check engine MITSUBISHI LANCER EVOLUTION VIII 2004 Workshop Manual

ENGINE (4G6) – GENERAL, BASE ENGINE (6 M/T)19
1. O2 sensor2. Air flow sensor3. Air intake sensor4. Throttle position
sensor
5. Cam position sensor6. Crack angle sensor7. Atmospheric pressure
sensor
8. Water temperature
sensor
9. Knock sensor•Power supply
• Ignition switch IG
•Ignition switch ST
•Vehicle speed sensor
• A/C switch
1. Injector2. ISC servo (stepper
motor)
3. Fuel pressure control
solenoid valve
4. No.1 wastegate solenoid
valve
5. No.2 wastegate solenoid
valve
6. Purge control solenoid
valve
7. Secondary air control
solenoid valve•Engine control relay
•Fuel pump relay 2, 3
•A/C relay
•Ignition coil
• Fan controller
Engine ECU
6. Purge control
solenoid valveCanister
7. Secondary air
control solenoid valveFrom fuel tank
Secondary
air valveBypass
valve
1. O2sensor
3. Fuel pressure
control solenoid valve
4. Throttle
position
sensor
7. Atmospheric pressure
sensor
3. Air intake
sensor2. Air flow sensor
4. No.1
wastegate
solenoid valve
5. No.2 wastegate
solenoid valve
Only operates on 6M/TWastegate actuatorFuel pressure
regulator
1. Injector5.Cam position sensor8.Water temperature sensor
9.Knock sensor
Crack angle sensor
Catalytic converter Air
intakeCheck
valve
2. ISC servo
Vacuum
tank
From fuel
pump To fuel
tank
Control system diagram

REFERENCE MA
TERIAL – MAIN EQUIPMENT, COLD CLIMATE SPECIFICATIONS88
4WD
RSGSR
Equipment
5/MT6/MT
ABSrll
SRS airbags
Fuel level
Parking brake
Charge
Brake fluid
Engine check
Warning
lights
Door not properly closed
Lighting monitor warningBuzzer
Ignition key reminder warning
lll
Fixed time
intermittentll
Variable
intermittent(speed
sensitive)l
Windscre
en wipers2 speed
Mist spray
Equip
ment
Windscreen washer (synchronized with
wiper, 4jet)
lll
4WD
RSGSR
Equipment
5/MT6/MT
Rear
windowwiper /
washerFixed time intermittent,
synchronized with (R) gearpositionl
AM/FM tuner radio + MD player
+ DVDMMCS (DVD navigation
Mitsubishi MultiCommunication
System)r
Roof aeriallll
Roof and window aerial (diversity
aerial)r
W/out audiolll
Audio
parts
6 speakers (2 DIN compatible)r*3
Digital clock
Immobiliser system
lll
Manual heater
Air conditioning kit
ll
Equip
ment
Air
conditioning
Fully automatic air
conditioningl
Notes:
*3: Brackets for an aerial and radio are installed as standard.
Cold Climate Specifications
4WD
RSGSR
Equipment
5M/T6M/T
Battery
Weather strip silicon coating
Rear seat heater duct
Cold Climate Specification label
rrr
Door mirrors with heating elementsr

MPI General13A2
General
Service information issued contains the changes noted below. Other service details remain unchanged.
• Change from one to two wastegate solenoid valves. However, the No.2 wastegate solenoid valve on the 5 M/T is not
functional.
• Diagnosis code No. P1500 changed to P0622. <6M/T>
MPI system diagram
1.O2 sensor2. Air flow sensor3. Air intake sensor4. Throttle position
sensor
5. Cam position sensor6. Crack angle sensor7.Barometric pressure
sensor
8. Water temperature
sensor
9. Knock sensor•Power supply
• Ignition switch IG
• Ignition switch ST
•Vehicle speed sensor
• A/C switch
• A/C load signal
•Power steering fluid
pressure switch
•Alternator FR signal
•Intercooler water spray
switch (auto)
•Intercooler water spray
switch (manual)
1.Injector2. ISC servo (stepper
motor)
3.Fuel pressure control
solenoid valve
4.No.1 wastegate solenoid
valve
5. No.2 wastegate solenoid
valve
6. Purge control solenoid
valve
7. Secondary air control
solenoid valve•Engine control relay
•Fuel pump relay 2, 3
• A/C relay
•Ignition coil
• Fan controller
• Condenser fan relay (HI)
•Condenser fan relay
(LOW)
•Engine warning lamp
•Diagnosis output
• Alternator G terminal
•Intercooler water spray
relay
•Intercooler water spray
lamp
Engine ECU
6.Purge control
solenoid valveCanister
7.Secondary air
control solenoid valveFrom fuel tank
Secondary
air valveBypass
valve
1. O2sensor
3.Fuel pressure
control solenoid valve
4.Throttle
position
sensor
7. Barometric pressure
sensor
3. Air intake
sensor2. Air flow sensor
4. No.1
wastegate
solenoid valve
5.No.2 wastegate
solenoid valve
Only operates on 6M/TWastegate actuatorFuel pressure
regulator
1. Injector5.Cam position sensor8.Water temperature sensor
9.Knock sensor
Crack angle sensor
Catalytic converter Air
intakeCheck
valve
2.ISC servo
Vacuum
tank
From fuel
pump To fuel
tank

MPI – Troubleshooting13A3
Connector inspection : B32
Change No.2 wastegate solenoid valve.
Check connector:B19X
Inspect, repair harness between No.2 wastegate
solenoid valve and engine control relay.
• Check for broken wire and shorting.
Check connector:C49
Replace engine ECU
Check harness between No.2 wastegate
solenoid valve and engine ECU.
• Check output wire to see if broken or shorting.
Check connector: C49
Replace engine ECU.
B32 No.2: measure at wastegate solenoid valve
connector
• Undo connector and take measurement on
solenoid valve side
• Resistance between 1 and 2
OK:29 35Ω(at 20˚C)
Measure at B32 No.2 waste gate solenoid valve
connector.
• Undo connector and take measurement on
harness side.
• Ignition switch ON:
• Resistance between 1 – earth
OK:battery voltage
Measurement at C49 engine ECU connector
•Engine ECU terminal voltage measurement
• Ignition switch: ON
• Voltage between 6 – Earth
OK:battery voltage
Check harness between No.2 wastegate
solenoid valve and engine ECU.
• Check for damage to output wire.
Check harness between No.2 wastegate
solenoid valve and engine control relay.
•Check for damage to power supply cable.
TROUBLESHOOTING
1.Inspection procedures for different types of malfunction
Inspection procedure 37
No.2 Wastegate solenoid valve system <6M/T>
The No.2 wastegate solenoid valve controls excess pressure
introduced via the turbocharger wastegate actuator.
Assumed cause of concern
• No.2 wastegate solenoid valve malfunction
• Engine ECU malfunction
Repair
Repair
Repair
Repair
OK
OK
OK
OK
OK
OK
OK
NG
NG
NG
NG
NG
NG
NG
NGRepair
NGRepair
Repair
OK OK OK

MPI – TROUBLESHOOTING13A4
2.ENGINE ECU CHECKS
21 List of terminal voltages
22 List of resistances and conductance between harness side connector – terminal
Terminal No.Check itemCheck item (engine condition)Normal value
41No.1 wastegate
solenoid valveIgnition switch ONBattery voltage
Engine: warm, idling (using premium petrol)1V or less
6No.2 wastegate
solenoid valve
<6M/T>Ignition switch: ONBattery voltage
Accelerating in 2nd gear with throttle full open (at least 3500 rpm)Voltage decrease
Terminal No.Check itemStandard value, normal condition (check condition)
4147No.1 wastegate solenoid valve2935Ω(at 20˚C)
647No.2 wastegate solenoid valve <6 M/T>2935 Ω(at 20˚C)

151INTAKE, EXHAUST GENERAL, SERVICING STANDARD VALUES, VEHICLE SERVICING
SECTION 15
INTAKE, EXHAUST
CONTENTS
General........................................................1
Servicing standard values ........................1
Vehicle Servicing .......................................11. Turbocharger boost pressure check ..................1
2.Checking boost pressure control system ..........2
Air cleaner ..................................................3
General
The important service points were added as a result of the following changes. Other service points remain the same.
• Change to the turbocharger boost pressure (on 6M/T)
• Change from one to two wastegate solenoid valves. However, the No.2 wastegate on the 5M/T is not functional.
Servicing Standard Values
ITEMSTANDARD VALUE
Turbocharger boost pressure kPa <6M/T>97144
Vehicle servicing
1. Checking turbocharger boost pressure
<5M/T>
Since the No.2 wastegate solenoid valve does not function, the
same check of the No.1 wastegate solenoid valve as before iscarried out.
6M/T
Note
The driving test, which is done with the throttle fully open,
must be done in a safe place with two people in the vehicle.
The person sitting in the passenger seat should take the
reading of the values on the pressure gauge.
(1) Remove the hose (black) from the No.1 wastegate solenoid
valve, and fit the pressure gauge to this hose. Fit a plug to
solenoid valve nipple from which the hose (black) has been
removed.
(2) Remove the No.2 wastegate solenoid valve connector.(3)Accelerate at full throttle in 2nd gear, and then take the boost
pressure measurement when engine speed gets to at least
3,000rpm.
Standard value: 97 – 144kPa
(4) When the boost pressure is lower than the standard value, the
cause could be one of the following:
1. Wastegate actuator misoperation
2. Boost pressure leak
3. Turbocharger NG
(5) When boost pressure is higher than standard value, the boost
pressure control may be faulty, so please check the following
points.
Air cleaner
No.1 Wastegate
solenoid valveNo.2 Wastegate
solenoid valve

INTAKE – EXHAUST – VEHICLE SERVICING152
1) Wastegate actuator misoperation
2) Wastegate valve misoperation3) Wastegate actuator rubber hose detachment, cracking.
2. Boost pressure control system inspection <6M/T>
Note
The driving test, which is done with the throttle fully open,
must be done in a safe place with two people in the vehicle.
The person sitting in the passenger seat should take thereading of the values on the pressure gauge.
(1) Remove hose (black) from No.1 wastegate solenoid valve, then
connect a threeway coupling between the hose and the
solenoid valve.
(2) Connect a hand vacuum pump to the threeway coupling.
(3)Remove boost hose from the wastegate actuator control boost
nipple on the air outlet fitting, and fit a plug over the nipple.
(4)Apply a vacuum whilst covering and releasing the tip of the
hose to check the vacuum condition.
(5) Ignition switch to “LOCK” (OFF) position.
(6) Remove wastegate solenoid valve connector.
(7) Apply a vacuum whilst covering and releasing the tip of the
hose, to check the vacuum condition (stop the hose tip with a
plug when driving).
Note
When vacuum condition is not normal, it may be assumed that
there is a problem with the wastegate actuator, wastegate solenoid
valve, or hose.
Engine conditionBoost hose tipNormal condition
Stop (ignition
switch:“ON”
position)ReleasedVacuum leaks
CoveredVacuum is maintained
Idle running after
warming up.Vacuum leaks
Engine conditionBoost hose tipNormal condition
Stop (ignition s
witch:
“ON” position)ReleasedV
acuum leaks
CoveredVacuum is maintained
Accelerating with
throttle full open in
2nd gear (at least
3500rpm)Vacuum leaks
Air cleaner
No.1 Wastegate
solenoid valve
No.2 Wastegate
solenoid valve
Wastegate
actuator
Boost hose

MANUAL TRANSMISSION TROUBLESHOOTING2219
3.Fault classification
4. Fault classification procedure
Checking procedure 2
FaultCheck procedure No.Page ref.
No communication between MUTII/III and 4WDECU22219
When ignition switch is ON, (engine stopped), ACD mode indicator lamp does not come on.32220
Even after engine starts, at least 2 ACD mode indicator lamps remain lit 42220
No communication between MUTII/III and 4WDECUAssumed cause of concern
Diagnosis output circuit, 4WDECU power supply circuit,
earth circuit or 4WDECU malfunctions are possible.• Harness, connector malfunction
•4WDECU malfunction
Measurement at C122, diagnosis code connector and
C37 4WDECU connector.
• Resistance between C122 1 and C37 46
• Resistance between C122 7 and C37 35
OK:2Ω or less
Measurement at C38 4WDECU connector
•Measure ECU terminal voltage
• Ignition switch ON
OK:battery voltage
Measurement at C37, C38, 4WDECU connector
• Undo connector, take measurement on harness side
• Resistance between C38 26 and body earth
Connector check:C37, C38
NG > repair
Fault confirmation Replace 4WDECU
Connector check:C37, C23, C22, C20, C122,
C110, C06
NG > repair
Fault confirmationHarness check between 4WDECU and diagnosis
connector
Connector check:C38, C212, C210, C133
NG > repair
Fault confirmation
Check harness between ignition switch and 4WDECU
•Check power supply wire to see if broken or
damaged
NG > repair
Connector check:C37, C38
NG > repair
Fault confirmation
Check harness between 4WDECU – earth
• Check earth wire to see if broken or damaged
NG > repair
OK
OK
OK
OK
NG
OK
NG
NG
OK
OK
NG
NG
NG
NG

MANUAL TRANSMISSION TROUBLESHOOTING2220
The ACD mode injector lamp does not come on when the ignition
switch is ON (engine stopped)Assumed cause of concern
ACD mode indicator lamp circuit or 4WDECU malfunctions are possible.• Harness, connector malfunction
• ACD mode indicator lamp ASSY malfunction
• 4WDECU malfunction
Measurement at C106, combi. meter connector.
• Undo connector, take measurement on harness side
• Ignition switch ON
OK:battery voltage
Measurement at C37 4WDECU connector
• Undo connector, take measurement on harness side
• Ignition switch ON
• Earth 40, 51, 52 to body earth
OK:indicator lamp on
Connector check:C37
NG > repair
Fault confirmation Replace 4WDECU
Connector check:C106, C212, C210
NG > repair
Fault confirmation
Check harness between ignition switch – ACD mode
indicator lamp ASSY
• Check power supply wire to see if broken or
damaged
•NG > repair
Check ACD mode indicator lamp ASSY
NG > replace
Connector check:C37, C133, C106
NG > repair
Fault confirmation
Check harness between ACD mode indicator lamp
ASSY 4WDECU
• Check output wire to see if broken or damaged
When C37 4WDECU connector is undone, do all
ACD mode indicator lamps all go out?
Replace 4WDECU
Check connector:C37, C133, C106
NG > repair
Fault confirmation Check harness between ACD mode indicator ASSY
4WDECU
• Check output wire for earthing, shorting
NG > repair
Replace ACD mode indicator ASSY
Checking procedure 3
Checking procedure 4
Even after engine starts, at least 2 ACD mode indicator lamps
remain litAssumed cause of concern
ACD mode indicator lamp output circuit malfunction is possible.•Harness, connector malfunction
• 4WDECU malfunction
• ACD mode indicator lamp ASSY malfunction
Remarks
This phenomenon is limited to when communication with MUTII/III is possible (4WDECU power supply normal), and diagnosis
code is normal/correct.
OK
NG
NG
NO
OK
OK
NG
NG
OK
OK
OK
NG
YESOK
NG
OK