fuel MITSUBISHI LANCER EVOLUTION VI 1999 Service Manual

MPI – Troubleshooting13-54
INSPECTION PROCEDURE 46 <EVOLUTION-VI>
Check fuel pump circuit.
Measure at the fuel pump relay connector D-18.

Disconnect the connector and measure at the harness side.

Continuity between 1 and earth
OK:ContinuityNGCheck the following connector:
D-04NG
Repair
OK
Check trouble symptom.
NG
Check the harness wire between fuel pump and earth, and repair
if necessary.
OK
Check the following connectors: A-123, B-64, D-18, D-32NG
Repair OKCheck trouble symptom.
NG
Check the harness wire between fuel pump and fuel pump relay
No.2 connector.NG
Repair
OK
Replace the fuel pump.
INSPECTION PROCEDURE 47
Check the fuel pump drive control circuit.
NG
Check the harness wire between the fuel pump relay and engine-
ECU connector.
OK
Check trouble symptom.
OK
Check trouble symptom.
NG
Check the harness wire
between fuel pump relay
and ignition switch con-
nector.NG
Repair
OK
Check the ignition switch. (Refer to GROUP 54.)OK
Check trouble symptom.
NG
Replace the engine-ECU.
NG
Repair
OK
Check the following connector: B-59
OK
Measure at the engine-ECU connector B-59.

Disconnect the connector and measure at the harness side.

Voltage between 8 and earth (Ignition switch: ON)
OK:System voltageNG
Measure at the fuel pump relay connector B-28.

Disconnect the connector and measure at the harness side.

Voltage between 3, 4 and earth (Ignition switch: ON)
OK:System voltageNGCheck the following
connectors: B-65, B-76NG
Repair
Check the following
connector: B-28NG
Repair

MPI – Troubleshooting13-56
DATA LIST REFERENCE TABLE
Item
No.Inspection
itemInspection contentsNormal conditionInspection
procedure
No.Reference
page
11Oxygen
sensorEngine:After having
warmed up
Air/fuel mixture is
made leaner when de-
When at 4,000 r/min,
engine is suddenly
decelerated200 mV or lessProcedure
No. 3113-42
made leaner when de-
celerating, and is made
richer when racing.
When engine is
suddenly raced600 – 1,000 mV
Engine:After having
warmed up
The oxygen sensor
si
gnal is used to check
Engine is idling400 mV or less
(Changes)
signal is used to check
the air/fuel mixture
ratio, and control
condition is also
checked by the ECU.2,500 r/min600 – 1,000 mV
12Air flow
sensor*
Engine coolant
tem
perature: 80 –
Engine is idling17 – 43 Hz––
sensor
<EVOLU-
TION-IV>temperature: 80
95C

Lamps, electric
li f d ll
2,500 r/min46 – 86 Hzp
cooling fan and all
accessories: OFF

Transmission:
Neutral (A/T:
P range)Engine is racedFrequency
increases in
response to
racing
12Air flow
sensor*
Engine coolant
tem
perature: 80 –
Engine is idling12 – 38 Hz––
sensor
<EVOLU-
TION-V, VI>temperature: 80
95C

Lamps, electric
li f d ll
2,500 r/min36 – 76 Hzp
cooling fan and all
accessories: OFF

Transmission:
Neutral (A/T:
P range)Engine is racedFrequency
increases in
response to
racing
13Intake air
temperature
sensor
Ignition switch: ON or
with engine runningWhen intake air
temperature is –20C–20CCode No.
1313-9
sensorWhen intake air
temperature is 0C0C
When intake air
temperature is 20C20C
When intake air
temperature is 40C40C
When intake air
temperature is 80C80C
NOTE
*: In a new vehicle [driven approximately 500 km or less], the air flow sensor output frequency is sometimes
10% higher than the standard frequency.

MPI – Troubleshooting13-61
8. ACTUATOR TEST REFERENCE TABLE
Item
No.Inspection
itemDrive contentsInspection contentsNormal conditionInspection
procedure
No.Reference
page
01InjectorsCut fuel to No.
1 injectorEngine:
After having warmed
up/Engine is idling
Idling condition
becomes different
(becomes unsta
Code No.
4113-15
02Cut fuel to No.
2 injectorup/Engine is idling
(Cut the fuel supply to each
injector in turn and check
li d hi h d’ff
(becomes unsta-
ble, resulting in
engine stall).
03Cut fuel to No.
3 injector
j
cylinders which don’t affect
idling.)
04Cut fuel to No.
4 injector
07Fuel pumpFuel pump
operates and
fuel is recircu-
lated.
Engine:
Cranking

Fuel
pump:
Forced
driving
Inspect ac-
cording to
Pinch the
return hose
with fingers
to feel the
pulse of the
fuel being
recirculated.Pulse is felt.Procedure
No. 2513-36
cording to
both the
above condi-
tions.
Listen near
the fuel tank
for the
sound of
fuel pump
operation.Sound of opera-
tion is heard.
09Fuel
pressure
control
valveSolenoid valve
turns from
OFF to ON.Ignition switch: ONSound of opera-
tion can be heard
when solenoid
valve is driven.Procedure
No. 3413-45
12Waste
gate
solenoid
valveSolenoid valve
turns from
OFF to ON.Ignition switch: ONSound of opera-
tion can be heard
when solenoid
valve is driven.Procedure
No. 3513-45
13Fuel pump
relay No.2Turn fuel
pump relay
No.2 from
OFF to ON.
Ignition switch: ON

Listen to pump operation
sound near fuel tank.Sound of opera-
tion can be heard.Procedure
No. 2513-36
17Basic igni-
tion timingSet to ignition
timing adjust-
ment mode
Engine: Idling

Timing light is set5BTDC––

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 – Troubleshooting13-64
Terminal
No.Normal condition Check condition (Engine condition) Check item
20Radiator fan motor
relay (HI)
<EVOLUTION VI>
Radiator fan not operating (coolant temperature:
95C or below)System voltage
<EVOLUTION-VI>Radiator fan at high speed (coolant temperature:
105C or above)0 – 3 V
21Fan motor relay (LOW)
<EVOLUTION-IV, V>Fan not operating (coolant temperature: 95C or
below)System voltage
Fan at low speed (coolant temperature: 95 – 100C)0 – 3 V
21Radiator fan motor
relay (LOW)
<EVOLUTION VI>
Radiator fan not operating (coolant temperature:
95C or below)System voltage
<EVOLUTION-VI>Radiator fan at low speed (coolant temperature: 95
– 105C)0 – 3 V
22A/C relay
Engine: Idling

A/C switch: OFF to ON (Compressor is being
driven.)System voltage, or 6
V or more instanta-
neously to 0 – 3 V
32A/C condenser fan
motor relay (HI)
<EVOLUTION VI>
A/C condenser fan not operating (A/C switch: ON,
coolant temperature: 105C or below)System voltage
<EVOLUTION-VI>A/C condenser fan at high speed (A/C switch: ON,
coolant temperature: 105C or above)0 – 3 V
33Alternator G terminal
Engine: Warm, idle (radiator fan: OFF)

Headlamp: OFF to ON

Brake lamp: OFF to ON

Rear defogger switch: OFF to ONVoltage rises by 0.2 –
3.5 V.
34A/C condenser fan
motor relay (LOW)
<EVOLUTION VI>
A/C condenser fan not operating (A/C switch: OFF,
coolant temperature: 105C or below)System voltage
<EVOLUTION-VI>A/C condenser fan at low speed (A/C switch: OFF,
coolant temperature: 105C or above)0 – 3 V
36Engine warning lampIgnition switch: OFF → ON0 – 3 V → System
voltage (After several
seconds have
elapsed)
37Power steering fluid
pressure switchEngine: Idling after
warming upWhen steering wheel is
stationarySystem voltage
When steering wheel is
turned0 – 3 V
38Control relayIgnition switch: OFFSystem voltage
Ignition switch: ON0 – 3 V
39Fuel pump relay No.2While engine is idling, suddenly depress the
accelerator pedal.Momentarily rises
slightly from 0 to 3 V.
40Exhaust temperature
warning lampIgnition switch: OFF to ON0 – 3 V to system
voltage (After several
seconds have
elapsed)

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

MPI – On-vehicle Service13-68
ON-VEHICLE SERVICE
FUEL PUMP RESISTOR CHECK
<EVOLUTION-VI>
Standard value: 0.45 – 0.65 Ω
The inspection procedures are the same as for the preceding
year-models.
FUEL PUMP RELAY No.2 CONTINUITY CHECK
<EVOLUTION-VI>
Battery voltageTerminal No.
1234
Not supplied
Supplied
ENGINE CONTROL RELAY AND FUEL PUMP
RELAY CONTINUITY CHECK
Battery voltageTerminal No.
1234
Not supplied
Supplied
Equipment side connector for engine
control relay and fuel pump relay
Fuel pump relay
Engine control relay

FUEL SUPPLY – General / Fuel Tank13-69
FUEL SUPPLY
GENERAL
OUTLINE OF CHANGE
The service procedures have been revised as shown below because of change in the fuel pump & gauge
assembly and the fuel gauge unit. <EVOLUTION-VI>
FUEL TANK <EVOLUTION-VI>
REMOVAL AND INSTALLATION
4
32 1
65
7
11
Removal steps
1. Fuel hose
2. Fuel pump & gauge assembly
3. Packing
A4. High-pressure fuel hose5. Fuel pipe assembly
6. Fuel gauge unit
7. Packing
NOTE
The service procedures other than those mentioned above
remain unchanged.
INSTALLATION SERVICE POINT
AHIGH-PRESSURE FUEL HOSE INSTALLATION
Caution
After connecting the quick-release joint of the
high-pressure fuel hose, pull it gently in the direction
of removal to check that the hose is firmly connected
with a play of about 3 mm.

CHASSIS ELECTRICAL – Ignition Switch and Immobilizer SystemCHASSIS ELECTRICAL – Ignition Switch and Immobilizer System54-17
Inspection Procedure 2
ID code cannot be registered using the MUT-II.
Probable cause
The cause is probably that there is no ID code registered in the immobilizer-ECU,
or there is a malfunction of the immobilizer-ECU.
Malfunction of the transponder

Malfunction of the ignition key ring antenna

Malfunction of harness or connector

Malfunction of the immobilizer-ECU
No ignition key can be registered.NOReplace the ignition key that cannot be
registered.Re-register the ID code.
(Refer to P.54-21.)
YES
Is a diagnosis code output?NOTo INSPECTION CHART FOR DIAG-
NOSIS CODE (Refer to P.54-13.)
YES
Check the immobilizer-ECU power
source and earth circuit. (Refer to
INSPECTION PROCEDURE 4.)OKCheck trouble symptoms.NGReplace the immobilizer-ECU.
Inspection Procedure 3
Engine does not start (cranking but no initial combustion).
Probable cause
If the fuel injectors are not operating, there might be a problem with the MPI system
in addition to a malfunction of the immobilizer system.
It is normal for this to occur if an attempt is made to start the engine using a key
that has not been properly registered.
Malfunction of the MPI system

Malfunction of the immobilizer-ECU
Is a diagnosis code output from the
immobilizer-ECU?NOTo INSPECTION CHART FOR DIAG-
NOSIS CODE (Refer to P.54-13.)
YES
Is a diagnosis code output from the
engine-ECU?NORefer to GROUP 13A – Troubleshoot-
ing.
YES
To inspection procedure for when there
is no initial combustion. (Refer to
GROUP 13A – Troubleshooting.)
OK
Check trouble symptoms.
NG
Check the immobilizer-ECU power sup-
ply and earth circuit (Refer to INSPEC-
TION PROCEDURE 4.)OKCheck trouble symptoms.NGReplace the immobilizer-ECU.

CHASSIS ELECTRICAL – Combination MetersCHASSIS ELECTRICAL – Combination Meters54-22
COMBINATION METERS
SERVICE SPECIFICATIONS
ItemsStandard valueLimit
SpeedometerAllowable indication range km/h
(Speedometer indication error to be
4037 – 45–
(Speedometer indication error to be
with –6% to +10%)8075 – 88–)
120113 – 132–
160150 – 176–
Pointer fluctuation km/h (at vehicle speeds of higher than 35
km/h)–±3
Tachometer indica-
tion error r/min
700All types of tachometer±100–
tion error r/min3,000Meters measurable up to 6,000 rpm and
meters measurable up to 8,000 rpm+ 150–
Meters measurable up to 9,000 rpm and
meters measurable up to 10,000 rpm+ 225
– 100–
4,750Meters measurable up to 6,000 rpm±160–
5,000Meters measurable up to 8,000 rpm±250–
Meters measurable up to 9,000 rpm and
meters measurable up to 10,000 rpm+ 325
– 125–
6,000Meters measurable up to 8,000 rpm±300–
7,000Meters measurable up to 9,000 rpm and
meters measurable up to 10,000 rpm+ 400
– 100–
8,000Meters measurable up to 10,000 rpm+ 400
– 0–
Fuel gauge unit
resistanceΩ
Main tankFloat point F1.8 ±1.2–
resistance ΩFloat point E65.2 ±4–
Sub tankFloat point F1.2 ±0.8–
Float point E44.8 ±3–
Fuel gauge unit
f
loat height mm
Main tankFloat point F16.4–
float height mmFloat point E122.6–
Sub tankFloat point F17.5–
Float point E134.6–
Engine coolant temperature gauge unit resistance (at 70 C) Ω104 ±13.5–
Fuel gauge resis-
tanceΩ
Power supply and earth192 ±19.2–
tance ΩPower supply and fuel gauge89 ±8.9–
Fuel gauge and earth103 ±10.3–
Engine coolant
temperature gauge
Power supply and earth187 ±18.7–
temperature gauge
resistance ΩPower supply and engine coolant temperature gauge90 ±4.5–
Engine coolant temperature gauge and earth247 ±24.7–