MITSUBISHI LANCER EVOLUTION 2007 Service Repair Manual

CHASSIS ELECTRICAL 54A....................................
SMART WIRING SYSTEM (SWS) 54B............................
54A-1
CHASSIS
ELECTRICAL
CONTENTS

54A-2
CHASSIS
ELECTRICAL
CONTENTS
BATTERY 4..............................
SERVICE SPECIFICATION 4....................
ON-VEHICLE SERVICE 4......................
Fluid Level and Specific Gravity Check 4........
Charging 4.................................
Battery Testing Procedure 5...................
IGNITION SWITCH AND IMMOBILIZER
SYSTEM 6...............................
SPECIAL TOOLS 6............................
TROUBLESHOOTING 6........................
IMMOBILIZER-ECU CHECK 10.................
IGNITION SWITCH 11..........................
COMBINATION METER 14................
SERVICE SPECIFICATIONS 14.................
SEALANT 14..................................
SPECIAL TOOLS 15...........................
TROUBLESHOOTING 15.......................
ON-VEHICLE SERVICE 19.....................Speedometer Check 19......................
Tachometer Check 20........................
Fuel Gauge Unit Check 20....................
Engine Coolant Temperature Gauge
Unit Check 21...............................
COMBINATION METER 22.....................
HEADLAMP ASSEMBLY 24...............
SERVICE SPECIFICATIONS 24.................
TROUBLESHOOTING 24.......................
ON-VEHICLE SERVICE 24.....................
Headlamp Aiming 24.........................
Headlamp Intensity Measurement 28...........
Headlamp Bulb(low beam)Replacement28 ....
Headlamp Bulb(high beam)Replacement29 ...
Position Lamp Bulb Replacement29 ...........
Front Turn Signal Lamp Bulb Replacement29 ...
Headlamp Auto Cut Adjustment Procedure29 ...
HeadlampAuto Cut Function Check 29.........
HEADLAMP ASSEMBLY 30....................
CONTINUED ON NEXT PAGE

54A-3
SIDE TURN-SIGNAL LAMP 31............
SPECIAL TOOL 31............................
SIDE TURN-SIGNAL LAMP 31..................
ROOM LAMP 31.........................
TROUBLESHOOTING 31.......................
REAR COMBINATION LAMP 32...........
SPECIAL TOOL 32............................
TROUBLESHOOTING 32.......................
REAR COMBINATION LAMP 32................
HIGH-MOUNTED STOP LAMP 34.........
ON-VEHICLE SERVICE 34......................
High-mounted Stop Lamp Bulb Replacement 34.
HIGH-MOUNTED STOP LAMP 34................
LICENCE PLATE LAMP 35...............
ON-VEHICLE SERVICE 35.....................
License Plate Lamp Replacement 35...........
LICENCE PLATE LAMP 35.....................
HAZARD WARNING LAMP SWITCH 36....
SPECIAL TOOL 36............................
HAZARD WARNING LAMP SWITCH 36.........
HORN 37................................
CIGARETTE LIGHTER 37.................
COLUMN SWITCH 38....................
SPECIAL TOOL 38............................
COLUMN SWITCH 38..........................
CLOCK 40...............................
SPECIAL TOOL 40............................
CLOCK 40....................................
POLE ANTENNA 41......................
ROOF ANTENNA 42......................
DEFOGGER 42...........................
TROUBLESHOOTING 42......................
ON-VEHICLE SERVICE 43.....................
Printed Heater Check 43......................
Defogger Relay Continuity Check 43...........
DEFOGGER SWITCH 43.......................

CHASSIS ELECTRICAL -BatteryCHASSIS ELECTRICAL -Battery54A-4
BATTERY
SERVICE SPECIFICATION
ItemSpecification
Specific gravity of the battery fluid1.220 - 1.290 [20_C]
ON-VEHICLE SERVICE
FLUID LEVEL AND SPECIFIC GRAVITY CHECK
1. Inspect whether or not the battery fluid is between the
UPPER LEVEL and LOWER LEVEL marks.
Caution
(1) If the battery fluid is below the LOWER LEVEL,
the battery could explode in using.
(2) If the battery fluid is over the UPPER LEVEL,
leakage could result.
2. Use a hydrometer and thermometer to check the specific
gravity of the battery fluid.
Standard value: 1.220 - 1.290 [20_C]
The specific gravity of the battery fluid varies with the
temperature, so use the following formula to calculate
the specific gravity for 20_C. Use the calculated value
to determine whether or not the specific gravity is
satisfactory.
D20 = (t - 20)×0.0007 + Dt
D20: Specific gravity of the battery fluid calculated
for 20_C.
Dt: Actually measured specific gravity
t: Actually measured temperature
CHARGING
1. Remove the battery from the vehicle.
2. The normal charging current is a value in amperes which is 1/10th of the battery capacity. If the
battery needs to be charged rapidly because of reasons such as time limitations, the maximum charging
current for rapid charging is the battery capacity expressed as an ampere value.
Battery typeCapacity (5-hour rate)Normal charging currentRapid charging current
44B2034 A3.4 A34 A
3. Determine when charging is finished.
DWhen the specific gravity of the battery electrolyte is constantly within 1.250 - 1.290 for a
continuous period of one hour or more
DWhen the voltage per cell during charging is 2.5 - 2.8 V constantly for a continuous period
of one hour or more
Thermometer
HydrometerGood

CHASSIS ELECTRICAL -Battery54A-5
Caution
1. The battery plugs should be removed during charging.
2. The battery electrolyte level may rise and overflow from the battery during charging.
3. Explosions may occur if the battery is brought close to naked flames during charging.
4. Be careful to avoid tasks that might produce sparks or other danger while the battery is
charging.
5. After charging is complete, replace the battery plugs, pour water over the battery to rinse
away any sulphuric acid, and let the battery stand to dry.
6. Charge the battery in a well-ventilated location.
7. Do not let the battery electrolyte temperature rise above approximately 45_C
(approximately 55_Cduring rapid charging).
BATTERY TESTING PROCEDURE
TEST STEP
(1) Turn headlamps on for 15 seconds.
(2) Turn headlamps off for 2 minutes to allow battery voltage to
stabilize.
(3) Disconnect cables.
OK
Read open circuit voltage.
OK:Open circuit voltage is more than 12.4 VNGCharge battery at 5 amps. (Refer to LOAD TEST RATE CHART)
RetestOK
(1) Connect a load tester to the battery.
(2) Load the battery at the recommended discharge rate (see LOAD
TEST RATE CHART) for 15 seconds.
(3) Read voltage after 15 seconds, then remove load.
(4) Compare the measured value with the minimum voltage (see
LOAD TEST CHART).
OK:Higher than minimum voltageNG
Replace battery
OK
Normal
ROAD TEST RATE CHART
Battery type44B20L
Charging time when fully discharged h
[5-amp. rated current charging]6.8
Load test (Amps)150
ROAD TEST CHART
Temperature_C21 and above16 – 2010 –154–9-1–3-7 – -2-12 – 8-18 – -13
Minimum voltage V9.69.59.49.39.18.98.78.5

CHASSIS ELECTRICAL -Ignition Switch and Immobilizer System54A-6
IGNITION SWITCH AND IMMOBILIZER SYSTEM
SPECIAL TOOLS
ToolNumberNameUse
MB991502MUT-IISub as-
semblyChecking the immobilizer system
MB990784Ornament removerInstrument panel under cover and column
cover removal
TROUBLESHOOTING
IGNITION SWITCH
The ignition switch is controlled by the Smart Wiring System (SWS). For troubleshooting procedures,
refer to GROUP 54B.
IMMOBILIZER
STANDARD FLOW OF DIAGNOSIS TROUBLESHOOTING
Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points.
DIAGNOSIS FUNCTION
READING DIAGNOSIS CODES
The diagnosis codes can be read using the MUT-IIor by using the Simple Check Diagnosis mode. (Refer
to GROUP 00 - How to Use Troubleshooting/Inspection Service Points.)
NOTE
Connect the MUT-IIto the 16-pin diagnosis connector (black).
DIAGNOSIS CODE MEMORY ERASING PROCEDURE
Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points.
INSPECTION USING SIMPLE CHECK DIAGNOSIS MODE
1. Change to Simple Check Diagnosis mode and activate switch diagnosis mode. (Refer to GROUP
00 - How to Use Troubleshooting/Inspection Service Points.)
2. In this condition, the input signals for the following switches can be checked.
CHART CLASSIFIED BY DIAGNOSIS CODES
Code No.Diagnosis contentsReference page
11Problem related to communication with the ignition key54A-7
12Ignition key is not registered, or encrypted code from ignition key does not match.54A-7

CHASSIS ELECTRICAL -Ignition Switch and Immobilizer System54A-7
INSPECTION PROCEDURES FOR EACH DIAGNOSIS CODE
Code No. 11 Problem related to communication with the
ignition keyProbable cause
When the ignition switch is at the ON position, the encrypted codes are not
transmitted from the ignition key to the immobilizer-ECU.DMalfunction of ignition key
DMalfunction of immobilizer-ECU
YES
NOCan other keys which have been registered be used to start
the engine?Replace the ignition key which cannot start the engine.
If code No. 12 is
output
Check the diagnosis codes.To inspection procedure 12 classified by diagnosis code (Refer
to P.54A-7.)
Replace the immobilizer-ECU.
Register the ignition key.
If code No. 11 is
output
Code No. 12 Ignition key is not registered, or encrypted
code from ignition key does not match.Probable cause
The ignition key has not been registered with the immobilizer-ECU.DThe ignition key has not been registered with the
immobilizer-ECU.
DMalfunction of immobilizer-ECU
OK
NG
Replace the immobilizer-ECU.
Check the trouble symptoms.Register the encrypted code.
INSPECTION CHART FOR TROUBLE SYMPTOMS
Trouble symptomInspection
procedure
No.Reference page
Communication with MUT-IIis not possible.–GROUP 13A -
Troubleshooting
Diagnosis code No. P1610 is generated by the engine-ECU.154A-8
The ignition keys cannot be registered using the MUT-II.254A-9
The engine does not start.(The engine cranks but does not fire.)354A-9
Immobilizer-ECU power supply and earth circuit system check454A-10

CHASSIS ELECTRICAL -Ignition Switch and Immobilizer System54A-8
INSPECTION PROCEDURES FOR TROUBLE SYMPTOMS
Inspection procedure 1
Diagnosis code No.1610 is generated by the
engine-ECU.
Probable cause
The cause is probably a problem with communication between the engine-ECU
and the immobilizer-ECU.DMalfunction of harness or connector
DMalfunction of engine-ECU
DMalfunction of immobilizer-ECU
DMalfunction of ignition key
DThe ignition key has not been registered with the
immobilizer-ECU.
OKImmobilizer-ECU power supply and earth circuit system check
(Refer to Inspection Procedure 4.)
OK
Check the trouble symptoms.
NGRepair
NGCheck the following connectors:C-202-1, C-202, C-130,
C-118
Repair
NGCheck the harness between the engine-ECU or and the
immobilizer-ECU, and repair if necessary.
NG
Replace the immobilizer-ECU.
Check the trouble symptoms.
Check the trouble symptoms.Replace the engine-ECU.OK
Is a normal diagnosis code output from the immobilizer-ECU?
NOTo Chart Classified by Diagnosis Codes (Refer to P.54A-6.) YES
NG

CHASSIS ELECTRICAL -Ignition Switch and Immobilizer System54A-9
Inspection procedure 2
The ignition keys cannot be registered using the MUT-II.
Probable cause
The ignition key has not been registered with the immobilizer-ECU. Or that there
is a problem with the immobilizer-ECU.DMalfunction of ignition key
DMalfunction of harness or connector
DMalfunction of immobilizer-ECU
Register the ignition key.
YES
NO YESIs a normal diagnosis code output?
NOCan none of the ignition keys be registered?Replace the ignition key that cannot be registered.
To Chart Classified by Diagnosis Codes (Refer to P.54A-6.)
OKImmobilizer-ECU power supply and earth circuit system check
(Refer to Inspection Procedure 4.)
NG
Replace the immobilizer-ECU.
Check the trouble symptoms.
Inspection procedure 3
The engine does not start. (The engine cranks but does
not fire.)
Probable cause
If the fuel injection does not operate, the cause is probably a problem with the
immobilizer-ECU, or it could also be a problem with the MPI system. If an
attempt has been made to start the engine with a key that has not been
properly registered, the above symptom is a sign of normal operation.DMalfunction of MPI system.
DMalfunction of immobilizer-ECU
NGBattery check (Refer to P.54A-4)
YES
NO
Refer to GROUP 13A - Troubleshooting.YES
NO
To Chart Classified by Diagnosis Codes (Refer to P.54A-6.)Is a normal diagnosis code output from the immobilizer-ECU?
OK
Voltage check during cranking
OK:8 V or higher
Is a normal diagnosis code output by the engine-ECU?
NG
OKImmobilizer-ECU power supply and earth circuit system check
(Refer to Inspection Procedure 4.)
NG
Replace the immobilizer-ECU.
Check the trouble symptoms.
Check the trouble symptoms.
NG
To inspection procedures if the engine does not fire (Refer to
GROUP 13A - Troubleshooting.)

CHASSIS ELECTRICAL -Ignition Switch and Immobilizer System54A-10
Inspection procedure 4
Immobilizer-ECU power supply and earth circuit system check
NG
Check the harness between the engine control relay and the
immobilizer-ECU, and repair if necessary.
OK
Check the trouble symptoms.
(2) NG
Repair
Measure at immobilizer-ECU connector C-202-1.
DIgnition switch: ON
DDisconnect the connector and measure at the harness
side.
(1) Voltage between terminal (1) and body earth
OK:System voltage
(2) Voltage between terminal (4) and body earth
OK:Continuity(1) NGCheck the following connectors:
C-202 - 1, C-202, C-129, D-108
C-202 - 1, C-202, C-130, D-108
NG
NG
OK
Check the trouble symptoms.Repair
NG
Check the following connectors:C-202-1, C-202, C-08
Check the harness between the immobilizer-ECU and body
earth, and repair if necessary.
IMMOBILIZER-ECU CHECK
TERMINAL VOLTAGE CHECK TABLE
Terminal No.SignalInspection conditionsTerminal voltage
1Immobilizer-ECU power supplyIgnition switch: ONSystem voltage
2---
3Engine-ECU--
4Immobilizer-ECU earthAt all times0V