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SERVICE MANUAL

1. Diagnosis code no Diagnosis item Page ref 12 Power supply voltage valve power supply system Broken wire or short 22 2 21 Vehicle wheel speed sensor FR system lt ACD fitted vehicles gt Broken wire or short 22 3 22 Vehicle wheel speed sensor FL system lt ACD fitted vehicles gt Broken wire or short 22 3 23 Vehicle wheel speed sensor lt RR gt system lt ACD fitted vehicles gt Broken wire or short 22 3 24 Vehicle wheel speed sensor lt RL gt system lt ACD fitted vehicles gt Broken wire or short 22 3 25 Abnormal diameter tyres lt ACD fitted vehicle gt 22 5 26 Vehicle wheel speed sensor system output signal abnormal lt ACD fitted vehicles gt 22 6 41 TPS system Broken wire or earthing 22 7 42 Short 22 7 45 Pressure sensor system Broken wire or earthing 22 8 46 Earth wire broken 22 8 47 Abnormal power supply 22 9 51 Longitudinal G sensor system Broken wire or short 22 10 52 Sensor malfunction 22 11 56 Lateral G sensor system Broken wire or short 22 12 57 Sensor malfunction 22 13 61 Stop lamp switch system Broken wire 22 14 62 ACD mode switch system Sticking 22 15 63 Parking brake switch system Short or failing to return 22 16 65 ABS monitor system lt ACD AYC fitted vehicles gt Broken wire or ABS failure 22 17 74 Proportional control valve lt ACD gt system Broken wire or short 22 18 81 Electrical pump relay system Broken wire or short 22 18 22 2 MANUAL TRANSMISSION
2. If when idling TPS output is 0 2V or less code No 41 is output indicating that output is too low is too high If at 10kph or less TPS output is 4 8V or more for a period e 4WD ECU malfunction of 2 minutes or more code No 42 is output indicating output e TPS malfunction e Harness connector malfunction Remarks 2 refer to 01 1 Lancer Evolution VII Service Manual No 1036K02 YES MUT II III Diagnosis code Refer to Group 13D Troubleshooting e Has MPI diagnosis code No PO120 been output MUT II III Service Data je No 13 TPS voltage OK P 22 32 Refer to Service Data List OK gt Intermittent malfunction A NG Measurement at C 37 4WD ECU connector e Measure ECU terminal voltage e Ignition switch ON e Voltage between 39 earth 1 Throttle pedal fully open OK 535 735 mV 2 Throttle pedal fully open TPS adjustment Refer to Group 13D Vehicle Servicing 2 yo Connector check C 37 B 06 C 23 NG gt repair yon Check harness between TPS 4WD ECU Check connector C 37 NG gt Repair e Check to see if output wire is broken short or damaged NG gt repair OK 4500 5500 mV PX OK MUT INIIL Service data e No 13 TPS voltage OK P 22 32 Refer to Service Data List NG gt replace 4WD ECU OK gt intermittent malfunction 22 8 MANUAL TRANSMISSION TROUBL
3. TROUBLESHOOTING 2 Check procedures by diagnosis code Code No 12 Power supply voltage valve power supply system Assumed cause of concern If the 4WD ECU 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 e harness connector malfunction e 4WD ECU malfunction Remarks Battery inspection NG gt replace In cases where other diagnosis codes are output please refer to the MUT II IIl Service data No 10 Battery voltage ig OK battery voltage OK gt Intermittent malfunction ee an e ECU terminal voltage measurement e Ignition switch ON Voltage 13 earth OK battery voltage ie a Connector check C 38 NG gt repair MUT II III Service data e No 10 battery voltage OK battery voltage NG gt replace 4WD ECU OK gt intermittent malfunction Measurement at C 38 4WD ECU connector ING gt Connector check C 38 C 133 C212 C 210 relevant item NG gt repair EE Check harness between ignition switch 4WD ECU e Check to see if power supply wire broken short or damage NG gt repair MANUAL TRANSMISSION TROUBLESHOOTING 22 3 Code No 21 Vehicle wheel speed sensor FR systems Code No 22 Vehicle wheel speed sensor FL systems Code No 23 Veh
4. body earth ya OK battery voltage OK Fault confirmation NG Check harness between ignition switch and 4WD ECU e Check power supply wire to see if broken or damaged NG gt repair Measurement at C 37 C 38 4WD ECU connector e Undo connector take measurement on harness side e Resistance between C 38 26 and body earth ING Connector check C 37 C 38 Resistance between C 37 42 and body earth NG gt repair OK 2Q or less OK jor y Fault confirmation Connector check C 37 C 38 NG NG gt repair OK Check harness between 4WD ECU earth y e Check earth wire to see if broken or damaged Fault confirmation NG gt repair NG y Replace 4WD ECU 22 20 MANUAL TRANSMISSION TROUBLESHOOTING Checking procedure 3 The ACD mode injector lamp does not come on when the ignition Assumed cause of concern switch is ON engine stopped ACD mode indicator lamp circuit or 4WD ECU malfunctions are possible Harness connector malfunction e ACD mode indicator lamp ASSY malfunction e 4WD ECU malfunction Measurement at C 106 combi meter connector NG Connector check C 106 C 212 C 210 e Undo connector take measurement on harness side NG gt repair e Ignition switch ON OK e Voltage between 9 body earth j OK battery voltage Fault confirmation OK yo Check harness between ignition switch ACD mode indicat
5. 31 lateral G sensor connector e Undo connector and measure on harness side e Ignition switch ON 1 Voltage between 1 earth OK battery voltage 2 Resistance between 3 earth OK 2Q or less m Harness side connector Remove longitudinal G sensor e Connect the special tool between D 31 longitudinal G sensor connector harness side connector and longitudinal G sensor e Ignition switch ON e Voltage between 2 body earth when longitudinal G sensor is set on a flat surface OK 2 4 2 6V e Voltage between 2 body earth when longitudinal G sensor is placed so that the label surface faces NG sideways yon OK 3 3 3 7V Connector check D 31 C 38 C 20 B 109 ACD AYC fitted vehicles gt D 31 C 20 C 38 lt ACD fitted vehicles NG gt repair emn n Check harness between lateral G sensor 4WD ECU e Check for broken output wire earth damage Check harness between lateral G sensor ABS ECU lt ACD AYC fitted vehicles gt Check output wire for earth damage NG gt repair OK Connector check D 31 C 212 C 210 NG gt repair yon Check harness between lateral G sensor ignition switch e Check for broken power supply wire earth damage NG gt repair Connector check D 31 C 20 B 109 ACD AYC fitted vehicles D 31 C 20 C 38 ACD fitted vehicles yon NG gt repair Check harness between
6. engine ECU OK ING Repair Check harness between No 2 wastegate solenoid valve and engine ECU e Check for damage to output wire OG ING 3 Repair Check harness between No 2 wastegate NG pep lr solenoid valve and engine control relay e Check for damage to power supply cable OK Replace engine ECU MPI TROUBLESHOOTING 13A 4 2 ENGINE ECU CHECKS 2 1 List of terminal voltages Terminal No Check item Check item engine condition Normal value 41 No 1 wastegate Ignition switch ON Battery voltage solenoid valve Engine warm idling using premium petrol 1V or less 6 No 2 wastegate Ignition switch ON Battery voltage solenoid valve lt 6M T gt Accelerating in 2nd gear with throttle full open at least 3500 rpm Voltage decrease 2 2 List of resistances and conductance between harness side connector terminal Terminal No Check item Standard value normal condition check condition 41 47 No 1 wastegate solenoid valve 29 35Q at 20 C 6 47 No 2 wastegate solenoid valve lt 6 M T gt 29 35Q at 20 C 13B 1 FUEL SUPPLY GENERAL FUEL TANK SECTION 13B FUEL SUPPLY CONTENTS General nrnannnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnunnnnnnnnnnnen 1 Fuel tank nrnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnunnnen 1 General As well as changing the filler neck hose clamp from an M6 x 39 to M6 x 49 the mounting position has be
7. lateral G sensor ABS ECU lt ACD AYC fitted vehicles gt e Check to see if earth wire broken or damaged Check harness between lateral G sensor 4WD ECU ACD fitted vehicles gt e Check to see if earth wire broken or damaged NG gt repair yon MUT INIIL Service data e No 15 lateral G sensor voltage OK Refer to P 22 32 Service Data List NG gt Refer to Group 35C Troubleshooting lt ACD AYC fitted vehicles gt or 4WD ECU lt ACD fitted vehicles gt Replace OK gt intermittent malfunction Replace lateral G sensor MUT II III Service data e No 15 longitudinal G sensor voltage OK Refer to P 22 32 Service Data List 2 NG gt Refer to Group 35C Troubleshooting lt ACD AYC fitted vehicles gt or 4WD ECU lt ACD fitted vehicles gt Replace OK si functi MANUAL TRANSMISSION TROUBLESHOOTING 22 13 Code No 57 Lateral G sensor system Assumed cause of concern At 10kph or over with ABS and brakes not applied code No e Harness connector malfunction 57 is output in cases where G sensor indicates higher than e Longitudinal G sensor malfunction specified value ABS ECU malfunction lt ACD AYC fitted vehicles gt e 4WD ECU malfunction Remarks 2 refer to 01 1 Lancer Evolution VII Service Manual No 1036K02 MUT INIIL Service data e No 15 longitudinal sensor voltage OK P 22 32 Refer to Service Data List OK gt Intermittent malfun
8. parts be careful not to knock or apply force to these components e When assembling fix the air cleaner body ASSY securely to the air cleaner cover using the clamp on the body Remarks Parts marked with a symbol use plastic that may contain recycled paper so when scrapped are burnable 6 0 1 0 N m 4 0 1 0 N m 1 FR 3 90 1 0Nm 12 9 0 1 0 Nm KR 9 0 1 0 N m Ne an r FSP 90 10nm 13 V ol gt 49 1 0 N m 14 AC314157AB Removal procedure 1 Battery e Air pipe E air hose D air by pass valve 2 Air duct assembly air by pass hose 3 Air flow sensor connector e Oil level gauge assembly 4 Air cleaner assembly 11 Air intake hose 5 Air flow sensor 12 Wastegate solenoid valve connector 6 Gasket 13 Vacuum hose connection 7 Air cleaner cover 14 Wastegate solenoid valve assembly 8 Air cleaner element 15 Air cleaner bracket 9 Air cleaner body assembly 10 Vacuum hose lt Memo gt MANUAL TRANSMISSION GENERAL TROUBLESHOOTING 22 1 SECTION 22 MANUAL TRANSMISSION CONTENTS GONG ki ok ok kk kk oi kk a ak a n lk ko ik 1 Troubleshooting works ankinn aki kaki asia annan 1 General The following troubleshooting items have been changed along with the changes to the wiring Troubleshooting points other than those mentioned below remain unchanged and are the same as on the existing Lancer Evolution VII VIII Troubleshooting 1 Diagnosis Code List
9. pump operation OK the electric pump operating sound is audible NG replace 4WD ECU OK gt MANUAL TRANSMISSION TROUBLESHOOTING 22 19 3 Fault classification Fault Check procedure No Page ref No communication between MUT II IIl and 4WD ECU 2 22 19 When ignition switch is ON engine stopped ACD mode indicator lamp does not come on 3 22 20 Even after engine starts at least 2 ACD mode indicator lamps remain lit 4 22 20 4 Fault classification procedure Checking procedure 2 No communication between MUT IV III and 4WD ECU Assumed cause of concern Diagnosis output circuit AWD ECU power supply circuit Harness connector malfunction earth circuit or 4WD ECU malfunctions are possible e 4WD ECU malfunction Measurement at C 122 diagnosis code connector and NG gt Connector check C 37 C 23 C 22 C 20 C 122 C 37 4WD ECU connector C 110 C 06 e Resistance between C 122 1 and C 37 46 NG gt repair e Resistance between C 122 7 and C 37 35 OK OK 2Q or less y OK Fault confirmation NG Harness check between 4WD ECU and diagnosis connector e Check output wire to see if broken or damaged e NG gt repair Measurement at C 38 4WD ECU connector e Measure ECU terminal voltage NG Connector check C 38 C212 C 210 C133 e Ignition switch ON NG gt repair e Voltage between 13
10. 18 AC314131 AB EXTERIOR FRONT BUMPER 51 3 Dismantling procedure Three diamonds badge Licence plate garnish Licence plate bracket Licence plate bracket ASSY Front bumper plate Cover Front air dam panel Front bumper lower plate ASSY Front bumper lower reinforcement ASSY 10 Front bumper upper plate ASSY oRNOQURWN Ap DAY 11 Bumper net 12 Front bumper side cover 13 Bumper side net LH 14 Oil cooler duct 15 Bumper side net RH e Water spray hose and nozzle ref Section 15 16 Front bumper side plate ASSY 17 Front bumper upper reinforcement ASSY 18 Front bumper facing Important notes on dismantling Ab Front bumper side plate removal Same as for existing front bumper rivet removal Important notes on assembly DA Fitting front bumper side plate Same as for existing front bumper rivet fitting 51 4 EXTERIOR MARKINGS Markings Removal and fixing AC314133 DAY 1 Three diamonds badge DAG 2 EVOLUTION MR mark Important fitting notes DAY Fixing the markings 1 Positions 1 Three diamonds badge Boot lid press line Lou Vehicle centre point EXTERIOR MARKINGS 51 5 2 EVOLUTION MR MARK Boot lid end line Ties 1 mm r Boot lid end line 18 1 mm AC314117 2 Important fixing notes 1 Clean and remove any grease from the body surface where markings will be affixed using unleaded petrol 2 Remove the paper bac
11. ESHOOTING Code No 45 Pressure sensor system broken wire or earth Assumed cause of concern is O 2V or less Code No 45 is output when output signal from pressure sensor e Harness connector malfunction e Pressure sensor malfunction e 4WD ECU malfunction Remarks 2 refer to 01 1 Lancer Evolution VII Service Manual No 1036K02 MUT II IIl Service data No 18 pressure sensor OK P 22 32 Refer to Service Data List OK gt Intermittent malfunction pe Measurement at C 37 4WD ECU connector eMeasure ECU terminal voltage e Ignition switch ON Voltage between 32 earth NG Check connector C 37 NG gt Repair OK 0 5V 1 5V px px MUT INIIL Service data No 18 Pressure sensor OK P 22 32 Refer to Service Data List NG gt replace 4WD ECU OK gt intermittent malfunction Z Check connector C 37 C 20 C 30 F 22 F 27 NG gt Repair ie pet ann Check harness between pressure sensor 4WD ECU e Check to see if power supply line is broken earth or damaged e Check for broken output wire earth or damage NG gt Repair pr Replace pressure sensor Code No 46 Pressure sensor system earth wire broken Assumed cause of concern sensor is 2 0V or more Code No 46 is output when output signal from pressure Measurement at F 27 pressure sensor connector eUndo connector take measure
12. MITSUBISHI Evolution VZ Mire SERVICE MANUAL SERVICE MANUAL LANCER EVOLUTION VIII MR FOREWORD This manual contains details of the main changes to the 2004 model Lancer Evolution VIII MR Only differences to the current Lancer Evolution VIII are included so please use this manual in conjunction with the related information specified on the next page Please ensure that proper servicing is carried out promptly and that the information contained in the relevant manuals is carefully read and understood before doing any servicing work This information relates to the current vehicle February 2004 Since specifications will change some of the information contained here will inevitably be superseded Note that SI units are used in this manual Old units are not shown alongside them However old units are used for some figures we have taken from existing documents Any opinions requests or questions concerning this manual should be written on the Servicing Comments Form at the end and sent to us by fax February 2004 PA MITSUBISHI MOTOR CORPORATION This manual is printed on recycled paper CONTENTS Intake Exhaust ennnnnonnnnnnennnnn Manual Transmission ss annnnnnnrn Front Suspension Rear Suspension rxxssrsnnnnnnnnner Exterior Related information Title No Issue date Title No Issue date New model manuals Body S
13. NG signal abnormal Code No 26 Vehicle wheel speed sensor system output Assumed cause of concern Abnormal vehicle wheel speed sensor Code No 26 is output Tyre malfunction in cases where when the vehicle speed is 20kph or more e Vehicle speed sensor malfunction one of the vehicle wheel speed sensors is outside the Rotor malfunction specified range However the warning lamp does come on e Wheel bearing malfunction e Harness connector malfunction e 4WD ECU malfunction lt ACD fitted vehicles gt Remarks 1 refer to 00 5 Lancer Sedia Service Manual No 1036K00 2 refer to 01 1 Lancer Evolution VII Service Manual No 1036K02 Vehicle speed sensor fitting check NG gt repair pa MUT II III Service Data e No 01 Vehicle speed sensor FR e No 02 Vehicle speed sensor FL No 03 Vehicle speed sensor lt RR gt e No 04 Vehicle speed sensor lt RL gt OK Speed shown on speedometer and MUT II IIl agree OK gt Intermittent malfunction EE NG e Undo connector and take measurement on harness side 1 Resistance between 9 22 vehicle speed sensor lt FR gt 2 Resistance between 6 19 vehicle speed sensor lt FL gt 3 Resistance between 7 20 vehicle speed sensor RR 4 Resistance between 8 21 vehicle speed sensor RL ig OK 1 2 1 6kQ Check vehicle wheel speed sensor output voltage ref p 22 41 2 Va yon MUT II III Serv
14. NG gt repair e Ignition switch OFF OK Voltage between 47 earth 1 Press ACD mode switch Check harness between 4WD ECU ACD mode OK battery voltage switch 2 Release ACD mode switch e Check to see if output wire is broken or damaged OK 1V or less NG gt repair Connector check C 37 NG gt repair ye MUT II III Service data eNo 63 ACD mode switch 1 Press ACD mode switch OK ON 2 Release ACD mode switch OK OFF NG gt replace 4WD ECU OK gt intermittent malfunction 22 16 MANUAL TRANSMISSION TROUBLESHOOTING Code No 63 Parking brake switch Assumed cause of concern In cases where at 15kph or over the parking brake switch remains ON for 15 minutes or more code No 63 is output e Parking brake switch malfunction e Harness connector malfunction e ABS ECU malfunction lt ACD AYC fitted vehicles gt e 4WD ECU malfunction Remarks 1 Refer to 00 5 Lancer Sedia Service Manual No 1036K00 MUT INIIL Service data e No 62 Parking brake switch 1 Apply parking brake lever OK ON 2 Release parking brake lever OK OFF OK gt intermittent malfunction NG When parking brake lever is released does the brake warning lamp go off yNo Measurement at D 25 parking brake switch connector e Undo connector take measurement on harness side e Ignition switch ON e Voltage between 1 earth OK battery v
15. ON TROUBLESHOOTING 22 17 Code No 65 ABS monitor system Assumed cause of concern continuously for at least 1 minute code No 65 is output e Harness connector malfunction e ABS ECU malfunction lt ACD AYC fitted vehicles gt e 4WD ECU malfunction In cases where the ABS is detected to have been operating lt ACD AYC fitted vehicles gt MUT II Ill Service data eNo 61 ABS monitor 1 ABS ECU connector undo OK ON 2 ABS ECU connector connect OK OFF OK gt intermittent malfunction NG Measurement at C 37 4WD ECU e Undo connector take measurement on harness side e Voltage between 48 body earth OK battery voltage yon Connector check C 37 NG gt repair a MUT II IIl Service data eNo 61 ABS monitor 1 Press ACD mode switch OK OFF NG gt replace 4WD ECU OK gt intermittent malfunction Connector check C 37 B 109 NG gt repair yor Check harness between 4WD ECU and ABS ECU e Check output wire for shorting damage NG gt repair Connector check C 37 B 109 NG gt repair yon Check harness between 4WD ECU and ABS ECU e Check output wire to see if broken shorting or damaged NG gt repair DA Lo B 109 Measurement at ABS ECU connector e ECU terminal voltage measurement e Voltage between 3 body earth e Carry out ABS actuator test no 05 ABS signal OK For 10 seconds during test 1V o
16. OOLS 33A 1 SECTION 33A FRONT SUSPENSION CONTENTS GONG irak kow kk kt kn kn kk ko ai 1 Strut Assembly 2 Special TOONS Lassen 1 General Important servicing information has been added along with the adoption of Bilstein shock absorbers However apart from the information below other servicing information remains unchanged Special Tools Tool Number Name Details MB991367 Special spanner Dismantling and assembly of strut ASSY Vehicles fitted with Bilstein shock absorbers MB991385 Pin 33A 2 FRONT SUSPENSION STRUT ASSEMBLY STRUT ASSY Vehicles fitted with Bilstein shock absorbers Dismantling and Assembly 1 60 10 N m g 20 NOTE When applying grease ensure that n 3 none of it is left on the insulator rubber as this could lead to insulator 1 rubber damage 4 Go gue GB 5 6 l Li Li ee AAC400101 Dismantling procedure 1 Dust cover 6 Dust cover Ap pA 2 Self locking nut 7 Coil spring 3 Strut insulator ASSY 8 Lower spring pad 4 Upper spring seat lt B gt 9 Strut ASSY 5 Bumper rubber Important note on dismantling Procedure remains unchanged apart from the following point Ab Removal of self locking nut 1 Compress the coil spring using the following special tool e Spring compressor body MB991237 Arm set MB991238 MB991237 FRONT SUSPENSION STRUT ASSEMBLY 33A 3 CAUTION 1 To compress the coi
17. Repair MANUAL TRANSMISSION TROUBLESHOOTING 22 5 Code No 25 Abnormal tyre diameter Assumed 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 e Tyre malfunction e Vehicle speed sensor malfunction Rotor malfunction e Wheel bearing malfunction Harness connector malfunction e 4WD ECU malfunction lt ACD fitted vehicles gt Remarks 1 refer to 00 5 Lancer Sedia Service Manual No 1036K00 2 refer to 01 1 Lancer Evolution VII Service Manual No 1036K02 Vehicle speed sensor fitting check NG gt repair es MUT II III Service Data e No 01 Vehicle speed sensor FR e No 02 Vehicle speed sensor FL e No 03 Vehicle speed sensor lt RR gt e No 04 Vehicle speed sensor lt RL gt OK Speed shown on speedometer and MUT II III agree OK gt Intermittent malfunction NG Measurement at C 38 4WD ECU connector NG Vehicle wheel speed sensor e Undo connector and take measurement on harness Refer to Group 35B Vehicle wheel speed sensor side NG gt Repair 1 Resistance between 9 22 vehicle speed sensor yon FR 2
18. Resistance between 6 19 vehicle speed sensor Connector checks C 38 A 05 A 31 D 11 D 05 lt FL gt D 12 C 131 C 20 C 115 C 34 3 Resistance between 7 20 vehicle speed sensor NG Repair lt RR gt you 4 Resistance between 8 21 vehicle speed sensor RL Harness check between 4WD ECU each vehicle OK 1 2 1 6kQ wheel speed sensor OK e Check output wire for broken wire earthing short e Check earth wire to see if broken or damaged NG NG repair Check vehicle wheel speed sensor output voltage ref fox p 22 41 2 jer MUT II III Service data e No 1 Vehicle speed sensor FR Check connector C 38 e No 2 Vehicle speed sensor FL NG gt repair No 3 Vehicle speed sensor RR Yo e No 4 Vehicle speed sensor RL OK Speed shown on speedometer and MUT II III MUT IN IIL Service data agree e No 1 Vehicle speed sensor FR NG gt Replace 4WD ECU No 2 Vehicle speed sensor lt FL gt OK gt Intermittent malfunction e No 3 Vehicle speed sensor RR e No 4 Vehicle speed sensor lt RL gt OK Speed shown on speedometer and MUT II III L Vehicle wheel speed sensor and rotor check agree Refer to Group 35B Vehicle Wheel Speed Sensor NG gt Replace 4WD ECU NG gt Repair OK gt Intermittent malfunction KR Wheel bearing check Refer to Group 26 Vehicle Servicing Group 27B Rear Hub Assembly 2 NG gt Repair 22 6 MANUAL TRANSMISSION TROUBLESHOOTI
19. T II III Service data e No 56 Stop lamp switch 1 Depress brake pedal OK ON 2 Release brake pedal OK OFF NG gt replace 4WD ECU OK gt Intermittent malfunction MANUAL TRANSMISSION TROUBLESHOOTING 22 15 Code No 62 ACD mode switch system Assumed cause of concern In cases where the ACD mode switch remains ON for 60 seconds or more code No 61 is output e ACD mode switch malfunction e Harness connector malfunction e 4WD ECU malfunction Remarks 2 refer to 01 1 Lancer Evolution VII Service Manual No 1036K02 MUT II IIl Service data eNo 63 ACD mode switch 1 Press ACD mode switch OK ON 2 Release ACD mode switch OK OFF OK gt intermittent malfunction ps Check ACD mode switch refer to P 22 53 2 NG gt replace OK Measurement at C 134 ACD mode switch connector NG y Connector check C 134 C 209 C 210 e Undo connector take measurement on harness side NG gt repair Ignition switch ON OK Voltage between 2 earth OK battery voltage Check harness between ACD mode switch ignition switch e Check for broken power supply wire damage NG gt repair OK Check harness between junction block combi Meter OK e Check power supply wire for earth damage NG gt repair Measurement at C 37 4WD ECU connector NG gt Connector check C 134 C 133 C 37 eMeasure ECU terminal voltage
20. UBLESHOOTING 1 Inspection procedures for different types of malfunction Inspection procedure 37 No 2 Wastegate solenoid valve system lt 6M T gt Assumed cause of concern The No 2 wastegate solenoid valve controls excess pressure No 2 wastegate solenoid valve malfunction introduced via the turbocharger wastegate actuator e Engine ECU malfunction Connector inspection B 32 gt Repair OK B 32 No 2 measure at wastegate solenoid valve NG 3 Change No 2 wastegate solenoid valve connector e Undo connector and take measurement on solenoid valve side Resistance between 1 and 2 OK 29 35Q at 20 C OK Measure at B 32 No 2 waste gate solenoid valve NG Check connector B 19X Lee Repair connector OK e Undo connector and take measurement on harness side e Ignition switch ON Inspect repair harness between No 2 wastegate Resistance between 1 earth solenoid valve and engine control relay OK battery voltage e Check for broken wire and shorting OK Measurement at C 49 engine ECU connector ING gt Check connector C 49 NG gt Repair e Engine ECU terminal voltage measurement OK e Ignition switch ON e Voltage between 6 Earth Check harness between No 2 wastegate NG OK battery voltage solenoid valve and engine ECU gt Repair je e Check output wire to see if broken or shorting OK Check connector C 49 Replace
21. ck C 37 C 20 C 30 F 22 F 27 NG gt repair yon Check harness between pressure sensor 4WD ECU eCheck to see if power supply wire is broken earth or damaged fo NG gt repair Replace pressure sensor 22 10 MANUAL TRANSMISSION TROUBLESHOOTING Code No 51 Longitudinal G sensor system Assumed cause of concern falls below 0 5V or rises above 4 5V Code No 51 is output when the longitudinal G sensor signal e Harness connector malfunction e Longitudinal G sensor malfunction e ABS ECU malfunction lt AYC fitted vehicles gt e 4WD ECU malfunction Remarks 2 refer to 01 1 Lancer Evolution VII Service Manual No 1036K02 MUT IN IIL Service data e No 14 longitudinal G sensor power voltage OK P 22 32 Refer to Service Data List OK gt Intermittent malfunction i Measurement at D 29 longitudinal G sensor connector e Undo connector and measure on harness side e Ignition switch ON 1 Voltage between 1 earth OK battery voltage 2 Resistance between 3 earth Connector check D 29 C 212 C 210 NG gt repair pr OK 2Q or less yo Check harness between longitudinal G sensor ignition switch e Check for broken power supply wire earth damage eNG repair MB991348 D 29 Harness side connector e Remove longitudinal G sensor e Connect the special tool between D 29 longitudinal G
22. ction i Lateral G sensor check refer to P 22 20 NG gt replace yon NG Measurement at C 38 4WD ECU connector Connector check C 38 D 31 C 20 B 109 e ECU terminal voltage measurement lt ACD AYC fitted vehicles gt C 38 C 20 D 31 lt ACD e Ignition switch ON fitted vehicles gt e Voltage between 11 earth NG gt repair OK 2 4 2 6V when vehicle is standing on flat yon ground OK Check harness between lateral G sensor 4WD ECU e Check to see if output wire is broken earth or Connector check C 38 damaged NG gt repair Check harness between lateral G sensor ABS ECU yon Check to see if output wire earth or damaged NG gt repair MUT INIIL Service data yon e No 15 lateral sensor voltage OK P 22 32 Refer to Service Data List MUT II III Service data NG gt Replace 4WD ECU e No 15 lateral G sensor voltage OK gt Intermittent malfunction OK Refer to P 22 32 Service Data List 2 NG gt Refer to Group 35C Troubleshooting lt ACD AYC fitted vehicles gt or replace 4WD ECU OK gt intermittent malfunction 22 14 MANUAL TRANSMISSION TROUBLESHOOTING Code No 61 Stop lamp switch system Assumed cause of concern ON for 15 minutes or longer code No 61 is output In cases where at 15kph or over the stop lamp switch stays Brake pedal malfunction e Stop lamp switch malfunction e Harness connector ma
23. el speed sensor check Refer to Group 35B Vehicle wheel speed sensor NG gt Replace pes Connector checks C 38 A 05 A 31 D 11 D 05 D 12 C 131 C 20 C 115 C 34 NG gt Repair 7 Harness check between 4WD ECU each vehicle wheel speed sensor e Check output wire for broken wire earthing short e Check earth wire to see if broken or damaged NG gt Repair a MUT II III Service data e No 1 Vehicle speed sensor FR e No 2 Vehicle speed sensor FL e No 3 Vehicle speed sensor lt RR gt e No 4 Vehicle speed sensor lt RL gt OK Speed shown on speedometer and MUT II III agree NG gt Replace 4WD ECU OK gt Intermittent malfunction 22 4 MANUAL TRANSMISSION TROUBLESHOOTING From previous page Check vehicle wheel speed sensor output voltage ref p 22 41 2 NG l Check connector C38 NG gt Repair l MUT II III Service data e No 1 Vehicle speed sensor FR e No 2 Vehicle speed sensor FL e No 3 Vehicle speed sensor lt RR gt e No 4 Vehicle speed sensor lt RL gt OK Speed shown on speedometer and MUT II III agree NG gt Replace 4WD ECU OK gt Intermittent malfunction Vehicle speed sensor and rotor check Refer to Group 35B Vehicle wheel speed sensor NG gt Repair a Wheel bearing check Refer to Group 26 Vehicle Servicing Group 27B Rear Hub Assembly NG gt
24. en changed There were no changes other than the following Fuel Tank Removal and fitting AC400023AB NOTE Fit the filler neck hose clamp so that it does not interfere with the rear cross member INTAKE EXHAUST GENERAL SERVICING STANDARD VALUES VEHICLE SERVICING 15 1 SECTION 15 INTAKE EXHAUST CONTENTS Generali EG 1 1 Turbocharger boost pressure check 1 Servicing standard values 1 2 Checking boost pressure control system 2 Vehicle Servicing rrnnrnnrrnnrnnvnnnvrnnvrnvrnnnrnnn 1 Alr CIC OMEN seen 3 General The important service points were added as a result of the following changes Other service points remain the same e Change to the turbocharger boost pressure on 6M T e Change from one to two wastegate solenoid valves However the No 2 wastegate on the 5M T is not functional Servicing Standard Values ITEM STANDARD VALUE Turbocharger boost pressure kPa lt 6M T gt 97 144 Vehicle servicing 1 Checking turbocharger boost pressure lt 5M T gt Since the No 2 wastegate solenoid valve does not function the same check of the No 1 wastegate solenoid valve as before is carried out Z 6M T No 1 Wastegate N Note solenoid valve ELI The driving test which is done with the throttle fully open No 2 Wastegate must be done in a safe place with two people in the vehicle solenoid valve The person sitting in the passenger seat should ta
25. ervice Data List NG gt Replace 4WD ECU OK gt Intermittent malfunction Connector check C 38 D 29 C 20 B 109 gt lt ACD AYC fitted vehicles gt C 38 C 20 D 29 ACD fitted vehicles gt NG gt repair yon Check harness between longitudinal G sensor 4WD ECU e Check to see if output wire is broken earth or damaged Check harness between longitudinal G sensor ABS ECU lt ACD AYC fitted vehicles gt e Check to see if output wire earth or damaged NG gt repair yon MUT II III Service data e No 14 longitudinal G sensor voltage OK Refer to P 22 32 Service Data List NG gt Refer to Group 35C Troubleshooting lt ACD AYC fitted vehicles gt or replace 4WD ECU OK gt intermittent malfunction 22 12 MANUAL TRANSMISSION TROUBLESHOOTING Code No 56 Longitudinal G sensor system Assumed cause of concern falls below 0 5V or rises above 4 5V Code No 56 is output when the longitudinal G sensor signal e Ha rness connector malfunction e Longitudinal G sensor malfunction e ABS ECU malfunction lt ACD AYC fitted vehicles gt e 4WD ECU malfunction Remarks 2 refer to 01 1 Lancer Evolution VII Service Manual No 1036K02 MUT II III Service data No 15 longitudinal G sensor power voltage OK P 22 32 Refer to Service Data List OK gt Intermittent malfunction l G Measurement at D
26. ervice Manuals e Mirage Lancer 1036F30 10 1995 e Mirage Lancer 1036F52 8 1996 supplement e Mirage Lancer 1036F31 1 1996 e Lancer Sedia 1036K50 5 2000 e Mirage Lancer 1036F32 8 1996 e Lancer Sedia 1036K51 7 2000 supplement e Mirage Lancer 1036F33 7 1997 e Lancer Evolution VII 1036K52 5 2001 supplement e Lancer 1036F34 1 1998 e Lancer Sedia 1036K53 10 2001 supplement e Lancer Evolution VIII 1036K54 2 2004 MR supplement e Mirage Lancer 1036F35 10 1998 e Lancer 1036F36 1 1999 e Lancer 1036F37 12 1999 e Lancer Sedia 1036K30 5 2000 e Lancer Sedia 1036K31 7 2000 e Lancer Evolution VII 1036K32 1 2001 Wiring layout diagram Service Manuals e Lancer Sedia 1036K33 5 2001 e Lancer Evolution VIII 1036K77 1 2003 e Lancer Sedia 1036K34 5 2001 e Lancer Evolution VIII 1036K80 2 2004 MR supplement e Lancer Evolution VII 1036K35 1 2001 e Lancer Sedia 1036K36 5 2002 e Lancer Evolution VIII 1036K37 1 2003 e Lancer 1036K38 2 2003 e Lancer 1036K39 12 2003 e Lancer Evolution VIII MR 1036K40 2 2004 Service Manuals Engine Service Manuals e Lancer Sedia 1036K00 5 2002 e 4G6 Engine 1039G46 1 2001 e Lancer Sedia 1036K01 7 2000 e 4G6 Engine 1039G63 1 2003 e Lancer Evolution VII 1036K02 1 2001 supplement e Lancer Sedia supplement 1036K03 5 2001 e Lancer Sedia supplement 1036K04 10 2001 Transmission Service Manuals e Lancer Evo
27. hicles gt Check output wire for earth damage NG gt repair OK MUT INIIL Service data e No 14 longitudinal G sensor voltage OK Refer to P 22 32 Service Data List NG gt Refer to Group 35C Troubleshooting lt ACD AYC fitted vehicles gt or 4WD ECU lt ACD fitted vehicles gt Replace OK gt intermittent malfunction MANUAL TRANSMISSION TROUBLESHOOTING 22 11 Code No 52 Longitudinal G sensor system Assumed cause of concern specified value At 10kph or over with ABS and brakes not applied code No 52 is output in cases where G sensor indicates higher than e Harness connector malfunction e Longitudinal G sensor malfunction e ABS ECU malfunction lt ACD AYC fitted vehicles gt e 4WD ECU malfunction Remarks 2 refer to 01 1 Lancer Evolution VII Service Manual No 1036K02 MUT INIIL Service data e No 14 longitudinal sensor voltage OK P 22 32 Refer to Service Data List OK gt Intermittent malfunction Longitudinal G sensor check refer to P 22 32 NG gt replace yon Measurement at C 38 4WD ECU connector e ECU terminal voltage measurement e Ignition switch ON Voltage between 23 earth OK 2 4 2 6V when vehicle is standing on flat NG ground px Connector check C 38 NG gt repair ok MUT INMIIL Service data e No 14 longitudinal sensor voltage OK P 22 32 Refer to S
28. ice data e No 1 Vehicle speed sensor FR e No 2 Vehicle speed sensor FL e No 3 Vehicle speed sensor lt RR gt e No 4 Vehicle speed sensor lt RL gt Check connector C 38 NG gt repair agree NG gt Replace 4WD ECU OK gt Intermittent malfunction Measurement at C 38 4WD ECU connector Vehicle wheel speed sensor Refer to Group 35B Vehicle wheel speed sensor NG gt Repair yon Connector checks C 38 A 05 A 31 D 11 D 05 D 12 C 131 C 20 C 115 C 34 NG gt Repair yon Harness check between 4WD ECU each vehicle wheel speed sensor e Check output wire for broken wire earthing short e Check earth wire to see if broken or damaged NG gt repair yon MUT II III Service data e No 1 Vehicle speed sensor FR e No 2 Vehicle speed sensor FL e No 3 Vehicle speed sensor RR e No 4 Vehicle speed sensor lt RL gt OK Speed shown on speedometer and MUT II III agree NG gt Replace 4WD ECU OK gt Intermittent malfunction OK Speed shown on speedometer and MUT II III gt Vehicle wheel speed sensor and rotor check Refer to Group 35B Vehicle Wheel Speed Sensor NG gt Repair yon Wheel bearing check Refer to Group 26 Vehicle Servicing Group 27B Rear Hub Assembly NG gt Repair MANUAL TRANSMISSION TROUBLESHOOTING 22 7 Code No 41 42 TPS system Assumed cause of concern
29. icle wheel speed sensor RR systems Code No 24 Vehicle wheel speed sensor lt RL gt systems Assumed 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 e Wheel speed sensor malfunction e Rotor malfunction e Wheel bearing malfunction e Harness connector malfunction e 4WD ECU malfunction lt ACD fitted vehicle gt Remarks 1 refer to 00 5 Lancer Sedia Service Manual No 1036K00 2 refer to 01 1 Lancer Evolution VII Service Manual No 1036K02 Vehicle speed sensor fitting check NG gt repair pon MUT IN IIL Service Data e No 01 Vehicle speed sensor FR e No 02 Vehicle speed sensor FL e No 03 Vehicle speed sensor RR e No 04 Vehicle speed sensor lt RL gt OK Speed shown on speedometer and MUT IN III agree OK gt Intermittent malfunction i NG e Undo connector and take measurement on harness side 1 Resistance between 9 22 vehicle speed sensor lt FR gt 2 Resistance between 6 19 vehicle speed sensor lt FL gt 3 Resistance between 7 20 vehicle speed sensor lt RR gt 4 Resistance between 8 21 vehicle speed sensor lt RL gt OK 1 2 1 6 KQ OK To next page Measurement at C 38 4WD ECU connector y Vehicle whe
30. ke 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 15 2 INTAKE EXHAUST VEHICLE SERVICING 1 Wastegate actuator misoperation 2 Wastegate valve misoperation 3 Wastegate actuator rubber hose detachment cracking 2 Boost pressure control system inspection lt 6M T gt 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 pe 1 Remove hose black from No 1 wastegate solenoid valve then ET N i connect a three way coupling between the hose and the ke solenoid valve 0 1 Wastegate 2 Connect a hand vacuum pump to the three
31. king on the rear of the markings and fix in position 3 Remove the application tape Note e Do this job in an ambient temperature of 20 38 C in a dust free location e If temperature is less than 20 C warm up the markings and the body where they will be fitted to between 20 30 C e Stick the markings on and press firmly so that no air bubbles get trapped RJSY402025 46
32. l spring securely ensure that the special tool is extended as far as the spring will allow then fitted evenly to the coil spring 2 There is a danger of special tool damage so do not use an impact wrench 2 Using the following special tools release the self locking nut e Special spanner MB991367 e Pin MB991385 CAUTION There is a danger of the lock nut inside the strut piston rod working loose so when loosening the self locking nut do not use an impact wrench MB991385 Important note on assembly DAA Fitting self locking nut 1 With the coil spring compressed with the special tool temporarily tighten the self locking nut 2 Match up strut assembly hole in lower spring seat and hole in upper spring seat Remarks Using a lever to align the holes can make this job easier 3 Match both tips of coil spring precisely with the slots on the spring seats and release the special tool 4 Using the special tool tighten the self locking nut to the specified torque Tightening torque 60 10N m CAUTION There is a danger of the lock nut inside the strut piston rod Ay working loose so when loosening the self locking nut do MB991385 AL not use an impact wrench 34 1 REAR SUSPENSION GENERAL SHOCK ABSORBER ASSY SECTION 34 REAR SUSPENSION CONTENTS GONG ki ko a a kk a ka kk ko 1 Shock Absorber ASSy swwwnnnnnnnnnnnvvnnnnnnnnnn 1 General Important servicing information has been specified along
33. lfunction e AWD ECU malfunction Remarks 1 Refer to 00 5 Lancer Sedia Service Manual No 1036K00 Check height of brake pedal Refer to Group 35A Vehicle Servicing NG gt Adjust P MUT II III Service data No 56 Stop lamp switch 1 Depress brake pedal OK ON 2 Release brake pedal OK OFF OK gt Intermittent malfunction NG Check connector C 118 NG gt repair Pr Check stop lamp switch Refer to Group 35A Brake pedal NG gt replace pe Measurement at C 118 stop lamp switch connector e Undo connector measure on harness side Voltage between 2 earth OK battery voltage P Measurement at C 37 4WD ECU connector e ECU terminal voltage measurement Voltage between 38 earth 1 Depress brake pedal OK battery voltage 2 Release brake pedal OK 1V or less NG Connector check C 118 C 22 C 23 C 37 NG gt repair OK Check harness between 4WD ECU stop lamp switch Check for broken or damaged output wire NG gt repair OK Check harness between stop lamp switch stop lamp e Check for broken or damaged output wire NG gt repair NI y Connector check C 118 C 31 NG gt repair Va Check harness between stop lamp switch battery e Check power supply wire to see if broken or damaged NG gt repair m Connector check C 37 NG gt repair ye MU
34. lution VII 1036K05 1 2002 e W5M51 Manual 1039M17 1 2001 supplement Transmission e Lancer Sedia supplement 1036K06 5 2002 e W5M51Manual 1039M22 1 2003 transmission Supplement e Lancer Evolution VIII 1036K07 1 2003 e W6MAA Manual 1039M23 1 2003 supplement transmission e Lancer supplement 1036K08 2 2003 e Lancer supplement 1036K09 12 2003 Precautions to be taken when servicing vehicles with seatbelts fitted with SRS Airbag and Pretensioners 1 Incorrect inspection or servicing of SRS airbag and pretensioner fitted seatbelt parts as well as any related components could lead to major damage or non operation as a result of sudden unintentional operation of SRS airbag and pretensioner fitted seatbelts incorrect deployment In cases where heating from painting processes occurs the SRS ECU driver side airbag module passenger side airbag module pre tensioner fitted seatbelts and cross springs should be removed e 93 C and above SRS ECU driver side airbag module passenger side airbag module cross springs e 90 C and above pretensioner fitted seatbelts Inspections and servicing of SRS airbag and pretensioner fitted seatbelt parts and any related components must without fail be done by a Mitsubishi Motors authorized dealer Inspections and servicing of SRS airbag and pretensioner fitted seatbelt parts and any related components must be done paying scrupulous attention to
35. ment on harness side e Resistance between 3 earth NG OK 2Q or less px Check connector F 27 NG repair yon Replace pressure sensor PS Connector check C 37 C 20 F 22 F 27 e Harness connector malfunction e Pressure sensor malfunction e 4WD ECU malfunction NG gt repair ok Check harness between pressure sensor 4WD ECU e Check to see if earth wire is broken or damaged NG gt repair fo Replace 4WD ECU MANUAL TRANSMISSION TROUBLESHOOTING 22 9 Code No 47 Pressure sensor system abnormal power supply Assumed cause of concern is ON the pressure sensor power supply voltage is 4 0V or less Code No 47 is output when with pressure sensor power supply OFF the pressure eHarness connector malfunction sensor power supply voltage is 4 0V or more and when pressure sensor power supply e Pressure sensor malfunction e 4WD ECU malfunction MUT II III Service data e No 19 pressure sensor power supply OK 5V OK gt Intermittent malfunction NG e Measure ECU terminal voltage e Ignition switch ON e Voltage between 43 earth OK 4 9V 5 1V ps yon Check connector C 37 NG gt Repair MUT II Ill Service data e No 19 Pressure sensor OK 5V NG gt replace 4WD ECU OK gt intermittent malfunction Measurement at C 37 4WD ECU connector Connector che
36. nsor 3 Fuel pressure control k Ignition coil 5 6 7 8 9 Cam position sensor Crack angle sensor Barometric pressure sensor Water temperature sensor Knock sensor Power steering fluid pressure switch Alternator FR signal Intercooler water spray switch auto Intercooler water spray switch manual Engine ECU gt gt Ye4 w5 w6 WT No 1 wastegate solenoid valve No 2 wastegate solenoid valve Purge control solenoid valve Secondary air control solenoid valve Condenser fan relay LOW Engine warning lamp Diagnosis output Alternator G terminal Intercooler water spray relay Intercooler water spray lamp Canister lt _ From fuel tank 2 ISC servo 6 Purge control solenoid valve 4 Throttle position sensor fr Vacuum e tank 7 Secondary air L control solenoid valve A EE mi T Ho I Cop ig 3 Fuel pressure Secondary control solenoid valve air valve Fuel pressure regulator From fuel pump 7 Barometric pressure sensor 3 Air intake sensor 2 Air flow sensor Air intake 1 Injector 5 Cam position sensor 8 Water temperature sensor 9 Knock sensor Crack angle sensor W 4 No 1 wastegate solenoid valve Catalytic converter 36010AU 5 No 2 wastegate solenoid valve Only operates on 6M T 13A 3 MPI Troubleshooting TRO
37. oltage yon Connector check D 25 NG gt repair OK y Check and if necessary adjust the play in the parking brake lever refer to Group 36 Vehicle Servicing yon NG gt Adjust Check parking brake switch refer to Group 36 Vehicle Servicing NG gt adjust Connector check C 37 D 25 C 20 NG gt repair OK Connector check D 25 C 37 C 20 B 109 lt ACD AYC fitted vehicles gt D 25 C20 C 37 lt ACD fitted vehicles gt NG gt repair 1 Check harness between parking brake switch 4WD ECU e Check output wire for earth damage 2 Check harness between parking brake switch combi meter e Check power supply wire for earth damage 3 Check harness between parking brake switch ABS ECU lt ACD AYC fitted vehicles gt e Check output wire for earth damage NG gt repair p OK Replace hydraulic unit ABS ECU Check harness between parking break switch 4WD ECU e Check output wire to see if broken or damaged NG gt repair en MUT II III Service data e No 62 Parking brake switch 1 Apply parking brake lever OK ON 2 Release parking brake lever OK OFF NG gt replace 4WD ECU OK gt intermittent malfunction 2 OK pe Check brake warning lamp bulb NG gt replace e Replace combi meter MANUAL TRANSMISSI
38. or lamp ASSY e Check power supply wire to see if broken or damaged eNG repair LA Measurement at C 37 4WD ECU connector NG e Undo connector take measurement on harness side Check ACD mode indicator lamp ASSY e Ignition switch ON NG gt replace e Earth 40 51 52 to body earth OK OK indicator lamp on j OK Connector check C 37 C 133 C 106 NG gt repair Connector check C 37 jon NG gt repair yon Fault confirmation ye Fault confirmation ING Check harness between ACD mode indicator lamp Y ASSY 4WD ECU Replace 4WD ECU e Check output wire to see if broken or damaged Checking procedure 4 Even after engine starts at least 2 ACD mode indicator lamps Assumed cause of concern remain lit ACD mode indicator lamp output circuit malfunction is possible Harness connector malfunction e 4WD ECU malfunction e ACD mode indicator lamp ASSY malfunction Remarks This phenomenon is limited to when communication with MUT II III is possible 4WD ECU power supply normal and diagnosis code is normal correct When C 37 4WD ECU connector is undone do all NO y Check connector C 37 C 133 C 106 ACD mode indicator lamps all go out NG gt repair ye OK y Replace 4WD ECU Fault confirmation NG y Check harness between ACD mode indicator ASSY 4WD ECU e Check output wire for earthing shorting NG gt repair yon Replace ACD mode indicator ASSY FRONT SUSPENSION GENERAL SPECIAL T
39. r less after which battery voltage NG gt replace hydraulic unit ABS ECU 22 18 MANUAL TRANSMISSION TROUBLESHOOTING Code No 74 Proportional valve lt ACD gt system Assumed cause of concern In cases where the proportional valve ACD control circuit is shorting code No 74 is output e Proportional valve ACD malfunction Harness connector malfunction e 4WD ECU malfunction Remarks 2 refer to 01 1 Lancer Evolution VII Service Manual No 1036K02 MUT II IIl Service data e No 11 Proportional valve current lt ACD gt OK P 22 32 Refer to Service Data List OK gt Intermittent malfunction yon connector e Undo connector take measurement on harness side Resistance between 2 body earth OK 2Q or less ye Connector check F 25 F 22 NG gt repair yon Check harness between proportional valve ACD body earth Check earih wire to see if broken or damaged NG gt repair Measurement at F 25 proportional valve lt ACD gt NG gt Replace hydraulic unit connector e Undo connector take measurement on proportional valve side Resistance between 2 3 OK 4 7Q or less yon Measurement at F 25 proportional valve lt ACD gt OK y Connector check F 25 F 22 C 30 C 133 C 38 NG gt repair fok Check harness between 4WD ECU and Proportional valve ACD e Check output wire
40. sensor connector harness side connector and longitudinal G sensor e Ignition switch ON e Voltage between 2 body earth when longitudinal G sensor is set on a flat surface OK 2 4 2 6V Voltage between 2 body earth when longitudinal G sensor is placed so that the label surface faces Connector check D 29 C 20 B 109 lt ACD AYC fitted vehicles gt D 29 C 20 C 38 lt ACD fitted vehicles gt NG gt repair P Check harness between longitudinal G sensor ABS ECU lt ACD AYC fitted vehicles gt e Check to see if earth wire broken or damaged NG gt repair Check harness between longitudinal G sensor 4WD ECU lt ACD fitted vehicles gt e Check to see if earth wire broken or damaged NG gt repair gi MUT II III Service data e No 14 longitudinal G sensor voltage OK Refer to P 22 32 Service Data List 2 NG gt Refer to Group 35C Troubleshooting lt ACD AYC fitted vehicles gt or 4WD ECU lt ACD fitted vehicles gt Replace OK gt intermittent malfunction NG sideways a Replace longitudinal G sensor OK 3 3 3 7V Connector check D 29 C 38 C 20 B 109 ACD AYC fitted vehicles gt D 29 C 20 C 38 lt ACD fitted vehicles jon NG gt repair Check harness between longitudinal G sensor 4WD ECU e Check for broken output wire earth damage Check harness between longitudinal G sensor ABS ECU lt ACD AYC fitted ve
41. the relevant service manual particularly in the case of Group 52B SRS airbags GENERAL MODEL COMPOSITION APPLIED VEHICLE NUMBERS 00 1 SECTION 00 GENERAL CONTENTS Model composition snssnnnnnnnnnnnnnnnnnnnnnnnnnnnn 1 Applied vehicle numbers snannnnnnnnnnnnnnnner 1 Model line up Model Version 04 Model Grade Engine Model Transmission Fuel System GH CT9A SNDFZ O RS 4G63 W5M51 4WD 5M T MPI 2 000 DOHC 16 valve intercooler turbo SJDFZ 6 RS W6MAA 4WD 6 M T SJGFZ O GSR Note O Continued model Applied vehicles GH CT9A CT9A 0300001 13A 1 SECTION 13A MPI Multi point Fuel Injection CONTENTS Generdluunsaauenennnniuksup junininvidvji ik 2 Troubleshooting k suusuuussnssnansnnvunnnn 3 MPI General 13A 2 General Service information issued contains the changes noted below Other service details remain unchanged e Change from one to two wastegate solenoid valves However the No 2 wastegate solenoid valve on the 5 M T is not functional e Diagnosis code No P1500 changed to P0622 lt 6M T gt MPI system diagram sensor A C switch A C load signal solenoid valve Fan controller Condenser fan relay HI 1 02 sensor e Power supply 3x1 Injector e Engine control relay 2 Air flow sensor Mi eaten ae sa 2 ISC servo stepper Are relay 2 3 3 Air intake sensor motor GE 4 Throttle position i Vehicle speed se
42. to see if broken shorting or damaged NG gt repair yon MUT II III Service data e No 11 Proportional valve current lt ACD gt OK refer to P 22 32 Service Data List 2 NG replace 4WD ECU OK gt Intermittent malfunction Code No 81 Electric pump relay system Assumed cause of concern Output when the circuit on the pump relay coil side is broken or shorting e Electric pump relay malfunction Harness connector malfunction e 4WD ECU malfunction Remarks 2 refer to 01 1 Lancer Evolution VII Service Manual No 1036K02 MUT II III actuator test e No 04 Electric pump operation OK the electric pump operating sound is audible OK gt Intermittent malfunction YNG Check electric pump relay refer P 22 53 2 YOK Measurement at B 127 electric pump relay connector e Undo connector take measurement on harness side Resistance between 1 body earth OK 2Q or less NG OK NG Connector check B 127 NG gt repair yon Check harness between electric pump relay body earih e Check earth wire to see if broken or damaged NG gt repair HI se Replace electric pump relay Connector check B 127 C 38 NG gt repair YOK Check harness between 4WD ECU and electric pump relay e Check power supply wire to see if broken shorting or damaged NG gt repair YOK MUT INIIL Actuator test e No 04 Electric
43. way coupling solenoid valve No 2 Wastegate solenoid valve 3 Remove boost hose from the wastegate actuator control boost nipple on the air outlet fitting and fit a plug over the nipple 4 Apply a vacuum whilst covering and releasing the tip of the hose to check the vacuum condition Wastegate a m actuator Engine condition Boost hose tip Normal condition Stop ignition Released Vacuum leaks switch ON E P position Covered Vacuum is maintained Ho Y6292AU Idle running after Vacuum leaks warming up 5 Ignition switch to LOCK OFF position 6 Remove wastegate solenoid valve connector 7 Apply a vacuum whilst covering and releasing the tip of the hose to check the vacuum condition stop the hose tip with a plug when driving Engine condition Boost hose tip Normal condition Stop ignition switch Released Vacuum leaks ON position Covered Vacuum is maintained Accelerating with Vacuum leaks throttle full open in 2nd gear at least 3500rpm Note When vacuum condition is not normal it may be assumed that there is a problem with the wastegate actuator wastegate solenoid valve or hose INTAKE EXHAUST AIR CLEANER 15 3 Air Cleaner Removal and Fitting Note The parts marked with a x symbol are plastic components which contain recycled paper Please note the following e When fixing or removing or after fitting
44. with the adoption of Bilstein shock absorbers Shock Absorber Assy Vehicles fitted with Bilstein shock absorbers Dismantling and Assembly AAC400102 Dismantling procedure 6 Collar 7 Bush A Ab DU 1 Self locking nut 8 Cup ASSY 2 Washer 9 Dust cover va bad 10 Coil sprin pet Bracket ASSY 11 Sines faba gt B4 5 Spring upper pad i p 12 Shock absorber Remarks Carry out dismantling and assembly following existing servicing instructions EXTERIOR GENERAL 51 1 SECTION 51 EXTERIOR CONTENTS General aannannannnnnannnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnen 1 Front DUMPET nesse eee eiaa a 2 Front BWNPOEN aie ank ia kin 2 LETT kisal pok paai asasen konsno bosi 4 AKESIV S EEA SEE anlot vende shebaeatectOeesdecvas 2 General Important servicing information has been specified along with the following changes and additions Other servicing information however remains the same as the information relating to the Lancer Evolution VIII e Changes and additions to front bumper components e Changes to the position of the 3 diamonds badge and addition to the EVOLUTION MR mark 51 2 EXTERIOR FRONT BUMPER Front bumper Adhesives Locations used Brand Three diamonds badge Double sided tape ordinary tape widely available on the market width 20mm thickness 0 8mm Front Bumper Dismantling Assembling Locations where double sided tape is applied Cross section B B

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