1999 MITSUBISHI LANCER EVOLUTION VI battery

MPI – Troubleshooting13-25
INSPECTION PROCEDURE 8
Unstable idling (Rough idling, hunting)
Probable cause
In cases as the above, the cause is probably that the ignition system, air/fuel mixture,
idle speed control (ISC) or compression pressure is defective.
Because the range of possible causes is broad, inspection is narrowed down to simple
items.
Malfunction of the ignition system

Malfunction of air-fuel ratio control system

Malfunction of the ISC servo system

Poor compression

Drawing air into exhaust system

Secondary air backflow to the intake system
Were the battery terminals disconnected recently?Ye sAfter warming-up, let the engine run at idling for about 10 minutes.
No
MUT-II Self-Diag code
Are diagnosis codes displayed?Ye sRefer to P.13-8, INSPECTION CHART FOR DIAGNOSIS CODES.
No
Does idling speed fluctuate excessively?Ye sCheck if hunting occurs.
(Refer to P.13-48, INSPECTION PROCEDURE 40.)
No
Check the ISC servo for operation sound.NGCheck the ISC servo system.
(Refer to P.13-44, INSPECTION PROCEDURE 33.)
OK
Check the injector for operation.NGCheck the injector system. (Refer to P.13-15, INSPECTION PRO-
CEDURE FOR DIAGNOSIS CODE 41.)
OK
MUT-II: Check if idling speed is unstable.
(Refer to P.13-49, INSPECTION PROCEDURE 41.)
OK
Check the ignition timing.
(Refer to GROUP 11 – Engine Adjustment.)*NGCheck that the crank angle sensor and the timing belt cover are
installed properly.
OK
Check the following items.

Check the ignition coil, spark plugs, spark plug cables.

Check the secondary air supply system. (Ensure that there is no back flow of secondary air into the intake system.)

Check the compression pressure.

Check if foreign materials (water, alcohol, etc.) got into fuel.
NOTE
*: Refer to Workshop Manual for LANCER EVOLUTION-IV and EVOLUTION-V (Pub. No. S9806CNCP9).

MPI – Troubleshooting13-28
INSPECTION PROCEDURE 11
When the engine is cold, it stalls at idling. (Die out)
Probable cause
In such cases as the above, the cause is probably that the air/fuel mixture is inappropriate
when the engine is cold, or that the intake air volume is insufficient.
Malfunction of the ISC servo system

Malfunction of the throttle body

Malfunction of the injector system

Malfunction of the ignition system
Were the battery terminals disconnected recently?Ye sAfter warming-up, let the engine run at idling for about 10 minutes.
No
MUT-II Self-Diag code
Are diagnosis codes displayed?Ye sRefer to P.13-8, INSPECTION CHART FOR DIAGNOSIS CODES.
OK
Check the fuel pressure. (Refer to P.13-30.)*
OK
Check the ignition timing.
(Refer to GROUP 11 – Engine Adjustments.)*NGCheck that the crank angle sensor and the timing belt cover are
installed properly.
OK
Check the following items.

Check the ignition coil, spark plugs, spark plug cables.

Check the compression pressure.

Check the engine oil viscosity.
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.)
OK
Check the injector for operation sound.NGCheck the injector system. (Refer to P.13-15, INSPECTION PRO-
CEDURE FOR DIAGNOSIS CODE 41.)
Ye s
Check the ISC servo for operation sound.NGCheck the ISC servo system.
(Refer to P.13-44, INSPECTION PROCEDURE 33.)
No
Is engine-idling stable after the warming-up?NoCheck for unstable idling (Rough idling, hunting).
(Refer to P.13-25, INSPECTION PROCEDURE 8.)
No
Does the engine stall right after the accelerator pedal is released?Ye sClean the throttle valve
area.Adjust the fixed SAS.
(Refer to P.13-30.)*
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.)
NOTE
*: Refer to Workshop Manual for LANCER EVOLUTION-IV and EVOLUTION-V (Pub. No. S9806CNCP9).

MPI – Troubleshooting13-29
INSPECTION PROCEDURE 12
When the engine is hot, it stalls at idling. (Die out)
Probable cause
In such cases as the above, the cause is probably that ignition system, air/fuel mixture,
idle speed control (ISC) or compression pressure is defective.
In addition, if the engine suddenly stalls, the cause may also be a defective connector
contact.
Malfunction of the ignition system

Malfunction of air-fuel ratio control system

Malfunction of the ISC servo system

Drawing air into intake system

Improper connector contact

Backflow of secondary air to the intake system
Were the battery terminals disconnected recently?Ye sAfter warming-up, let the engine run at idling for about 10 minutes.
No
MUT-II Diagnosis code
Are diagnosis codes displayed?Ye sRefer to P.13-8, INSPECTION CHART FOR DIAGNOSIS CODES.
No
Check the ISC servo for operation sound.NGCheck the ISC servo system.
(Refer to P.13-44, INSPECTION PROCEDURE 33.)
OK
Check the injector for operation sound.NGCheck the injector system. (Refer to P.13-15, INSPECTION PRO-
CEDURE FOR DIAGNOSIS CODE 41.)
OK
Does the engine stall right after the accelerator pedal is released?Ye sClean the throttle valve
area.Adjust the fixed SAS.
(Refer to P.13-30.)*
No
Does the engine stall easily again?NoWhile carrying out an intermittent malfunction simulation test (Refer
to GROUP 00 – Points to Note for Intermittent Malfunctions.), check
for sudden changes in the signals shown below.

Crank angle sensor signal

Injector drive signal

Fuel pump drive signal

Air flow sensor signal
Secondary ignition signal

Engine-ECU power supply
voltage
Ye s
MUT-II: Engine stalling inspection when the engine is warm and
idling. (Refer to P.13-50, INSPECTION PROCEDURE 42.)
OK
Check the ignition timing.
(Refer to GROUP 11 – ENGINE ADJUSTMENTS.)*NGCheck that the crank angle sensor and the timing belt cover are
installed properly.
OK
Check the following items.

Check the ignition coil, spark plugs, spark plug cables.

Check the secondary air supply system. (Ensure that there is no backflow of secondary air into the intake system.)

Check if the injectors are clogged.

Check the compression pressure.

Check if foreign materials (water, alcohol, etc.) got into fuel.
NOTE
*: Refer to Workshop Manual for LANCER EVOLUTION-IV and EVOLUTION-V (Pub. No. S9806CNCP9).

MPI – Troubleshooting13-30
INSPECTION PROCEDURE 13
The engine stalls when starting the car. (Pass out)
Probable cause
In cases such as the above, the cause is probably misfiring due to a weak spark,
or an inappropriate air/fuel mixture when the accelerator pedal is depressed.
Drawing air into intake system

Malfunction of the ignition system
MUT-II Self-Diag code
Are diagnosis codes displayed?Ye sRefer to P.13-8, INSPECTION CHART FOR DIAGNOSIS CODES.
No
Check the following items.

Check the ignition coil, spark plugs, spark plug cables.

Check if air was drawn into the intake system.
Broken intake manifold gasket
Broken or disconnected vacuum hose
Improper operation of the PCV valve
Broken air intake hose
INSPECTION PROCEDURE 14
The engine stalls when decelerating.
Probable cause
In cases such as the above, the cause is probably that the intake air volume is insufficient
due to a defective idle speed control (ISC) servo system.
Malfunction of the ISC servo system
No
MUT-II Data list
26 Idle position switch (Refer to P.13-XX.)NGCheck the idle position switch system.
(Refer to P.13-XX, INSPECTION PROCEDURE 26.)
OK
MUT-II Data list
14 Throttle position sensor (Refer to P.13-57.)NGCheck the throttle position sensor system. (Refer to P.13-9, IN-
SPECTION PROCEDURE FOR DIAGNOSIS CODE 14.)
OK
MUT-II Data list
45 ISC servo position

Is the idle speed control (ISC) servo position drops to 0–2
steps when decelerating (engine r/min less than 1,000)?Ye sCheck the vehicle speed sensor system. (Refer to P.13-13, INSPEC-
TION PROCEDURE FOR DIAGNOSIS CODE 24.)
No
Check the following items.

Check the ignition coil, spark plugs, spark plug cables.

Clean the throttle valve area.

Check and adjust the fixed SAS.
No
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
MUT-II Self-Diag code
Are diagnosis codes displayed?Ye sRefer to P.13-8, INSPECTION CHART FOR DIAGNOSIS CODES.
Were the battery terminals disconnected recently?Ye sAfter warming-up, let the engine run at idling for about 10 minutes.

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.)

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 – On-vehicle Service13-68
ON-VEHICLE SERVICE
FUEL PUMP RESISTOR CHECK

Standard value: 0.45 – 0.65 Ω
The inspection procedures are the same as for the preceding
year-models.
FUEL PUMP RELAY No.2 CONTINUITY CHECK

Battery voltageTerminal No.
1234
Not supplied
Supplied
ENGINE CONTROL RELAY AND FUEL PUMP
RELAY CONTINUITY CHECK
Battery voltageTerminal No.
1234
Not supplied
Supplied
Equipment side connector for engine
control relay and fuel pump relay
Fuel pump relay
Engine control relay

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .