ECU MITSUBISHI LANCER EVOLUTION VI 1999 Service Manual

MPI – Troubleshooting13-45
INSPECTION PROCEDURE 34
Fuel pressure control valve system
Probable cause
The fuel pressure control valve switches the pressure introduction into the fuel pressure
regulator between the intake manifold and atmosphere.
Malfunction of solenoid valve

Improper connector contact, open or short-circuited
harness wire

Malfunction of engine-ECU
NGReplace the engine-ECU.
OK
Check trouble symptom.
NG
Check the harness wire between engine-ECU and solenoid valve
connector, and repair if necessary.
OK
Check trouble symptom.
OK
Check the following connector: B-59NG
Repair
OK
Measure at the engine-ECU connector B-59.

Disconnect the connector, and measure at the harness side.

Voltage between 3 and earth
(Ignition switch: ON)
OK:System voltageNGCheck the following connector: A-12NG
Repair NG
Check the harness wire between control relay and solenoid valve
connector, and repair if necessary.
OK
Measure at the fuel pressure control valve connector A-12.

Disconnect the connector, and measure at the harness side.

Voltage between 1 and earth
(Ignition switch: ON)
OK:System voltage
Check the fuel pressure control valve.NG
Replace
INSPECTION PROCEDURE 35
Waste gate solenoid valve
Probable cause
The waste gate solenoid valve controls the boost pressure introduced into the waste
gate actuator in the turbocharger.
Malfunction of solenoid valve

Improper connector contact, open or short-circuited
harness wire

Malfunction of engine-ECU
NGReplace the engine-ECU.
OK
Check trouble symptom.
NG
Check the harness wire between engine-ECU and solenoid valve
connector, and repair if necessary.
OK
Check trouble symptom.
OK
Check the following connector: B-59NG
Repair
OK
Measure at the engine-ECU connector B-59.

Disconnect the connector, and measure at the harness side.

Voltage between 11 and earth
(Ignition switch: ON)
OK:System voltageNGCheck the following connector: A-23NG
Repair NG
Check the harness wire between control relay and solenoid valve
connector, and repair if necessary.
OK
Measure at the waste gate solenoid valve connector A-23.

Disconnect the connector, and measure at the harness side.

Voltage between 2 and earth
(Ignition switch: ON)
OK:System voltage
Check the waste gate solenoid valve.
(Refer to Group 15 – On-vehicle service.)*NG
Replace
NOTE
*: Refer to Workshop Manual for LANCER EVOLUTION-IV and EVOLUTION-V (Pub. No. S9806CNCP9).

MPI – Troubleshooting13-46
INSPECTION PROCEDURE 36
Secondary air control solenoid valve system
Probable cause
The secondary air control solenoid valve switches the pressure introduction into the
secondary air valve between the intake manifold and atmosphere.
Malfunction of solenoid valve

Improper connector contact, open or short-circuited
harness wire

Malfunction of engine-ECU
NGReplace the engine-ECU.
OK
Check trouble symptom.
NG
Check the harness wire between engine-ECU and solenoid valve
connector, and repair if necessary.
OK
Check trouble symptom.
NG
Check the harness wire between control relay and solenoid valve
connector, and repair if necessary.
OK
Check trouble symptom.
OK
Check the following connector: B-59NG
Repair
OK
Measure at the engine-ECU connector B-59.

Disconnect the connector, and measure at the harness side.

Voltage between 6 and earth
(Ignition switch: ON)
OK:System voltageNGCheck the following connectors:
A-127, A-88NG
Repair
OK
Measure at the secondary air control solenoid connector A-127.

Disconnect the connector, and measure at the harness side.

Voltage between 1 and earth
(Ignition switch: ON)
OK:System voltageNGCheck the following connector: A-88NG
Repair
Check the secondary air control solenoid valve.
(Refer to Group 15 – INTAKE AND EXHAUST.)*NG
Replace
NOTE
*: Refer to Workshop Manual for LANCER EVOLUTION-IV and EVOLUTION-V (Pub. No. S9806CNCP9).

MPI – Troubleshooting13-47
INSPECTION PROCEDURE 37
MUT-II: Inspection of no initial combustion
MUT-II Data list
16 engine-ECU power supply voltage (Refer to P.13-57.)NGCheck the power supply and ignition switch-IG system.
(Refer to P.13-35, INSPECTION PROCEDURE 24.)
OK
Does the camshaft rotate at the engine cranking?
(When oil filler cap is removed.)NoCheck timing belt for breakage.
Ye s
MUT-II Self-Diag code
Are diagnosis codes displayed?Ye sRefer to P.13-8, INSPECTION CHART FOR DIAGNOSIS CODES.
No
MUT-II Data list
22 Crank angle sensor
OK:Cranking speed is displayed.NGCheck the crank angle sensor system.
(Refer to P.13-11, INSPECTION PROCEDURE FOR DIAGNOSIS
CODE 22.)
OK
MUT-II Actuator test
07 Fuel pump (Refer to P.13-61.)NGCheck the fuel pump system.
(Refer to P.13-36, INSPECTION PROCEDURE 25.)
OK
MUT-II Data list
21 Engine coolant temperature sensor (Refer to P.13-57.)NGCheck the engine coolant temperature sensor system.
(Refer to P.13-10, INSPECTION PROCEDURE FOR DIAGNOSIS
CODE 21.)
INSPECTION PROCEDURE 38
Ignition system: Inspection of no initial combustion.
OK
Check the ignition timing when cranking.
OK:Approx. 5BTDCNGCheck that the crank angle sensor and the timing belt cover are
installed properly.
NGCheck the ignition circuit system.
(Refer to P.13-44, INSPECTION PROCEDURE 32.)Check by connecting a timing light to the spark plug cable.
OK:Timing light flashes during cranking.

MPI – Troubleshooting13-53
INSPECTION PROCEDURE 45
Check the engine-ECU power supply and earth circuit.
Measure at the engine-ECU connectors, B-59, B-60, B-62.

Disconnect the connector and measure at the harness side
1. Voltage between 82 and earth (Ignition switch: ON)
OK:System voltage
2. Voltage between 38 and earth
OK:System voltage
3. Voltage between 12, 25 and earth (Ignition switch: ON)
OK:System voltage (when the terminal 38 is earthed)
4. Continuity between 13, 26 and earth
OK:Continuity
5. Voltage between 80 and earth
OK:System voltage1. NGCheck the following
connectors: B-65, B-76NG
Repair
OK
Check trouble symptom.
NG
Check the harness wire
between engine-ECU and
ignition switch connector.NG
Repair
OK
Check the ignition switch. (Refer to GROUP 54.)
2, 3. NG
4. NG
Check the harness wire between engine-ECU and earth, and repair
if necessary.
5. NG
OK
Check the following
connectors:
B-59, B-60, B-62NG
Repair
OK
Check trouble symptom.
NG
Replace the engine-ECU.
Check the following connectors:
B-65, B-49, B-75, B-73NG
Repair
OK
Check trouble symptom.
NG
Check the harness wire between engine-ECU and battery, and
repair if necessary.
Check the harness wire between engine-ECU and control relay
connector, and repair if necessary.
INSPECTION PROCEDURE 46
Check fuel pump circuit.
Measure at the fuel pump connector D-18.

Disconnect the connector and measure at the harness side.

Continuity between 1 and earth
OK:ContinuityNGCheck the following connector:
D-04NG
Repair
OK
Check trouble symptom.
NG
Check the harness wire between fuel pump and earth, and repair
if necessary.
OK
Check the following connectors: D-04, B-64NG
Repair OKCheck trouble symptom.
NG
Check the harness wire between terminal for fuel pump drive and
fuel pump connector.NG
Repair
OK
Replace the fuel pump.

MPI – Troubleshooting13-54
INSPECTION PROCEDURE 46
Check fuel pump circuit.
Measure at the fuel pump relay connector D-18.

Disconnect the connector and measure at the harness side.

Continuity between 1 and earth
OK:ContinuityNGCheck the following connector:
D-04NG
Repair
OK
Check trouble symptom.
NG
Check the harness wire between fuel pump and earth, and repair
if necessary.
OK
Check the following connectors: A-123, B-64, D-18, D-32NG
Repair OKCheck trouble symptom.
NG
Check the harness wire between fuel pump and fuel pump relay
No.2 connector.NG
Repair
OK
Replace the fuel pump.
INSPECTION PROCEDURE 47
Check the fuel pump drive control circuit.
NG
Check the harness wire between the fuel pump relay and engine-
ECU connector.
OK
Check trouble symptom.
OK
Check trouble symptom.
NG
Check the harness wire
between fuel pump relay
and ignition switch con-
nector.NG
Repair
OK
Check the ignition switch. (Refer to GROUP 54.)OK
Check trouble symptom.
NG
Replace the engine-ECU.
NG
Repair
OK
Check the following connector: B-59
OK
Measure at the engine-ECU connector B-59.

Disconnect the connector and measure at the harness side.

Voltage between 8 and earth (Ignition switch: ON)
OK:System voltageNG
Measure at the fuel pump relay connector B-28.

Disconnect the connector and measure at the harness side.

Voltage between 3, 4 and earth (Ignition switch: ON)
OK:System voltageNGCheck the following
connectors: B-65, B-76NG
Repair
Check the following
connector: B-28NG
Repair

MPI – TroubleshootingMPI – Troubleshooting13-55
INSPECTION PROCEDURE 48
Check air flow sensor control circuit.
2, 3. NGCheck the following
connector: B-62NG
Repair
OK
Check trouble symptom.
NG
Check the harness wire
between the engine-ECU
and air flow sensor con-
nector.NG
Repair
OK
Replace the engine-ECU.
OK
Check trouble symptom.
NG
Replace the air flow sensor.
NG
Repair
OK
Check the following connector: A-25
Measure at the air flow sensor connector A-25.

Disconnect the connector and measure at the harness side.
1. Voltage between 4 and earth (Ignition switch: ON)
OK:System voltage
2. Voltage between 3 and earth (Ignition switch: ON)
OK:4.8–5.2 V
3. Continuity between 5 and earth
OK:Continuity1. NGCheck the harness wire between the air flow sensor and control
relay connector, and repair if necessary.
INSPECTION PROCEDURE 49
Check throttle position sensor output circuit.
Measure at the engine-ECU connector B-62.

Connect the connector.

Voltage between 84 and earth (Ignition switch: ON)
OK:0.3–1.0 V (Throttle valve at idle position)
4.5–5.5 V (Throttle valve fully open)NGCheck the following
connector: B-62NG
Repair
OK
Check trouble symptom.
NG
Replace the engine-ECU.
OK
Check the harness wire between engine-ECU and throttle position
sensor connector, and repair if necessary.
INSPECTION PROCEDURE 50
Check injector control circuit.
Measure at the engine-ECU connector B-59.

Disconnect the connector and measure at the harness side.

Voltage between 1, 2, 14, 15 and earth (Ignition switch: ON)
OK:System voltageNGCheck the following
connectors:
A-53, A-54, A-55, A-56NG
Repair
OK
Check trouble symptom.
NG
Check the harness between engine-ECU and injector connector,
and repair if necessary.
OK
Check the following connector: B-59
OK
Check trouble symptom.
NG
Replace the engine-ECU.NG
Repair

MPI – Troubleshooting13-56
DATA LIST REFERENCE TABLE
Item
No.Inspection
itemInspection contentsNormal conditionInspection
procedure
No.Reference
page
11Oxygen
sensorEngine:After having
warmed up
Air/fuel mixture is
made leaner when de-
When at 4,000 r/min,
engine is suddenly
decelerated200 mV or lessProcedure
No. 3113-42
made leaner when de-
celerating, and is made
richer when racing.
When engine is
suddenly raced600 – 1,000 mV
Engine:After having
warmed up
The oxygen sensor
si
gnal is used to check
Engine is idling400 mV or less
(Changes)
signal is used to check
the air/fuel mixture
ratio, and control
condition is also
checked by the ECU.2,500 r/min600 – 1,000 mV
12Air flow
sensor*
Engine coolant
tem
perature: 80 –
Engine is idling17 – 43 Hz––
sensor
TION-IV>temperature: 80
95C

Lamps, electric
li f d ll
2,500 r/min46 – 86 Hzp
cooling fan and all
accessories: OFF

Transmission:
Neutral (A/T:
P range)Engine is racedFrequency
increases in
response to
racing
12Air flow
sensor*
Engine coolant
tem
perature: 80 –
Engine is idling12 – 38 Hz––
sensor
TION-V, VI>temperature: 80
95C

Lamps, electric
li f d ll
2,500 r/min36 – 76 Hzp
cooling fan and all
accessories: OFF

Transmission:
Neutral (A/T:
P range)Engine is racedFrequency
increases in
response to
racing
13Intake air
temperature
sensor
Ignition switch: ON or
with engine runningWhen intake air
temperature is –20C–20CCode No.
1313-9
sensorWhen intake air
temperature is 0C0C
When intake air
temperature is 20C20C
When intake air
temperature is 40C40C
When intake air
temperature is 80C80C
NOTE
*: In a new vehicle [driven approximately 500 km or less], the air flow sensor output frequency is sometimes
10% higher than the standard frequency.

MPI – Troubleshooting13-63
ENGINE-ECU INSPECTION
TERMINAL VOLTAGES
Engine ECU connector
Terminal
No.Check itemCheck condition (Engine condition)Normal condition
1No.1 injectorWhile engine is idling after having been warmed up,
suddenly depress the accelerator pedal
Momentarily drops
slightlyfrom 1114V
14No.2 injector
suddenly depress the accelerator pedal.slightly from 11 – 14 V.
2No.3 injector
15No.4 injector
3Fuel pressure control
valve
Ignition switch: ONSystem voltage
valve
Engine: Cranking to idling (within about two minutes)0 – 3 V to sytem
voltage
4Stepper motor coil (A1)Engine: Immediately after engine has been started
f
or warming up
Changes repeatedly
f
rom system voltage
17Stepper motor coil (A2)
for warming upfrom system voltage
to 0 – 6 V and from 0
6 V to system5Stepper motor coil (B1)– 6 V to system
voltage.
18Stepper motor coil (B2)
6Secondary air control
solenoid valveIgnition switch: ONSystem voltage
8Fuel pump relayIgnition switch: ONSystem voltage
Engine: Idling0 – 3 V
10Power transistor unit
(A)Engine speed: 3,000 r/min0.3 – 3.0 V
23Power transistor unit
(B)
11Wastegate solenoid
valve
Ignition switch: ONSystem voltage
valve
Engine: At idle after having been warmed up (when
premium gasoline is used)0 – 3 V
12Power supplyIgnition switch: ONSystem voltage
25
19Air flow sensor reset
signal
Engine: Idling0 – 1 V
signal
Engine speed: 3,000 r/min6 – 9 V
20Fan motor relay (HI)
Fan not operating (coolant temperature: 90C or
below)System voltage
Fan at high speed (coolant temperature: 105C or
above)0 – 3 V

MPI – Troubleshooting13-67
RESISTANCE AND CONTINUITY BETWEEN HARNESS SIDE CONNECTORS AND TERMINALS
Engine-ECU Harness Side Connector Terminal Arrangement
Terminal No.Inspection itemNormal condition (Check condition)
1 – 12No.1 injector2 – 3 Ω (At 20C)
14 – 12No.2 injector
2 – 12No.3 injector
15 – 12No.4 injector
3 – 12Fuel pressure control valve28 – 36 Ω (At 20C)
4 – 12Stepper motor coil (A1)28 – 33 Ω (At 20C)
17 – 12Stepper motor coil (A2)
5 – 12Stepper motor coil (B1)
18 – 12Stepper motor coil (B2)
6 – 12Secondary air control solenoid valve28 – 36 Ω (At 20C)
11 – 12Wastegate solenoid valve62 – 74 Ω (At 20C)
60 – 12Oxygen sensor heater
11 – 18 Ω (at 20C)
13 – Body earthEngine-ECU earthContinuity established (0 Ω)
26 – Body earth
72 – 92Intake air temperature sensor5.3 – 6.7 kΩ (When intake air temperature is 0C)
2.3 – 3.0 kΩ (When intake air temperature is 20C)
1.0 – 1.5 kΩ (When intake air temperature is 40C)
0.30 – 0.42 kΩ (When intake air temperature is 80C)
74 – 77High temperature sensor3 Ω or less
83 – 92Engine coolant temperature sensor5.1 – 6.5 kΩ (When coolant temperature is 0C)
2.1 – 2.7 kΩ (When coolant temperature is 20C)
0.9 – 1.3 kΩ (When coolant temperature is 40C)
0.26 – 0.36 kΩ (When coolant temperature is 80C)
87 – 92Idle position switchContinuity established (when throttle valve is at idle
position)
No continuity (when throttle valve is slightly open)
91 – Body earth–Continuity established

27-1
REAR AXLE
CONTENTS
GENERAL 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outline of Change 2. . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE SPECIFICATIONS 2. . . . . . . . . . . . . .
LUBRICANT 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 3. . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 4. . . . . . . . . . . . .
ON-VEHICLE SERVICE
31. . . . . . . . . . . . . . .
Rear Axle Total Backlash Check 31. . . . . . . . . . .
Gear Oil Level Check 31. . . . . . . . . . . . . . . . . . . .
Gear Oil Change 32. . . . . . . . . . . . . . . . . . . . . . . . .
Fluid Level Check 33. . . . . . . . . . . . . . . . . . . . . . . . Bleeding 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AYC Operation Check 34. . . . . . . . . . . . . . . . . . . .
Hydraulic Pressure Check 35. . . . . . . . . . . . . . . . .
Differential Carrier Oil Seal
Replacement 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel Speed Sensor Output Voltage
Measurement 37. . . . .
Action When Battery Runs Out 38. . . . . . . . . . . .
HYDRAULIC UNIT
39. . . . . . . . . . . . . . .
SENSOR RELAY
41. . . . . . . . . . . . . . .
AYC-ECU 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .