ECU MITSUBISHI LANCER EVOLUTION IV 1998 Repair Manual

REAR SUSPENSION – Rear Suspension Assembly34-5
REMOVAL SERVICE POINTS
ABRAKE CALIPER ASSEMBLY REMOVAL
Remove the brake caliper assembly and secure it with a
wire.
BPROPELLER SHAFT DISCONNECTION
(1) Make an alignment mark on the differential carrier
companion flange and propeller shaft flange yoke.
(2) Remove the mounting bolts and nuts of the differential
carrier and propeller shaft.
CCROSSMEMBER MOUNTING BOLT REMOVAL
Support the differential case with a garage jack or transmission
jack and then remove the crossmember mounting bolt.
INSTALLATION SERVICE POINTS
ACROSSMEMBER MOUNTING BOLT
INSTALLATION
Tighten the mounting bolts in the numerical order shown.
NOTE
To ensure both good installation accuracy and ease of
installation, the crossmember mounting holes have different
diameters between front and rear. This is the reason for
specifying the tightening sequence of the mounting bolts.
BPROPELLER SHAFT CONNECTION
Align the alignment mark on the differential carrier with that
of the propeller shaft at installation.
Caution
Oil or grease on the threads of the mounting bolt or nut
can allow the bolt or nut to come loose. Be sure to
degrease the threads before installation.
Bolt size (thread dia. × length mm)
1 to 3: Flange bolt (with washer) 12 × 70
4: Flange bolt (with washer) 12 × 152
5: Bolt (with spring washer + washer) 12 × 105 Front of vehicle
13
3
44
2
55

REAR SUSPENSION – Stabilizer Bar34-16
STABILIZER LINK BALL JOINT DUST COVER
REPLACEMENT
Only when the dust cover is damaged accidentally during
service work, replace the dust cover as follows:
(1) Remove the clip ring and the dust cover.
(2) Apply the specified grease to the lip and inside of the
dust cover.
Specified grease:
SHOWA SHELL SEKIYU VARIANT R-2 or
equivalent
(3) Wrap plastic tape on the stabilizer link threads as shown
in the illustration, and then install the dust cover to the
stabilizer link.
(4) Secure the dust cover with the clip ring.
When installing the clip ring, align the ends at a 90

angle from the axis of the stabilizer link.
(5) Check the dust cover for cracks or damage by pushing
it with finger.
Clip ring
Clip ring ends (180
on
opposite side also possible)

BASIC BRAKE SYSTEM – General / On-vehicle Service35A-2
GENERAL
OUTLINE OF CHANGE

The service procedures for left-hand drive vehicles have been established as described below.

The service procedures for the front and rear disc brakes have been changed since they had been
replaced by a different type. <EVOLUTION-VI with BREMBO braking system>
ON-VEHICLE SERVICE
BRAKE PEDAL CHECK AND ADJUSTMENT
<L.H. DRIVE VEHICLES>
1. Turn up the carpet, etc under the brake pedal.
2. Measure the brake pedal height as illustrated. If the brake
pedal height is not within the standard value, follow the
procedure below.
Standard value: 163.5 –166.5 mm
(1) Disconnect the stop lamp switch connector.
(2) Adjust the brake pedal height by turning the operating
rod with pliers (with the operating rod lock nut
loosened), until the correct brake pedal height is
obtained.
(3) Secure by tightening the lock nut of the operating
rod.
(4) Push the stop lamp switch in the direction of the
pedal stroke until it stops. (The switch will slide if
it is pushed firmly.)
(5) Lift up the pedal until the operating rod is fully
extended, and then slide the stop lamp switch back
to the required position. Adjust the position of the
switch by turning it until the distance shown in the
illustration is correct.
(6) Connect the connector of the stop lamp switch.
(7) Check that the stop lamp is not illuminated with the
brake pedal unpressed.
3. With the engine stopped, depress the brake pedal two
or three times. After eliminating the vacuum in the power
brake booster, press the pedal down by hand, and confirm
that the amount of movement before resistance is met
(the free play) is within the standard value range.
Standard value: 3 – 8 mmOperating
rod
Operating
rod lock nutStop lamp
switch
Pedal down
Pedal up
Lock nut
Lock nut
Outer case
0.5 – 1.0 mm

BASIC BRAKE SYSTEM – Master Cylinder and Brake Booster35A-6
INSTALLATION SERVICE POINTS
AVACUUM HOSE CONNECTION
Insert securely and completely until the vacuum hose at the
engine side contacts the edge of the hexagonal part of the
fitting, and then secure by using the hose clip.
BCLEARANCE ADJUSTMENT BETWEEN BRAKE
BOOSTER PUSH ROD AND PRIMARY PISTON
Calculate clearance A from the B, C and D measurements.
A = B – C – D
Standard value: 0.65–0.85 mm
If the clearance is not within the standard value range, adjust
by changing the push rod length by turning the screw of
the push rod.
Measuring
distance BMeasuring
distance D
Block
gaugeB
AC
D

35B-1
ANTI-LOCK
BRAKING
SYSTEM (ABS)
CONTENTS
TROUBLESHOOTING 2. . . . . . . . . . . . . . . . . . . .
1. Inspection Chart for Diagnosis Codes 2. . .
2. Inspection Procedure for Diagnostic
Trouble Codes 3. . . . . . . . . . . . . . . . . . . . . . . .
3. Inspection Chart for Trouble Symptoms 11
4. Inspection Procedure for Trouble
Symptoms 12. . . . . . . . . . . . . . . . . . . . . . . . . . .
5. Check at ABS-ECU Terminals 15. . . . . . . . .
ON-VEHICLE SERVICE 17. . . . . . . . . . . . . . . .
Wheel Speed Sensor Output Voltage
Measurement <EVOLUTION-V> 17. . . . . . . . . . .
LATERAL ACCELERATION SENSOR 17. . .
WHEEL SPEED SENSOR 18. . . . . . . . . . . . . .

ABS – Troubleshooting35B-2
The EVOLUTION-V is provided with a lateral acceleration sensor in addition to the longitudinal acceleration
sensor, and the ABS-ECU connector is changed in terminal arrangement. When servicing EVOLUTION-V,
therefore, use the following service procedures.
TROUBLESHOOTING
1. INSPECTION CHART FOR DIAGNOSIS CODES
Diagnosis
code No.Diagnosis itemsReference Page
11Wheel speed sensor (FR) system (open- or short-circuit)35B-3
12Wheel speed sensor (FL) system (open- or short-circuit)35B-3
13Wheel speed sensor (RR) system (open- or short-circuit)35B-3
14Wheel speed sensor (RL) system (open- or short-circuit)35B-3
15Wheel speed sensor system (abnormal output signal)35B-4
16ABS-ECU power supply voltage system (abnormal voltage drop or rise)35B-5
21Wheel speed sensor (FR) system35B-2
22Wheel speed sensor (FL) system35B-2
23Wheel speed sensor (RR) system35B-2
24Wheel speed sensor (RL) system35B-2
27AYC monitor system (detective AYC)35B-6
32Longitudinal acceleration sensor circuit system35B-6
33Stop lamp switch system35B-7
41Solenoid valve (FR) system35B-7
42Solenoid valve (FL) system35B-7
43Solenoid valve (RR) system35B-7
44Solenoid valve (RL) system35B-7
51Valve relay system35B-8
53Motor relay system35B-9
63ABS-ECU failureReplace ABS-ECU.
71Lateral acceleration sensor system35B-10

ABS – Troubleshooting35B-3
2. INSPECTION PROCEDURE FOR DIAGNOSTIC TROUBLE CODES
Code Nos.11, 12, 13 and 14: Wheel speed sensor
(open circuit or short circuit)Probable cause
Code Nos.21, 22, 23 and 24: Wheel speed sensor
Code Nos 11, 12, 13 and 14 are output if the ABS-ECU detects an open circuit or
short-circuit in the (+) wire or (–) wire in any one of the four wheel speed sensors.
Malfunction of wheel speed sensor

Malfunction of wiring harness or connector

Malfunction of ABS-ECU
Code Nos.21, 22, 23 and 24 are output in the following cases.

When there is no input from any one of the four wheel speed sensors when travelling
at 8 km/h or more, even though open circuit can not be verified.

When a chipped or blocked-up ABS rotor is detected and if the anti-lock system
operates continuously because a malfunctioning sensor or a warped ABS rotor
is causing sensor output to drop.
Malfunction of wheel speed sensor

Malfunction of wiring harness or connector

Too much gap between the sensor and the rotor

Malfunction of ABS-ECU

Malfunction of wheel bearing
NG
Check the harness wire, and repair
if necessary.

Between each wheel speed sensor
and ABS-ECU
NG
Replace the ABS-ECU.
OK
Check the trouble symptom.
OK
Check the following connector:
B-24NG
Repair
NG
Repair
OK
Wheel bearing check
OK
ABS rotor check
OK
Wheel speed sensor output voltage
check (Refer to P.35B-17.)NGWheel speed sensor checkNG
Replace
OK
Check the following connectors:
B-24, B-52, B-17, A-26, A-50, D-04,
D-14, D-19OKCheck the trouble symptom.
OK
Measure at the ABS-ECU connector
B-24.

Disconnect the connector, and
measure at the harness side
connector.

Resistances between 8 and 21,
10 and 19, 7 and 20, 9 and 22
OK:1.4 – 1.8 kΩNGWheel speed sensor check
(Refer to P.35B-29.)NG
Replace
Wheel speed sensor installation checkNG
Replace
NG
Replace

ABS – Troubleshooting35B-4
Code No.15: Wheel speed sensor (abnormal output
signal)Probable cause
This code is output when there is an abnormality in the output signal from any one
of the four wheel speed sensors while driving (except for an open circuit or short
circuit).
The four vehicle tires are of different sizes

Malfunction of wheel speed sensor

Malfunction of wiring harness or connector

Malfunction of ABS-ECU

Malfunction of wheel bearing
OK
Check the harness wire, and repair
if necessary.

Between each wheel speed sensor
and ABS-ECU
OK
Wheel bearing checkNG
Replace the ABS-ECU.
OK
ABS rotor checkNG
RepairOK
Check the trouble symptom.
OK
Check the following connector:
B-24NG
Repair
OK
Check the trouble symptom.
OK
Wheel speed sensor output voltage
check (Refer to P.35B-17.)NGWheel speed sensor checkNG
Replace
YES
Wheel speed sensor installation checkNG
Repair
Are the sizes of all four tires identical?NOEquip the vehicle with tires of identical
sizes.
NG

ABS – Troubleshooting35B-5
Code No.16: ABS-ECU power supply system (abnormal
voltage drop or rise)Probable cause
This code is output if the ABS-ECU or valve relay power supply voltage drops below
or rises above the rated values.
The valve relay power supply voltage is detected based on the voltage in the valve
relay monitor line.
Malfunction of battery

Malfunction of wiring harness or connector

Malfunction of valve relay

Malfunction of ABS-ECU
Caution
If battery voltage drops or rises during inspection, this code will be output as well, making it
impossible to obtain correct diagnostic results.
Before carrying out the following inspection, check the battery level, and refill it if necessary.
OK
Replace ABS-ECU.
OK
Replace the ABS-ECU.
OK
Check the trouble symptom.NGCheck the harness wire, and repair
if necessary.

Between ignition switch and
ABS-ECU
OK
Check the trouble symptom.NGCheck the harness wire, and repair
if necessary.

Between general-purpose fuse
No. 6 and valve relay
NG
Repair
OK
Check the harness wire for short
circuit, and repair if necessary.

Between valve relay and hydraulic
unit

Between valve relay and motor
relayNG
Repair OK
NG
Check the harness wire, and repair
if necessary.

Between valve relay and ABS-ECUNG
Repair
OK
Check the trouble symptom.
OK
Check the trouble symptom.NGCheck the harness wire, and repair
if necessary.

Between general-purpose fuse
No. 6 and valve relay
OK
Measure at the ABS-ECU connector
B-25.

Connector connected

Ignition switch: ON
(1) Voltage between 37 and body
ground
OK:Battery voltage
(2) Voltage between 48 and body
ground
OK:Battery voltage(1) NGCheck the following connectors:
A-76, B-25NG
Repair
(2) NG
Check the following connectors:
A-76, B-25NG
Repair
OK
Check the valve relay.NG
Replace
OK
Check the trouble symptom.NGCheck the harness wire, and repair
if necessary.

Between fusible link No. 8 and
valve relay
OK
Measure at the valve relay connector
A-76.

Disconnect the connector, and
measure at the harness side
connector.

Ignition switch: ON
(1) Voltage between 6 and body
ground
OK:Battery voltage
(2) Voltage between 2 and body
ground
OK:Battery voltage(1) NGCheck the following connector:
A-76NG
Repair
(2) NGCheck the following connector:
A-76NG
Repair
Measure at the ABS-ECU connector
B-24.

Disconnect the connector, and
measure at the harness side
connector.

Start the engine.

Voltage between 13 and body
ground
OK:Battery voltageNGCheck the following connectors:
B-24, B-52, B-74, B-76NG
Repair

ABS – TroubleshootingABS – Troubleshooting35B-6
Code No. 27: AYC monitor system (defective AYC)Probable cause
This code is output when the AYC monitor signal becomes faulty.
Defective AYC-ECU

Defective ABS-ECU

Defective harness or connector
OK
Replace the ABS-ECU.
OK
MUT-II data list
AYC signal
OKOFF to be displayed when the
engine runs at idle with the
vehicle stationary.NGReplace AYC-ECU.
OK
Check the harness between ABS-ECU
and AYC-ECU.NG
Repair
Check the following connectors:
B-25, B-96NG
Repair
Code No. 32: Acceleration sensor (longitudinal accelera-
tion) circuit systemProbable cause
This code is output under either of the following conditions:

The output from the acceleration sensor (longitudinal acceleration) becomes 0.5
V or less, or 4.5 V or more.

The acceleration sensor (longitudinal acceleration) harness is open- or
short-circuited.
Defective acceleration sensor (longitudinal accelera-
tion)

Defective harness or connector

Defective ABS-ECU
OK
Check the trouble symptom.NGReplace ABS-ECU.
OK
Check the trouble symptom.NGCheck and repair the harness between
acceleration sensor (longitudinal
acceleration) and ABS-ECU.
OK
Check the trouble symptom.NGCheck and repair the harness between
general-purpose fuse No. 6 and
acceleration sensor (longitudinal
acceleration).
OK
Replace ABS-ECU.
OK
Check the following connector:
B-24NG
Repair
OK
Measure at B-24 ABS-ECU connector.

Connect the connector.

Ignition switch: ON

Voltage across 4 and 17
OK:2.4 – 2.6 V
(horizontal position)NGCheck the following connectors:
B-24, D-20, B-52NG
Repair
NG
Check the harness between accelera-
tion sensor (longitudinal acceleration)
and ABS-ECU.NG
Repair
OK
Check the trouble symptom.
OK
Check the valve relay.NG
Replace
(1) NGCheck the following connectors:
D-20, B-49, B-75NG
Repair
Check the following connector:
D-20, B-49, B-75NG
Repair
(2) NG
Measure at D-20 acceleration sensor
(longitudinal acceleration) connector.

Disconnect the connector and
measure at the harness side.

Ignition switch: ON
(1) Voltage across 1 and body ground
OK:Battery voltage
(2) Continuity across 3 and body
ground
OK:Conducting