relay MITSUBISHI LANCER EVOLUTION VIII 2004 Workshop Manual

ENGINE (4G6) – GENERAL, BASE ENGINE (6 M/T)18
Control system (6M/T)
The following changes have been made, based on the control system in the 4G63DOHCT/C engine fitted in the current
Lancer Evolution VIII.
* Addition of wastegate solenoid valve (1 valve –> 2 valves)
System Block Diagram
Air flow sensor (AFS)
Air temperature sensor
Atmospheric pressure sensor
Water temperature sensor
Throttle position sensor (TPS)
A/C switch
A/C load signal
Cam position sensor
Crank angle sensor
Alternator FR terminal
Vehicle speed sensor
Power steering fluid pressure
switch
Knock sensor
Intercooler water spray (auto)
Intercooler water spray (manual)
O
2sensor
Ignition switch –IG
Ignition switch –STPower supplyEngine ECU
Fuel injection control
Idle speed control (ISC)
Ignition timing control
Engine control relay control
Fuel pump relay control
A/C relay control
Fan motor control (radiator)
Fan relay control (A/C
condenser)
Alternator control
Air flow sensor filter reset
control
Fuel pressure control
Supercharging pressure
control
Secondary air controlIntercooler water spay control
Engine warning light control
O
2sensor heater control
Purge control
Diagnosis output
RAM data transmissionNo. 1 indicator
No. 2 indicator
No. 3 indicatorNo. 4 indicator
ISC servo (stepper motor)
Ignition coil A (No.1 – No.4)
Ignition coil B (No.2 – No.3)
Engine control relay
Fuel pump relay 2
Fuel pump relay 3
A/C relay
Fan controller (radiator fan)
Fan motor relay (HI, LOW)
(A/C condenser)
Alternator G terminal
Air flow sensor
Fuel pressure control valve
No. 1 wastegate solenoid valve
No. 2 wastegate solenoid valve
Secondary air control solenoid
valve
Intercooler water spray relay
Intercooler water spray lamp
Tachometer
Engine warning lights O
2sensor heater
Purge control solenoid valve
Diagnosis output terminal
Diagnosis output terminal (for
MUTII)

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

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

SECTION 22
MANUAL TRANSMISSION
CONTENTS
General........................................................1 Troubleshooting .........................................1
General
The following troubleshooting items have been changed along with the changes to the wiring. Troubleshooting points other than
those mentioned below remain unchanged, and are the same as on the existing Lancer Evolution VII/VIII.
Troubleshooting
1. Diagnosis Code ListMANUAL TRANSMISSION – GENERAL, TROUBLESHOOTING
221
Diagnosis code no.Diagnosis itemPage ref.
12Power supply voltage (valve power supply) systemBroken wire or short222
21Vehicle wheel speed sensor <FR> system <ACD fitted vehicles>Broken wire or short223
22Vehicle wheel speed sensor <FL> system <ACD fitted vehicles>Broken wire or short223
23Vehicle wheel speed sensor <RR> system <ACD fitted vehicles>Broken wire or short223
24Vehicle wheel speed sensor <RL> system <ACD fitted vehicles>Broken wire or short223
25Abnormal diameter tyres <ACD fitted vehicle>225
26Vehicle wheel speed sensor system (output signal abnormal) <ACD fitted vehicles>226
41TPS systemBroken wire or earthing227
42Short227
45Pressure sensor systemBroken wire or earthing228
46Earth wire broken228
47Abnormal power supply229
51Longitudinal G sensor systemBroken wire or short2210
52Sensor malfunction2211
56Lateral G sensor systemBroken wire or short2212
57Sensor malfunction2213
61Stop lamp switch systemBroken wire2214
62ACD mode switch systemSticking2215
63Parking brake switch systemShort or failing to return2216
65ABS monitor system <ACD+AYC fitted vehicles>Broken wire or ABS failure2217
74Proportional control valve <ACD> systemBroken wire or short2218
81Electrical pump relay systemBroken wire or short2218

MANUAL TRANSMISSION TROUBLESHOOTING2218
Code No.74 Proportional valve <ACD> systemAssumed cause of concern
In cases where the proportional valve <ACD> control circuit
is shorting, code No.74 is output.• Proportional valve <ACD> malfunction
• Harness, connector malfunction
Remarks*2: refer to ’011 Lancer Evolution VII Service Manual (No.1036K02)
MUTII/III Service data
• No.11 Proportional valve current <ACD>
OK:P.2232 Refer to (Service Data List)*2
OK > Intermittent malfunction
Measurement at F25 proportional valve <ACD>
connector
• Undo connector, take measurement on proportional
valve side
• Resistance between 2 3
OK:4.7Ωor less
Measurement at F25 proportional valve <ACD>
connector
• Undo connector, take measurement on harness side
• Resistance between 2 – body earth
OK:2Ω or less
Connector check:F25, F22
NG > repair
Check harness between proportional valve <ACD>
body earth
•Check earth wire to see if broken or damaged
NG > repair Replace hydraulic unit
Connector check:F25, F22, C30, C133, C38
NG > repair
Check harness between 4WDECU and Proportional
valve <ACD>
•Check output wire to see if broken, shorting, or
damaged
NG > repair
MUTII/III Service data
• No.11 Proportional valve current <ACD>
OK:refer to P.2232 (Service Data List)*2
NG: replace 4WD ECU
OK > Intermittent malfunction
Code No.81 Electric pump relay systemAssumed cause of concern
Output when the circuit on the pump relay coil side is broken
or shorting.• Electric pump relay malfunction
• Harness, connector malfunction
• 4WDECU malfunction
Remarks*2: refer to ’011 Lancer Evolution VII Service Manual (No.1036K02)
MUTII/III actuator test
• No.04 Electric pump operation
OK:the electric pump operating sound is audible
OK > Intermittent malfunction
Check electric pump relay (refer P.2253)
*2
Measurement at B127 electric pump relay connector
• Undo connector, take measurement on harness side
• Resistance between 1 – body earth
OK:2Ωor less
Connector check:B127
NG > repair
Check harness between electric pump relay body earth
•Check earth wire to see if broken or damaged
NG > repair Replace electric pump relay
Connector check:B127, C38
NG > repair
Check harness between 4WDECU and electric pump relay
•Check power supply wire to see if broken, shorting,
or damaged
NG > repair
MUTII/III Actuator test
• No.04 Electric pump operation
OK:the electric pump operating sound is audible
NG:replace 4WD ECU
OK > NG
OK
OK
OK
OK
OK
NG
OK
OK
NG
NG
OK
OK
OK
NG
OK

WIRING DIAGRAMS - ENGINE TRANSMISSION1-2
ENGINE TRANSMISSION
M3010000400494
B-01 (1-black) Engine oil pressure switch
B-02 (1) Alternator
B-03 (4-grey) Alternator
B-04 (1) Starter
B-05 (1-black) Starter
B-06 (4-black) Throttle position sensorB-07 (2-black) Purge control solenoid valve
B-08 (7-black) Airflow sensor
B-12 (5-grey) Windscreen wiper motor
B-13X (1) Engine speed detection connector
B-14X (5) Starter relay
B-17X (4) Ignition coil relay
Connector
symbol -
B
-01
∫
-32
AC311230AB
Control harness
Battery harness

WIRING DIAGRAMS - ENGINE TRANSMISSION1-3
B-19X (4) Engine control relay
B-20X (4) A/C compressor relay
B-21 (10-black) Junction between control harness and
battery harness
B-25 (4-black) O
2sensor
B-26 (2-black) Indicator 4
B-27 (2-black) Indicator 3
B-28 (2-black) Indicator 2
B-29 (2-black) Indicator 1(2-grey) Wastegate solenoid valve 1
B-31 (6-black) Junction between control harness and
transmission harness
(2-grey) Wastegate solenoid valve 2
Note : Boxed connector numbers indicate
connectors with changed names, or new,
additional connectors.
B-32
B-32
Earth cable
Transmission harness
AC311231AB

CIRCUIT DIAGRAMS - CENTRAL JUNCTION3-8
Central Junction
M3030000300552
Fusible link (Relay box inside engine space)
No.CircuitTypeHousing colourRated current (A)
2Full auto air conditioning;
manual air conditioning;
coolingConnector typeRed50
Forward
direction of
vehicle

CIRCUIT DIAGRAMS - CENTRAL JUNCTION3-9
Fusible link (Relay box inside engine space)
Power supply circuitFuse No.Rated
current (A)ID
colourApplied loads
Battery / Alternator (fusible
link No. 6)320YellowO2sensor, secondary are
control solenoid valve, idle
speed control servo, ignition
coil 1, ignition coil 2, waste
gate solenoid valve 1, waste
gate solenoid valve 2, air
flow sensor, engine ECU,
engine control relay, cam
position sensor, crank angle
sensor, purge control
solenoid valve, fuel pressure
solenoid valve, radiator fan
control relay, register (for
injector)
1020YellowFuel pump relay 3, fuel pump
register, fuel pump & fuel
gauge unit (main)
Forward
direction of
vehicle