2004 MITSUBISHI LANCER EVOLUTION VIII service

151INTAKE, EXHAUST GENERAL, SERVICING STANDARD VALUES, VEHICLE SERVICING
SECTION 15
INTAKE, EXHAUST
CONTENTS
General........................................................1
Servicing standard values ........................1
Vehicle Servicing .......................................11. Turbocharger boost pressure check ..................1
2.Checking boost pressure control system ..........2
Air cleaner ..................................................3
General
The important service points were added as a result of the following changes. Other service points remain the same.
• Change to the turbocharger boost pressure (on 6M/T)
• Change from one to two wastegate solenoid valves. However, the No.2 wastegate on the 5M/T is not functional.
Servicing Standard Values
ITEMSTANDARD VALUE
Turbocharger boost pressure kPa <6M/T>97144
Vehicle servicing
1. Checking turbocharger boost pressure
<5M/T>
Since the No.2 wastegate solenoid valve does not function, the
same check of the No.1 wastegate solenoid valve as before iscarried out.
6M/T
Note
The driving test, which is done with the throttle fully open,
must be done in a safe place with two people in the vehicle.
The person sitting in the passenger seat should take the
reading of the values on the pressure gauge.
(1) Remove the hose (black) from the No.1 wastegate solenoid
valve, and fit the pressure gauge to this hose. Fit a plug to
solenoid valve nipple from which the hose (black) has been
removed.
(2) Remove the No.2 wastegate solenoid valve connector.(3)Accelerate at full throttle in 2nd gear, and then take the boost
pressure measurement when engine speed gets to at least
3,000rpm.
Standard value: 97 – 144kPa
(4) When the boost pressure is lower than the standard value, the
cause could be one of the following:
1. Wastegate actuator misoperation
2. Boost pressure leak
3. Turbocharger NG
(5) When boost pressure is higher than standard value, the boost
pressure control may be faulty, so please check the following
points.
Air cleaner
No.1 Wastegate
solenoid valveNo.2 Wastegate
solenoid valve

MANUAL TRANSMISSION TROUBLESHOOTING222
2. Check procedures by diagnosis code
Remarks
In cases where other diagnosis codes are output, please refer to the relevant item.
Code No.12 Power supply voltage (valve power supply) systemAssumed cause of concern
If the 4WDECU power supply voltage drops below 9V or rises
above 18V, Code No.12 is output, indicating either a broken wire in
the power supply circuit, a short, or a drop in the battery voltage.• battery malfunction
• harness, connector malfunction
• 4WDECU malfunction
Battery inspection
NG > replace
MUTII/III Service data
• No.10 Battery voltage
OK:battery voltage
OK > Intermittent malfunction
Measurement at C38 4WDECU connector
•ECU terminal voltage measurement
• Ignition switch: ON
OK:battery voltage
Connector check: C38
NG > repair
MUTII/III Service data
•No.10 battery voltage
OK:battery voltage
NG > replace 4WDECU
OK > intermittent malfunction
Connector check:C38, C133, C212, C210
NG > repair
Check harness between ignition switch – 4WDECU
• Check to see if power supply wire broken, short, or
damage
NG > repair
OK
OK
OK
OK
NG
NG

MANUAL TRANSMISSION TROUBLESHOOTING223
Vehicle speed sensor fitting check
NG > repair
MUTII/III Service Data
• No.01 Vehicle speed sensor
•No.02 Vehicle speed sensor
• No.03 Vehicle speed sensor
OK:Speed shown on speedometer and MUTII/III agree
OK > Intermittent malfunction
Measurement at C38 4WDECU connector
• Undo connector and take measurement on harness
side
(1) Resistance between 9 – 22 (vehicle speed sensor )
(2) Resistance between 6 19 (vehicle speed sensor )
(3) Resistance between 7 20 (vehicle speed sensor )
(4) Resistance between 8 – 21 (vehicle speed sensor )
OK:1.2 – 1.6 kΩ
To next pageVehicle wheel speed sensor check
(Refer to Group 35B – Vehicle wheel speed sensor)
*1
NG > Replace
Connector checks:C38, A05, A31, D11, D05,
D12, C131, C20, C115, C34
NG > Repair
Harness check between 4WDECU – each vehicle
wheel speed sensor
MUTII/III Service data
•No.1 Vehicle speed sensor
•No.2 Vehicle speed sensor
• No.3 Vehicle speed sensor
• No.4 Vehicle speed sensor
OK: Speed shown on speedometer and MUTII/III agreeNG > Replace 4WDECU
OK > Intermittent malfunction
Code No.21 Vehicle wheel speed sensor systems
Code No.22 Vehicle wheel speed sensor systems
Code No.23 Vehicle wheel speed sensor systems
Code No.24 Vehicle wheel speed sensor systemsAssumed cause of concern
When one of the vehicle wheel speed sensors detects a
vehicle speed of 15kph or more, and when even one of the
remaining 3 sensors cannot detect vehicle speed, the
diagnosis code for wheel speed sensor broken wire or short is
output.• Wheel speed sensor malfunction
• Rotor malfunction
•Wheel bearing malfunction
• Harness, connector malfunction
• 4WDECU malfunction

Remarks*1: refer to ’005 Lancer Sedia Service Manual (No.1036K00)*2: refer to ’011 Lancer Evolution VII Service Manual (No.1036K02)
OK
OK
OK
OK
OK
NG
NG

MANUAL TRANSMISSION TROUBLESHOOTING224
From previous page
Check vehicle wheel speed sensor output voltage (ref.
p.2241)
*2
Check connector: C38
NG > Repair
MUTII/III Service data
• No.1 Vehicle speed sensor
•No.2 Vehicle speed sensor
• No.3 Vehicle speed sensor
• No.4 Vehicle speed sensor
OK:Speed shown on speedometer and MUTII/III
agree
NG > Replace 4WDECU
OK > Intermittent malfunctionVehicle speed sensor and rotor check
(Refer to Group 35B – Vehicle wheel speed sensor)
*1
NG > Repair
Wheel bearing check (Refer to Group 26 – Vehicle
Servicing, Group 27B – Rear Hub Assembly)
*2
NG > Repair
NG
OK
OK
OK

Vehicle speed sensor fitting check
NG > repair
MUTII/III Service Data
• No.01 Vehicle speed sensor
• No.02 Vehicle speed sensor
• No.03 Vehicle speed sensor
• No.04 Vehicle speed sensor
OK:Speed shown on speedometer and MUTII/III agree
OK > Intermittent malfunction
Measurement at C38 4WDECU connector
•Undo connector and take measurement on harness
side
(1) Resistance between 9 – 22 (vehicle speed sensor
)
(2) Resistance between 6 19 (vehicle speed sensor
)
(3) Resistance between 7 20 (vehicle speed sensor
)
(4) Resistance between 8 – 21 (vehicle speed sensor
)
OK:1.2 – 1.6kΩ
Check vehicle wheel speed sensor output voltage (ref.
p.2241)
*2
Check connector:C38
NG > repair
MUTII/III Service data
• No.1 Vehicle speed sensor
• No.2 Vehicle speed sensor
• No.3 Vehicle speed sensor
OK:Speed shown on speedometer and MUTII/III
agree
NG > Replace 4WDECU
OK > Intermittent malfunctionVehicle wheel speed sensor
(Refer to Group 35B – Vehicle wheel speed sensor)
*1
NG > Repair
Connector checks:C38, A05, A31, D11, D05,
D12, C131, C20, C115, C34
NG: Repair
Harness check between 4WDECU – each vehicle
wheel speed sensor
• Check output wire for broken wire, earthing, short
• Check earth wire to see if broken or damaged
NG:repair
MUTII/III Service data
•No.1 Vehicle speed sensor
•No.2 Vehicle speed sensor
• No.3 Vehicle speed sensor
• No.4 Vehicle speed sensor
OK:Speed shown on speedometer and MUTII/III
agree
NG > Replace 4WDECU
OK > Intermittent malfunction
Vehicle wheel speed sensor and rotor check
(Refer to Group 35B – Vehicle Wheel Speed Sensor)
*1
NG > Repair
Wheel bearing check (Refer to Group 26 – Vehicle
Servicing, Group 27B – Rear Hub Assembly)
*2
NG > Repair
MANUAL TRANSMISSION TROUBLESHOOTING225
Code No.25 Abnormal tyre diameterAssumed cause of concern
Abnormal tyre Code No. 25 is output in cases where, when
the steering wheel is in a central position, and vehicle speed
is 20kph or more, there is a discrepancy between one of the
vehicle wheel speed sensors and the average of the 4 wheel
speed sensors, in that it is outside the specified range.However, the warning lamp does not come on.• Tyre malfunction
•Vehicle speed sensor malfunction
• Rotor malfunction
• Wheel bearing malfunction
• Harness, connector malfunction

Remarks*1: refer to ’005 Lancer Sedia Service Manual (No.1036K00)*2: refer to ’011 Lancer Evolution VII Service Manual (No.1036K02)
OK
OK
OK
OK NG
NG
OK
NG
OK
OK
OK

MANUAL TRANSMISSION TROUBLESHOOTING226
Vehicle speed sensor fitting check
NG > repair
MUTII/III Service Data
• No.01 Vehicle speed sensor
• No.02 Vehicle speed sensor
•No.03 Vehicle speed sensor
•No.04 Vehicle speed sensor
OK:Speed shown on speedometer and MUTII/III agree
OK > Intermittent malfunction
Measurement at C38 4WDECU connector
• Undo connector and take measurement on harness
side
(1) Resistance between 9 – 22 (vehicle speed sensor
)
(2) Resistance between 6 19 (vehicle speed sensor
)
(3) Resistance between 7 20 (vehicle speed sensor
)
(4) Resistance between 8 – 21 (vehicle speed sensor
)
OK:1.2 – 1.6kΩ
Check vehicle wheel speed sensor output voltage (ref.
p.2241)
*2
Check connector:C38
NG > repair
MUTII/III Service data
• No.1 Vehicle speed sensor
• No.2 Vehicle speed sensor
• No.3 Vehicle speed sensor
OK:Speed shown on speedometer and MUTII/III
agree
NG > Replace 4WDECU
OK > Intermittent malfunctionVehicle wheel speed sensor
(Refer to Group 35B – Vehicle wheel speed sensor)
*1
NG > Repair
Connector checks:C38, A05, A31, D11, D05,
D12, C131, C20, C115, C34
NG > Repair
Harness check between 4WDECU – each vehicle
wheel speed sensor
• Check output wire for broken wire, earthing, short
• Check earth wire to see if broken or damaged
NG > repair
MUTII/III Service data
•No.1 Vehicle speed sensor
• No.2 Vehicle speed sensor
• No.3 Vehicle speed sensor
• No.4 Vehicle speed sensor
OK:Speed shown on speedometer and MUTII/III
agree
NG > Replace 4WDECU
OK > Intermittent malfunction
Vehicle wheel speed sensor and rotor check
(Refer to Group 35B – Vehicle Wheel Speed Sensor)
*1
NG > Repair
Wheel bearing check (Refer to Group 26 – Vehicle
Servicing, Group 27B – Rear Hub Assembly)
*2
NG > Repair
Code No.26 Vehicle wheel speed sensor system (output
signal abnormal)Assumed cause of concern
Abnormal vehicle wheel speed sensor Code No. 26 is output
in cases where, when the vehicle speed is 20kph or more,
one of the vehicle wheel speed sensors is outside the
specified range. However, the warning lamp does come on.•Tyre malfunction
• Vehicle speed sensor malfunction
•Rotor malfunction
• Wheel bearing malfunction
•Harness, connector malfunction
• 4WDECU malfunction

Remarks*1: refer to ’005 Lancer Sedia Service Manual (No.1036K00)*2: refer to ’011 Lancer Evolution VII Service Manual (No.1036K02)
OK
OK
OK
OK NG
NG
OK
NG
OK
OK
OK

MANUAL TRANSMISSION TROUBLESHOOTING227
MUTII/III Diagnosis code
• Has MPI diagnosis code No.P0120 been output?
MUTII/III Service Data
• No.13 TPS voltage
OK:P.2232 (Refer to Service Data List)*2
OK > Intermittent malfunction
Measurement at C37 4WDECU connector
• Measure ECU terminal voltage
• Ignition switch: ON
• Voltage between 39 – earth
(1)Throttle pedal fully open
OK:535 – 735 mV
(2)Throttle pedal fully open
OK:4500 – 5500 mV
Check connector:C37
NG > Repair
MUTII/III Service data
• No.13 TPS voltage
OK:P.2232 (Refer to Service Data List)*2
NG > replace 4WDECU
OK > intermittent malfunctionRefer to Group 13D – Troubleshooting
*2
TPS adjustment (Refer to Group 13D – Vehicle
Servicing)*2
Connector check:C37, B06, C23
NG > repair
Check harness between TPS – 4WDECU
• Check to see if output wire is broken, short, or
damaged
NG > repair
Code No.41,42 TPS systemAssumed cause of concern
If, when idling, TPS output is 0.2V or less, code No.41 is
output, indicating that output is too low.
If, at 10kph or less, TPS output is 4.8V or more for a period
of 2 minutes or more, code No.42 is output, indicating output
is too high.• TPS malfunction
•Harness, connector malfunction
• 4WDECU malfunction
Remarks*2: refer to ’011 Lancer Evolution VII Service Manual (No.1036K02)
NO
NG
OK
OK
OK
OKYES
NG

MANUAL TRANSMISSION TROUBLESHOOTING228
Code No.45 Pressure sensor system (broken wire or earth)Assumed cause of concern
Code No.45 is output when output signal from pressure sensor
is 0.2V or less.• Harness, connector malfunction
• Pressure sensor malfunction
• 4WDECU malfunction
Remarks*2: refer to ’011 Lancer Evolution VII Service Manual (No.1036K02)
MUTII/III Service data
• No.18 pressure sensor
OK:P.2232 (Refer to Service Data List)*2
OK > Intermittent malfunction
Measurement at C37 4WDECU connector
•Measure ECU terminal voltage
•Ignition switch: ON
• Voltage between 32 – earth
OK:0.5V – 1.5V
Check connector:C37
NG > Repair
MUTII/III Service data
• No.18 Pressure sensor
OK:P.2232 (Refer to Service Data List)*2
NG > replace 4WDECU
OK > intermittent malfunction
Measurement at F27 pressure sensor connector
•Undo connector, take measurement on harness side
• Resistance between 3 – earth
OK:2Ω or less
Check connector:F27
NG: repair
Replace pressure sensor
Check connector:C37, C20, C30, F22, F27
NG > Repair
Chec
k harness between pressure sensor – 4WD ECU
• Check to see if power supply line is broken, earth, or
damaged.
• Check for broken output wire, earth, or damage
NG > Repair
Replace pressure sensor
Connector check:C37, C20, F22, F27
NG > repair
Check harness between pressure sensor – 4WDECU
•Check to see if earth wire is broken or damaged
NG > repair
Replace 4WDECU
Code No.46 Pressure sensor system (earth wire broken)Assumed cause of concern
Code No.46 is output when output signal from pressure
sensor is 2.0V or more.• Harness, connector malfunction
• Pressure sensor malfunction
• 4WDECU malfunction
NG
OK
OK
OKNG
OK
OK
OKNG
OK
OK