oil pressure MITSUBISHI LANCER EVOLUTION VI 1999 Owner's Manual

MPI – Troubleshooting13-29
INSPECTION PROCEDURE 12
When the engine is hot, it stalls at idling. (Die out)
Probable cause
In such cases as the above, the cause is probably that ignition system, air/fuel mixture,
idle speed control (ISC) or compression pressure is defective.
In addition, if the engine suddenly stalls, the cause may also be a defective connector
contact.
Malfunction of the ignition system

Malfunction of air-fuel ratio control system

Malfunction of the ISC servo system

Drawing air into intake system

Improper connector contact

Backflow of secondary air to the intake system
Were the battery terminals disconnected recently?Ye sAfter warming-up, let the engine run at idling for about 10 minutes.
No
MUT-II Diagnosis code
Are diagnosis codes displayed?Ye sRefer to P.13-8, INSPECTION CHART FOR DIAGNOSIS CODES.
No
Check the ISC servo for operation sound.NGCheck the ISC servo system.
(Refer to P.13-44, INSPECTION PROCEDURE 33.)
OK
Check the injector for operation sound.NGCheck the injector system. (Refer to P.13-15, INSPECTION PRO-
CEDURE FOR DIAGNOSIS CODE 41.)
OK
Does the engine stall right after the accelerator pedal is released?Ye sClean the throttle valve
area.Adjust the fixed SAS.
(Refer to P.13-30.)*
No
Does the engine stall easily again?NoWhile carrying out an intermittent malfunction simulation test (Refer
to GROUP 00 – Points to Note for Intermittent Malfunctions.), check
for sudden changes in the signals shown below.

Crank angle sensor signal

Injector drive signal

Fuel pump drive signal

Air flow sensor signal
Secondary ignition signal

Engine-ECU power supply
voltage
Ye s
MUT-II: Engine stalling inspection when the engine is warm and
idling. (Refer to P.13-50, INSPECTION PROCEDURE 42.)
OK
Check the ignition timing.
(Refer to GROUP 11 – ENGINE ADJUSTMENTS.)*NGCheck that the crank angle sensor and the timing belt cover are
installed properly.
OK
Check the following items.

Check the ignition coil, spark plugs, spark plug cables.

Check the secondary air supply system. (Ensure that there is no backflow of secondary air into the intake system.)

Check if the injectors are clogged.

Check the compression pressure.

Check if foreign materials (water, alcohol, etc.) got into fuel.
NOTE
*: Refer to Workshop Manual for LANCER EVOLUTION-IV and EVOLUTION-V (Pub. No. S9806CNCP9).

MPI – Troubleshooting13-31
INSPECTION PROCEDURE 15
Hesitation, sag or stumble
Probable cause
In cases such as the above, the cause is probably that ignition system, air/fuel mixture
or compression pressure is defective.
Malfunction of the ignition system

Malfunction of air-fuel ratio control system

Malfunction of the fuel supply system

Poor compression

Malfunction of the turbocharger system

Malfunction of the secondary air supply system
MUT-II Self-Diag code
Are diagnosis codes displayed?Ye sRefer to P.13-8, INSPECTION CHART FOR DIAGNOSIS CODES.
No
Check the injectors for operation sound.NGCheck the injector system. (Refer to P.13-15, INSPECTION PRO-
CEDURE FOR DIAGNOSIS CODE 41.)
OK
Check the ignition timing.
(Refer to GROUP 11 – Engine Adjustments.)*NGCheck that the crank angle sensor and the timing belt cover are
installed properly.
OK
MUT-II: Check if hesitation, sag, stumble or poor acceleration
occurs. (Refer to P.13-51, INSPECTION PROCEDURE 43.)
OK
Check the fuel pressure. (Refer to P.13-30.)*
OK
Check the following items.

Check the ignition coil, spark plugs, spark plug cables.

Check the turbocharger boost pressure.

Check the boost pressure control system.

Check the turbocharger turbine wheel for smooth rotation.

Check the compression pressure.

Check the fuel filter or fuel line for clogging.

Check the secondary air supply system.
NOTE
*: Refer to Workshop Manual for LANCER EVOLUTION-IV and EVOLUTION-V (Pub. No. S9806CNCP9).
INSPECTION PROCEDURE 16
The feeling of impact or vibration when accelerating
Probable cause
In cases such as the above, the cause is probably that there is an ignition leak
accompanying the increase in the spark plug demand voltage during acceleration.
Malfunction of the ignition system
MUT-II Self-Diag code
Are diagnosis codes displayed?Ye sRefer to P.13-8, INSPECTION CHART FOR DIAGNOSIS CODES.
No
Check the following items.

Check the ignition coil, spark plugs, spark plug cables.

Check for occurrence of ignition leak.

MPI – Troubleshooting13-32
INSPECTION PROCEDURE 17
The feeling of impact or vibration when decelerating
Probable cause
Malfunction of the ISC servo system is suspected.
Malfunction of the ISC servo system
MUT-II Self-Diag code
Are diagnosis codes displayed?Ye sRefer to P.13-8, INSPECTION CHART FOR DIAGNOSIS CODES.
No
Check the ISC servo for operation sound.NGCheck the ISC servo system.
(Refer to P.13-44, INSPECTION PROCEDURE 33.)
OK
MUT-II Data list
14 Throttle position sensor (Refer to P.13-57.)NGCheck the throttle position sensor system. (Refer to P.13-9, IN-
SPECTION PROCEDURE FOR DIAGNOSIS CODE 14.)
OK
MUT-II Data list
26 Idle position switch (Refer to P.13-58.)NGCheck the idle position switch system.
(Refer to P.13-38, INSPECTION PROCEDURE 26.)
OK
Clean the throttle valve area.
INSPECTION PROCEDURE 18
Poor acceleration
Probable cause
Defective ignition system, abnormal air-fuel ratio, poor compression pressure, etc.
are suspected.
Malfunction of the ignition system

Malfunction of air-fuel ratio control system

Malfunction of the fuel supply system

Poor compression pressure

Clogged exhaust system

Malfunction of the turbocharger system
MUT-II Self-Diag code
Are diagnosis codes displayed?Ye sRefer to P.13-8, INSPECTION CHART FOR DIAGNOSIS CODES.
No
Check the injectors for operation sound.NGCheck the injector system. (Refer to P.13-15, INSPECTION PRO-
CEDURE FOR DIAGNOSIS CODE 41.)
OK
Check the ignition timing.
(Refer to GROUP 11 – Engine Adjustments.)*NGCheck that the crank angle sensor and the timing belt cover are
installed properly.
OK
MUT-II: Check if hesitation, sag, stumble or poor acceleration occur.
(Refer to P.13-51, INSPECTION PROCEDURE 43.)
OK
Check the fuel pressure. (Refer to P.13-30.)*
OK
Check the following items.

Check the ignition coil, spark plugs, spark plug cables.

Check the turbocharger boost pressure.

Check the boost pressure control system.

Check the turbocharger turbine wheel for smooth rotation.

Check the compression pressure.

Check the fuel filter or fuel line for clogging.

Broken air intake hose

Clogged air cleaner

Clogged exhaust system
NOTE
*: Refer to Workshop Manual for LANCER EVOLUTION-IV and EVOLUTION-V (Pub. No. S9806CNCP9).

MPI – Troubleshooting13-33
INSPECTION PROCEDURE 19
Surge
Probable cause
Defective ignition system, abnormal air-fuel ratio, etc. are suspected.
Malfunction of the ignition system

Malfunction of air-fuel ratio control system
MUT-II Self-Diag code
Are diagnosis codes displayed?Ye sRefer to P.13-8, INSPECTION CHART FOR DIAGNOSIS CODES.
No
Check the injectors for operation sound.NGCheck the injector system. (Refer to P.13-15, INSPECTION PRO-
CEDURE FOR DIAGNOSIS CODE 41.)
OK
Check the ignition timing.
(Refer to GROUP 11 – Engine Adjustments.)*NGCheck that the crank angle sensor and the timing belt cover are
installed properly.
OK
MUT-II: Check if surge occurs.
(Refer to P.13-52, INSPECTION PROCEDURE 44.)
OK
Check the fuel pressure. (Refer to P.13-30.)*
OK
Check the following items.

Check the ignition coil, spark plugs, spark plug cables.

Check the waste gate actuator.
NOTE
*: Refer to Workshop Manual for LANCER EVOLUTION-IV and EVOLUTION-V (Pub. No. S9806CNCP9).
INSPECTION PROCEDURE 20
Knocking
Probable cause
In cases as the above, the cause is probably that the detonation control is defective
or the heat value of the spark plug is inappropriate.
Defective detonation sensor

Inappropriate heat value of the spark plug
MUT-II Self-Diag code
Are diagnosis codes displayed?Ye sRefer to P.13-8, INSPECTION CHART FOR DIAGNOSIS CODES.
No
Does knocking occur when driving with the sensor disconnected?
At this time, use the MUT-II to check if the timing is retarded
compared to when the detonation sensor connector is con-
nected.NoCheck the detonation sensor system. (Refer to P.13-15, INSPEC-
TION PROCEDURE FOR DIAGNOSIS CODE 31.)
Ye s
Check the following items.

Spark plugs

Check if foreign materials (water, alcohol, etc.) got into fuel.
INSPECTION PROCEDURE 21
Dieseling
Probable cause
Fuel leakage from injectors is suspected.
Fuel leakage from injectors
Check the injectors for fuel leakage.

MPI – Troubleshooting13-34
INSPECTION PROCEDURE 22
Too high CO and HC concentration when idling
Probable cause
Abnormal air-fuel ratio is suspected.
Malfunction of the air-fuel ratio control system

Deteriorated catalyst
Check trouble symptom.
No
Check the ignition timing.
(Refer to GROUP 11 – Engine Adjustments.)*NGCheck that the crank angle sensor and the timing belt cover are
installed properly.
OK
MUT-II Data list
21 Engine coolant temperature sensor. (Refer to P.13-57.)NGCheck the engine coolant temperature sensor system.
(Refer to P.13-10, INSPECTION PROCEDURE FOR DIAGNOSIS
CODE 21.)
OK
MUT-II Data list
13 Intake air temperature sensor (Refer to P.13-56.)NGCheck the intake air temperature sensor system. (Refer to P.13-9,
INSPECTION PROCEDURE FOR DIAGNOSIS CODE 13.)
OK
MUT-II Data list
25 Barometric pressure sensor (Refer to P.13-58.)NGCheck the barometric pressure sensor system. (Refer to P.13-14,
INSPECTION PROCEDURE FOR DIAGNOSIS CODE 25.)
OK
MUT-II Data list
11 Oxygen sensor
OK:600–1,000 mV when racing suddenlyNGCheck the oxygen sensor system. (Refer to P.13-15, INSPECTION
PROCEDURE FOR DIAGNOSIS CODE 31.)
OK
MUT-II Data list
11 Oxygen sensor
OK:Repeat 0–400 mV and 600–1,000 mV alternately when
idling.OK
NG
Check the fuel pressure. (Refer to P.13-30.)*
OK
NG
Check the following items.

Check the injectors for operation sound.

Check the injectors for fuel leakage.

Check the ignition coil, spark plugs, spark plug cables.

Check the compression pressure.

Check the positive crankcase ventilation system.

Check the evaporative emission control system.
Check the trouble symptom.
NG
Replace the catalytic converter.
Replace the oxygen sensor.
MUT-II Self-Diag code
Are diagnosis codes displayed?Ye sRefer to P.13-8, INSPECTION CHART FOR DIAGNOSIS CODES.
NOTE
*: Refer to Workshop Manual for LANCER EVOLUTION-IV and EVOLUTION-V (Pub. No. S9806CNCP9).

MPI – Troubleshooting13-63
ENGINE-ECU INSPECTION
TERMINAL VOLTAGES
Engine ECU connector
Terminal
No.Check itemCheck condition (Engine condition)Normal condition
1No.1 injectorWhile engine is idling after having been warmed up,
suddenly depress the accelerator pedal
Momentarily drops
slightlyfrom 1114V
14No.2 injector
suddenly depress the accelerator pedal.slightly from 11 – 14 V.
2No.3 injector
15No.4 injector
3Fuel pressure control
valve
Ignition switch: ONSystem voltage
valve
Engine: Cranking to idling (within about two minutes)0 – 3 V to sytem
voltage
4Stepper motor coil (A1)Engine: Immediately after engine has been started
f
or warming up
Changes repeatedly
f
rom system voltage
17Stepper motor coil (A2)
for warming upfrom system voltage
to 0 – 6 V and from 0
6 V to system5Stepper motor coil (B1)– 6 V to system
voltage.
18Stepper motor coil (B2)
6Secondary air control
solenoid valveIgnition switch: ONSystem voltage
8Fuel pump relayIgnition switch: ONSystem voltage
Engine: Idling0 – 3 V
10Power transistor unit
(A)Engine speed: 3,000 r/min0.3 – 3.0 V
23Power transistor unit
(B)
11Wastegate solenoid
valve
Ignition switch: ONSystem voltage
valve
Engine: At idle after having been warmed up (when
premium gasoline is used)0 – 3 V
12Power supplyIgnition switch: ONSystem voltage
25
19Air flow sensor reset
signal
Engine: Idling0 – 1 V
signal
Engine speed: 3,000 r/min6 – 9 V
20Fan motor relay (HI)
<EVOLUTION-IV, V>Fan not operating (coolant temperature: 90C or
below)System voltage
Fan at high speed (coolant temperature: 105C or
above)0 – 3 V

MPI – Troubleshooting13-67
RESISTANCE AND CONTINUITY BETWEEN HARNESS SIDE CONNECTORS AND TERMINALS
Engine-ECU Harness Side Connector Terminal Arrangement
Terminal No.Inspection itemNormal condition (Check condition)
1 – 12No.1 injector2 – 3 Ω (At 20C)
14 – 12No.2 injector
2 – 12No.3 injector
15 – 12No.4 injector
3 – 12Fuel pressure control valve28 – 36 Ω (At 20C)
4 – 12Stepper motor coil (A1)28 – 33 Ω (At 20C)
17 – 12Stepper motor coil (A2)
5 – 12Stepper motor coil (B1)
18 – 12Stepper motor coil (B2)
6 – 12Secondary air control solenoid valve28 – 36 Ω (At 20C)
11 – 12Wastegate solenoid valve62 – 74 Ω (At 20C)
60 – 12Oxygen sensor heater
<EVOLUTION-V, VI>11 – 18 Ω (at 20C)
13 – Body earthEngine-ECU earthContinuity established (0 Ω)
26 – Body earth
72 – 92Intake air temperature sensor5.3 – 6.7 kΩ (When intake air temperature is 0C)
2.3 – 3.0 kΩ (When intake air temperature is 20C)
1.0 – 1.5 kΩ (When intake air temperature is 40C)
0.30 – 0.42 kΩ (When intake air temperature is 80C)
74 – 77High temperature sensor3 Ω or less
83 – 92Engine coolant temperature sensor5.1 – 6.5 kΩ (When coolant temperature is 0C)
2.1 – 2.7 kΩ (When coolant temperature is 20C)
0.9 – 1.3 kΩ (When coolant temperature is 40C)
0.26 – 0.36 kΩ (When coolant temperature is 80C)
87 – 92Idle position switchContinuity established (when throttle valve is at idle
position)
No continuity (when throttle valve is slightly open)
91 – Body earth–Continuity established

27-1
REAR AXLE
CONTENTS
GENERAL 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outline of Change 2. . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE SPECIFICATIONS 2. . . . . . . . . . . . . .
LUBRICANT 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 3. . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING <AYC> 4. . . . . . . . . . . . .
ON-VEHICLE SERVICE
<VEHICLES WITH AYC> 31. . . . . . . . . . . . . . .
Rear Axle Total Backlash Check 31. . . . . . . . . . .
Gear Oil Level Check 31. . . . . . . . . . . . . . . . . . . .
Gear Oil Change 32. . . . . . . . . . . . . . . . . . . . . . . . .
Fluid Level Check 33. . . . . . . . . . . . . . . . . . . . . . . . Bleeding 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AYC Operation Check 34. . . . . . . . . . . . . . . . . . . .
Hydraulic Pressure Check 35. . . . . . . . . . . . . . . . .
Differential Carrier Oil Seal
Replacement 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel Speed Sensor Output Voltage
Measurement <Vehicles without ABS> 37. . . . .
Action When Battery Runs Out 38. . . . . . . . . . . .
HYDRAULIC UNIT
<VEHICLES WITH AYC> 39. . . . . . . . . . . . . . .
SENSOR RELAY
<VEHICLES WITH AYC> 41. . . . . . . . . . . . . . .
AYC-ECU 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REAR AXLE – General / Service Specifications / Lubricant27-2
GENERAL
OUTLINE OF CHANGE

The descriptions of the service procedures for the AYC system including the troubleshooting using
an MUT-II tester has been incorporated.
SERVICE SPECIFICATIONS
<Vehicles with AYC>
ItemsStandard valueLimit
Rear axle total backlash mm–5
Pressure generated by hydraulic unit MPa0 – 1.6–
Wheel bearing axial play mm–0.05
Wheel bearing rotation starting torque Nm–1.0 or less
LUBRICANT
<Vehicles with AYC>
ItemsSpecified lubricantCapacity
Gear oilTorque
transfer
differential
DifferentialHypoid gear oil API classification GL-5 or higher
SAE viscosity No. 90, 80W0.41 ± 0.02

differentialTorque transfer
mechanismMITSUBISHI GENUINE DIA QUEEN AYC FLUID0.700
0.05

Hydraulic piping fluidDia Queen ATF SPII or equivalent1

Torque transfer mechanism oil seal lipsVaselineAs required

REAR AXLE – Special Tools27-3
SPECIAL TOOLS
ToolNumberNameUse
MB991502MUT-II sub-
assemblyInspection of AYC
(diagnosis display by MUT-II)
MB991529Diagnosis code
check harnessInspection of AYC
(diagnosis display by AYC warning lamp)
MD998330
(MD998331)Oil pressure
gauge
(2,942 kPa)Hydraulic pressure measurement
<vehicles with AYC>
MB991705Hose adapter
MB990925Bearing & oil seal
installer setPressfitting of oil seal <differential>
MB991115Oil seal installerPressfitting of oil seal <differential>
(used in combination with MB990938)
MD998812Installer capPressfitting of oil seal <torque transfer mecha-
nism of vehicles with AYC>
MD998813Installer 100
MD998829Installer adapter
(60)