oil change MITSUBISHI LANCER EVOLUTION VI 1999 Workshop Manual

MPI – Troubleshooting13-15
Code No. 31 Detonation sensor systemProbable cause
Range of Check

Ignition switch: ON

Excluding 60 seconds after the ignition switch is turned to ON or immediately
after the engine starts.

Engine speed is approx. 5,000 r/min or more

Set conditions

The change in the detonation sensor output voltage (detonation sensor peak voltage
at each 1/2 revolution of the crankshaft) is less than 0.06 V for 200 times in
succession.
Malfunction of the detonation sensor

Improper connector contact, open or short-circuited
harness wire of the detonation sensor circuit

Malfunction of the engine-ECU
Measure at the detonation sensor con-
nector A-96.

Disconnect the connector and
measure at the harness side.

Continuity between 2 and earth
OK:ContinuityOKCheck the following connector:
B-62NG
Repair
OK
Check trouble symptom.
NG
Check the harness wire between the
engine-ECU and the detonation sensor
connector.OKReplace the detonation sensor.
Check trouble symptom.
NG
Replace the engine-ECU.
NG
Repair
NG
Check the harness wire between the
detonation sensor and earth, and repair
if necessary.
Code No. 41 Injector systemProbable cause
Range of Check

Engine speed is approx. 50–1,000 r/min

The throttle position sensor output voltage is 1.15 V or less.

Actuator test by MUT-II is not carried out.
Set conditions

Surge voltage of injector coil is not detected for 4 seconds.
Malfunction of the injector

Improper connector contact, open or short-circuited
harness wire of the injector circuit

Malfunction of the engine-ECU
OK
Check trouble symptom.NGCheck the harness wire between the
resistor and the injector connector, and
repair if necessary.
Check the injector control circuit.
(Refer to P.13-55, INSPECTION PRO-
CEDURE 50.)OK
OK
Measure at the injector connectors
A-53, A-54, A-55, A-56

Disconnect the connector, and
measure at the harness side.

Voltage between 1 and earth
(Ignition switch: ON)
OK:System voltageNGCheck the following connector:
A-125NG
Repair
OK
Measure at the resistor connector
A-125.

Disconnect the connector, and
measure at the harness side.

Voltage between 3 and earth
(Ignition switch: ON)
OK:System voltageNGCheck the harness wire between the
control relay and the resistor connector,
and repair if necessary.
Check the injector. (Refer to P.13-34.)*
Check the resistor. (Refer to P.13-34.)*NG
Replace
NOTE
*: Refer to Workshop Manual for LANCER EVOLUTION-IV and EVOLUTION-V (Pub. No. S9806CNCP9).

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 – Troubleshooting13-63
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

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 – On-vehicle Service <Vehicles with AYC>27-32
TORQUE TRANSFER MECHANISM
1. Remove the filler plug.
2. Check that the gear oil level is up to the bottom end
of the filler plug hole.
3. If the gear oil level is lower than the bottom end of the
filler plug hole, add the specified gear oil up to the bottom
end of the filler plug hole.
Specified gear oil:
MITSUBISHI GENUINE DIA QUEEN SUPER AYC
FLUID
4. Fit the filler plug and tighten it to the specified torque.
GEAR OIL CHANGE
DIFFERENTIAL
1. Remove the drain plug to discharge the gear oil.
2. Fit the drain plug and tighten it to the specified torque.
Tightening torque: 49 Nm
3. Remove the filler plug and add the specified gear oil
up to the bottom end of the filler plug hole.
Specified gear oil:
Hypoid gear oil API classification GL-5 or higher
SAE viscosity Number 90, 80W.
Quantity used: 0.41 ± 0.02

NOTE
10C or more: #90, less than 10C: #80
4. Fit the filler plug and tighten it to the specified torque.
Filler plug
49 Nm
Gear oil
Filler plug
49 Nm
Gear oil
Drain plug

General / Service Specifications /
Lubricants / Special Tools HEATER AND MANUAL
AIR CONDITIONER –55-3
HEATER AND MANUAL AIR CONDITIONER
GENERAL
OUTLINE OF CHANGE

The following service procedures have been established.
SERVICE SPECIFICATIONS
ItemsStandard value
Idle speed r/min700 ± 50
Idle up speed r/min850 ± 50
Resistor (for blower motor) ΩHI – LO (between terminals 3 and 2)2.81 ± 10%
HI – ML (between terminals 3 and 4)1.28 ± 10%
HI – MH (between terminals 3 and 1)0.33 ± 10%
Air gap (Compressor) mm0.4 – 0.6
LUBRICANTS
ItemsSpecified lubricantsQuantity
Compressor oil m
SUN PAG 56120 – 140
Pipe jointSUN PAG 56As required
Refrigerant gR134a (HFC-134a)555 – 595
SPECIAL TOOLS
ToolNumberNameUse
MB991367Special spannerRemoval and installation of armature mounting
nut of compressor
MB991386Pin

FULL-AUTOMATIC AIR CONDITIONER –
General / Service Specifications /
Lubricants / Special Tools55-33
FULL-AUTOMATIC AIR CONDITIONER
GENERAL
OUTLINE OF CHANGE

The following service procedures have been established.
SERVICE SPECIFICATIONS
ItemsStandard value
Idle speed r/min750
50
Idle-up speed r/min850
50
Air gap (Compressor) mm0.4 – 0.6
Air mix damper potentiometer
resistance kΩ
MAX. HOT position4.82
resistance kΩMAX. COOL position0.18
Outlet air changeover damper
potentiometer resistance kΩ
DEF position0.18
potentiometer resistance kΩFACE position4.82
LUBRICANTS
ItemsSpecified lubricantsQuantity
Compressor oil mSUN PAG 56120 – 140
Each connection of refrigerant lineSUN PAG 56As required
Refrigerant gR134a (HFC-134a)555 – 595
SPECIAL TOOLS
ToolNumberNameUse
MB991502MUT-II
sub-assemblyInspection of full-automatic air conditioner
MB991529Diagnosis code
check harnessInspection of full-automatic air conditioner
using a voltmeter

– Luggage Compartment WIRING HARNESS
CONFIGURATION DIAGRAMS
Connector
symbol
F
Glass
antenna
amplifier
NOTE
The connectors with framed
number are newly introduced.
C-14
LUGGAGE COMPARTMENT
F-01 (1-B) Defogger (–) <vehicles without choke coil>
F-02 (1-B) Defogger (–) <vehicles with choke coil>
F-03 (2) Choke coil
F-04 (3) Choke coil
F-05 (2) Trunk room lamp
F-06 (2) Vacant connector or high mounted stop
lamp (installed on rear shelf)
F-08 (2-B) Rear speaker (RH)
F-09 (1-B) Defogger (+) <vehicles with choke coil>
F-10 (1-B) Defogger (+) <vehicles without choke coil>
F-11 (3) Rear wiper motor
F-12 (1-B) Rear door switch (RH)
F-13 (2) High mounted stop lamp (installed on rear
spoiler)
F-15 (6) Rear combination lamp (RH)
F-16 (2-GR) Licence plate lamp (RH)
F-17 (1-B) Trunk room lamp switch
F-18 (2-GR) Licence plate lamp (LH)F-20 (6) Rear combination lamp (LH)
F-23 (2-B) Rear speaker (LH)
F-24 (1) Glass antenna
<vehicles with diversity glass antenna>
F-25 (1) Glass antenna
F-26 (1-B) Rear door switch (LH)
F-27 (3-B) Proportioning valve <vehicles with AYC>
F-28 (2-B) Direction valve (LH) <vehicles with AYC>
F-29 (2-B) Direction valve (RH) <vehicles with AYC>
F-30 (8-B) Rear harness and AYC harness combina-
tion
F-31 (2-B) Accumulator pressure switch
<vehicles with AYC>
F-32 (2-B) AYC motor
F-33 (6) CD changer
F-34 (2) Rear window washer
F-35 (2) Windshield washer motor