warning MITSUBISHI LANCER EVOLUTION VI 1999 Workshop Manual

WARNING!
(1) Improper service or maintenance of any component of the SRS, or any SRS-related component,
can lead to personal injury or death to service personnel (from inadvertent firing of the air
bag) or to the driver and passenger (from rendering the SRS inoperative).
(2) SRS components should not be subjected to heat over 93C, so remove the SRS-ECU, air
bag module and clock spring before drying or baking the vehicle after painting.
(3) Service or maintenance of any SRS component or SRS-related component must be performed
only at an authorized MITSUBISHI dealer.
(4) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP
52B – Supplemental Restraint System (SRS), before beginning any service or maintenance
of any component of the SRS or any SRS-related component.
NOTE
Section titles with asterisks (*) in the table of contents in each group indicate operations requiring warnings.

GENERAL – How to Use Troubleshooting/Inspection Service Points00-8
WHEN USING THE WARNING LAMP
1. Use the special tool to earth No.1 terminal (diagnosis
control terminal) of the diagnosis connector.
2. To check ABS system, remove the valve relay.
NOTE
That is because the valve relay is off and the warning
lamp remains illuminated if there is a fault in the ABS
system.
3. Turn on the ignition switch.
4. Read out a diagnosis code by observing how the warning
lamp flashes.
Applicable systems
System nameWarning lamp name
MPIEngine warning lamp
AY CAYC warning lamp
ABSABS warning lamp
Indication of diagnosis code by warning lamp
When the diagnosis code No.24 is outputWhen no diagnosis code is output*
On
Off
1.5 secs.0.5 sec.0.5 sec.
Pause
time 3
secs.Tens
signalPlace
division
2 secs.Units
signal
On
Off
0.5 sec.
NOTE
*: Even if the ABS system is normal, removing the valve relay causes the diagnosis code No.52 to
be output.
WHEN USING THE VOLTMETER
Use the special tool to connect the diagnosis output terminals
and the earth terminal of the diagnosis connector to a voltmeter
and take a reading of the diagnosis codes from the movement
of the needle.
Voltmeter connection terminals
System namePositive connection
terminalNegative connec-
tion terminal
Full-auto air
conditioner114 or 5
Diagnosis connector
MB991529
Earth terminal
Full-auto air con-
ditioner terminal
MB991529

GENERAL – Precautions Before Service00-15
PRECAUTIONS BEFORE SERVICE
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
1. Items to follow when servicing SRS
(1) Be sure to read GROUP 52B – Supplemental Restraint System (SRS).
For safe operations, please follow the directions and heed all warnings.
(2) Always use the designated special tools and test equipment.
(3) Wait at least 60 seconds after disconnecting the battery cable before doing any further work.
The SRS system is designed to retain enough voltage to deploy the air bag even after the battery
has been disconnected. Serious injury may result from unintended air bag deployment if work
is done on the SRS system immediately after the battery cable is disconnected.
(4) Never attempt to disassemble or repair the SRS components. (SRS air bag control unit, air bag
module and clock spring.) If faulty, replace it.
(5) Warnings labels must be needed when servicing and handling SRS components. Warning labels
are located in the following locations.
Sun visor
Glove box
SRS air bag control unit
Steering wheel
Steering gear and linkage
Air bag module
Clock spring
(6) Store components removed from the SRS in a clean and dry place.
The air bag module should be stored on a flat surface and placed so that the pad surface is
facing upwards.
(7) Be sure to deploy the air bag before disposing of air bag module or disposing of a vehicle equipped
with an air bag. (Refer to GROUP 52B – Air Bag Module Disposal Procedures.)
(8) Whenever you finish servicing the SRS, check the SRS warning lamp operation to make sure
that the system functions properly.
2. Observe the following when carrying out operations on place where SRS components are installed,
including operations not directly related to the SRS air bag.
(1) When removing or installing parts do not allow any impact or shock to the SRS components.
(2) SRS components should not be subjected to heat over 93C, so remove the SRS components
before drying or baking the vehicle after painting.
After re-installing them, check the SRS warning lamp operation to make sure that the system
functions properly.

MPI – General13-3
MPI System Diagram
1 Injector
2 ISC servo
3 Fuel pressure control valve
4 Waste gate solenoid valve
5 Secondary air control solenoid valve

Control relay

Fuel pump relay

A/C relay

Ignition coil

Exhaust temperature warning lamp

Engine warning lamp

Diagnosis output

Alternator G terminal

Fan motor relay

Tachometer

Fuel pump relay No.2 1 Oxygen sensor
2 Air flow sensor
3 Intake air temperature sensor
4 Throttle position sensor
5 Idle switch
6 Camshaft position sensor
7 Crank angle sensor
8 Barometric pressure sensor
9 High temperature sensor
10 Engine coolant temperature sensor
11 Detonation sensor

Power supply voltage

Ignition switch-IG

Ignition switch-ST

Vehicle speed sensor

A/C switch

Power steering fluid pressure switch

Alternator FR signalEngine ECU
1 Oxygen sensor
2 Air flow sensor3
Intake air tem-
perature sensor
4,
5
6 Camshaft position
sensor
7 Crank angle sensor 8 Barometric
pressure sensor
9 High temperature
sensor 10 Coolant temperature sensor
11 Detonation sensor1 Injector 2 ISC servo
3 Fuel pressure
control valve
4 Waste gate
solenoid valve 5 Secondary air
control solenoid
valveCanister
Check valveFrom
fuel
tank
Throttle position
sensor (with a
built-in
idle
switch)
Secondary
air valve
AirTo fuel
tankFuel
pressure
regulatorFrom
fuel
pump
Waste gate
actuator
Catalytic converter

MPI – Troubleshooting13-6
TROUBLESHOOTING
DIAGNOSIS TROUBLESHOOTING FLOW
Refer to GROUP 00 – How to Use Troubleshooting/Inspection
Service Points.
DIAGNOSIS FUNCTION
ENGINE WARNING LAMP (CHECK ENGINE LAMP)
If an abnormality occurs in any of the following items related
to the Multipoint Fuel Injection (MPI) system, the engine
warning lamp will illuminate.
If the lamp remains illuminated or if the lamp illuminates while
the engine is running, check the diagnosis code output.
Engine warning lamp inspection items
Engine-ECU
Air flow sensor
Intake air temperature sensor
Throttle position sensor
Engine coolant temperature sensor
Crank angle sensor
Camshaft position sensor
Barometric pressure sensor
Detonation sensor
Injector
Ignition coil, power transister unit
METHOD OF READING AND ERASING DIAGNOSIS
CODES
Refer to GROUP 00 – How to Use Troubleshooting/Inspection
Service Points.
INSPECTION USING MUT-II DATA LIST AND
ACTUATOR TESTING
1. Carry out inspection by connecting the MUT-II.
If there is an abnormality, check and repair the chassis
harnesses and components.
2. After repairing, check that the abnormal input and output
have returned to normal as a result of the repairs.
3. Erase the diagnosis code memory.
4. Remove the MUT-II and carry out a road test to confirm
that the problem has disappeared.
Engine warning lamp
(check engine lamp)

MPI – Troubleshooting13-18
INSPECTION CHART FOR TROUBLE SYMPTOMS
Trouble symptomInspection
procedure
No.Reference page
Communication
with MUT-IIis
Communication with all systems is impossible.113-20
with MUT-II is
impossible.
Communication with engine-ECU only is impossible.213-20
Engine warning
lamp and
related parts
The engine warning lamp does not illuminate right after the
ignition switch is turned to the ON position.313-21
related partsThe engine warning lamp remains illuminating and never goes
out.413-21
StartingNo initial combustion (starting impossible)513-22
Initial combustion but no complete combustion
(starting impossible)613-23
Long time to start (improper starting)713-24
Idling stability
(Improper idling)
Unstable idling (Rough idling, hunting)813-25
(Improper idling)
Idling speed is high. (Improper idling speed)913-26
Idling speed is low. (Improper idling speed)1013-27
Idling stability
(Engine stalls)
When the engine is cold, it stalls at idling. (Die out)1113-28
(Engine stalls)
When the engine is hot, it stalls at idling. (Die out)1213-29
The engine stalls when starting the car. (Pass out)1313-30
The engine stalls when decelerating.1413-30
DrivingHesitation, sag or stumble1513-31
The feeling of impact or vibration when accelerating1613-31
The feeling of impact or vibration when decelerating1713-32
Poor acceleration1813-32
Surge1913-33
Knocking2013-33
Dieseling2113-33
Too high CO and HC concentration when idling2213-34
Low alternator output voltage (approx. 12.3 V)2313-35

MPI – Troubleshooting13-21
INSPECTION PROCEDURE 3
The engine warning lamp does not illuminate right after
the ignition switch is turned to the ON position.
Probable cause
For checking for burnt-out bulb, the engine-ECU causes the engine warning lamp
to illuminate for five seconds immediately after the ignition switch is turned to ON.
If the engine warning lamp does not illuminate immediately after the ignition switch
is turned to ON, one of the malfunctions listed at right has probably occurred.
Burnt-out bulb of the engine warning lamp

Defective engine warning lamp circuit

Malfunction of the engine-ECU
MUT-II Data list
16 engine-ECU power supply voltage (Refer to P.13-57)NGCheck the engine-ECU power supply and earth circuit.
(Refer to P.13-53, INSPECTION PROCEDURE 45.)
OK
Measure at the engine-ECU connector B-60.

Disconnect the connector, and measure at the harness side.

Earth the terminal No.36. (Ignition switch: ON)
OK:The engine warning lamp illuminates.OKCheck the following
connector: B-60NG
Repair
OK
Check trouble symptom.
NG
Replace the engine-ECU.
NG
Check for burnt-out bulb.NG
Replace
OK
Measure at the combination meter connector B-08.

Disconnect the connector, and measure at the harness side.

Voltage between 42 and earth (Ignition switch: ON)
OK:System voltageNGCheck the engine warning lamp power supply circuit, and repair
if necessary.
OK
Check the following connectors:
B-08, B-65, B-60NG
Repair
OK
Check trouble symptom.NGCheck the harness wire between combination meter and engine-
ECU connector, and repair if necessary.
INSPECTION PROCEDURE 4
The engine warning lamp remains illuminating and never
goes out.
Probable cause
In cases such as the above, the cause is probably that the engine-ECU is detecting
a problem in a sensor or actuator, or that one of the malfunctions listed at right has
occurred.
Short-circuit between the engine warning lamp and
engine-ECU

Malfunction of the engine-ECU
MUT-II Self-Diag code
Are diagnosis codes displayed?Ye sRefer to P.13-8, INSPECTION CHART FOR DIAGNOSIS CODES.
No
Measure at the combination meter connector B-08.

Disconnect the connector, and measure at the harness side.

Disconnect the engine-ECU connector

Continuity between 53 and earth
OK:No continuityNGCheck the harness wire between combination meter and engine-
ECU connector, and repair if necessary.
OK
Replace the engine-ECU.

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)

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)

REAR AXLE – Special Tools / Troubleshooting <AYC>27-4
MB990925
Brass bar
Bar (one-touch type)Toolbox
Installer adapter
Tool number (MB990925)O.D. mmTool number (MB990925)O.D. mm
AMB99092639.0AMB99093363.5
MB99092745.0MB99093467.5
MB99092849.5MB99093571.5
MB99092951.0MB99093675.5
MB99093054.0MB99093779.0
MB99093157.0BMB990938–
MB99093261.0CMB990939–
TROUBLESHOOTING <AYC>
BASIC TROUBLESHOOTING CONDITIONS
Refer to Group 00 – How to Use Troubleshooting / Inspection Service Points.
NOTE
Before starting the troubleshooting procedure, make sure that the following items have been checked
okay.

The correct steering wheel has been properly installed in the neutral position of the steering column
shaft.

Tire and wheel sizes are correct with correct specifications. Inflation pressure, balance, and wear
conditions are okay.

Wheel alignment is correct.

The engine, suspension, and other parts have not been remodeled so as to affect the AYC system.
DIAGNOSIS FUNCTION
READING THE DIAGNOSIS CODE
Read the diagnosis code using an MUT-II tester or the AYC warning lamp.
(Refer to Group 00 – How to Use Troubleshooting / Inspection Service Points.)
ERASING THE DIAGNOSIS CODE
Refer to Group 00 – How to Use Troubleshooting / Inspection Service Points.