ECU MITSUBISHI LANCER EVOLUTION 2007 Service Repair Manual

ENGINE AND EMISSION CONTROL -Emission Control System17-13
EXHAUST GAS RECIRCULATION (EGR) SYSTEM
GENERAL INFORMATION
The exhaust gas recirculation (EGR) system lowers
the nitrogen oxide (NOx) emission level. When the
air/fuel mixture combustion temperature is high,
a large quantity of nitrogen oxides (NOx) is
generated in the combustion chamber. Therefore,
this system recirculates part of emission gas fromthe exhaust port of the cylinder head to the
combustion chamber through the intake manifold
to decrease the air/fuel mixture combustion
temperature, resulting in reduction of NOx.
The EGR flow rate is controlled by the EGR valve
so as not to decrease the driveability.
OPERATION
The EGR valve is being closed and does not
recirculate exhaust gases under one of the following
conditions. Otherwise, the EGR valve is opened
and recirculates exhaust gases.DThe engine coolant temperature is low.
DThe engine is at idle.
DThe throttle valve is widely opened.
SYSTEM DIAGRAM
ON Throttle body
EGR control
solenoid valve
Engine
control
relay
Battery EGR valve
Crank angle sensor
Throttle position sensor Engine-ECU
Engine coolant
temperature sensor Air flow sensor

22A-2
MANUAL
TRANSMISSION
CONTENTS
GENERAL 3.................................
Outline of Changes 3...........................
GENERAL INFORMATION 3..................
SERVICE SPECIFICATION 3..................
LUBRICANTS 3..............................
SPECIAL TOOLS 4...........................
TROUBLESHOOTING 5...............
ON-VEHICLE SERVICE 40....................
Transmission Oil Check 40......................
Transmission Oil Replacement 40................
Transfer Oil Check 40..........................
Transfer Oil Replacement 40....................
Fluid Check ACD and AYC> 41.............................
Bleeding ACD and AYC> 42.............................ACD Operation Check vehicles with ACD and AYC> 42................
Hydraulic Pressure Check vehicles with ACD and AYC> 43................
Wheel Speed Sensor Output Voltage
Measurement ACD and AYC> 44.............................
TRANSMISSION CONTROL* 46...............
TRANSFER ASSEMBLY 49...................
TRANSMISSION ASSEMBLY 52...............
4WD-ECU VEHICLES WITH ACD AND AYC> 55.........
SENSOR, SWITCH AND RELAY WITH ACD OR VEHICLES WITH ACD AND
AYC> 56.....................................
HYDRAULIC UNIT Refer to GROUP27B.......
WARNING REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM (SRS) EQUIPPED VEHICLES
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 driver and passenger (from rendering
the SRS inoperative).
(2) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized
MITSUBISHI dealer.
(3) 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
The SRS includes the following components: SRS-ECU, SRS warning lamp, air bag module, clock spring, and interconnecting
wiring. Other SRS-related components (that may have to be removed/installed in connection with SRS service or maintenance) are
indicated in the table of contents by an asterisk (*).

MANUAL TRANSMISSION - Troubleshooting 22A-6
INSPECTION CHART FOR DIAGNOSIS CODES
Diagnosis
code No.Diagnosis itemsReference page
12Power supply voltage (valve power supply) systemopen circuit or short-circuit22A-8
13Fail-safe relay system open circuit or short-circuit22A-8
21Wheel speed sensor systemopen circuit or short-circuit22A-9
22Wheel speed sensor systemopen circuit or short-circuit22A-9
23Wheel speed sensor systemopen circuit or short-circuit22A-9
24Wheel speed sensor systemopen circuit or short-circuit22A-9
25Wrong-diameter tire22A-11
26Wheel speed sensor (faulty output signal)22A-13
31Steering wheel sensor systemopen circuit or short-circuit22A-15
32Steering wheel sensor systemshort-circuit22A-16
33fixed22A-16
34Steering wheel sensor systemshort-circuit or output
fixed22A-17
41TPS systemopen circuit or ground22A-18
42short-circuit22A-18
45Pressure sensor systemopen circuit or ground22A-19
46open earth22A-19
47abnormal power supply22A-20
51Longitudinal G sensor systemopen circuit or short-circuit22A-21
52defective sensor22A-22
56Lateral G sensor systemopen circuit or short-circuit22A-23
57defective sensor22A-24
61Stop lamp switch systemopen circuit22A-25
62ACD mode switch systemstuck22A-26
63Parking brake switch systemshort-circuit or not re-
turned to original position22A-27
65ABS monitor systemopen circuit or defective
ABS22A-28
71Proportional valve systemopen circuit or short-circuitRefer to
GROUP27B
72Directional control valve systemopen circuit or short-circuit
GROUP27B.
73Directional control valve systemopen circuit or short-circuit
74Proportional valve systemopen circuit or short-circuit22A-29

MANUAL TRANSMISSION - Troubleshooting 22A-7
Diagnosis
code No.Reference page Diagnosis items
81Electric pump relay systemopen circuit or short-circuit22A-29
82electric pump malfunction
or pressure sensor defect22A-30
84AYC control errorRefer to
GROUP 27B.
85ACD control error-
NOTE
Code No.85 is not a code number output due to malfunction, but a code number output when control
for the 4WD-ECU to protect the ACD is stopped in excessive driving. ACD control can be recovered
by turning the ignition switch ON to OFF to ON.

MANUAL TRANSMISSION - Troubleshooting 22A-8
INSPECTION PROCEDURES FOR DIAGNOSIS CODES
Code No.12 Power supply voltage (valve power supply)
systemProbable cause
The power supply circuit opens or short-circuits if the power supply voltage of the
4WD-ECU is below 9 V or above 18 V.
Or code No.12 is output when the battery voltage drops.DDefective harness or connector
DDefective battery
DDefective 4WD-ECU
NOTE
Refer to the corresponding item if any other diagnosis code is being output.
OKOK
NG
NG
OK
Check the battery.
NG→Replace
Measure at 4WD-ECU connector C-44.
DMeasure the ECU terminal voltage.
DIgnition switch: ON
DVoltage between terminal 13 and earth
OK:System voltageCheck the following connectors:
C-44, C-130, C-213, C-210
C-44, C-213, C-210
NG→Repair
MUT-IIData List
DNo.10 battery voltage
OK:System voltage
OK→Intermittent malfunction (Refer to GROUP 00 - Points to
Note for Intermittent Malfunctions)
OK
Check the following connector:C-44
NG→Repair
MUT-IIData List
DNo.10 battery voltage
OK:System voltage
NG→Replace the 4WD-ECU
OK→Intermittent malfunction (Refer to GROUP 00 - Points to
Note for Intermittent Malfunctions)
Check the harness between the ignition switch and 4WD-ECU
DCheck for the open circuit, short circuit, or damage of the
power supply
NG→Repair
Code No.13 Fail-safe relay system Probable cause
Code No.13 will be output as the open circuit or short circuit of the fail-safe relay
when the voltage is above 6 V during failsafe relay OFF or when the voltage is
below 6 V during ON.DDefective 4WD-ECU
Replace the 4WD-ECU.

MANUAL TRANSMISSION - Troubleshooting 22A-9
Code No.21 Wheel speed sensor system
Code No.22 Wheel speed sensor system
Code No.23 Wheel speed sensor system
Code No.24 Wheel speed sensor systemProbable cause
A diagnosis code corresponding to the open circuit or short circuit of the wheel
speed sensor is output when one wheel speed sensor has detected a vehicle
speed of above 15 km/h, but any one of the remaining three wheel speed
sensors could not detect the vehicle speed.DWheel speed sensor fault
DRotor fault
DWheel bearing fault
DHarness or connector fault
DABS-ECU fault
D4WD-ECU fault

OKNGYES
NO
OK
Measure at 4WD-ECU connector C-44.
DMeasure the ECU terminal voltage.
DIgnition switch: ON
DRotate the tire corresponding to the measured terminal by
one and a half to one rotate per second.
(1) Voltage between terminal 9 and body earth
(2) Voltage between terminal 6 and body earth
(3) Voltage between terminal 7 and body earth
(4) Voltage between terminal 8 and body earth
OK:Changes at 0 V↔5VCheck the following connector:C-44
NG→Repair
Check the following connectors:
C-44, B-123
C-44, C-147, B-123
NG→Repair
MUT-IIDiagnosis Code
DAre the ABS Diagnosis Code Numbers.11, 12, 13, 14, 21,
22, 23, and 24 output?Refer to GROUP 35B - Troubleshooting.
NG
MUT-IIData List
DNo.01 Vehicle speed sensor
DNo.02 Vehicle speed sensor
DNo.03 Vehicle speed sensor
DNo.04 Vehicle speed sensor
OK:The speed meter display and MUT-IIdisplay match.
OK→Intermittent malfunction (Refer to GROUP 00 - Points to
Note for Intermittent Malfunctions.)
OK
Check the harness between 4WD-ECU and ABS-ECU.
DCheck for open circuit, ground, and short-circuit of the
output line.
NG→Repair
MUT-IIData List
DNo.01 Vehicle speed sensor
DNo.02 Vehicle speed sensor
DNo.03 Vehicle speed sensor
DNo.04 Vehicle speed sensor
OK:The speed meter display and MUT-IIdisplay match.
NG→Replace the 4WD-ECU
OK→Intermittent malfunction (Refer to GROUP 00 - Points to
Note for Intermittent Malfunctions.)

MANUAL TRANSMISSION - Troubleshooting 22A-10

OK OK NG
OK NG
OK OK
OK
NG
Measure at 4WD-ECU connector C-44.
DDisconnect the connector and measure at the harness
side.
(1) Resistance between terminals 9 and 22 (vehicle speed
sensor )
(2) Resistance between terminals 6 and 19 (vehicle speed
sensor )
(3) Resistance between terminals 7 and 20 (vehicle speed
sensor )
(4) Resistance between terminals 8 and 21 (vehicle speed
sensor )
OK:1.2 - 1.6 kΩCheck the wheel speed sensor.
(Refer to GROUP 35B - Wheel Speed Sensor.)
NG→Replace
Check the installation of the wheel speed sensor.
NG→Repair
Check the wheel speed sensor and rotor
(Refer to GROUP 35B - Wheel Speed Sensor.)
NG→Repair
Check the wheel beearing. (Refer to GROUP 26 - On-vehicle
Service, and GROUP 27B - Rear Hub Assembly.)
NG→RepairOK
MUT-IIData List
DNo.01 Vehicle speed sensor
DNo.02 Vehicle speed sensor
DNo.03 Vehicle speed sensor
DNo.04 Vehicle speed sensor
OK:The speed meter display and MUT-IIdisplay match.
OK→Intermittent malfunction (Refer to GROUP 00 - Points to
Note for Intermittent Malfunctions.)
Check the following connectors:
C-44, A-03, A-37, D-10, D-04, D-30,
C-146, C-111, C-128, A-43
C-44, A-03, A-37, D-10, D-04, D-30,
C-146, C-111, C-136, C-147
NG→Repair
Check the harness between the 4WD-ECU and each wheel
speed sensor.
DCheck for open circuit, grounding, and short circuit of the
output line.
DCheck for open circuit and damage of the earth line
NG→Repair
MUT-IIData List
DNo.01 Vehicle speed sensor
DNo.02 Vehicle speed sensor
DNo.03 Vehicle speed sensor
DNo.04 Vehicle speed sensor
OK:The speed meter display and MUT-IIdisplay match.
NG→Replace the 4WD-ECU.
OK→Intermittent malfunction (Refer to GROUP 00 - Points to
Note for Intermittent Malfunctions) OK
Check the following connector:C-44
NG→Repair
MUT-IIData List
DNo.01 Vehicle speed sensor
DNo.02 Vehicle speed sensor
DNo.03 Vehicle speed sensor
DNo.04 Vehicle speed sensor
OK:The speed meter display and MUT-IIdisplay match.
NG→Replace the 4WD-ECU
OK→Intermittent malfunction (Refer to GROUP 00 - Points to
Note for Intermittent Malfunctions.)
Check the wheel speed sensor output voltage. (Refer to
P.22A-44.)

MANUAL TRANSMISSION - Troubleshooting 22A-11
Code No.25 Wrong-diameter tireProbable cause
Code No.25 is output as wrong-diameter tire when one of the four vehicle
speeds is outside the range of specified values in respect to the average of the
four vehicle speed sensors, when the vehicle speed is above 20 km/h with the
steering wheel in the straight ahead position.
However the warning lamp does not light up.DTire fault
DWheel speed sensor fault
DRotor fault
DWheel bearing fault
DHarness or connector fault
DABS-ECU fault
D4WD-ECU fault

OK NG
OK
Check the following connector:C-44
NG→Repair
Check the following connectors:
C-44, B-123
C-44, C-147, B-123
NG→Repair OKYES
OK
OK
Check the wheel speed sensor and rotor.
(Refer to GROUP 35B - Wheel Speed Sensor.)
NG→Repair
Check the wheel speed sensor output voltage. (Refer to
GROUP 35B - On-vehicle Service.)OK
Check the wheel speed sensor installation.
NG→Repair
NG
OK
Check the wheel beearing. (Refer to GROUP 26 - On-vehicle
Service, and GROUP 27B - Rear Hub Assembly.)
NG→Repair
OK
Check the following connectors:
B-123, A-03, A-37, D-10, D-04, D-30,
C-146, C-111, C-128, A-43
B-123, A-03, A-37, D-10, D-04, D-30,
C-146, C-111, C-128, C-136
NG→Repair NG
MUT-IIData List
DNo.01 Vehicle speed sensor
DNo.02 Vehicle speed sensor
DNo.03 Vehicle speed sensor
DNo.04 Vehicle speed sensor
OK:The speed meter display and MUT-IIdisplay match.
OK→Intermittent malfunction (Refer to GROUP 00 - Points to
Note for Intermittent Malfunctions.)
Measure at 4WD-ECU connector C-44.
DMeasure the ECU terminal voltage.
DIgnition switch: ON
DRotate the tire corresponding to the measured terminal by
one and a half to one rotate per second.
(1) Voltage between terminal 9 and body earth
(2) Voltage between terminal 6 and body earth
(3) Voltage between terminal 7 and body earth
(4) Voltage between terminal 8 and body earth
OK:Changes by 0 V↔5V.
MUT-IIData List
DNo.01 Vehicle speed sensor
DNo.02 Vehicle speed sensor
DNo.03 Vehicle speed sensor
DNo.04 Vehicle speed sensor
OK:The speed meter display and MUT-IIdisplay match.
NG→Replace the 4WD-ECU.
OK→Intermittent malfunction (Refer to GROUP 00 - Points to
Note for Intermittent Malfunctions)
Refer to GROUP 35B - Troubleshooting. (Refer to Diagnosis
Code No.11, 12, 13, 14, 21, 22, 23, and 24.)
Are all four wheels mounted to normal tires?
NO→Repair
Check the harness between the ABS-ECU and each wheel
speed sensor.
DCheck for open circuit and ground of the output line.
DCheck for open circuit and damage of the earth line.
NG→Repair
OK
Check the harness between the 4WD-ECU and
ABS-ECU.
DCheck for open circuit, ground and damage of
the power line.
NG→RepairOK

MANUAL TRANSMISSION - Troubleshooting 22A-12

OK OK NG
OK NG
OK OK
OK
NG
Measure at 4WD-ECU connector C-44.
DDisconnect the connector and measure at the harness
side.
(1) Resistance between terminals 9 and 22 (vehicle speed
sensor )
(2) Resistance between terminals 6 and 19 (vehicle speed
sensor )
(3) Resistance between terminals 7 and 20 (vehicle speed
sensor )
(4) Resistance between terminals 8 and 21 (vehicle speed
sensor )
OK:1.2 - 1.6 kΩCheck the wheel speed sensor.
(Refer to GROUP 35B - Wheel Speed Sensor.)
NG→Replace
Check the installation of the wheel speed sensor.
NG→Repair
Check the wheel speed sensor and rotor.
(Refer to GROUP 35B - Wheel Speed Sensor.)
NG→Repair
Check the wheel beearing. (Refer to GROUP 26 - On-vehicle
Service, and GROUP 27B - Rear Hub Assembly.)
NG→RepairOK
MUT-IIData List
DNo.01 Vehicle speed sensor
DNo.02 Vehicle speed sensor
DNo.03 Vehicle speed sensor
DNo.04 Vehicle speed sensor
OK:The speed meter display and MUT-IIdisplay match.
OK→Intermittent malfunction (Refer to GROUP 00 - Points to
Note for Intermittent Malfunctions)
Check the following connectors:
C-44, A-03, A-37, D-10, D-04, D-30,
C-146, C-111, C-128, A-43
C-44, A-03, A-37, D-10, D-04, D-30,
C-146, C-111, C-136, C-147
NG→Repair
Check the harness between the 4WD-ECU and each wheel
speed sensor.
DCheck for open circuit and ground of the output line.
DCheck for open circuit and damage of the earth line.
NG→Repair
MUT-IIData List
DNo.01 Vehicle speed sensor
DNo.02 Vehicle speed sensor
DNo.03 Vehicle speed sensor
DNo.04 Vehicle speed sensor
OK:The speed meter display and MUT-IIdisplay match.
NG→Replace the 4WD-ECU.
OK→Intermittent malfunction (Refer to GROUP 00 - Points to
Note for Intermittent Malfunctions) OK
Check the following connector:C-44
NG→Repair
MUT-IIData List
DNo.01 Vehicle speed sensor
DNo.02 Vehicle speed sensor
DNo.03 Vehicle speed sensor
DNo.04 Vehicle speed sensor
OK:The speed meter display and MUT-IIdisplay match.
NG→Replace the 4WD-ECU.
OK→Intermittent malfunction (Refer to GROUP 00 - Points to
Note for Intermittent Malfunctions)
Check the wheel speed sensor output voltage. (Refer to
P.22A-44.)

MANUAL TRANSMISSION - Troubleshooting 22A-13
Code No.26 Wheel speed sensor system (faulty output
signal)Probable cause
Code No.26 is output as output signal error of the wheel speed sensor when
one wheel speed is outside the specified range at the vehicle speed of above
20 km/h.
However, warning lamp will light up.DTire fault
DWheel speed sensor fault
DRotor fault
DWheel bearing fault
DHarness or connector fault
DABS-ECU fault
D4WD-ECU fault

OK NG
OK
Check the following connector:C-44
NG→Repair
Check the following connectors:
C-44, B-123
C-44, C-147, B-123
NG→Repair OK
Check the harness between the 4WD-ECU and ABS-ECU.
DCheck for open circuit, ground and damage of the power
line.
NG→RepairYES
OK OK
Check the wheel speed sensor and rotor.
(Refer to GROUP 35B - Wheel Speed Sensor.)
NG→RepairCheck the wheel speed sensor output voltage. (Refer to
GROUP 35B - On-vehicle Service.)OK
Check the installation of the wheel speed sensor.
NG→Repair
NG
OK
Check the wheel beearing.
(Refer to GROUP 26 - On-vehicle Service, and GROUP 27B
- Rear Hub Assembly.)
NG→Repair
OK
Check the following connectors:
B-123, A-03, A-37, D-10, D-04, D-30,
C-146, C-111, C-128, A-43
B-123, A-03, A-37, D-10, D-04, D-30,
C-146, C-111, C-128, C-136
NG→Repair NG
MUT-IIData List
DNo.01 Vehicle speed sensor
DNo.02 Vehicle speed sensor
DNo.03 Vehicle speed sensor
DNo.04 Vehicle speed sensor
OK:The speed meter display and MUT-IIdisplay match.
OK→Intermittent malfunction (Refer to GROUP 00 - Points to
Note for Intermittent Malfunctions)
Measure at 4WD-ECU connector C44.
DMeasure the ECU terminal voltage.
DIgnition switch: ON
DRotate the tire corresponding to the measured terminal by
one and a half to one rotate per second.
(1) Voltage between terminal 9 and the body earth
(2) Voltage between terminal 6 and body earth
(3) Voltage between terminal 7 and body earth
(4) Voltage between terminal 8 and body earth
OK:Changes at 0 V↔5V.
MUT-IIData List
DNo.01 Vehicle speed sensor
DNo.02 Vehicle speed sensor
DNo.03 Vehicle speed sensor
DNo.04 Vehicle speed sensor
OK:The speed meter display and MUT-IIdisplay match.
NG→Replace the 4WD-ECU.
OK→Intermittent malfunction (Refer to GROUP 00 - Points to
Note for Intermittent Malfunctions)Check the harness between the ABS-ECU and each wheel
speed sensor.
DCheck for open circuit, ground, and short circuit of the
output line.
DCheck for open circuit and damage of the earth line.
NG→Repair YES
NO
Refer to GROUP 35B - Troubleshooting.
Are the four wheels mounted to normal tires.
NO→RepairMUT-IIDiagnosis Code
DAre the ABS Diagnosis Code Nos.11, 12, 13, 14, 21, 22,
23, 24 output?