4WD MITSUBISHI LANCER EVOLUTION 2007 Service Workshop Manual

REAR AXLE-Troubleshooting 27B-11
INSPECTION PROCEDURES FOR DIAGNOSIS CODES
Code No. 71 Proportioning valve systemProbable cause
This code is output when the proportioning valve control circuit is open- or short-circuited.DDefective proportioning valve
DDefective harness or connector
DDefective 4WD-ECU

NG
Check and repair the harness between
proportioning valve and body earth.
OK
Check the trouble symptom.
OK
Measure at proportioning valve con-
nector F-28.
DDisconnect the connector and
measure at the harness side.
DResistance between 2 and body
earth
OK:2Ωor lessNGCheck the following connectors:
F-28, F-24NG
Repair
Measure at proportioning valve con-
nector F-28.
DDisconnect the connector and
measure at the proportioning valve.
DResistance between 2 and 3
OK:4.7Ωor lessNGReplace the hydraulic unit. (Refer to
P.27B-61.)
OK
Replace 4WD-ECU.
NG
Check the harness between propor-
tioning valve and 4WD-ECU.NG
Repair
OK
Check the trouble symptom.
OK
Check the following connectors:
C-44, C-130*, C-134, F-24, F-28NG
Repair
*: L.H. drive vehicles

OK
Replace 4WD-ECU.
OK
Check the following connector:
C-43NG
Repair
OK
Check and repair the harness between
4WD-ECU and body earth.
Measure at 4WD-ECU connector
C-43.
DDisconnect the connector and
measure at the harness side.
DResistance between 50 and body
earth
OK:2Ωor lessNGCheck the following connector:
C-43NG
Repair
NG
Repair

REAR AXLE -Troubleshooting 27B-12
Code No. 72 Directional control valve (right) systemProbable cause
This code is output when the directional control valve (right) control circuit is open-
or short-circuited.DDefective directional control valve (right)
DDefective harness or connector
DDefective 4WD-ECU

NG
Check and repair the harness between
directional control valve (right) and
body earth.
OK
Check the trouble symptom.
OK
Replace 4WD-ECU.
NG
Check the harness between directional
control valve (right) and 4WD-ECU.NG
Repair
OK
Check the trouble symptom.
OK
Check the following connectors:
C-44, C-130*, C-134, F-24, F-26NG
Repair
OK
Measure at directional control valve
(right) connector F-26.
DDisconnect the connector and
measure at the directional control
valve side.
DResistance between 1 and body
earth
OK:2Ωor lessNGCheck the following connectors:
F-26, F-24NG
Repair
Measure at directional control valve
(right) connector F-26.
DDisconnect the connector and
measure at the directional control
valve side.
DResistance between 1 and 2
OK:19 - 21Ωor lessNGReplace the hydraulic unit. (Refer to
P.27B-61.)
*: L.H. drive vehicles

OK
Check and repair the harness between
4WD-ECU and body earth.
Measure at 4WD-ECU connector
C-43.
DDisconnect the connector and
measure at the harness side.
DResistance between 50 and body
earth
OK:2Ωor lessNGCheck the following connector:
C-43NG
Repair
OK
Replace 4WD-ECU.
OK
Check the following connector:
C-43NG
RepairNG
Repair

REAR AXLE -Troubleshooting 27B-13
Code No. 73 Directional control valve (left) systemProbable cause
This code is output when the directional control valve (left) control circuit is open-
or short-circuited.DDefective directional control valve (left)
DDefective harness or connector
DDefective 4WD-ECU

NG
Check and repair the harness between
directional control valve (left) and body
earth.
OK
Check the trouble symptom.
OK
Replace 4WD-ECU.
NG
Check the harness between directional
control valve (left) and 4WD-ECU.NG
Repair
OK
Check the trouble symptom.
OK
Check the following connectors:
C-44, C-130*, C-134, F-24, F-25NG
Repair
OK
Measure at directional control valve
(left) connector F-25.
DDisconnect the connector and
measure at the directional control
valve side.
DResistance between 1 and body
earth
OK:2Ωor lessNGCheck the following connectors:
F-25, F-24NG
Repair
Measure at directional control valve
(left) connector F-25.
DDisconnect the connector and
measure at the directional control
valve side.
DResistance between 1 and 2
OK:19 - 21Ωor lessNGReplace the hydraulic unit. (Refer to
P27B-61.)
*: L.H. drive vehicles

OK
Check and repair the harness between
4WD-ECU and body earth.
Measure at 4WD-ECU connector
C-43.
DDisconnect the connector and
measure at the harness side.
DResistance between 50 and body
earth
OK:2Ωor lessNGCheck the following connector:
C-43NG
Repair
OK
Replace 4WD-ECU.
OK
Check the following connector:
C-43NG
RepairNG
Repair

REAR AXLE -Troubleshooting REAR AXLE -Troubleshooting 27B-14
INSPECTION CHART FOR TROUBLE SYMPTOMS
Trouble symptomInspection
procedure No.Reference
page
Communication between MUT-IIand the whole system is not possible.1Refer to
GROUP22
Communication between MUT-IIand 4WD-ECU is not possible.2
GROUP22.
3 ACD mode indicator lamps do not light up when the ignition key is turned to “ON”
(engine stationary).3
3 ACD mode indicator lamps remain lit up after the engine has started.4
AYC is inoperative.
Unable to start or accelerate on slippery road surfaces.527B-14
Rear tires are noisy during low-speed cornering.
Vehicle skews.627B-15
Noise is produced from the torque transfer differential during turning.727B-15
INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS
INSPECTION PROCEDURE 5
AYC is inoperative.
Unable to start or accelerate on slippery road surfaces.
Probable cause
The hydraulic oil level is probably low, there is an oil leak, the hydraulic unit is defective,
or the torque transfer differential is defective.DLow hydraulic oil level
DOil leak
DDefective hydraulic unit
DDefective torque transfer differential
NOTE
This symptom is limited only when the diagnosis code is correct.
NG
Replace the hydraulic unit. (Refer to
P.27B-61.)
NG
Add fluid. (Refer to P.27B-19.)
OKRepair
Check the trouble symptom.NO
Replace the torque transfer differential.
OK
Is foreign matter trapped in the hydrau-
lic line?YES
Repair
OK
Check the fluid level.
(Refer to P.27B-19.)Check the hydraulic pressure line for
leak.
OK
Add gear oil. (Refer to P.27B-16.)
OK
Check hydraulic pressure.
(Refer to P.27-21.)NGBleed the system of air.
(Refer to P.27-19.)
Check the gear oil level. (Refer to
P.27B-16.)NGCheck for oil leak.NG
Repair
Check the AYC for operation.
(Refer to P.27B-20.)Check the trouble symptom. OKOK
NGNormal
NGNG

REAR AXLE -On-vehicle Service27B-16
DATA LIST REFERENCE TABLE
For check, refer to GROUP 22.
ACTUATOR TEST REFERENCE TABLE
For check, refer to GROUP 22.
CHECK AT 4WD-ECU TERMINALS
For check, refer to GROUP 22.
ON-VEHICLE SERVICE
REAR AXLE TOTAL BACKLASH CHECK
1. Park the vehicle on a flat, level surface.
2. Move the transmission control lever to the neutral position.
Apply the parking brake. Raise the vehicle on a jack.
3. Turn the companion flange clockwise as far as it will go.
Make the mating mark on the dust cover of the companion
flange and on the differential carrier.
4. Turn the companion flange anti-clockwise as far as it
will go, and measure the amount of distance the mating
marks moved.
Limit: 6 mm
5. If the backlash exceeds the limit value, replace the
differential carrier assembly.
GEAR OIL LEVEL CHECK

1. Remove the filler plug.
2. Check that the gear oil level is within the specified range
from the bottom end of the filler plug hole.
3. If the gear oil level exceeds the standard value, add the
specified gear oil up to the bottom end of the filler plug
hole.
Specified gear oil:
Hypoid gear oil
MITSUBISHI Genuine Gear Oil Part No. 8149630
EX, CASTROL HYPOY LS (GL-5, SAE 90),
SHELL-LSD (GL-5, SAE 80W - 90) or equivalent
4. Fit the filler plug and tighten it to the specified torque.
Tightening torque: 49±9 N·m
Mating marks
Upper
limit
Lower
limit
Gear oil
8mm

BASIC BRAKE SYSTEM 35A.........................................
ANTI-SKID BRAKING SYSTEM (ABS) <4WD> 35B......................
35A-1
SERVICE BRAKES
CONTENTS

35B-1
ANTI-SKID
BRAKING SYSTEM
(ABS) <4WD>
CONTENTS
GENERAL INFORMATION 2..................
SERVICE SPECIFICATIONS 3.................
LUBRICANTS Refer to GROUP 35A..........
SEALANT Refer to GROUP 35A..............
SPECIAL TOOLS 4...........................
TROUBLESHOOTING 4.......................
ON-VEHICLE SERVICE 26....................
Brake Pedal Check and Adjustment
Refer to GROUP 35A ..........................
Brake Booster Operating Test
Refer to GROUP 35A ..........................
Check Valve Operation Check
Refer to GROUP 35A ..........................
Bleeding Refer to GROUP 35A..................
Brake Fluid Level Sensor Check
Refer to GROUP 35A ..........................
Disc Brake Pad Check and
Replacement Refer to GROUP 35A..............Disc Brake Rotor Check Refer to GROUP 35A...
Brake Disc Thickness Check
Refer to GROUP 35A ..........................
Brake Disc Run-out Check and Correction
Refer to GROUP 35A ..........................
Wheel Speed Sensor Output Voltage Check
26 ............................................
Hydraulic Unit Check 28........................
Remedy for a Flat Battery 29...................
BRAKE PEDAL Refer to GROUP 35A........
MASTER CYLINDER AND BRAKE
BOOSTER Refer to GROUP 35A............
DISC BRAKE Refer to GROUP 35A..........
HYDRAULIC UNIT AND ABS-ECU 30.........
WHEEL SPEED SENSOR 33..................
G SENSORS AND STEERING WHEEL
SENSOR 35..................................

ABS <4WD> -General Information35B-2
GENERAL INFORMATION
ABS has been adopted as optional equipment in
RS-IIto maintain directional stability and steering
performance during sudden braking or braking on
slippery road surfaces.
The ABS control method is a 4-sensor, 4-channel
method which provides independent control for all
wheels.
Following system for Lancer EVOLUTION-VII has
been modified from Lancer EVOLUTION-VI Tommi
Makinen Edition.DBy adding lateral G sensor, longitudinal G
sensor and steering wheel sensor, optimized
ABS control at the time of cornering.
DBy inputting parking brake switch signal to
ABS-ECU with pulling parking brake lever, ABS
control has been optimized.
DABS-ECU outputs ABS signal to 4WD-ECU.
DG sensor (lateral), steering wheel sensor and
parking brake switch have been added to the
diagnosis and service data.
DABS-ECU connector has been changed.
EBD CONTROL
In ABS, electronic control method is used by which
the rear wheel brake hydraulic pressure during
braking is regulated by rear wheel control solenoid
valves in accordance with the vehicle’s rate of
deceleration and the front and rear wheel slippage
which are calculated from the each wheel speed
sensor’s signal. EBD control is a control system
which provides a high level of control for both vehicle
braking force and vehicle stability. The system has
the following features:
DBecause the system provides the optimum rear
wheel braking force regardless of the vehicleladen condition and the condition of the road
surface, the system reduces the required pedal
depression force, particularly when the vehicle
is heavily laden or driving on road surfaces
with high frictional coefficients.
DBecause the duty placed on the front brakes
has been reduced, the increases in pad
temperature can be controlled to improve the
wear resistance characteristics of the pad,
during front brakes applying.
DControl valves such as the proportioning valve
are no longer required.
SPECIFICATIONS
ItemSpecifications
ABS control method4-sensor, 4-channel
No. of ABS rotor teethFront43
Rear43
ABS speed sensorTypeMagnet coil typep
Gap between sensor and rotor mm0.85 / 0.60 (non-adjustable type)

ABS <4WD> -General Information/Service Specifications35B-3
CONSTRUCTION DIAGRAM
Stop lamp
switch*Parking brake
switch
Diagnosis
connector*
Wheel speed sensorWheel speed sensor Hydraulic unit
assembly*
(integrated with
the ABS-ECU) ABS warning lamp
Lateral G sensor
Longitudinal G sensor Steering
wheel
sensor*
NOTE
For R.H. drive vehicles, only the position indicated by the * is symmetrical.
SERVICE SPECIFICATIONS
ItemsStandard value
Wheel speed sensor internal resistance kΩ1.24 - 1.64
Wheel speed sensor insulation resistance kΩ100 or more
Lateral G sensor/Longitudinal G
sensoroutputvoltageV
On stationary vehicle2.4 - 2.6
sensor outputvoltageV
With front mark downward3.4 - 3.6

ABS <4WD> -Special Tools/Troubleshooting35B-4
SPECIAL TOOLS
ToolNumberNameUse
MB991502MUT-IIsub
assemblyFor checking of ABS
(Diagnosis code display when using the
MUT-II)
MB991529Diagnosis code
check harnessFor checking of ABS
(Diagnosis code display when using the ABS
warning lamp)
MB991348Test harness setFor checking of G sensor
TROUBLESHOOTING
STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING
Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points.
NOTES WITH REGARD TO DIAGNOSIS
1. The phenomena listed in the following table are not abnormal.
PhenomenonExplanation of phenomenon
System check soundWhen starting the engine, a thudding sound can sometimes be heard coming from inside
the engine compartment, but this is because the system operation check is being
performed, and is not an abnormality.
ABS operation sound1. Sound of the motor inside the ABS hydraulic unit operation. (whine)
2. Sound is the generated along with vibration of the brake pedal. (scraping)
3. When ABS operates, sound is generated from the vehicle chassis due to repeated
brake application and release.
(Thump: suspension; squeak: tyres)
System check soundWhen depressing the brake pedal during driving, a shock is sometime felt.
2. For road surfaces such as snow-covered roads and gravel roads, the braking distance for vehicles
with ABS can sometimes be longer than that for other vehicles. Accordingly, advise the customer
to drive safely on such roads by lowering the vehicle speed and not being too overconfident.
3. Diagnosis detection condition can vary depending on the diagnosis code.
Make sure that checking requirements listed in the “Comment” are satisfied when checking the trouble
symptom again.