relay MITSUBISHI LANCER EVOLUTION IV 1998 User Guide

MPI – On-vehicle Service13-35
11. FUEL PUMP RELAY NO.2 CHECK
(1) Remove fuel pump relay No.2.
(2) Using jumper wires, connect fuel pump relay No.2 terminal
(3) to battery (+) terminal, and terminal (1) to battery
(–) terminal, respectively.
(3) Connecting and disconnecting the jumper wire on the
battery (–) terminal end, check for continuity across
terminal (2) and terminal (5), and across terminal (4) and
terminal (5), of fuel pump relay No.2.
Jumper wireContinuity across
terminals (2) and (5)Continuity across
terminals (4) and (5)
ConnectedNoYe s
DisconnectedYe sNo
(4) If the continuity is checked abnormally, replace fuel pump
relay No.2.
12. FUEL PUMP RESISTOR CHECK
(1) Disconnect the fuel pump resistor connector.
(2) Measure resistance across the terminals.
Standard value: 0.6 – 0.9 Ω
(3) If the measurement falls outside the specified range,
replace the fuel pump resistor.
Fuel pump relay No.2
Fuel pump resistor

ENGINE COOLING – Radiator14-8
REMOVAL SERVICE POINTS
ARADIATOR UPPER HOSE / RADIATOR LOWER
HOSE DISCONNECTION
After making mating marks on the radiator hose and the hose
clamp, disconnect the radiator hose.
INSTALLATION SERVICE POINT
ARADIATOR LOWER HOSE / RADIATOR UPPER
HOSE CONNECTION
(1) Insert each hose as far as the projection of the water
inlet or outlet fitting.
(2) Align the mating marks on the radiator hose and hose
clamp, and then connect the radiator hose.
Caution
Fit the clamp on the hose at the same position as
before.
INSPECTION
1. RADIATOR FAN MOTOR CHECK
Apply the battery voltage across connector terminals 1 and
2, and terminals 3 and 4, of the radiator fan motor and check,
at that time, that the radiator fan turns.
2. POWER RELAY CONTINUITY CHECK
Battery voltageTerminal number
1345
When deenergized
When energized
Radiator fan motor relay LO

ENGINE COOLING – Radiator14-9
Battery voltageTerminal number
1234
When deenergized
When energized
Radiator fan motor relay HI

27-1
REAR AXLE
CONTENTS
SERVICE SPECIFICATIONS 2. . . . . . . . . . . . . .
LUBRICANT 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SEALANT 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 3. . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING <AYC> 5. . . . . . . . . . . . .
ON-VEHICLE SERVICE
<VEHICLES WITH AYC> 27. . . . . . . . . . . . . . .
1. Rear Axle Total Backlash Check 27. . . . . . .
2. Gear Oil Level Check 27. . . . . . . . . . . . . . . .
3. Gear Oil Change 28. . . . . . . . . . . . . . . . . . . . .
4. Fluid Level Check 29. . . . . . . . . . . . . . . . . . . .
5. Bleeding 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6. Differential Carrier Oil Seal
Replacement 30. . . . . . . . . . . . . . . . . . . . . . . . .
7. Speed Sensor Output Voltage
Measurement <Vehicles without ABS> 31.
8. Action When Battery Runs Out 32. . . . . . . .
REAR HUB ASSEMBLY 33. . . . . . . . . . . . . . . .
KNUCKLE 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DRIVE SHAFT 36. . . . . . . . . . . . . . . . . . . . . . . . .
DIFFERENTIAL CARRIER
<EVOLUTION-IV, EVOLUTION-V GSR> 39.
DIFFERENTIAL CARRIER
<EVOLUTION-V RS> 41. . . . . . . . . . . . . . . . . . .
TORQUE TRANSFER DIFFERENTIAL
<VEHICLES WITH AYC> 43. . . . . . . . . . . . . . .
LSD CASE ASSEMBLY
<VEHICLES WITHOUT AYC> 46. . . . . . . . . . .
HYDRAULIC UNIT
<VEHICLES WITH AYC> 50. . . . . . . . . . . . . . .
SENSOR RELAY
<VEHICLES WITH AYC> 52. . . . . . . . . . . . . . .
AYC-ECU 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REAR AXLE – Troubleshooting <AYC>27-6
3. INSPECTION CHART FOR DIAGNOSIS CODE
Diagnosis
code No.Diagnosis itemsRef. page
12Power supply voltage (valve power supply) system (open- or short-circuit)27-7
21FR wheel speed sensor system (open- or short-circuit)27-7
22FL wheel speed sensor system (open- or short-circuit)27-7
23RR wheel speed sensor system (open- or short-circuit)27-7
24RL wheel speed sensor system (open- or short-circuit)27-7
25Wrong-diameter tire27-9
26Faulty wheel speed sensor27-10
31Steer sensor (ST-1, ST-2, ST-N) system (open-circuit)27-11
32Steer sensor (ST-N) system (short-circuit)27-11
33Steer sensor (ST-N) system27-12
34Steer sensor (ST-1, ST-2) system (short-circuit)27-12
41TPS system (open- or short-circuit)27-13
51Longitudinal acceleration sensor system (open- or short-circuit)27-13
52Longitudinal acceleration sensor27-14
56Lateral acceleration sensor system (open- or short-circuit)27-13
61Stop lamp switch system (open-circuit)27-14
65ABS monitor system (open-circuit or defective ABS)27-15
71Proportioning valve system (open- or short-circuit)27-15
72Directional control valve (right) system (open- or short-circuit)27-16
73Directional control valve (left) system (open- or short-circuit)27-17
81AYC relay system (open- or short-circuit)27-18
82Electric pump system27-19
83Electric pump system27-20

REAR AXLE – Troubleshooting <AYC>27-15
Code No. 65: ABS monitor systemProbable cause
This code is output when ABS is considered to remain activated (motor relay remains
ON) for a continuous 1-min.-or-more period.
It is output also when there is an open-circuit in the harness between ABS motor
relay and AYC-ECU.
Defective harness or connector

Defective AYC-ECU
OK
Replace AYC-ECU.
NG
Check the harness between ABS
motor relay and AYC-ECU.NG
Repair
OK
Check the trouble symptom.
Is the ABS diagnosis code output?YESTroubleshooting
NO
Check the following connector:
B-95NG
Repair
Code No. 71: Proportioning valve systemProbable cause
This code is output when the proportioning valve control circuit is open- or short-circuited.
Defective proportioning valve

Defective harness or connector

Defective AYC-ECU
OK
Check and repair the harness between
proportioning valve and body ground.
OK
Check the trouble symptom.
OK
Measure at F-27 proportioning valve
connector.

Disconnect the connector and
measure at the harness side.

Continuity across 2 and body
ground
OK:ConductingNGCheck the following connectors:
F-27, F-30NG
Repair
Measure at F-27 proportioning valve
connector.

Disconnect the connector and
measure at the proportioning valve.

Resistance across 2 – 3
OK:4.7 Ω or lessNGReplace the hydraulic unit.
OK
Replace AYC-ECU.
NG
Check the harness between propor-
tioning valve and AYC-ECU.NG
Repair
OK
Check the trouble symptom.
NG
Check the following connectors:
B-96, B-94, D-06, F-30, F-27NG
Repair

REAR AXLE – Troubleshooting <AYC>27-18
Code No. 81: AYC relay systemProbable cause
This code is output when the coil circuit of the AYC relay is open- or short-circuited.
Defective AYC relay

Defective harness or connector

Defective AYC-ECU
NG
Check and repair the harness between
AYC relay and body ground.
OK
Check the trouble symptom.
OK
Replace AYC-ECU.
NG
Check the harness between AYC relay
and AYC-ECU.NG
Repair
NG
Check the trouble symptom.
OK
Check the following connectors:
B-96, B-126NG
Repair
OK
Measure at A-126 AYC relay connec-
tor.

Disconnect the connector and
measure at the harness side.

Continuity across 1 and body
ground
OK:ConductingNGCheck the following connector:
A-126NG
Repair
Check the AYC relay.
(Refer to P.27-52.)NGReplace the AYC relay.

REAR AXLE – Troubleshooting <AYC>27-19
Code No. 82: Electric pump systemProbable cause
This code is output if the pressure switch is not set to high-pressure position despite
the AYC-ECU’s command to drive the AYC relay for a given period of time.
Low hydraulic oil level

Oil leak

Defective fusible link

Defective AYC relay

Defective harness or connector

Defective AYC motor

Defective accumulator pressure switch

Defective AYC-ECU
OK
Replace AYC-ECU.
Check the harness
between AYC relay and
AYC motor, and between
AYC motor and body
ground.NG
Replace
NG
OK
Check the trouble symptom.
OK
Check the following
connectors:
A-126, B-94, B-27, F-32NG
Repair
OK
Replace AYC-ECU.
NG
Check the harness
between AYC-ECU and
accumulator pressure
switch.NG
Repair
NG
Check and repair the har-
ness between fusible link
no. 10 and AYC relay.
OK
Check the trouble symp-
tom.
OK
Replace the hydraulic unit
for a defective accumula-
tor pressure switch.
NO
Repair the leak.
OK
Check the trouble symptom.
NG
Check the following
connector: A-126NG
Repair
YES
Add hydraulic oil.
Is the hydraulic oil level correct in the reservoir tank?
(Refer to P.27-29.)NOIs there a hydraulic oil leak?
Measure at A-126 AYC relay connector.

Disconnect the connector and measure at the harness side.

Voltage across 5 and body ground
OK: Battery voltage
NG
NO
Can pump be operated?YESMeasure at F-31 accumulator pressure switch connector.

Disconnect the connector and measure at the harness side.

Ignition switch: ON

Voltage across 2 and body ground
OK:Battery voltage
YES
Is diagnosis code no. 81 output?YESCheck the AYC relay system. (Refer to P.27-18.)
NG
Check the following
connectors: B-95, B-94,
D-06, F-30, F-31NG
Repair
OK

Check AYC relay for
continuity.
(Refer to P.27-52.)

Check AYC motor for
operation.NG
Repair

REAR AXLE – Troubleshooting <AYC>27-20
Code No. 83: Electric pump systemProbable cause
This code is output if the pressure switch is not set to low-pressure position despite
the AYC-ECU’s command to change the driving force.
Defective accumulator pressure switch

Defective harness or connector
OK
Replace AYC-ECU.
NG
Check the harness between AYC-ECU
and accumulator pressure switch.NG
Repair
OK
Check the trouble symptom.
NG
Check and repair the harness between
accumulator pressure switch and body
ground.
OK
Check the trouble symptom.
(2) NG
Check the following connectors:
F-31, F-30NG
Repair
NO
Measure at F-31 accumulator pressure
switch connector.

Disconnect the connector and
measure at the harness side.

Ignition switch: ON
(1) Voltage across 2 and body ground
OK:Battery voltage
(2) Continuity across 1 and body
ground
OK:ConductingOKReplace the hydraulic unit for a defec-
tive accumulator pressure switch.
OK
Check and repair the harness between
AYC relay and AYC motor.
NO
Is diagnosis code no. 71, 72, or 73
output?YES
Check the proportioning valve
system (code no. 71).
(Refer to P.27-15.)

Check the directional control valve
(right) system (code no. 72).
(Refer to P.27-16.)

Check the directional control valve
(left) system (code no. 73).
(Refer to P.27-17.)
(1) NGCheck the following connectors:
B-95, B-94, D-06, F-30, F-31NG
Repair
Does the AYC motor continue turning
when the ignition switch is turned ON?YESCheck the AYC relay for continuity.
(Refer to P.27-52.)NG
Repair

REAR AXLE – Troubleshooting <AYC>27-25
Terminal
No.Normally Check requirement Check item
18TPSIgnition switch:
ON
Accelerator pedal: Fully closed0.3 – 1.0 V
ON
Accelerator pedal: Fully open4.5 – 5.0 V
23Diagnosis data input/output1 V or less
24Idle position switchIgnition switch:
ON
Accelerator pedal: Fully closed2 V or less
ON
Accelerator pedal: Fully open4.5 – 5.0 V
25Accumulator pressure
switchIgnition switch:
ONAccumulator internal pressure:
Low2 V or less
Accumulator internal pressure:
HighBattery voltage
26ECU groundAt all times0 V
31AYC-ECU power supplyIgnition switch: ONBattery voltage
Ignition switch: OFF0 V
35AYC motor relayIgnition switch:
ON
When motor is energizedBattery voltage
ON
When motor is deenergized2 V or less
36AYC warning lampIgnition switch:
ON
When lamp is OFFBattery voltage
ON
When lamp is ON2 V or less
37Directional control valve
(right)
Ignition switch:
ON
Right clutch: ONBattery voltage
(right)ON
Right clutch: OFF0 V
38Proportioning valveIgnition switch:
ONAYC-ON0 V to battery volt-
age
AYC-OFF0 V
39ECU backup power supplyAt all timesBattery voltage
45Directional control valve
(left)
Ignition switch:
ON
Left clutch: ONBattery voltage
(left)ON
Left clutch: OFF0 V
46ECU groundAt all times0 V
NOTE
*1: Indicates the vehicles with ABS.