wheel speed sensor
<RR>
04Wheel speed sensor
<RL>
05Wheel speed sensor
<FR> (0.2 km/h)
06Wheel speed sensor
<FL> (0.2 km/h)
07Wheel speed sensor
<RR> (0.2 km/h)
08Wheel speed sensor
<RL> (0.2 km/h)
09Vehicle speed
10Battery voltageIgnition switch: ONSystem voltage
11Proportional valve cur-
rent <ACD>During ACD operation50 - 1,000 mA
12Proportional valve cur-
rent <AYC>During AYC operation50 - 1,000 mA
13TPS voltageIgnition switch: ON
Engine: StoppedAccelerator pedal: Full
closed535 - 735 mV
Engine:Stopped
Accelerator pedal: PressGradually rises from
the above value
Accelerator pedal: Full
throttle4,500 - 5,000 mV
14Longitudinal G sensor
voltageIgnition switch: ONVehicle stopped (horizon-
tal) state2.4 - 2.6 V
g
Actual drivingThe displayed value
increases and de-
creases mainly around
2.5 V.
15Lateral G sensor volt-
ageIgnition switch: ONVehicle stopped (horizon-
tal) state2.4 - 2.6 V
g
Perform actual drivingThe displayed value
increases and de-
creases mainly around
2.5 V.
16Steering operation
angleIgnition switch: ONSteering wheel: Steer by 90
degrees to the rightR90 deg
g
Steering wheel: Steer by 90
degrees to the leftL90 deg
17Steering angle velocityIgnition switch: ONSteering wheel: No steering0 deg/sggyg
Steering wheel: SteerThe display changes
according to the revolu-
tion speed.
18Pressure sensorDuring electric pump motor operations1.0 - 1.6 MPa

MANUAL TRANSMISSION - Troubleshooting <ACD>22A-36
Item
no.Normal conditions Check condition Check item
19Pressure sensor power
supplyIgnition switch: ONApprox.5 V
20Valve power supplyIgnition switch: ONSystem voltage
21Steering wheel sensor
voltage <ST-1>Ignition switch: ONSteering wheel: Turn1 - 2 V and 2.5 - 4.5 V
are displayed alter-
nately.
22Steering wheel sensor
voltage <ST-2>Ignition switch: ONSteering wheel: Turn1 - 2 V and 2.5 - 4.5 V
are displayed alter-
nately.
23Steering wheel sensor
ltSTN
Ignition switch: ONSteering wheel: Neutral1-2Vg
voltage <ST-N>
g
Steering wheel: Turn2.5 - 4.5 V
51Idle switchIgnition switch: ONAccelerator pedal: Full
closedON
Accelerator pedal: PressOFF
52Steering wheel sensor
STN
Ignition switch: ONsteering wheel: NeutralONg
<ST-N>
g
Steering wheel: Turn from
the neutral positionOFF
53Steering wheel sensor
<ST-1>Ignition switch: ONSteering wheel: Turn slowlyON and OFF are dis-
played alternaltely.
54Steering wheel sensor
<ST-2>Ignition switch: ONSteering wheel: Turn slowlyON and OFF are dis-
played alternately
55Steering wheel sensor
learning <ST-N>Perform actual drivingSteering wheel sensor neu-
tral position learning exe-
cutedON
Steering wheel sensor neu-
tral position learning unex-
ecutedOFF
56Stop lamp switchIgnition switch: ONBrake pedal: DepressONppg
Engine: StoppedBrake pedal: ReleaseOFF
57Motor monitorElectric pump motor is currently operatingON
Electric pump motor is currently not operatingOFF
58Oil pressure stateElectric pump motor is currently operatingLOWp
Electric pump motor is currently not operatingHIGH
59Directional valve
Ri ht
AYC clutch right side is currently operatingON
<Right>AYC clutch right side is currently not operatingOFF
60Directional valve
Lft
AYC clutch left side is currently operatingON
<Left>AYC clutch left side is currently not operatingOFF
61ABS monitorABS is currently operatingON
ABS is currently not operatingOFF
62Parking brake switchIgnition switch: ONParking brake lever: PullONgg
Engine:StoppedParking brake lever: Re-
leaseOFF
63ACD mode switchIgnition switch: ONACD mode switch: PressONg
Engine:StoppedACD mode switch: ReleaseOFF

MANUAL TRANSMISSION - Troubleshooting <ACD>22A-37
ACTUATOR TEST JUDGEMENT VALUE
Item
no.Check itemTest descriptionNormal state
01Bleeding <ACD>Input current to the Proportional valve
according to the steering angle, and operate
the Proportional valve for five minutes.Make sure no air leaks from the bleeder
screw on the transfer.
02Bleeding <AYC>Input current to the Proportional valve
according to the steering angle, and operate
the directional valve for five minutes.Make sure no air leaks from the bleeder
screw on the torque transfer differential.
03Check the oil vol-
umeOperate the directional valve to the left and
right for 20 seconds.Check that the oil volume of the reservoir
tank is appropriate.
04Electric pump
driveOperate the electric pump for 5 seconds.Operation sounds of the electric pump
can be heard.
05Check the opera-
tions of the ACDOperate the Proportional valve <ACD> and
supply the maximum oil pressure to the multi
plate clutch.9Generate the tight corner braking
phenomenon.
06Check clutch op-
erations <Left>Operate the direction valve and supply the
maximum oil pressure to the left clutch.When the wheels are lifted, speed
difference will occur between the rear
left and right wheels.
07Check clutch op-
erations <Right>Operate the direction valve and supply the
maximum oil pressure to the right clutch.When the wheels are lifted, speed
difference will occur between the rear
left and right wheels.
08Control OFFTurn OFF the electric pump relay, and turn
OFF the control of the ACD and AYC.In actual driving, there is difference
between control ON and OFF.
(1) The actuator test can be executed only when all the following conditions are satisfied.
DAll wheel speed sensor inputs below 20 km/h
DNo system malfunction detected
DSteering angle is within±30 degrees from the neutral position
(2) When the actuator test corresponds to one of the following conditions, forced driving will be cleared.
DWhen any one of the wheel speed sensor input is detected to be above 20 km/h (excluding
Item No.08 “Control OFF”.)
DWhen system malfunction is detected (excluding diagnostic code No.82, 84, and 85)
DWhen the forced drive time is exceeded
DWhen the MUT-IIis removed
DWhen the Clear key of the MUT-IIis operated

MANUAL TRANSMISSION - Troubleshooting <ACD>22A-38
CHECK AT 4WD-ECU TERMINALS
NOTE:
1. *1indicates the eliminated terminal when only ACD is installed.
2. *2indicates the terminal added when only ACD is installed.
Termi-
nal no.
Check itemCheck conditionNormal state
1Proportional valve
<ACD>
Operate the Proportional
valveintheactuatortest
While executing the actuator testSystem voltage
<ACD>valveintheactuatortest
(Item No.01). <ACD>After completing the actuator test1 V or less
3*1Proportional valve
<AYC>
Operate the Proportional
valveintheactuatortest
While executing the actuator testSystem voltage
<AYC>valveintheactuatortest
(Item No. 02). <AYC>After completing the actuator test1 V or less
6Wheel speed sensor
FL
Vehicle is stopping1 V or lessp
<FL>Moving forward slowly0↔5 V flushing
7Wheel speed sensor
RR
Vehicle is stopping1 V or lessp
<RR>Moving forward slowly0↔5 V flushing
8Wheel speed sensor
RL
Vehicle is stopping1 V or lessp
<RL>Moving forward slowly0↔5 V flushing
9Wheel speed sensor
FR
Vehicle is stopping1 V or lessp
<FR>Moving forward slowly0↔5 V flushing
10Pressure sensor earthAny time1 V or less
11Lateral G sensorIgnition switch: ON
Vehicle horizontal state2.4 - 2.6 V
134WD-ECU power sup-
l
Ignition switch: OFF0Vpp
plyIgnition switch: ONSystem voltage
14*1Directional valve
<Right>Operate the directional
valve <right> in theWhile executing the actuator testSystem voltage
<Right>valve<right>inthe
actuator test (Item No.
07)After completing the actuator test1 V or less
15*1Directional valve
<Left>
Operate the directional
valve<left>intheactua
While executing the actuator testSystem voltage
<Left>valve <left>intheactua-
tor test (Item No. 06)After completing the actuator test1 V or less
16Electric pump relay
l
When the electric pump motor is not operating0Vppy
power supplyWhile the electric pump motor is operatingSystem voltage
19*2Wheel speed sensor
earth <FL>Any time1 V or less
20*2Wheel speed sensor
earth <RR>Any time1 V or less
21*2Wheel speed sensor
earth <RL>Any time1 V or less
22*2Wheel speed sensor
earth <FR>Any time1 V or less
23Longitudinal G sensorIgnition switch: ON
Vehicle horizontal state2.4 - 2.6 V

MANUAL TRANSMISSION - Troubleshooting <ACD>22A-39
Termi-
nal no.Normal state Check condition Check item
24*2Longitudinal G sensor
earth, lateral G sensor
earthAny time1 V or less
26ECU earthAny time1 V or less
31ECU backup power
supplyAny timeSystem voltage
32Pressure sensorIgnition switch: ON0.5 - 1.5 V
33Steering wheel sensor
<ST-1>Ignition switch: ONSteering wheel: Turn slowly1-2V↔2.5 -
4.5 V flushing
34Steering wheel sensor
<ST-2>Ignition switch: ONSteering wheel: Turn slowly1-2V↔2.5 -
4.5 V flushing
35Diagnosis data input/
output--
36Idle switchIgnition switch: ONAccelerator pedal: Full closed1 V or lessg
Accelerator pedal: Depress4.5 - 5.0 V
37Parking brake switchIgnition switch: ONParking brake lever: Pull1 V or lessgg
Parking brake lever: ReleaseSystem voltage
38Stop lamp switchIgnition switch: ONBrake pedal: DepressSystem voltageppg
Brake pedal: Release1 V or less
39TPSIgnition switch: ONAccelerator pedal: Full closed0.5 - 0.7 Vg
Accelerator pedal: Full throttle4.5 - 5.5 V
40ACD mode indicator
lamp <TARMAC>Ignition switch: ONACD mode indicator lamp position:
TARMAC0V
p
ACD mode indicator lamp position:
Except for aboveApprox. 10.5 V
42ECU earthAny time1 V or less
43Pressure sensor earthAny time1 V or less
44Steering wheel sensor
STN
Ignition switch: ONSteering wheel: Neutral1-2Vg
<ST-N>
g
Steering wheel: Turn from the
neutral position2.5 - 4.5 V
46Diagnosis control--
47ACD mode switchIgnition switch: ONSwitch: PressSystem voltageg
Switch: Release0V
49*1ABS monitorWith ABS not activeSystem voltage
With ABS active1.5 V or less
50*2EarthAny time1 V or less
51ACD mode indicator
lamp <SNOW>Ignition switch: ONACD mode indicator lamp position:
SNOW0V
p
ACD mode indicator lamp position:
Except for aboveApprox. 10.5 V
52ACD mode indicator
lamp <GRAVEL>Ignition switch: ONACD mode indicator lamp position:
GRAVEL0V
p
ACD mode indicator lamp position:
Except for aboveApprox. 10.5 V

MANUAL TRANSMISSION - On-vehicle Service MANUAL TRANSMISSION - On-vehicle Service22A-40
ON-VEHICLE SERVICE
TRANSMISSION OIL CHECK
1. Remove the oil filler plug.
2. Oil level should be at the lower portion of the filler plug
hole.
3. Check that the transmission oil is not noticeably dirty,
and that it has a suitable viscosity.
4. Tighten the filler plug to the specified torque.
Tightening torque: 32±2 N·m
TRANSMISSION OIL REPLACEMENT
1. Remove oil filler plug and oil drain plug.
2. Drain oil.
3. Tighten the oil drain plug to the specified torque.
Tightening torque: 32±2 N·m
4. Fill with specified oil till the level comes to the lower portion
of oil filler plug hole.
Specified transmission oil:
Gear oil SAE 75W-90 or 75W-85W conforming to
API GL-4
Quantity: 2.8 L
5. Tighten the oil filler plug to the specified torque.
Tightening torque: 32±2 N·m
TRANSFER OIL CHECK
1. Remove the oil filler plug.
2. Oil level should be at the lower portion of the filler plug
hole.
3. Check that the transfer oil is not noticeably dirty, and
that it has a suitable viscosity.
4. Tighten the filler plug to the specified torque.
Tightening torque: 32±2 N·m
TRANSFER OIL REPLACEMENT
1. Remove oil filler plug and oil drain plug.
2. Drain oil.
3. Tighten the oil drain plug to the specified torque.
Tightening torque: 32±2 N·m
Transmission oilFiller plug hole
Filler plug
Drain plug
Transfer oilFiller plug hole
Filler plug
Drain plug
Oil pan

MANUAL TRANSMISSION - On-vehicle Service22A-41
4. Fill with specified oil till the level comes to the lower portion
of oil filler plug hole.
Specified transfer oil:
MITSUBISHI Genuine Gear Oil Part No.8149630
EX, CASTROL HYPOY LS (GL-5, SAE 90),
SHELL-LSD (GL-5, SAE 80W - 90) or equivalent
Quantity:
0.55 L <Vehicles without ACD or vehicles without
ACD and AYC>
0.6 L <Vehicles with ACD or vehicles with ACD
and AYC>
5. Tighten the oil filler plug to the specified torque.
Tightening torque: 32±2 N·m
FLUID CHECK <VEHICLES WITH ACD OR
VEHICLES WITH ACD AND AYC>
1. Remove the maintenance lid located in the luggage
compartment.
2.<Not using MUT-II>
If the vehicle has been run, leave it for 90 min. or more
in an ordinary temperature (10_C–30_C) to allow the
accumulator internal pressure to drop.
NOTE
If the ambient temperature is 10_C or less, allow more
time to leave the vehicle to stand idle.
<Using MUT-II>
Set the MUT-IIto the 16-pin diagnosis connector. Turn ON
the ignition switch, perform MUT-IIactuator test (Item
No.03), forcibly drive the hydraulic unit and remove the
pressure in the accumulator.
Caution
Turn the ignition switch to the “LOCK”(OFF) position
before connecting or disconnecting the MUT-II.
NOTE
(1) In the actuator test (Item No. 03: Oil Level Check
Mode), the directional valve of the hydraulic unit is
moved to the left and right for 20 times, and then
the differential is cleared automatically. Drive can also
be cleared forcibly using the Clear key of the MUT-II.
(2) If the function has been stopped by fail-safe, the
hydraulic unit cannot be cleared forcibly.
3. Check that the fluid level in the oil reservoir is in the
range between MAX and MIN.
4. If the fluid level is lower than MIN, add the specified
fluid.
Specified fluid: Dia Queen ATF SP III
5. Reinstall the maintenance lid.

MANUAL TRANSMISSION - On-vehicle Service22A-42
BLEEDING <VEHICLES WITH ACD OR
VEHICLES WITH ACD AND AYC>
1. Lift up the vehicle.
2. Set the MUT-IIto the 16-pin diagnosis connector.
Caution
Turn the ignition switch to the “LOCK”(OFF) position
before connecting or disconnecting the MUT-II.
3. Turn the ignition switch to the “ON” position.
4. Set the steering wheel in the straight-ahead position.
5. Perform the MUT-IIactuator test (Item No.02), and forcibly
drive the hydraulic unit.
NOTE
(1) The actuator test (Item No.01: Bleeding Mode) will
be performed for 5 minutes, after which it will be
cleared automatically. Drive can also be cleared during
forced driving using the clear key of the MUT-II.
(2) If the hydraulic unit function has been stopped by
fail-safe, the hydraulic unit cannot be forcibly driven.
6. Remove the cap of the bleeder screw on the transfer,
and connect the vinyl hose.
7
.Slowly turn the steering wheel to the left or right from
the neutral state. Loosen the bleeder screw, and check
that air is discharged together with the fluid.
8
.After the air is discharged, tighten the bleeder screw,
and return the steering wheel to the neutral state.
Caution
During bleeding, replenish the fluid so that some
always remains in the oil reservoir.
9. Repeat steps 6 and 7 several 2 to 3 times, and after
checking that no more air mixes in, tighten the bleeder
screw at the specified torque.
Tightening torque: 5±1 N·m
10. After bleeding, check the fluid level. (Refer to P. 22A-41.)
Caution
If bleeding is not performed completely, noise may
be produced from the hydraulic unit, or the durability
of the pump, etc. may drop.
11. On vehicles with AYC, perform bleeding when the
hydraulic unit is removed. (Refer to GROUP 27B -
On-vehicle Service.)
ACD OPERATION CHECK <VEHICLES WITH
ACD OR VEHICLES WITH ACD AND AYC>
1. Lift up the vehicle.
2
.Set the MUT-IIto the 16-pin diagnosis connector.
Caution
Turn the ignition switch to the “LOCK”(OFF) position
before connecting or disconnecting the MUT-II.
3. Start the engine.
Bleeder screw
Front exhaust pipe