relay MITSUBISHI LANCER EVOLUTION VI 1999 Workshop Manual

GENERAL – How to Use Troubleshooting/Inspection Service Points00-8
WHEN USING THE WARNING LAMP
1. Use the special tool to earth No.1 terminal (diagnosis
control terminal) of the diagnosis connector.
2. To check ABS system, remove the valve relay.
NOTE
That is because the valve relay is off and the warning
lamp remains illuminated if there is a fault in the ABS
system.
3. Turn on the ignition switch.
4. Read out a diagnosis code by observing how the warning
lamp flashes.
Applicable systems
System nameWarning lamp name
MPIEngine warning lamp
AY CAYC warning lamp
ABSABS warning lamp
Indication of diagnosis code by warning lamp
When the diagnosis code No.24 is outputWhen no diagnosis code is output*
On
Off
1.5 secs.0.5 sec.0.5 sec.
Pause
time 3
secs.Tens
signalPlace
division
2 secs.Units
signal
On
Off
0.5 sec.
NOTE
*: Even if the ABS system is normal, removing the valve relay causes the diagnosis code No.52 to
be output.
WHEN USING THE VOLTMETER
Use the special tool to connect the diagnosis output terminals
and the earth terminal of the diagnosis connector to a voltmeter
and take a reading of the diagnosis codes from the movement
of the needle.
Voltmeter connection terminals
System namePositive connection
terminalNegative connec-
tion terminal
Full-auto air
conditioner114 or 5
Diagnosis connector
MB991529
Earth terminal
Full-auto air con-
ditioner terminal
MB991529

GENERAL – How to Use Troubleshooting/Inspection Service Points00-13
INSPECTION SERVICE POINTS FOR A BLOWN
FUSE
Remove the fuse and measure the resistance between the
load side of the fuse and the earth. Set the switches of all
circuits which are connected to this fuse to a condition of
continuity. If the resistance is almost 0 Ω at this time, there
is a short somewhere between these switches and the load.
If the resistance is not 0 Ω, there is no short at the present
time, but a momentary short has probably caused the fuse
to blow.
The main causes of a short circuit are the following.
Harness being clamped by the vehicle body
Damage to the outer casing of the harness due to wear
or heat
Water getting into the connector or circuitry
Human error (mistakenly shorting a circuit, etc.)
POINTS TO NOTE FOR INTERMITTENT
MALFUNCTIONS
Intermittent malfunctions often occur under certain conditions,
and if these conditions can be ascertained, determining the
cause becomes simple. In order to ascertain the conditions
under which an intermittent malfunction occurs, first ask the
customer for details about the driving conditions, weather
conditions, frequency of occurrence and trouble symptoms,
and then try to recreate the trouble symptoms. Next, ascertain
whether the reason why the trouble symptom occurred under
these conditions is due to vibration, temperature or some
other factor. If vibration is thought to be the cause, carry
out the following checks with the connectors and components
to confirm whether the trouble symptom occurs.
The objects to be checked are connectors and components
which are indicated by inspection procedures or given as
probable causes (which generates diagnosis codes or trouble
symptoms.)
Gently shake the connector up, down and to the left and
right.
Gently shake the wiring harness up, down and to the
left and right.
Gently rock each sensor and relay, etc. by hand.
Gently shake the wiring harness at suspensions and other
moving parts.
NOTE
If determining the cause is difficult, the flight recorder function
of the MUT-II can also be used.
Battery
Fuse
Load
switch
LoadConnector
inspection0 Ω

13-1
FUEL
CONTENTS
MULTIPOINT INJECTION (MPI) 2. . . . . . .
GENERAL 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outline of Change 2. . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE SPECIFICATIONS 4. . . . . . . . . . . . . .
SEALANT 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 5. . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 6. . . . . . . . . . . . . . . . . . . . ON-VEHICLE SERVICE 68. . . . . . . . . . . . . . . .
Fuel Pump Resistor Check 68. . . . . . . . . . . . . . . .
Fuel Pump Relay No.2
Continuity Check 68. . . . . . . . . . . . . . . . . . . . . . . . .
Engine Control Relay and Fuel Pump Relay
Continuity Check 68. . . . . . . . . . . . . . . . . . . . . . . . .
FUEL SUPPLY 69. . . . . . . . . . . . . . . . . . . . .
GENERAL 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outline of Change 69. . . . . . . . . . . . . . . . . . . . . . . .
FUEL TANK 69. . . . . . . . . . . . . . . . . . . . . . . . . . .

MPI – General13-2
MULTIPOINT INJECTION (MPI)
GENERAL
OUTLINE OF CHANGE

The descriptions of the troubleshooting using an MUT-II tester have been added.

The fuel system and its management of EVOLUTION-VI are different from those of EVOLUTION-V
in the following items. Accordingly, the service procedures for these items are described herein. The
service procedures for the remaining item are the same as those for EVOLUTION-V.

Fan motor control

Fuel pump drive control

Fuel pump relay No.2

Fuel pump resistor

Actuator test function of MUT-II (The test of the following items has been made possible.)
a) Item No.36: Secondary air control solenoid valve
b) Item No.37: Air conditioner condenser fan (High)
c) Item No.38: Air conditioner condenser fan (Low)

MPI – General13-3
MPI System Diagram
1 Injector
2 ISC servo
3 Fuel pressure control valve
4 Waste gate solenoid valve
5 Secondary air control solenoid valve

Control relay

Fuel pump relay

A/C relay

Ignition coil

Exhaust temperature warning lamp

Engine warning lamp

Diagnosis output

Alternator G terminal

Fan motor relay

Tachometer

Fuel pump relay No.2 1 Oxygen sensor
2 Air flow sensor
3 Intake air temperature sensor
4 Throttle position sensor
5 Idle switch
6 Camshaft position sensor
7 Crank angle sensor
8 Barometric pressure sensor
9 High temperature sensor
10 Engine coolant temperature sensor
11 Detonation sensor

Power supply voltage

Ignition switch-IG

Ignition switch-ST

Vehicle speed sensor

A/C switch

Power steering fluid pressure switch

Alternator FR signalEngine ECU
1 Oxygen sensor
2 Air flow sensor3
Intake air tem-
perature sensor
4,
5
6 Camshaft position
sensor
7 Crank angle sensor 8 Barometric
pressure sensor
9 High temperature
sensor 10 Coolant temperature sensor
11 Detonation sensor1 Injector 2 ISC servo
3 Fuel pressure
control valve
4 Waste gate
solenoid valve 5 Secondary air
control solenoid
valveCanister
Check valveFrom
fuel
tank
Throttle position
sensor (with a
built-in
idle
switch)
Secondary
air valve
AirTo fuel
tankFuel
pressure
regulatorFrom
fuel
pump
Waste gate
actuator
Catalytic converter

MPI – Troubleshooting13-11
Code No. 22 Crank angle sensor systemProbable cause
Range of Check

Engine is cranking.
Set conditions

Sensor output voltage does not change for 4 seconds (no pulse signal input.)
Malfunction of the crank angle sensor

Improper connector contact, open or short-circuited
harness wire of the crank angle sensor

Malfunction of the engine-ECU
Measure at the crank angle sensor connector A-51.

Connect the connector. (Use the test harness: MD998478.)

Voltage between 2 (black clip) and earth (Engine: cranking)
OK:0.4–4.0 V

Voltage between 2 (black clip) and earth (Engine: idling)
OK:1.5–2.5 V
NGOKReplace the engine-ECU.
Measure at the crank angle sensor connector A-51.

Disconnect the connector, and measure at the harness side.
1. Voltage between 3 and earth (Ignition switch: ON)
OK:System voltage
2. Voltage between 2 and earth (Ignition switch: ON)
OK:4.8–5.2 V
3. Continuity between 1 and earth
OK:Continuity
OK
Check the following con-
nector: A-51NG
Repair
OK
Check trouble symptom.
NG
Replace the crank angle sensor.1. NG
Check the harness wire between the crank angle sensor and the
control relay connector, and repair if necessary.
2. NGCheck the following con-
nector: B-62NG
Repair
OK3. NG
Check trouble symptom.
NG
Check the harness wire
between the engine-ECU
and the crank angle sensor
connector.NG
Repair
OK
Replace the engine-ECU.
Check the harness wire between the crank angle sensor and the
earth, and repair if necessary.

MPI – Troubleshooting13-12
Code No. 23 Camshaft position sensor systemProbable cause
Range of Check

Ignition switch: ON

Engine speed is approx. 50 r/min or more.
Set conditions

Sensor output voltage does not change for 4 seconds (no pulse signal input.)
Malfunction of the camshaft position sensor

Improper connector contact, open or short-circuited
harness wire of the camshaft position sensor circuit

Malfunction of the engine-ECU
Measure at the camshaft position sensor connector A-97.

Connect the connector.

Voltage between 2 and earth (Engine: cranking)
OK:0.4–3.0 V

Voltage between 2 and earth (Engine: idling)
OK:0.5–2.0 VOKReplace the engine-ECU.
NG
Measure at the camshaft position sensor connector A-97.

Disconnect the connector, and measure at the harness side.
1. Voltage between 3 and earth (Ignition switch: ON)
OK:System voltage
2. Voltage between 2 and earth (Ignition switch: ON)
OK:4.8–5.2 V
3. Continuity between 1 and earth
OK:Continuity1. NGCheck the harness wire between the camshaft position sensor
and the control relay connector, and repair if necessary.
2. NGCheck the following con-
nector: B-62NG
Repair
OK
Check trouble symptom.
NG
Check the harness wire
between the engine-ECU
and the camshaft position
sensor connector.NG
Repair
OK
Replace the engine-ECU. 3. NG
Check the harness wire between the camshaft position sensor
and the earth, and repair if necessary.
OK
Check the following con-
nector: A-97NG
Repair
OK
Check trouble symptom.
NG
Replace the camshaft position sensor.

MPI – Troubleshooting13-15
Code No. 31 Detonation sensor systemProbable cause
Range of Check

Ignition switch: ON

Excluding 60 seconds after the ignition switch is turned to ON or immediately
after the engine starts.

Engine speed is approx. 5,000 r/min or more

Set conditions

The change in the detonation sensor output voltage (detonation sensor peak voltage
at each 1/2 revolution of the crankshaft) is less than 0.06 V for 200 times in
succession.
Malfunction of the detonation sensor

Improper connector contact, open or short-circuited
harness wire of the detonation sensor circuit

Malfunction of the engine-ECU
Measure at the detonation sensor con-
nector A-96.

Disconnect the connector and
measure at the harness side.

Continuity between 2 and earth
OK:ContinuityOKCheck the following connector:
B-62NG
Repair
OK
Check trouble symptom.
NG
Check the harness wire between the
engine-ECU and the detonation sensor
connector.OKReplace the detonation sensor.
Check trouble symptom.
NG
Replace the engine-ECU.
NG
Repair
NG
Check the harness wire between the
detonation sensor and earth, and repair
if necessary.
Code No. 41 Injector systemProbable cause
Range of Check

Engine speed is approx. 50–1,000 r/min

The throttle position sensor output voltage is 1.15 V or less.

Actuator test by MUT-II is not carried out.
Set conditions

Surge voltage of injector coil is not detected for 4 seconds.
Malfunction of the injector

Improper connector contact, open or short-circuited
harness wire of the injector circuit

Malfunction of the engine-ECU
OK
Check trouble symptom.NGCheck the harness wire between the
resistor and the injector connector, and
repair if necessary.
Check the injector control circuit.
(Refer to P.13-55, INSPECTION PRO-
CEDURE 50.)OK
OK
Measure at the injector connectors
A-53, A-54, A-55, A-56

Disconnect the connector, and
measure at the harness side.

Voltage between 1 and earth
(Ignition switch: ON)
OK:System voltageNGCheck the following connector:
A-125NG
Repair
OK
Measure at the resistor connector
A-125.

Disconnect the connector, and
measure at the harness side.

Voltage between 3 and earth
(Ignition switch: ON)
OK:System voltageNGCheck the harness wire between the
control relay and the resistor connector,
and repair if necessary.
Check the injector. (Refer to P.13-34.)*
Check the resistor. (Refer to P.13-34.)*NG
Replace
NOTE
*: Refer to Workshop Manual for LANCER EVOLUTION-IV and EVOLUTION-V (Pub. No. S9806CNCP9).

MPI – Troubleshooting13-26
INSPECTION PROCEDURE 9
Idling speed is high. (Improper idling speed)
Probable cause
In such cases as the above, the cause is probably that the intake air volume during
idling is too great.
Malfunction of the ISC servo system

Malfunction of the throttle body
OK
MUT-II Data list
26 Idle position switch (Refer to P.13-58.)NGCheck the idle position switch system.
(Refer to P.13-38, INSPECTION PROCEDURE 26.)
No
Check the ISC servo for operation sound.NGCheck the ISC servo system.
(Refer to P.13-44, INSPECTION PROCEDURE 33.)
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.)
OK
MUT-II Data list
28 A/C switch (Refer to P.13-58.)NGCheck the A/C switch and A/C relay system.
(Refer to P.13-39, INSPECTION PROCEDURE 29.)
OK
Basic idle speed adjustment (Refer to P.13-30.)*
Check trouble symptom.NGClean the throttle valve area.
Adjust the fixed SAS. (Refer to P.13-30.)*
MUT-II Self-Diag code
Are diagnosis codes displayed?Ye sRefer to P.13-8, INSPECTION CHART FOR DIAGNOSIS CODES.
NOTE
*: Refer to Workshop Manual for LANCER EVOLUTION-IV and EVOLUTION-V (Pub. No. S9806CNCP9).

MPI – Troubleshooting13-35
INSPECTION PROCEDURE 23
Low alternator output voltage (approx. 12.3 V)
Probable cause
The alternator may be defective, or malfunctions, which are listed in the right column,
may be suspected.
Malfunction of charging system

Short circuit in harness between alternator G terminal
and engine-ECU

Malfunction of engine-ECU
Measure at the alternator connector
side. A-05

Connect the connector.
(Test harness: MB991519)

Voltage between 1 (black clip) and
earth
Engine: at idle
Radiator fan: does not run
Headlamp: OFF → ON
Brake lamp: OFF → ON
Rear defogger switch:
OFF → ON
OK:Voltages rises
by 0.2 – 3.5 V.NGMeasure at the alternator connector.
A-05

Disconnect the connector, and
measure at the harness side.

Disconnect the engine-ECU con-
nector.

Continuity between 1 and earth
OK:No continuityNGCheck the harness wire between the
alternator and the engine-ECU connec-
tor, and repair if necessary.
OK
Check the alternator.
OK
Check the harness wire between the
alternator and the engine-ECU connec-
tor.NG
Repair
OK
Replace the engine-ECU.
INSPECTION PROCEDURE 24
Power supply system and ignition switch-IG system
Probable cause
When an ignition switch ON signal is input to the engine-ECU, the engine-ECU turns
the control relay ON. This causes system voltage to be supplied to the engine-ECU,
injectors and air flow sensor.
Malfunction of the ignition switch

Malfunction of the control relay

Improper connector contact, open or short-circuited
harness wire

Disconnected engine-ECU earth wire

Malfunction of the engine-ECU
Check the control relay. (Refer to P.13-68.)NG
Replace
OK
Measure at the control relay connector B-27.

Disconnect the connector, and measure at the harness side.

Voltage between 3, 4 and earth
OK:System voltageNGCheck the following
connector: A-28NG
Repair
OK
Check trouble symptom.
NG
Check the harness wire between battery and control relay connector,
and repair if necessary.
OK
Check the engine-ECU power supply and earth circuit.
(Refer to P.13-53, INSPECTION PROCEDURE 45.)