Page 1 www.TuningEvo.Club...
Page 2: Table Of Contents
LANCER CONTENTS EVOLUTION VIII General Engine FOREWORD Fuel This manual contains details of the main changes to the ’03 Engine Cooling model Lancer Evolution VIII. Since only differences to the Lancer Evolution VII have been included, please use this manual in conjunction with the relevant pages in the material previously published.
Page 3 Related materials Title Issue date New model manuals • Mirage, Lancer 1036F30 10/1995 • Mirage, Lancer 1036F31 1/1996 • Mirage, Lancer 1036F32 8/1996 • Mirage, Lancer 1036F33 7/1997 • Lancer 1036F34 1/1998 • Mirage, Lancer 1036F35 10/1998 • Lancer 1036F36 1/1999 •...
Page 4: General
GENERAL - MODEL LINE-UP, APPLIED VEHICLES 00-1 SECTION 00 GENERAL CONTENTS Model line-up..........1 Troubleshooting and Inspection ....2 Applied vehicle numbers ......1 Model line-up Model Version ’03 Model Grade Engine Model Transmission Fuel System GH-CT9A SNDFZ 4G63 W5M51 (4WD, 5M/T) (2 000 DOHC 16 valve SYGFZ GT-A intercooler turbo)
Page 5: General
GENERAL - TROUBLESHOOTING AND INSPECTION 00-2 TROUBLESHOOTING AND INSPECTION Diagnosis connector Diagnosis Functions Reading Diagnosis Code Connect the MUT-III to 16 pin diagnosis connector and read diagnosis code as described below. NB. Please refer to the User Manual for a detailed explanation of how to use the MUT-III.
Page 6: Engine
4G6 ENGINE – GENERAL, SEALANTS, SPECIAL TOOLS 11A-1 SECTION 11A ENGINE CONTENTS General ............1 1. Checking compression pressure .....2 Camshaft, valve stem seals .....2 Sealants .............1 Timing belt, timing belt B ......11 Special Tools ..........1 Engine adjustment ........2 4G6 ENGINE General The servicing information specified below accompanies changes to the 4G63-MPI-T/C engine installed on the new Lancer Evolution VIII.
Page 7 11A-2 4G6 ENGINE – SPECIAL TOOLS, ENGINE ADJUSTMENT, CAMSHAFT, VALVE STEM SEAL Tool Number Name Function Camshaft oil seal insertion MD998713 Camshaft Oil seal Installer ENGINE ADJUSTMENT 1. Checking compression pressure The crank angle sensor connector position has been changed. crank angle sensor connector CAMSHAFT, VALVE STEM SEAL...
Page 8 4G6 ENGINE- CAMSHAFT , VALVE STEM SEAL 11A-3 Removal procedure 6. PCV hose 1. Breather hose 7. Radiator upper hose • Air bag ASSY 8. Camshaft position sensor connector (refer to Chapter 15-2 Secondary Air Control 9. Connecting earth cable System) 10.
Page 9 11A-4 4G6 ENGINE – CAMSHAFT, VALVE STEM SEAL When assembling, apply engine oil to all sliding parts 14. Camshaft position sensor 23. Camshaft bearing cap No.5 support cover 24. Camshaft bearing cap No.3 15. Camshaft position sensor 25. Camshaft bearing cap No.4 support cover gasket 26.
Page 10 4G6 ENGINE- CAMSHAFT , VALVE STEM SEAL 11A-5 Lubricant and seal application locations <View of rocker cover lower surface> Semi-dry sealant: Three Bond 1207D <View from A> Rocker Cover Cylinder head Semi-dry sealant: Three Bond 1207D Semi-dry sealant: Three Bond 1211 (Lip part) Engine oil Ø...
Page 11 11A-6 4G6 ENGINE – CAMSHAFT, VALVE STEM SEAL MAIN POINTS REGARDING REMOVAL DETACHING RADIATOR UPPER HOSE Align the matching marks on radiator upper hose and hose clamp, then detach radiator upper hose. Matching marks REMOVING CAMSHAFT SPROCKETS Hold camshaft hexagonal part with a wrench, loosen mounting bolt, and remove camshaft sprocket.
Page 12 4G6 ENGINE- CAMSHAFT , VALVE STEM SEAL 11A-7 FITTING VALVE SPRING Fit so that the valve spring small radius end is on the rocker arm side. Rocker arm side FITTING VALVE SPRING RETAINER LOCK Compress the valve spring using the same valve spring compressor tool (MD998772) as the one used for removal and fit the valve spring retainer lock.
Page 13 11A-8 4G6 ENGINE – CAMSHAFT, VALVE STEM SEAL 2. The camshaft bearing caps No.2~5 are the same shape, so check the identification marks before fitting in the direction shown in the diagram, in order to avoid getting bearing cap number, and intake and exhaust Bearing cap sides, mixed up.
Page 14 4G6 ENGINE – CAMSHAFT, VALVE STEM SEAL 11A-9 FITTING CAMSHAFT POSITION SENSOR SUPPORT 1. Remove any sealant on the camshaft position sensor support. 2. Apply sealant to the camshaft position sensor support flange, as shown in the diagram, then fit to the cylinder head. Semi-dry sealant: Three Bond 1207F 3.
Page 15 11A-10 4G6 ENGINE – CAMSHAFT, VALVE STEM SEAL FITTING CAMSHAFT END SEALS Apply sealant to the locations on the camshaft end seal, as shown in the diagram, then fit to the cylinder head. Semi-dry sealant: Three Bond 1211 Cylinder head FITTING ROCKER COVER ASSY Engine forward direction 1.
Page 16 4G6 ENGINE – TIMING BELT, TIMING BELT B 11A-11 TIMING BELT and TIMING BELT B Removal and Fitting Caution When Brembo brake callipers are used, there is concern over paint peeling off, so when doing servicing work, make sure they are not scratched by other components and tools. Furthermore, if any brake fluid gets onto the calipers, it should be wiped off immediately.
Page 17 11A-12 4G6 ENGINE – TIMING BELT, TIMING BELT B (Engine oil) 11. Crank angle sensor 14. Timing belt B tensioner 12. Crank shaft sprocket 15. Timing belt B 13. Crank shaft sensing blade • Timing belt B tension adjustment Note Carry out removal and fitting in accordance with existing instructions...
Page 18: Fuel
1ЗА-1 SECTION 13 FUEL CONTENTS Multipoint lnjection (MPl) ........1 ЗА Fuel supply ............138...
Page 19 13A-1 SECTION 13A MPI (Multipoint Injection) CONTENTS General..............2 Special tools ............3 Troubleshooting ............5 Injectors ..............100 Engine control registers and relays.......102...
Page 20 13A-2 MPI - GENERAL General The following changes have been made to vehicles fitted with the 4G63-DOHC-T/C engine. Otherwise the system remains the same. • The engine ECU has been changed • An immobiliser system has been fitted • A plated metal delivery pipe has been adopted •...
Page 21 MPI – SPECIAL TOOLS 13A-3 Special Tools Tool Number Name MB991502 MUT-II sub-ASSY MPI system inspection MB991955 MUT-III sub-ASSY A: MB991824 A:V.C.I. (Vehicle B: MB991827 Communication C: MB991910 Interface) D: MB991911 B:USB cable E: MB991825 C:MUT-III main F: MB991826 harness B (for use on vehicles that have not adopted communication)
Page 22 13A-4 MPI – SPECIAL TOOLS Tool Number Name MB991709 Test harness • Troubleshooting voltage measurement • Inspection using an oscilloscope MB991536 TPS adjustment check Troubleshooting voltage measurement harness MB991658 Test harness Inspection using an oscilloscope MB998464 Test harness Troubleshooting voltage measurement (4P, square) MD998478 Test harness...
Page 23 MPI – TROUBLESHOOTING 13A-5 TROUBLESHOOTING 1. Diagnosis Function 1-1. Engine warning light (engine check lamp) Engine warning light checks have been changed. Items that are linked to the engine warning light are: Engine ECU Air flow sensor (AFS) Intake air temperature sensor Throttle position sensor (TPS) Water temperature sensor Crank angle sensor...
Page 24 13A-6 MPI – TROUBLESHOOTING 3. CHECKING PROCEDURES BY DIAGNOSIS CODE Code No. P0100 Air Flow Sensor (AFS) Checking Procedure Probable Causes Inspection Conditions • AFS malfunction • Engine speed: at least 500rpm • AFS circuit broken, short-circuit, or poor connector Evaluation conditions contact •...
Page 25 MPI – TROUBLESHOOTING 13A-7 From previous page Check connector C-49 Repair B-08 AFS connector measurement • Using test harness (MB991709), connect to connector, and take Check harness between AFS and measurement at pick up Engine ECU harness Repair • Check for broken reset signal •...
Page 26 13A-8 MPI – TROUBLESHOOTING Code No. P0105 Barometric Pressure Sensor System Probable causes Inspection Conditions • Barometric pressure sensor malfunction • Barometric pressure sensor circuit broken, short- • Ignition switch ON circuit, or poor connector contact • Excluding a 2 second period after turning ignition switch to ON position, or •...
Page 27 MPI – TROUBLESHOOTING 13A-9 From previous page (1), (2) NG B-08 AFS connector Check connector C-49, C-50 Repair measurement • Using test harness (MB991709), connect only to connector Check and repair harness terminal Nos.1,.2, and 5, and between AFS and Engine ECU take measurement at pick up •...
Page 28 13A-10 MPI – TROUBLESHOOTING Code No. P0110 Intake Air Temperature Sensor System Probable causes Inspection Conditions • Air intake temperature sensor malfunction • Ignition switch ON • Air intake temperature sensor circuit broken, • Excluding a 2 second period after turning ignition switch to ON position, or short-circuit, or poor connector contact immediately after engine has fully started •...
Page 29 MPI – TROUBLESHOOTING 13A-11 From previous page B-08 AFS connector Check connector C-49, C-50 Repair measurement • Using test harness (MB991709), connect only to connector terminal Nos.5, and 6, and take Check and repair harness measurement at pick up between AFS and Engine ECU harness •...
Page 30 13A-12 MPI – TROUBLESHOOTING From previous page B-108 Water temperature sensor Replace water temperature connector measurements sensor • Undo connector and take harness measurement • Resistance across 1 – 2 OK: Water temp. -20ºC 14 ~ 17kΩ Water temp. 0ºC 5.1 ~ 6.5 kΩ Water temp.
Page 31 MPI – TROUBLESHOOTING 13A-13 From previous page Repair B-108 water temperature sensor Check connector C-50 connector measurement • Using test harness (MB991658), connect to connector, and take Check and repair harness measurement at pick up harness between water temp. sensor and •...
Page 32 13A-14 MPI – TROUBLESHOOTING From previous page (1) NG Check connector C50 B-06 TPS connector C-50 Engine ECU connector measurements measurements • Undo connector, and take • Measure engine ECU terminal harness measurement voltage Repair (1) Voltage across 1 - earth •...
Page 33 MPI – TROUBLESHOOTING 13A-15 From previous page (1), (2) NG B-06 TPS connector Repair Check connector C-50 measurement • Using test harness (MB991536), take measurement at pick up Check and repair harness harness between TPS and Engine ECU • Ignition switch: ON •...
Page 34: Engine Cooling
13A-16 MPI – TROUBLESHOOTING Code No. P0130 O 2 Sensor System Probable causes Inspection Conditions • O 2 sensor malfunction • For at least 3 minutes after engine has fully started • O 2 sensor circuit broken, short-circuit, or poor •...
Page 35 MPI – TROUBLESHOOTING 13A-17 From previous page C-51 Engine UCU sensor Repair Check connector C-51 connector measurement • Measure ECU terminal voltage • Engine warmed up • Voltage across 71 - earth • When decelerating rapidly from Check and repair harness 4000rpm between O 2 sensor and Engine OK: 200mV or less...
Page 36 13A-18 MPI – TROUBLESHOOTING Code No. P0135 O 2 Sensor Heater System Probable causes Inspection Conditions • O 2 sensor heater malfunction • Engine cooling water temperature approx. 20ºC or more • O 2 sensor heater circuit broken, short-circuit, or poor •...
Page 37 MPI – TROUBLESHOOTING 13A-19 Code No. P0170 Fuel System Abnormality Probable causes Inspection Conditions • Fuel supply system malfunction • Engine Air-fuel ratio learning • O 2 sensor malfunction Evaluation conditions • Intake air temperature sensor malfunction • At least 5 second duration when injected fuel correction value is •...
Page 38 13A-20 MPI – TROUBLESHOOTING Code No.P0201 No.1 Injector System Probable causes Inspection Conditions • No.1 injector malfunction • Engine speed: 50 ~ 1,000rpm • No.1 injector circuit broken, has short circuit, or poor • TPS output voltage 1.15V or less connector contact •...
Page 39 MPI – TROUBLESHOOTING 13A-21 Code No.P0202 No.2 Injector System Probable causes Inspection Conditions • No.2 injector malfunction • Engine speed: 50 ~ 1,000rpm or less • No.2 injector circuit broken, has short circuit, or poor • TPS output voltage 1.15V or less connector contact •...
Page 40 13A-22 MPI – TROUBLESHOOTING Code No.P0203 No.3 Injector System Probable causes Inspection Conditions • No.3 injector malfunction • Engine speed: 50 ~ 1,000rpm or less • No.3 injector circuit broken, has short circuit, or • TPS output voltage 1.15V or less poor connector contact •...
Page 41 MPI – TROUBLESHOOTING 13A-23 Code No.P0204 No.4 Injector System Probable causes Inspection Conditions • No.4 injector malfunction • Engine speed: 50 ~ 1,000rpm or less • No.4 injector circuit broken, has short circuit, or poor • TPS output voltage 1.15V or less connector contact •...
Page 42 13A-24 MPI – TROUBLESHOOTING Code No.P0300 Injection Coil (housing a power transistor) System Probable causes Inspection Conditions • Ignition coil malfunction • Engine speed: 1500 ~ 3,500rpm or less • Spark plug malfunction • Volumetric efficiency 40% - 80% • Spark plug cable malfunction •...
Page 43 MPI – TROUBLESHOOTING 13A-25 From previous page Check harness between ignition Repair coil and ignition coil relay • Check for damage to power supply cable Check harness between ignition Repair coil and engine ECU • Check for damage to output cable Confirm fault symptoms Intermittent malfunction (ref.
Page 44 13A-26 MPI – TROUBLESHOOTING Code No.P0335 Crank Angle Sensor System Probable causes Inspection Conditions • Crank angle sensor malfunction • Engine cranking • Crank angle sensor circuit broken, has a short Evaluation conditions circuit, or poor connector contact • No change in sensor output voltage for duration of 4 seconds (pulse •...
Page 45 MPI – TROUBLESHOOTING 13A-27 From previous page B-122 Crank angle sensor Repair Check connector B-19X connector output waveform measurement (using an oscilloscope) Check harness between crank Repair • Using test harness (MB998478), angle sensor and Engine control connect to connector, then take relay measurement at pick up harness •...
Page 46 13A-28 MPI – TROUBLESHOOTING Code No.P0340 Cam Position Sensor System Probable causes Inspection Conditions • Cam position sensor malfunction • Ignition switch: ON • Cam position sensor circuit broken, has a short • Engine speed approx. 50rpm or more circuit, or poor connector contact Evaluation conditions •...
Page 47 MPI – TROUBLESHOOTING 13A-29 From previous page B-115 Cam position sensor Check connector B-19X Repair connector output waveform measurement (using an oscilloscope) Check harness between cam Repair • Using test harness (MB991709), position sensor and Engine connect to connector, then take control relay measurement at pick up harness •...
Page 48 13A-30 MPI – TROUBLESHOOTING Code No.P0500 Vehicle Speed Sensor System Probable causes Inspection Conditions • Vehicle speed sensor malfunction • Ignition switch: ON • Vehicle speed sensor circuit broken, has a • After ignition switch has been turned to ON position, or after 2 seconds short circuit, or poor connector contact from the time the engine has fully started up •...
Page 49 MPI – TROUBLESHOOTING 13A-31 Code No.P0513 Immobiliser System Probable causes Inspection Conditions • Circuit broken, has a short circuit, or poor • Ignition switch: ON connector contact Evaluation conditions • Immobiliser ECU malfunction • Communication error between engine ECU and immobiliser detected. •...
Page 50 13A-32 MPI – TROUBLESHOOTING Code No.P1500 Alternator FR Terminal System Probable causes Inspection Conditions • Alternator FR terminal circuit broken • Engine speed: at least 50rpm • Engine ECU malfunction Evaluation conditions • For a 20 second duration, input voltage from the FR terminal, 4.8 ~ 5.2V, or battery voltage Repair Check connector B-21...
Page 51 MPI – TROUBLESHOOTING 13A-33 Code No.P1603 Battery Back-up Line System Probable causes Inspection Conditions • Battery back-up line circuit is broken, has a short circuit, or • Ignition switch: ON connector contact is poor Evaluation conditions • Engine ECU malfunction •...
Page 52 13A-34 MPI – TROUBLESHOOTING 4. List of Fault Symptoms ITEMS Fault Symptoms Checking procedures Communicatio No communication between MUT-II/III and any other system n with MUT Only MUT-II/III and Engine ECU can communicate II/III Engine The engine warning light does not come on immediately after turning ignition switch to warning light “ON “...
Page 53 MPI – TROUBLESHOOTING 13A-35 4-1. List of Fault Symptoms Check Check Items Page procedures 13A-36 No communication between MUT-II/III and any other system 13A-37 Only MUT-II/III and Engine ECU can communicate 13A-38 The engine warning light does not come on immediately after turning ignition switch to “ON “...
Page 54 MPI – TROUBLESHOOTING 13A-36 6. Checking Procedure for each Fault Checking Procedure 1 No Communication between MUT-II/III and any other system Probable causes The probable causes are noted right. • Diagnosis connector malfunction • MUT-II/III malfunction Check connector C-122 (1) NG C-122 Diagnosis connector Check and repair harness between measurement...
Page 55 MPI – TROUBLESHOOTING 13A-37 Checking Procedure 2 Only MUT-II/III and engine ECU can communicate Probable causes The probable causes are noted right. • Ignition switch malfunction • Engine control relay malfunction • Engine ECU malfunction Confirm engine warning light Checking procedure 22: Check •...
Page 56 13A-38 MPI – TROUBLESHOOTING Checking Procedure 3 The engine warning light does not come on immediately after Probable causes turning ignition switch ON. To check whether the engine warning light bulb is broken or not, the • Engine warning lamp bulb is broken engine ECU checks the engine warning light for a duration of 5 seconds •...
Page 57 MPI – TROUBLESHOOTING 13A-39 Checking Procedure 4 Engine warning light stays lit (does not go off) Probable causes When the engine ECU records the generation of the diagnosis code, it • Engine ECU malfunction turns the engine warning light on. MUT-II/III Diagnosis Code Diagnosis Code List •...
Page 58 MPI – TROUBLESHOOTING 13A-40 Checking Procedure 5 Starting not possible (starter does not turn over) Probable causes The probable causes are noted right. • Battery malfunction • Ignition switch malfunction • Starter malfunction Check battery Replace battery (ref. Chapter 54 – Battery) Repair Check connector B-14X MUT-II/III Service Data...
Page 59 MPI – TROUBLESHOOTING 13A-41 From previous page From previous page Check harness between starter Repair interlock relay and starter interlock relay intermediate connector • Check to see if output wire is broken or has a short Check harness between starter Check connector C-42 interlock relay intermediate connector and starter...
Page 60 MPI – TROUBLESHOOTING 13A-42 Checking Procedure 6 Starting not possible (starter turns over but no initial firing) Probable causes The probable causes are noted right. • Battery malfunction • Ignition switch malfunction • Ignition system malfunction • Fuel system malfunction •...
Page 61 MPI – TROUBLESHOOTING 13A-43 From previous page Check spark plug cables (ref. Chapter 16 – Ignition Replace spark plug cables Devices) Check spark plugs (ref. Chapter 16 – Ignition Devices) Replace spark plugs Replace ignition coil Check ignition coils (ref. Chapter 16 – Ignition Devices) Check harness between ignition switch and ignition coil Repair for each cylinder, and check for damage to power supply...
Page 62 MPI – TROUBLESHOOTING 13A-44 Checking Procedure 7 Starting not possible (there is initial firing, but not full firing), start Probable causes malfunction (starting takes a long time) The probable causes are noted right. • Battery malfunction • Ignition system malfunction •...
Page 63 MPI – TROUBLESHOOTING 13A-45 From previous page Check spark plug cables (ref. Chapter 16 – Ignition Replace spark plug cables Devices) Check spark plugs (ref. Chapter 16 – Ignition Devices) Replace spark plugs Check connectors B-123, B-119 Repair Check ignition coils (ref. Chapter 16 – Ignition Devices) Replace ignition coil Check harness between ignition coil and body earth, and Repair...
Page 64 MPI – TROUBLESHOOTING 13A-46 Checking Procedure 8 Irregular idling (rough idling, hunting), incorrect idling speed (high or Probable causes low idling speed), engine stalls when idling (dies out) The probable causes are noted right. • ISC control system malfunction • Air fuel control system malfunction •...
Page 65 MPI – TROUBLESHOOTING 13A-47 From previous page (1) NG Repair C50 engine ECU connector Check connectors C-50, C-21, measurement C-07, C-209, C-211, C-32 • Engine ECU terminal voltage measurement Repair (1) Voltage across 60 – earth Check harness between engine (2) Voltage across 46 –...
Page 66 MPI – TROUBLESHOOTING 13A-48 From previous page Check spark plug cables (ref. Chapter 16 – Ignition Replace spark plug cables Devices) Check spark plugs (ref. Chapter 16 – Ignition Devices) Replace spark plugs Check connector B-123, B-119 Repair Replace ignition coil Check ignition coils (ref.
Page 67 MPI – TROUBLESHOOTING 13A-49 Checking Procedure 9 Engine stalling when pulling away from standing (pass out) Probable causes The probable causes are noted right. • Ignition system malfunction • Air intake system malfunction • Exhaust gas cleaning system malfunction • Throttle body malfunction •...
Page 68 MPI – TROUBLESHOOTING 13A-50 Checking Procedure 10 Engine stalling during deceleration Probable causes The probable causes are noted right. • ISC control system malfunction • Exhaust gas cleaning system malfunction • Throttle valve malfunction • Engine ECU malfunction After engine has warmed up, run in idling mode for about Has the battery been disconnected recently? 10 minutes MUT-II/III Diagnosis Codes...
Page 69 MPI – TROUBLESHOOTING 13A-51 From previous page Abnormal cylinder code No.P0201 ~ P0204: Check Check injector operating noise (Use sound scope) injector system MUT-II/III Service Data Go to checking procedure relevant to diagnosis code for • No.13: Intake air temp. sensor the sensor that has generated abnormal service data •...
Page 70 MPI – TROUBLESHOOTING 13A-52 From previous page Check turbocharger pressure (ref. Chapter 15 – Intake Repair Exhaust and Vehicle Servicing) Check turbocharging pressure control system (ref. Repair Chapter 15 – Intake Exhaust and Vehicle Servicing) MUT-II/III Actuator Test Checking procedure 31: Fuel pressure control solenoid No.
Page 71 MPI – TROUBLESHOOTING 13A-53 Checking Procedure 13 Acceleration Shock Probable causes ISC malfunction is a likely cause. • ISC control system malfunction Diagnosis Code List (ref. P.13A-5) MUT-II/III Diagnosis Codes • Has diagnosis code been output? Code No.P0120: Throttle position sensor system check MUT-II/III Service Data (ref.P13A-16) •...
Page 72 MPI – TROUBLESHOOTING 13A-54 Checking Procedure 15 Ignition timing delay Probable causes The probable causes are noted right. • Crank angle sensor malfunction • Cam position sensor malfunction • Timing belt malfunction • Engine ECU malfunction MUT-II/III Diagnosis Codes Diagnosis Code List (ref. P.13A-5) •...
Page 73 MPI – TROUBLESHOOTING 13A-55 Checking Procedure 16 Dieseling/pinking (run-on) Probable causes The probable causes are noted right. • Injector malfunction • Engine ECU malfunction Replace injectors on all cylinders Confirm fault symptoms Finish Replace engine ECU Checking Procedure 17 Smelly, white smoke, black smoke CO and HC densities are high Probable causes when idling The probable causes are noted right.
Page 74 MPI – TROUBLESHOOTING 13A-56 From previous page Repair Check air being taken in via intake hose and inlet manifold Check for leaks of exhaust gas from exhaust manifold Repair MUT-II/III Service Data Code No. P0130: Check O 2 sensor system (P.13A-19) •...
Page 75 MPI – TROUBLESHOOTING 13A-57 Checking Procedure 18 Flat Battery Probable causes The probable causes are noted right. • Battery malfunction • G terminal shorting • Alternator malfunction • Engine ECU malfunction Replace battery Check battery (ref. Chapter 54A – Battery) Check connector B-21 Repair B-21 Alternator intermediate...
Page 76 MPI – TROUBLESHOOTING 13A-58 From previous page C-49 Engine ECU connector Check battery charging device measurements (ref. Chapter 16 Battery Charging • Measure engine ECU terminal Devices) voltage • Engine idling (after warm up) • Radiator fan: not operating • Voltage across 8 – earth OK: Voltage increases 0.2 ~ 3.5V when headlamps go from Intermittent malfunction (ref.
Page 77 MPI – TROUBLESHOOTING 13A-59 Checking Procedure 20 Radiator Fan Motor Running Abnormally Probable causes • Fan controller malfunction The probable causes are noted right. • Engine ECU malfunction Check connector C-39 Repair Intermittent malfunction (ref. Check radiator fan motor Confirm fault symptoms Chapter 00 –...
Page 78 MPI – TROUBLESHOOTING 13A-60 Checking Procedure 21 A/C ineffective Probable causes The probable causes are noted right. • A/C coolant malfunction or overfilled • A/C compressor relay malfunction • Condenser fan system malfunction • A/C-ECU malfunction • Engine ECU malfunction MUT-II/III Diagnosis Codes Diagnosis Code List (ref.
Page 79 MPI – TROUBLESHOOTING 13A-61 Checking Procedure 22 Engine ECU Power Supply, Engine Control Relay, Ignition Switch IG1 Probable causes System When ignition switch ON signal is input to ECU, the engine ECU turns • Ignition switch malfunction engine control relay ON. •...
Page 80 MPI – TROUBLESHOOTING 13A-62 From previous page (1) NG Check connectors C-50, B-19X Repair C-50 Engine ECU connector measurements • Measure engine ECU terminal voltage Check and repair harness (1) Voltage across 57 – earth between engine control relay and (Ignition switch OFF) engine ECU OK: Battery voltage...
Page 81 MPI – TROUBLESHOOTING 13A-63 Checking Procedure 23 Fuel Pump System Probable causes • During cranking and driving, engine ECU turns fuel pump relay ON, and • Fuel pump relay 1 malfunction supplies power driving the fuel pump • Fuel pump relay 2 malfunction •...
Page 82 MPI – TROUBLESHOOTING 13A-64 From previous page Check and repair harness C-219 Fuel pump relay - 2 between fuel pump relay – 1 and connector measurement fuel pump relay - 2 • Undo connector, then take measurement on harness side (1) Voltage across 1, 2 - earth (Ignition switch: ON) OK: Battery voltage...
Page 83 MPI – TROUBLESHOOTING 13A-65 Checking Procedure 24 Radiator Fan Control Relay System Probable causes When engine control relay is turned ON, the radiator fan control relay • Radiator fan control relay malfunction switches ON at the same time, supplying power to the fan controller. •...
Page 84 MPI – TROUBLESHOOTING 13A-66 From previous page Check connector C-49 Repair Check radiator fan motor MUT-II/III Actuator test Intermittent malfunction (ref. operation • No.21: fan controller Chapter 00 – Intermittent • Undo C-49 engine ECU • Ignition switch: ON Malfunctions) connector OK: Radiator fan motor operates •...
Page 85 MPI – TROUBLESHOOTING 13A-67 Checking Procedure 25 Condenser Fan Relay Probable causes The signal from the engine ECU turns the condenser fan relay ON, • Condenser fan relay (HI) malfunction supplying power to the condenser fan motor. • Condenser fan relay (LO) malfunction •...
Page 86 MPI – TROUBLESHOOTING 13A-68 From previous page A-36 Condenser fan motor Check and repair harness connector measurement between condenser fan relay • Undo connector, then take (LO) and engine ECU measurement on harness side • Check to see if power supply •...
Page 87 MPI – TROUBLESHOOTING 13A-69 From previous page C-49 Engine ECU connector Check connectors C-49, C-34 measurement • Measure engine ECU terminal voltage Check and repair harness • Ignition switch: ON between condenser fan relay (HI) • Voltage across 30 –earth and engine ECU (Ignition switch: ON) •...
Page 88 MPI – TROUBLESHOOTING 13A-70 Checking Procedure 26 A/C Switch System Probable causes When the control panel A/C switch is turned ON, the A/C switch ON signal • Control panel A/C switch malfunction is input to the engine ECU. As a result, the engine ECU turns the A/C •...
Page 89 MPI – TROUBLESHOOTING 13A-71 Checking Procedure 27 A/C Compressor System Probable causes When the A/C switch ON signal is input to the engine ECU, • A/C compressor relay malfunction the engine ECU turns the A/C compressor relay ON. • A/C compressor magnet clutch malfunction As a result, the A/C compressor magnet clutch operates.
Page 90 MPI – TROUBLESHOOTING 13A-72 From previous page Check connectors C-20, C-119, C-209, C-210, C-201 Repair Check harness between ignition switch and A/C Repair compressor relay • Check power supply cable for any damage Check connector C-34 Repair Check harness between fan controller and engine ECU Repair •...
Page 91 MPI – TROUBLESHOOTING 13A-73 Checking Procedure 28 A/C Load Signal System Probable causes • A/C-ECU malfunction Detects the size of the A/C compressor load, which depends • Engine ECU malfunction on differences in the set temperature. When a high A/C load signal is input to the engine ECU, the engine ECU decides that the A/C compressor load is high and operates the throttle valve control servo so that idling speed increases.
Page 92 MPI – TROUBLESHOOTING 13A-74 Checking Procedure 29 Power Steering Fluid Pressure Switch System Probable causes Detects a power steering oil pump load caused by turning of • Power steering fluid pressure switch malfunction the steering wheel. When a power steering fluid pressure •...
Page 93 MPI – TROUBLESHOOTING 13A-75 Checking Procedure 30 Purge Control Solenoid Valve System Probable causes The engine ECU controls air purged from the canister, by • Purge control solenoid valve malfunction controlling the purge control solenoid valve. • Purge control solenoid valve circuit broken, has a short circuit, or poor connector contacts •...
Page 94 MPI – TROUBLESHOOTING 13A-76 Checking Procedure 31 Fuel Pressure Control Solenoid Valve System Probable causes The fuel pressure control solenoid valve switches pressure • Fuel pressure control solenoid malfunction introduced to the fuel pressure regulator between the inlet • Engine ECU malfunction manifold and atmosphere pressure.
Page 95 MPI – TROUBLESHOOTING 13A-77 Checking Procedure 32 Secondary Air Control Solenoid Valve System Probable causes The secondary air control solenoid valve, switches pressure • Secondary air control solenoid valve malfunction introduced to the secondary air valve between the intake • Engine ECU malfunction manifold and atmosphere pressure.
Page 96 MPI – TROUBLESHOOTING 13A-78 Checking Procedure 33 Waste Gate Solenoid Valve System Probable causes The waste gate solenoid valve controls pressure that is • Waste gate solenoid valve malfunction • Engine ECU malfunction introduced to the turbocharger waste gate actuator MUT-II/III Actuator Test Intermittent malfunction (ref.
Page 97 MPI – TROUBLESHOOTING 13A-79 Checking Procedure 34 Idle speed control (ISC) servo (servo motor) Probable causes The engine ECU controls the volume of air intake during • ISC servo malfunction idling, by opening and closing the servo valve in a by-pass •...
Page 98: Intake And Exhaust
MPI – TROUBLESHOOTING 13A-80 Checking Procedure 35 Intercooler Water Spray Circuit System Probable causes • When the intercooler water spray switch (manual) is turned ON, an • Intercooler water spray switch malfunction intercooler water spray manual ON signal is input to the engine ECU. •...
Page 99 MPI – TROUBLESHOOTING 13A-81 From previous page Check connectors C-209, C-220 Intercooler water spray Repair C-210, C201, C-208 relay connector measurement • Undo connector, then take measurement on harness side Check harness between intercooler Repair • Voltage across 3, 1 - earth water spray relay and ignition switch (Ignition switch: ON) •...
Page 100 MPI – TROUBLESHOOTING 13A-82 Checking Procedure 36 Intercooler Water Spray Light System Probable causes The engine ECU turns the intercooler water spray switch light • Intercooler water spray bulb breaking on when the intercooler water spray switch (auto) is ON. •...
Page 101 MPI – TROUBLESHOOTING 13A-83 6. SERVICE DATA TABLE Item Check Items Checking Conditions Normal Code No. or Page condition Checking Procedure No. sensor Engine warm (lean by When 200mV or Code No. P0130 13A-16 decelerating, rich by decelerating less racing) rapidly from 4,000rpm During harsh...
Page 102 MPI – TROUBLESHOOTING 13A-84 Item Check Items Checking Conditions Normal Code No. or Page condition Checking Procedure Water temp. Ignition switch: ON or When water -20ºC Code No. 13A-11 sensor engine running temp. is –20ºC P0115 When water 0ºC temp. is 0ºC When water 20ºC temp.
Page 103 MPI – TROUBLESHOOTING 13A-85 Item Check Items Checking Conditions Normal Code No. or Page condition Checking Procedure Injector Engine: cranking When water 25 to 37ms operating temperature 0ºC time *1 (all cylinders injecting simultaneously) When water 15 to 22ms temperature 20ºC When water 4.2 to 6.3ms temp.
Page 104 13A-86 MPI – TROUBLESHOOTING Item Check Checking Conditions Normal Code No. or Page Items condition Checking Procedure sensor Engine: after warming up Rapid 200mV or less Code 13A-16 ((lean by decelerating, deceleration No.P0130 rich by racing) from 4,000rpm During harsh 600 to 1,000mV racing Engine: after warming up...
Page 105 MPI – TROUBLESHOOTING 13A-87 7. ACTUATOR TEST TABLE Item Check Drive details Checking Conditions Normal Code No. or Page Items condition Checking Procedure No.1 Cuts fuel to No.1 Engine: after warming up, engine Idling Code 13A-20 injector injector idling condition No.P0201 (Fuel supply to each injector is changes...
Page 106 13A-88 MPI – TROUBLESHOOTING 8. ENGINE ECU CHECKS 8-1 Terminal voltage chart Engine ECU connectors 26038AU Item Check Items Checking Conditions (engine condition) Normal condition No.1 injector Engine: after warming up, from engine idling Momentary slight drop from 11 to 14V the throttle pedal is suddenly depressed (Fuel supply to each injector is cut in turn.
Page 107 MPI – TROUBLESHOOTING 13A-89 Item Check Items Checking Conditions (engine condition) Normal condition Condenser fan Fan not operating (cooling water temp. 90ºC) Battery voltage motor relay or less) (LOW) Fan low speed operation (cooling water temp. 1V or less 95ºC to 100ºC or more) Intercooler Ignition switch: ON Battery voltage...
Page 108 13A-90 MPI – TROUBLESHOOTING Item Check Items Checking Conditions (engine condition) Normal condition • • A/C load Engine: External air 1V or less idling temperature sensor • A/C switch: ambient temp.: 18ºC • ON (A/C A/C set temp.: compressor Minimum temperature •...
Page 109 MPI – TROUBLESHOOTING 13A-91 8-2. TABLE SHOWING HARNESS SIDE CONNECTOR TERMINAL RESISTANCES AND CONTINUITY Engine ECU harness side connectors Terminal number Check item Standard value, normal condition (Check condition) 1-47 No.1 injector 7.8 to 9.2Ω (at 20ºC) 9-47 No.2 injector 24-47 No.3 injector 2-47...
Page 110 13A-92 MPI – TROUBLESHOOTING 9. Checks using an oscilloscope Taking waveform measurements using an oscilloscope means that sensor outputs signals and actuator drive signals can be checked visually. 9-1 Air flow sensor Oscilloscope <Measurement Method> (1) Disconnect the air flow sensor connector, and connect the special tool (test harness MB991709).
Page 111 MPI – TROUBLESHOOTING 13A-93 <An explanation of waveforms> • The air flow sensor sends a frequency pulse signal relative in size to the air flow to the engine ECU. By measuring the pulse signal cycle time T (seconds), the output signal frequency can be calculated using the following formula: Frequency (Hz) = 1/T (seconds) <Waveform Observation Points>...
Page 112 13A-94 MPI – TROUBLESHOOTING <Standard waveform> Observation Conditions Camshaft position sensor Crank angle sensor Probe switch AC-GND-DC TIME/DIV. 10ms 10ms VOLTS/DIV. Other Engine Idling Standard waveform 2 engine revolutions (1 camshaft revolution) Crank angle sensor output waveform Camshaft position sensor output waveform <Explanation of waveforms>...
Page 113 MPI – TROUBLESHOOTING 13A-95 <Examples of abnormal waveforms> • Example 1 Waveform characteristics Rectangular waveform is output, even when the engine is not started. Cause of problem Sensor interface fault • Example 2 Waveform characteristics Waveform is displaced to the left or right Cause of problem Loose timing belt Sensor disk abnormality...
Page 114 13A-96 MPI – TROUBLESHOOTING Explanation of waveforms • A power supply voltage is normally applied, but when there is a signal from the engine ECU, the voltage drops to about 0V for the duration of that drive signal. • When the signal from the engine ECU is cut, a voltage peak is seen as a result of the counter-electromotive force, then a return to power supply voltage.
Page 115 MPI – TROUBLESHOOTING 13A-97 Standard waveform Observation conditions (2CH both the same) Probe switch AC-GND-DC VOLTS/DIV. TIME/DIV. 20ms Other Either ignition switch ON, OFF (engine cooling water temp. 20°C or less), or A/C switch ON, OFF (when idling) Engine speed Standard waveform Point B Point A...
Page 116 13A-98 MPI – TROUBLESHOOTING <Abnormal waveform> • Example 1 Waveform characteristics Motor turning induced electromotive force is absent. Cause of fault Motor malfunction (motor is not turning)s • Example 2 Waveform characteristics Open Current is not supplied to the motor coil on the open circuit side. (Voltage circuit does not drop to 0V).
Page 117 MPI – TROUBLESHOOTING 13A-99 Standard waveform T: Crank angle T1: Time calculated by engine Top Dead Centre θ : Ignition advance angle Crank angle sensor Output waveform Ignition timing Power transistor control signal waveform Dwell section <Explanation of waveform> • When spark angle is advanced by, for example, engine speed increasing, conditions such as those illustrated above arise. Ignition advance angle θ...
Page 118 13A-100 MPI <4G6> - INJECTORS INJECTORS Disassembly and reassembly Work that needs to be done before disassembly and after assembly • Measures to prevent fuel escaping (only prior to removal) • Removal and fitting of strut tower bar • Removal and fitting of air hose E, air by-pass hose, and air pipe C (ref. Chapter 15 Intercooler) •...
Page 119 MPI <4G6> - FUEL INJECTORS 13A-101 Disassembly procedure 10. Fuel return hose 1. Vacuum hose connection 11. Fuel pressure regulator 2. PCV hose connection 12. O-ring 3. Control harness clamp connection 13. Fuel return pipe 4. Throttle cable connection 14. Delivery pipe (throttle body side) 15.
Page 120 13A-102 MPI <4G6> – ENGINE CONTROL RESISTOR, RELAY Engine control resistor and relay Removal and Installation Pre-removal and post-installation operations • Removal and fitting of strut tower bar • Removal and fitting of harness connector connection AYC relay AC211464AB Removal procedure •...
Page 121 FUEL SUPPLY GENERAL INFORMATION 13B-1 SECTION 13B FUEL SUPPLY CONTENTS General Information........1 Fuel Tank ...........2 General Information The following servicing information has been issued in conjunction with changes to the fuel tank.
Page 122: Fuel Tank
13B-2 FUEL SUPPLY – FUEL TANK Fuel Tank Disassembly and Assembly Work that needs to be done before disassembly and after assembly • Measures to prevent fuel escaping (only prior to removal) • Removal and fitting of propeller shaft • Emptying or filling of fuel •...
Page 123 FUEL SUPPLY – FUEL TANK 13B-3 1. Drain plug 14. Fuel tank return hose 2. Gasket 15. Return hose 3. Filler neck hose connection 16. High pressure hose 4. Filler neck vapour hose connection 17. Fuel tank pipe ASSY 5. Vapour hose connection 18.
Page 124 13B-4 FUEL SUPPLY GENERAL – FUEL TANK REMOVAL Floor Fuel tank Fuel tank ASSY removal 1. Remove differential support member bolt, and tilt the differential carrier down. 2. Support the fuel tank with a transmission jack, then remove the nut connected to the fuel tank.
Page 125 ENGINE COOLING - GENERAL INFORMATION, SEALANTS 14-1 SECTION 14 ENGINE COOLING CONTENTS General Information ........1 Thermostat ..........2 Sealants .............1 2Water hose and water pipe ....4 General Information The following servicing information has been issued in conjunction with changes to the 4G63-MPI-T/C engine on the new Lancer Evolution VIII.
Page 126 14-2 ENGINE COOLING - THERMOSTAT Thermostat Removal and Fitting Pre-removal and post-fitting operations • Draining and filling of coolant • Removal and fitting or air ducts • Removal and fitting of air pipe ASSY (ref. Chapter 15-2 Secondary Air Control System) Semi-dry sealant: Three Bond 1207F Removal procedure...
Page 127 ENGINE COOLING - THERMOSTAT 14-3 FITTING Fitting thermostat Fit the thermostat being careful not to fold over or damage the rubber ring. Caution Make absolutely sure that no oil is adhering to the rubber ring of the thermostat. Moreover, if the rubber ring is damaged, replace the thermostat.
Page 128 14-4 ENGINE COOLING - THERMOSTAT Water hose and pipe Removal and Fitting Pre-removal and post-fitting operations • Removal and fitting of cover • Draining and filling of coolant • Removal and fitting of air cleaner ASSY • Removal and fitting of air by-pass valve ASSY, air by-pass hose, air hose D and E, and air pipe C (ref. Chapter 15 - Intercooler) •...
Page 129 ENGINE COOLING – WATER HOSE AND WATER PIPE 14-5 REMOVAL Disconnect radiator upper hose /radiator lower hose Disconnect radiator hoses after having first aligned matching marks on radiator hose and hose clamp. matching mark FITTING Water pump or thermostat case O-ring /water inlet pipe fitting Insert O-ring into the groove on the water inlet pipe, then insert the pipe after wetting the area around the circumference of the O-ring or the inner...
Page 130 INTAKE & EXHAUST- GENERAL INFORMATION, SERVICING SPECIFICATIONS, ON-VEHICLE SERVICING 15-1 SECTION 15 INTAKE & EXHAUST CONTENTS General Information ........1 Intercooler ..............2 Intercooler water spray ..........3 Servicing specifications......1 Secondary air control system.........6 On-vehicle servicing........1 Inlet manifold ..............7 1. Turbocharger super charging pressure check ...1 2.
Page 131 15-2 INTAKE & EXHAUST – INTERCOOLER WATER SPRAY Intercooler Removal and fitting Pre-removal and post-fitting operations • Removal and fitting of air duct and air cleaner ASSY Removal procedure 8. Air hose A 1. Vacuum hose connection • Front bumper ASSY 2.
Page 132 15-3 INTAKE & EXHAUST – INTERCOOLER WATER SPRAY Intercooler Water Spray Removal and fitting <Water spray nozzle, hose, washer tank>...
Page 133 15-4 INTAKE & EXHAUST – INTERCOOLER WATER SPRAY Water spray nozzle and hose disassembly 8. Washer valve procedure • Tape (for attaching clip) 1. Water spray hose connection 9. Clip • Front bumper ASSY 10. Pad (ref. Chapter 51) Washer tank removal procedure •...
Page 134 15-5 INTAKE & EXHAUST – INTERCOOLER WATER SPRAY 2. Attach the water spray hose ASSY to the front bumper using the water spray hose ASSY clip. 3. Stick tape on as illustrated, so that the water spray hose ASSY does not slip. View of front bumper rear surface Tape Tape...
Page 135 15-6 INTAKE & EXHAUST –SECONDARY AIR CONTROL SYSTEM Secondary Air Control System Removal and fitting Pre-removal and post-fitting operations • Removal and fitting of the air duct • Removal and fitting of the strut tower bar Air pipe C Removal procedure 6.
Page 136 15-7 INTAKE & EXHAUST –SECONDARY AIR CONTROL SYSTEM INLET MANIFOLD FITTING Protruding Gasket fitting part Fit so that the gasket protruding part points in the direction indicated in the diagram. Inlet manifold Fitting and removal Pre-removal and post-fitting operations • Removal and fitting of throttle body •...
Page 137 15-8 INTAKE & EXHAUST – SECONDARY AIR CONTROL SYSTEM Removal procedure 12. Fuel high pressure hose connection 1. Centre cover 13. O-ring 2. Ignition coil connector connection 14. Delivery pipe, injector & fuel pressure 3. O 2 sensor connector connection regulator ASSY 15.
Page 138 15-9 INTAKE & EXHAUST – INLET MANIFOLD Removal procedure 21. Knock sensor connector connection 27. Vacuum tank, ACV solenoid valve, vacuum hose & pipe 22. Purge control solenoid valve ASSY ASSY 23. Vacuum hose 28. Inlet manifold stay 24. Fuel pressure solenoid valve ASSY 29.
Page 139: Engine Electrical
ENGINE ELECTRICAL – STARTING SYSTEM 16-1 SECTION 16 ENGINE ELECTRICAL CONTENTS Starting devices .........1 Ignition devices .........2 General ............1 General............2 Starter ............1 Crank angle sensor ........2 Starting devices General The following servicing information has been issued in conjunction with changes to the 4G63-MPI-T/C engine starter ASSY on the new Lancer Evolution VIII.
Page 140 16-2 INTAKE & EXHAUST – INLET MANIFOLD Ignition devices General The following servicing information has been issued in conjunction with changes to the 4G63-MPI-T/C engine crank angle sensor on the new Lancer Evolution VIII. Other servicing information remains the same. Crank angle sensor Fitting and removal CAUTION...
Page 141 INTAKE & EXHAUST – INLET MANIFOLD 16-3 Removal procedure 4. Power steering oil pump bracket 5. Crank angle sensor connector 1. Power steering oil 6. Crank angle sensor pressure switch connector 2. Power steering oil pump heat protector 3. Power steering pump oil pump, bracket, and oil reservoir ASSY REMOVAL Power steering oil pump, bracket, and oil reservoir ASSY removal...
Page 142: Engine And Emission Control
17-1 ENGINE and EMISSION CONTROL – Emission Control <MPI> SECTION 17 ENGINE and EMISSION CONTROL CONTENTS Emission control <MPI> ......1 On-vehicle servicing .........2 General ..............1 System diagram ...........2 Vacuum hose layout ..........3 Checks ..............3 Exhaust gas cleaning device list......4 EMISSION CONTROL <MPI> General These are based on the existing Lancer Evolution VII 4G63-DOHC-T/C engine control system, and the Exhaust Gas Recirculation (EGR) devices have been deleted.
Page 143 17-2 ENGINE and EMISSION CONTROL – Emission Control <MPI> On-vehicle servicing System diagram From the fuel tank Canister Vacuum tank Check valve Fuel pressure control solenoid valve Purge control solenoid valve O 2 sensor Fuel pressure regulator From the To the fuel pump fuel tank PCV valve...
Page 144 17-3 ENGINE and EMISSION CONTROL – Emission Control <MPI> Vacuum Hose Layout Brown colour Vacuum tank Purge control solenoid valve Check valve Canister Fuel pressure control solenoid valve Secondary air control solenoid Throttle body valve Fuel pressure regulator Secondary air control solenoid Waste gate solenoid valve Air by-pass valve Turbocharger...
Page 145 17-4 ENGINE and EMISSION CONTROL – Emission Control <MPI> Exhaust Gas Cleaning Device List Related parts Air fuel ratio Blow-by Evaporative 3-way Component control emission catalytic page device circulation control converter reference device device Ο Engine ECU Ο sensor Ο Air flow sensor Ο...
Page 146: Manual Transmission
MANUAL TRANSMISSION – GENERAL, LUBRICANTS 22-1 SECTION 22 MANUAL TRANSMISSION CONTENTS General................1 2. Select cable (inside cabin) adjustment <6M/T>....9 Lubricants................1 Transmission Control*.............10 Special Tools..............2 Transfer ASSY <6M/T>*............12 Troubleshooting..............3 Transmission ASSY <6M/T>*...........14 On-vehicle Servicing............9 Sensors / Switches / Relays 1. Replacing transmission oil <6M/T>........9 <vehicles fitted with ACD, ACD+AYC>...
Page 147 22-2 MANUAL TRANSMISSION – SPECIAL TOOLS Special Tools Tools Number Name MB991502 MUT-II Sub-ASSY Diagnosis code checking MB991502 MB991955 MUT-III Sub-ASSY A: MB991824 A: V.C.I. (Vehicle B: MB991827 Communication Interface) C: MB991910 B: USB cable D: MB991911 C: MUT-III main harness A E: MB991825 (vehicles with CAN F: MB991826...
Page 148 MANUAL TRANSMISSION – SPECIAL TOOLS, TROUBLESHOOTING 22-3 Tools Number Name Recommended tools Engine lifter To hold the engine ASSY Anzen Jidosha (Co. Ltd) when removing or fitting the MZ203831 transmission. Note Banzai (Co. Ltd) 1. The engine lifter balancer MZ203830 (MB991454) is one part of the engine lifter ASSY Slide bracket (HI)
Page 149 22-4 MANUAL TRANSMISSION – TROUBLESHOOTING 2. Checking Procedure for each Diagnosis Code Note *1: Refer to ’00 – 5 Lancer Sedia Service Manual (No.103K00) *2: Refer to ’01-1 Lancer Evolution VII Service Manual (No.1036K02) Code No.31 Steering sensor <ST-1, ST-2, ST-3> Possible causes When a steering sensor output wire (ST-1, ST-2, or ST-N) is ∑...
Page 150 MANUAL TRANSMISSION - TROUBLESHOOTING 22-5 Code No.63 Parking brake switch system Probable causes At vehicle speeds of 15km/h and over, code No. 63 is output if • Parking brake switch malfunction the parking brake stays ON for 15 minutes or more. •...
Page 151 22-6 MANUAL TRANSMISSION - TROUBLESHOOTING Code No.65 ABS Monitoring System Probable causes When ABS operating for 1 minute or more continuously is • Harness, connector malfunction detected, code No. 65 is output. • ABS-ECU malfunction <vehicles fitted with ACD+AYC> • 4WD-ECU malfunction <Vehicles fitted with ACD+AYC>...
Page 152 MANUAL TRANSMISSION - TROUBLESHOOTING 22-7 Code No.82 Electric Pump Relay System Probable causes Code No.82 is output when the pressure sensor does not • Insufficient fluid reach the specified value, even if the 4WD-ECU has output • Pressure sensor malfunction the electric pump motor drive command.
Page 153 22-8 MANUAL TRANSMISSION - TROUBLESHOOTING 5. Inspection Chart for Trouble Symptoms Fault symptom Checking Procedure No. Page No communication possible between MUT-II/III and any other system 22-8 6. Trouble Symptom Checking Procedures Checking Procedure 1 No communication possible between MUT-II/III and any other system Possible causes It is possible that there is a malfunction in the diagnosis connector •...
Page 154 MANUAL TRANSMISSION - ON-VEHICLE SERVICING 22-9 On-vehicle Servicing Filler plug 1. Changing transmission oil <6 M/T> Servicing information other than that noted below remains the same. Transmission oil Specified transmission oil: Mitsubishi DIA QUEEN SUPER MULTIGRADE OIL <75W/85W> Quantity: 2.2 dm Drain plug 2.
Page 155 22-10 MANUAL TRANSMISSION - TRANSMISSION CONTROL<6M/T> Transmission Control <6M/T> Removal and Fitting CAUTION 1. On the gear stick ASSY, do not disassemble anything other than the distance piece and bush. (Non-supplied parts) 2. Never use mineral oil on the moving parts of the gear stick ASSY. This is because if mineral oil is used, it could cause plastic parts to break.
Page 156 MANUAL TRANSMISSION - TRANSMISSION CONTROL 22-11 Removal Removal of select cable connection (transmission side) Set the select cable clip in the position indicated in the diagram, then undo the select cable connection. Select cable Clip removal (transmission side) Use a screwdriver or similar device to undo the claws of the clip, then Select cable and shift remove the clip and each of the cables from the bracket.
Page 157 22-12 MANUAL TRANSMISSION - TRANSFER ASSY <6M/T> Transfer ASSY <6M/T> CAUTION 1. Before removing steering wheel and airbag module ASSY, without fail read Chapter 52-B Precautions for Servicing and Airbag Module and Clock Spring. 2. When Brembo brake calipers are used, there is concern over paint peeling off, so when doing servicing work, make sure they are not scratched by other components and tools.
Page 158 MANUAL TRANSMISSION - TRANSFER ASSY <6M/T> 22-13 Removal procedure 1. Centre member 3. Cross member ASSY • Power steering return hose and steering 4. Transfer pressure hose ASSY gear connection 5. Gasket • Power steering pressure hose and steering 6. Transfer ASSY gear connection 7.
Page 159 22-14 MANUAL TRANSMISSION - TRANSFER ASSY <6M/T> Transmission ASSY <6M/T> CAUTION 1. Before removing steering wheel and airbag module ASSY, be sure to read Chapter 52-B Precautions for Servicing, Airbag Module and Clock Spring. 2. When Brembo brake calipers are used, there is concern over paint peeling off, so when doing servicing work, make sure they are not scratched by other components and tools.
Page 160 MANUAL TRANSMISSION - TRANSMISSION ASSY <6M/T> 22-15 9. Transmission ASSY upper part coupling • Engine ASSY support bolts • For lifting the engine 10. Harness clamp 14. Bell housing cover 11. Transmission mount ASSY • Clutch release bearing connection 12. Transmission mount stopper 15.
Page 161 22-16 MANUAL TRANSMISSION - TRANSMISSION ASSY <6M/T> Engine ASSY Support <When using the special engine lifter tool (MZ203831 or MZ203830) 1. Fit the special engine lifter to the strut mounting nuts and radiator support upper insulator mounting bolts, shown in the diagram, in the engine bay.
Page 162 MANUAL TRANSMISSION - TRANSMISSION ASSY <6M/T> 22-17 Fitting Engine side Fitting transmission mount stopper Fit so that the arrow on the transmission mount stopper is vertical relative Transmission mount bracket to the vehicle body. Trans- mission mount stopper...
Page 163 22-18 MANUAL TRANSMISSION - SENSOR, SWITCH, RELAY <ACD, ACD+AYC> Sensor, Switch, Relay <ACD,ACD+AYC> Removal and fitting Electric pump relay Check Electric pump relay continuity check 1. Remove electric pump relay connector Check item Normal condition Tester connection Battery connection terminal No. terminal No.
Page 164: Rear Axle
27B-1 REAR AXLE – GENERAL, LUBRICANTS, REAR HUB ASSY SECTION 27B REAR AXLE CONTENTS General Information........1 Rear Hub ASSY ..........1 Lubricants...........1 Drive Shaft ..........2 General Information Service information changes are noted below. Servicing details otherwise remain the same as on the existing vehicle. •...
Page 165 27B-2 REAR AXLE – DRIVE SHAFT Drive Shaft CAUTION 1. When disassembling or assembling, do not damage the ABS rotor attached to the EBJ outer race. 2. The only part of the EBJ ASSY that can be dismantled is the EBJ boot. EBJ boots repair kit TJ boots repair kit TJ Repair kit...
Page 166 27B-3 REAR AXLE – DRIVE SHAFT Assembly Fitting the spider ASSY/TJ case Apart from changes noted below, all other details remain the same. Having filled the TJ case with the specified grease, insert the drive shaft, then fill with grease again. Specified grease: Repair kit grease Quantity: 135 ±...
Page 167 POWER PLANT – GENERAL 32-1 SECTION 32 POWER PLANT MOUNT CONTENTS General............1 Transmission Mount ........2 General The servicing information specified below accompanies transmission changes to the newly installed 6-speed manual transmission. Other servicing information remains the same.
Page 168: Body
32-2 POWER PLANT MOUNT – TRANSMISSION MOUNT Transmission Mount Removal and fitting CAUTION * Indicates parts which should be initially tightened, and then fully tightened when the engine weight is supported by the vehicle body. Jobs to do before removal and after fitting •...
Page 169 BODY – GENERAL, BONNET 42-1 SECTION 42 BODY CONTENTS General ............1 Boot lid …...........5 Bonnet ............2 Keyless entry system .......5 Doors............3 Troubleshooting ...........5 On-vehicle service ..........5 Door handles and latches ........3 General The following servicing information has been added in line with the changes described below. •...
Page 170 42-2 BODY – BONNET BONNET Removal and Installation Section C-C Section A-A Section B-B Clip A Clip B Clip C Remarks indicates the position of clip A indicates the position of clip B indicates the position of clip C Bonnet removal procedure •...
Page 171 BODY – BONNET, DOORS 42-3 Installation service point Bonnet hinge bolt installation Caution Because the bonnet is made from aluminium, a special coating is provided on the bonnet hinge bolt (bonnet side), and therefore special parts should be used. DOORS Door handles and latches Removal and Installation Post-Removal Operations...
Page 172 42-4 BODY – DOORS Installation service point The installation points are the same as the previous model. INSPECTION Front Front door lock actuator check (Left side) Unlock Lock Rod position Terminal No. Rod operation 1 2 3 4 6 View A ⊕...
Page 173 BODY – BOOT LID, KEYLESS ENTRY SYSTEM 42-5 Boot Lid The following servicing information now applies, due to changes in the boot lid torsion bar. Apart from the points described below, the servicing information is the same as that for the previous model. Installation service points Boot lid torsion bar installation Apart from the identification colours used for the boot lid torsion...
Page 174 42-6 BODY – BONNET 4. Switch the hazard switch ON and OFF 6 times, within the space of 10 seconds after connecting to the MUT-II/III (earth connection). Connect to MUT-II Remarks (1) When these 6 on/off operations are completed, the door lock locks and unlocks once, and assumes a registration mode.
Page 175: Exterior
EXTERIOR – GENERAL 51-1 SECTION 51 EXTERIOR CONTENTS General ............1 Rear spoiler ..........4 Front bumper ...........2 Adhesive ..........4 Adhesives ..........2 Rear spoiler ..........5 Front bumper ..........2 Marks ............6 GENERAL New servicing information now applies with the following changes and additions. Apart from the information below, servicing is the same as the Lancer Evolution VII.
Page 176 51-2 EXTERIOR – FRONT BUMPER Front Bumper Adhesive Application Brand Three Diamond Mark Double-sided tape: Generic product (width 20 mm, thickness 0.8 mm) Front bumper Removal and Installation Section A-A clip Section B-B clip Section C-C clip fender Removal procedure •...
Page 177 EXTERIOR – FRONT BUMPER 51-3 Disassembly and Reassembly Double-sided tape: Generic tape Width: 20 mm; Thickness 0.8 mm Section B-B Section A-A Clip Clip...
Page 178 51-4 EXTERIOR – FRONT BUMPER, REAR SPOILER Disassembly Procedure 10. Bumper net 1. Three diamond mark 11. Front bumper side cover 2. Licence plate trim 12. Bumper side net (LH) 3. Licence plate bracket 13. Oil cooler duct 4. Licence plate bracket assembly 14.
Page 179 EXTERIOR – REAR SPOILER 51-5 Rear Spoiler Removal and Installation Double-sided tape: Generic products A: width 5 mm, thickness 0.8 mm, B: width 5 mm, thickness 1.2 mm Primer: Sumitomo 3M 8107 PP parts primer Removal procedure • Boot lid bumper 1.
Page 180 51-6 EXTERIOR – MARKS Marks Removal and Installation 3. EVOLUTION mark 1. Three diamond mark 2. LANCER mark Installation service points Installation of marks 1. Installation position (2) LANCER mark Boot lid end line Boot lid end line...
Page 181 EXTERIOR – MARKS 51-7 (3) EVOLUTION mark Boot lid end line Boot lid end line 2. Installation procedure (1) Remove grease from installation surface of the body, using unleaded gasoline. (2) Peel off the protective backing of the mark and apply it to the installation position.
Page 183 INTERIOR – GENERAL, BOOT INTERIOR TRIM, INTERIOR MIRROR 52A-1 SECTION 52A INTERIOR CONTENTS General ............1 Interior mirror ..........1 Boot interior trim ........1 General • The removal information for the boot interior trim has been changed due to the addition of a front trim. •...
Page 184 SRS AIRBAGS – GENERAL, ON-VEHICLE SERVICE POINTS 52B-1 SECTION 52B SRS AIRBAGS CONTENTS General ……………..………......1 Caution labels……………….....29 Service precautions ……….......1 Front impact sensors………....30 Special tools………..……… .......2 Airbag modules and clock Test equipment ………..……… ....3 spring………..……… ........Troubleshooting………..……… ....4 Post-Collision diagnosis……… ....28 Seat belt pre-tensioner…….....34 Servicing SRS airbag and seat belt pre- Disposal procedures for airbag module...
Page 185: Special Tools
52B-2 SRS AIRBAGS – SPECIAL TOOLS Special Tools Tool Number Name MB991502 MUT-III Assembly Reading and erasing diagnosis codes A: V.C.I (Vehicle A: MB991824 Communication B: MB991827 Interface) C: MB991910 B: USB cable D: MB991911 C: MUT-III main E: MB991825 harness A (for F: MB991826 vehicles fitted...
Page 186: Test Equipment
SRS AIRBAGS – SPECIAL TOOLS, TEST DEVICES 52B-3 Tool Number Name MB991865 Dummy resistor Checking electrical circuits of SRS airbags and seat belt pre-tensioners MB991884 Resistance harness Checking electrical circuits of seat belt pre- (for pre-tensioners) tensioners MB991885 Seat belt pre- Operating seat belt pre-tensioners from inside or tensioner harness outside vehicle...
Page 187: Troubleshooting
52B-4 SRS AIRBAGS – TROUBLESHOOTING Troubleshooting With the exception of the following points, servicing follows the same procedure as in the previous model. Remarks In the Inspection procedure, based on the diagnosis code, the driver’s airbag module (squib) system is set up differently depending on the type of steering wheel, as indicated below.
Page 188 SRS AIRBAGS – TROUBLESHOOTING 52B-5 3. SRS System Circuit Diagram Ignition switch (IG1) J/B (fuse) Electrical Backup DC-DC circuit capacitor converter Combination meter Warning light drive Safing G sensor circuit Clock spring Driver’s Squib airbag detection module circuit (squib) Squib detection circuit Front...
Page 189 52B-6 SRS AIRBAGS – TROUBLESHOOTING 4. Chart of Diagnosis Codes Code No. Diagnostic Item Page Front impact sensor LH system Shorting between sensor 52B-7 terminals Front impact sensor LH system Disconnection of sensor circuit Front impact sensor LH system Shorting of power supply to sensor circuit Front impact sensor LH system Shorting of earth to sensor...
Page 190 SRS AIRBAGS – TROUBLESHOOTING 52B-7 5. Inspection Procedure Classified by Diagnosis Code Code No. 1A, 1B, 1C, 1D, 2A, 2B, 2C, 2D Front impact sensor system Possible cause These codes are output whenever the resistance between the input • Harness, contactor malfunction terminals of the front impact sensors of the SRS-ECU differs from the •...
Page 191 52B-8 SRS AIRBAGS – TROUBLESHOOTING Code No. 21 Driver’s airbag module (squib) system Possible cause This code is output when shorting occurs between the terminals of the • Fault in the connector fitting or fault in the short driver’s airbag module (squib) circuit of the SRS-ECU. bar* When normal operation is resumed, the SRS warning light goes out.
Page 192 SRS AIRBAGS – TROUBLESHOOTING 52B-9 (Type 1) (Checking the driver’s airbag module (squib)) Resistor harness Dummy resistor MB991866 MUT-II/III diagnosis code (MB991865) • Detach the (–) terminal of the battery resistance (3Ω) • Detach the driver’s airbag module connector C-207 •...
Page 193 52B-10 SRS AIRBAGS – TROUBLESHOOTING From previous page (Checking the circuit between the SRS-ECU and the Check connectors: C-125, C-204 clock spring) Measure at the SRS-ECU connector C-125 • Detach the SRS-ECU connector C-125 Confirm the symptoms Repair • Detach the clock spring connector C-204 Caution In the following operation, detach the SRS-ECU connector and short the squib circuit before...
Page 194 SRS AIRBAGS – TROUBLESHOOTING 52B-11 (Type 2) (Checking the driver’s airbag and clock spring) Dummy resistor MUT-II/III diagnosis code (MB991865) Resistor harness • Detach the (–) terminal of the battery resistance (3Ω ) (MB991866) • Detach the clock spring connector (4-pin) C-204 •...
Page 195 52B-12 SRS AIRBAGS – TROUBLESHOOTING Code No. 22 Driver’s airbag module (squib) system Possible cause This code is output when there is a disconnection in the driver’s airbag module • Disconnection of the clock spring (squib) circuit of the SRS-ECU. •...
Page 196 SRS AIRBAGS – TROUBLESHOOTING 52B-13 From previous page (Checking the circuit between the SRS-ECU and the Check connectors : C-125, C-205 clock spring) Measure at SRS-ECU connector C-125 and clock spring connector C-204 Confirm the fault symptoms Repair • Detach the SRS-ECU connector C-125 and the clock spring connector C-125 and measure at the harness side •...
Page 197 52B-14 SRS AIRBAGS – TROUBLESHOOTING (Type 2) (Checking the driver’s airbag and clock spring) Dummy resistor MUT-II/III diagnosis code (MB991865) Resistor harness resistance (3Ω ) • Detach the (–) terminal of the battery (MB991866) • Detach the clock spring connector (4-pin) C-204 •...
Page 198 SRS AIRBAGS – TROUBLESHOOTING 52B-15 Code No. 26 Driver’s seat belt pre-tensioner (squib) system Possible cause This code is output when shorting occurs between the terminals of the • Fault in the connector fitting or fault in the driver’s seat belt pre-tensioner (squib) circuit of the SRS-ECU. short bar* When normal operation is resumed, the SRS warning light goes out.
Page 199 52B-16 SRS AIRBAGS – TROUBLESHOOTING (Checking the driver’s seat belt pre-tensioner (squib)) Dummy resistor MUT-II/III diagnosis code (MB991865) Resistor harness Resistance (3Ω ) • Detach the (–) terminal of the battery (MB991884) • Detach the driver’s seat belt pre-tensioner connector D-02 (see p.52B-34) •...
Page 200 SRS AIRBAGS – TROUBLESHOOTING 52B-17 Code No. 27 Driver’s seat belt pre-tensioner (squib) system Possible cause seat belt pre-tensioner (squib) circuit of the SRS-ECU. • Connector contact fault When normal operation is resumed, the SRS warning light goes out. • Disconnection in the driver’s seat belt pre- (The diagnosis code is not erased.) tensioner (squib) circuit •...
Page 201 52B-18 SRS AIRBAGS – TROUBLESHOOTING Code No. 28 Front passenger’s seat belt pre-tensioner (squib) system Possible cause This code is output when shorting occurs between the terminals of the front • Fault in the connector fitting or fault in the short passenger’s seat belt pre-tensioner (squib) circuit of the SRS-ECU.
Page 202 SRS AIRBAGS – TROUBLESHOOTING 52B-19 (Checking the front passenger’s seat belt pre-tensioner Dummy resistor (MB991865) (squib)) Resistance (3Ω ) Resistor harness MUT-II/III diagnosis code (MB991884) • Detach the (–) terminal of the battery • Detach the front passenger’s seat belt pre-tensioner connector D-14 (see p.52B-34) •...
Page 203 52B-20 SRS AIRBAGS – TROUBLESHOOTING Code No. 29 Front passenger’s seat belt pre-tensioner (squib) system Possible cause This code is output when there is a disconnection in the front passenger’s • Disconnection in the driver’s seat belt pre- seat belt pre-tensioner (squib) circuit of the SRS-ECU. tensioner (squib) circuit When normal operation is resumed, the SRS warning light goes out.
Page 204 SRS AIRBAGS – TROUBLESHOOTING 52B-21 Code No. 39 All airbags deployed system Possible cause This code is output after an operation in which all the airbags SRS-ECU fault have deployed. If this code is output before all the airbags have deployed, then this indicates that there is an internal malfunction in the SRS-ECU.
Page 205 52B-22 SRS AIRBAGS – TROUBLESHOOTING Code No. 61 Driver's airbag module (squib) system (shorted to power Possible cause supply) Code No. 62 Driver's airbag module (squib) system (shorted to earth) This code is output when the driver's airbag module (squib) circuit of the •...
Page 206 SRS AIRBAGS – TROUBLESHOOTING 52B-23 From previous page YES (No.62 output) YES (No.61 output) (Checking the circuit between the SRS-ECU (Checking the circuit between the SRS-ECU and the clock spring) and the clock spring) Measure at SRS-ECU connector C-125 Measure at SRS-ECU connector C-125 •...
Page 207 52B-24 SRS AIRBAGS – TROUBLESHOOTING (Type 2) Dummy resistor (Checking the clock spring) Resistor harness (MB991865) MUT-II/III diagnosis code (MB991866) resistance (3Ω ) • Detach the (–) terminal of the battery • Detach the clock spring connector (4-pin) C-204 • Connect the dummy resistor (MB991865) to the resistor harness •...
Page 208 SRS AIRBAGS – TROUBLESHOOTING 52B-25 Code No. 66 Driver's seat belt pre-tensioner (squib) system (shorted to Possible cause power supply) Code No. 67 Driver's seat belt pre-tensioner (squib) system (shorted to earth) This code is output when the driver's seat belt pre-tensioner (squib) circuit of •...
Page 209 52B-26 SRS AIRBAGS – TROUBLESHOOTING Code No. 68 Front passenger's seat belt pre-tensioner (squib) Possible cause system (shorted to power supply) Code No. 69 Front passenger's seat belt pre-tensioner (squib) system (shorted to earth) This code is output when the front passenger's seat belt pre- •...
Page 210 SRS AIRBAGS – TROUBLESHOOTING 52B-27 6. Trouble Symptoms Category Chart Symptom Symptom Inspection Procedure No. Reference page Cannot communicate with MUT-II/III 52B-27 7. Trouble Symptoms Inspection Procedures Inspection Procedure 1 Cannot communicate with MUT-II/III Possible cause If there is no communication with any other parts of the system, then there is a •...
Page 211: Post-Collision Diagnosis
52B-28 SRS AIRBAGS – POST-COLLISION DIAGNOSIS Post-Collision Diagnosis The following procedure must be used to check and service the vehicle after a collision, regardless of whether or not the airbags have been deployed. Apart from the items listed below, servicing is the same as that for the previous model. 1.
Page 212: Servicing Srs Airbag And Seat Belt Pre- Tensioner Components
SERVICING OF SRS AIRBAG / SEAT BELT PRE-TENSIONER SRS AIRBAGS 52B-29 – COMPONENTS; CAUTION LABELS Servicing of SRS airbags and seat belt pre-tensioner components SRS airbag and seat belt pre-tensioner components must be removed and installed by means of the following procedure. (p.52B-29 –...
Page 213: Front Impact Sensors
52B-30 SRS AIRBAGS – FRONT IMPACT SENSORS Front Impact Sensors (Vehicle not fitted with front passenger’s seat airbag) Caution 1. After disconnecting the (–) terminal of the battery, wait for at least 60 seconds before starting work. Isolate the disconnected (–) terminal by winding tape around it. 2.
Page 214 SRS AIRBAGS – FRONT IMPACT SENSORS 52B-31 Installation Service Points Pre-installation check When installing a new front impact sensor, a check must be carried out before installation. (see Check items) Installing front impact sensors 1. Attach the connectors securely. 2. Place the arrow indicated on the front impact sensor label towards the front of the vehicle, and install securely.
Page 215: Airbag Modules And Clock Spring
52B-32 SRS AIRBAGS – AIRBAG MODULE AND CLOCK SPRING Airbag module and clock spring Apart from the following items, removal, installation and inspection procedures are the same as those for the previous model. Installation service points Installation of clock spring Alignment marks 1.
Page 216 SRS AIRBAGS – AIRBAG MODULE AND CLOCK SPRING 52B-33 Check procedure Case Apart from the following items, servicing is the same as in the previous model. Clock spring C-205 Clock spring If any of the following checks reveals a non-conformity, then the clock connector spring must be replaced with a new one.
Page 217: Seat Belt Pre-Tensioner
SEAT BELT PRE-TENSIONER; AIRBAG MODULE & 52B-34 SRS AIRBAGS – SEAT BELT PRE-TENSIONER DISPOSAL PROCEDURE Seat belt Pre-Tensioner Apart from the following items, servicing is the same as for the previous Locking button model. Removal service points Removal of seat belt pre-tensioner Using a flathead screwdriver, pull the locking button of the harness side connector two steps towards you, release the lock and remove the Harness side...
Page 218 AIRBAG MODULE & SEAT BELT PRE- SRS AIRBAGS – 52B-35 TENSIONER DISPOSAL PROCEDURE Disposal of seat belt pre-tensioner Apart from the pre-tensioner connector removal information and the pre-tensioner adapter harness described below, servicing is the same as that for the previous model. •...
Page 220: Chassis Electrical
CHASSIS ELECTRICAL – GENERAL 54A-1 SECTION 54A CHASSIS ELECTRICAL CONTENTS General ............1 Troubleshooting .........3 Ignition switch, engine immobiliser..2 Immobiliser ECU check......6 Special tools............2 Ignition switch, engine immobiliser ECU .............7 General New servicing information has been established with the adoption of an engine immobiliser system. Apart from the information below, servicing is the same as in the previous model.
Page 221: Ignition Switch, Engine Immobiliser
54A-2 CHASSIS ELECTRICAL – IGNITION SWITCH, ENGINE IMMOBILISER Ignition switch and engine immobiliser Special tools Tool Number Name MB990784 Ornament remover Removing under cover assembly and column cover MB991502 MUT-II sub- Reading diagnosis codes assembly MB991955 MUT-III sub- Reading diagnosis codes assembly A: MB991824 A: V.C.I.
Page 222: Troubleshooting
CHASSIS ELECTRICAL – 54A-3 IGNITION SWITCH, ENGINE IMMOBILISER Troubleshooting Engine immobiliser 1. Diagnosis functions 1-1. Reading diagnosis codes 1-1-1. Using the MUT-II/III The MUT-II/III is used to read the diagnosis codes. (See Chapter 00, How to Use Troubleshooting and Inspection Service Points.) 2.
Page 223 54A-4 CHASSIS ELECTRICAL – IGNITION SWITCH, ENGINE IMMOBILISER 4. Inspection Chart for Trouble Symptoms Trouble symptom Inspection Reference procedure No. page The diagnosis code No.54 is generated by the engine ECU and there is no communication 54A-5 between the MUT-II/III and the immobiliser ECU The ignition keys cannot be registered using the MUT-II/III 54A-6 The engine does not start.
Page 224 CHASSIS ELECTRICAL – 54A-5 IGNITION SWITCH, ENGINE IMMOBILISER Inspection Procedure 2 The ignition keys cannot be registered using the MUT-II/III Possible cause If only some of the ignition keys cannot be registered, then there is a probably a • Fault in ignition key fault with the ignition keys themselves.
Page 225: Immobiliser Ecu Check
54A-6 CHASSIS ELECTRICAL – IGNITION SWITCH, ENGINE IMMOBILISER Inspection Procedure 4 Checking the power supply and earth circuit system of the immobiliser ECU (1) NG Measure at the immobiliser ECU connector D-54 Check connectors: B-19X, C-23, C-22, C-54 • Detach the connector and measure on the harness side •...
Page 226: Ecu
CHASSIS ELECTRICAL – 54A-7 IGNITION SWITCH, ENGINE IMMOBILISER Ignition switch and Immobiliser ECU Removal and Installation Removal Procedure 1. Steering wheel (See Chapter 37A)* 4. Column switch 2. Power column cover (See Chapter 52A, 5. Steering lock cylinder Instrument Panel)* 6.
Page 227 54B-1 SECTION 54B SMART WIRING SYSTEM (SWS) CONTENTS General............2 On-vehicle servicing ......117 Special Tools ..........2 Adjustment function (User mode)......117 Adjustment function (Dealer mode)....118 Troubleshooting .........4 1. Before starting troubleshooting ......4 2. Standard flow of diagnostic troubleshooting ..4 3. SWS monitor connections.........5 4.
Page 228: General
54B-2 SWS – GENERAL, SPECIAL TOOLS General The SWS version has been changed from the previous Ver.0 to Ver.3. The following servicing information has been established accordingly. Special tools Tool Number Name MB991502 MUT-II sub-assembly Checking SWS communications line (ECU check, service data) MB991955 MUT-III sub-...
Page 229 SWS – SPECIAL TOOLS 54B-3 Tool Number Name MB991862 SWS monitor kit Checking SWS communications line (ECU A : SWS monitor check, service data) A: MB991806 cartridge B: MB991812 B : SWS monitor C: MB991822 harness (using column ECU) C : Probe harness MB991896 Door-to-door Checking door-to-door communications line...
Page 230: Troubleshooting
54B-4 SWS – TROUBLESHOOTING Troubleshooting 1. Before starting troubleshooting Before starting troubleshooting, make sure that there is no problem with either of the following: • Check the state of coupling of the connectors between the ETACS-ECU and the junction box, and between the front ECU and the relay box in the engine room •...
Page 231: Sws Monitor Connections
SWS – TROUBLESHOOTING 54B-5 (5) SWS monitor service data From the Diagnosis by Function menu, select the function which is causing the trouble, and check the service data shown for each item of the function. Note: The SWS monitor service data also includes a Service data menu, in addition to the Diagnosis by Function menu. All items for all ECUs can be checked.
Page 232 54B-6 SWS – TROUBLESHOOTING (Connecting to the diagnosis connector using the Diagnosis connector Intermediate harness for customizing the SWS monitor (using the MUT-II)) (1) Connect the MUT-II to the Intermediate harness for customizing the SWS monitor (MB991960). (2) Take the Intermediate harness for customizing the SWS monitor (connected at step (1)), and connect it to the diagnosis connector and the SWS monitor.
Page 233 SWS – TROUBLESHOOTING 54B-7 Note: Refer to the chart below for the connector and terminal nos. on the door-to-door communications line into which to insert the probe. Chart of connector numbers and terminal numbers in door-to-door communications line Insert the probe section of the probe harness into the terminal of the respective female connectors of the door-to-door communications line, from the rear side of the connector.
Page 234: Ecu Check Service Points
54B-8 SWS – TROUBLESHOOTING 4. ECU check service points (1) The ECU check is performed using the MUT-II/III and SWS monitor. (See MUT-II Reference Manual or MUT-III Instruction Manual) (2) The following ECU checks can be performed when the ECU is connected to the MUT-II/III and the SWS monitor. Note: If an abnormality arises during ECU checking, then troubleshooting should be performed by referring to the Inspection procedures classified by trouble symptoms.
Page 235: Service Data Check Service Points
SWS – TROUBLESHOOTING 54B-9 5. Service data check service points (1) The service data is checked using the MUT-II/III and the SWS monitor. A service data check performed using the SWS monitor only relates to the signals present on the SWS communications line and the door-to-door communications line.
Page 236 54B-10 SWS – TROUBLESHOOTING Item No. Check item MUT display Check conditions Normal state Windscreen Intermittent VOL Vehicle with intermittent volume intermittent wiper Vehicle without intermittent volume volume on/off • ETACS-ECU Item No. Check item MUT display Check conditions Normal state Ignition switch (IG1) Ignition SW IG1 Ignition switch : ON or START...
Page 237 SWS – TROUBLESHOOTING 54B-11 Item No. Check item MUT display Check conditions Normal state All door switch Security alarm Any door : open All doors : closed Reversing light Inhibitor SW Reversing light switch : ON switch Reversing light switch : OFF Wiper drive Wiper drive 1.
Page 238 54B-12 SWS – TROUBLESHOOTING Item No. Check item MUT display Check conditions Normal state Front ECU Front ECU Lighting switch : not OFF Normal response response response (except for high-beam on) or Wiper switch : not OFF • Ignition switch : ON or START Sleep response •...
Page 239 SWS – TROUBLESHOOTING 54B-13 • Door-to-door communications Item Check item MUT display Check conditions Normal state Front passenger Passenger Front passenger electric window switch : UP electric window window UP Front passenger electric window switch : not switch UP Front passenger Passenger Front passenger electric window switch : electric window...
Page 240 54B-14 SWS – TROUBLESHOOTING (Diagnosis by Function) In diagnosis by function, the service data displayed for each item of a function, and the normal states for each item, are collated into a single table. The normal state column indicates the value displayed when the named item is operated.
Page 241 SWS – TROUBLESHOOTING 54B-15 Item Input signal name Item No. MUT display Normal state Windscreen intermittent INT Wiper SW (High wiper switch speed) Windscreen low-speed LO Wiper SW wiper switch Windscreen high-speed Hi Wiper SW wiper switch Windscreen mist wiper Mist Wiper SW switch Windscreen washer switch...
Page 242 54B-16 SWS – TROUBLESHOOTING • Rear Wiper Item Input signal name Item No. MUT display Normal state Rear wiper switch Rear wiper SW Rear wiper Rear washer switch Rear washer SW Ignition switch (ACC) Ignition SW ACC Rear wiper switch Rear wiper SW Reverse Ignition switch (ACC)
Page 243 SWS – TROUBLESHOOTING 54B-17 • Item Input signal name Item No. MUT display Normal state Fog lamp Headlight switch Headlight SW Any ON Tail light switch Tail light SW Ignition switch (IG1) Ignition SW IG1 Headlight automatic cut-off HD light auto cut function Fog light light request Fog lamp...
Page 244 54B-18 SWS – TROUBLESHOOTING Item Input signal name Item No. MUT display Normal state Remove Ignition switch (IG1) Ignition SW IG1 Driver’s door switch Driver’s door SW reminder Buzzer Buzzer buzzer Back Ignition switch (IG1) Ignition SW IG1 buzzer Inhibitor switch (R) Inhibitor (R) Buzzer Buzzer...
Page 245 SWS – TROUBLESHOOTING 54B-19 • Sunroof Item Input signal name Item No. MUT display Normal state Sunroof Ignition switch (IG1) Ignition SW IG1 operation Electric window module P/W module response Normal response response Sunroof ECU response Sunroof ECU response Input check (only at instant of switch operation) (ETACS Switch Data Chart)
Page 246: Pulse Check Service Points (Mut-Ii/Iii Or Voltmeter)
54B-20 SWS – TROUBLESHOOTING (ETACS Analogue Data Chart) Item No. Check item MUT display Check conditions Windscreen wiper Wiper volume Displays voltage j of windscreen wiper intermittent volume voltage intermittent volume Changes according to position of windscreen wiper intermittent volume Vehicle speed signal Speed signal Displays vehicle speed...
Page 247: Chart Of Trouble Symptoms
SWS – TROUBLESHOOTING 54B-21 8. Chart of Trouble Symptoms (ESU communications system) Trouble Symptom Inspection Reference Procedure page No communication with SWS monitor 54B-26 No communication with column switch (column ECU) 54B-27 No communication with ETACS-ECU 54B-28 No communication with front ECU 54B-29 No communication with electric window main switch (electric window module) 54B-30...
Page 248 54B-22 SWS – TROUBLESHOOTING Trouble Symptom Inspection Reference Procedure No. page Windscreen Windscreen wipers not working at all 54B-58 wipers / Washer Windscreen wipers do not work at INT, washer or mist 54B-59 positions, and operate at low speed in both Lo & Hi positions.
Page 249 SWS – TROUBLESHOOTING 54B-23 Trouble Symptom Inspection Reference Procedure No. page Interior light Interior light does not light up or switch off correctly 54B-88 Interior light automatic cut-off function not working 54B-91 correctly (cars fitted with keyless entry system) Half door Door ajar Half door indicator light does not light up or switch off 54B-92...
Page 250: Confirming Problems In Input Signal Check
54B-24 SWS – TROUBLESHOOTING 9. Confirming problems in input signal check (Service data, Diagnosis by Function or Pulse Check) If a problem arises during the service data service points, then perform an inspection by referring to the table below. Trouble Symptom Inspection Reference Procedure...
Page 251 SWS – TROUBLESHOOTING 54B-25 Chart of operational functions classified by input signal inspection procedure number If a problem arises in a number of different functions when using the SWS, perform an input signal check by referring to the table below. (Only the input signals and functions which may possibly give rise to multiple problems are listed in the table) Name of function R-11 R-13 R-14 R-15 R-16 R-17 R-19...
Page 252: No Communication With Sws Monitor
54B-26 SWS – TROUBLESHOOTING 10. Inspection Procedures Classified by Trouble Symptoms Inspection Procedure No communication with SWS monitor Probable Cause There may be a malfunction in the connections to the SWS • Fault in SWS monitor main unit (I/F cartridge) monitor •...
Page 253: No Communication With Column Switch (Column Ecu
SWS – TROUBLESHOOTING 54B-27 Inspection Procedure A-2 No communication with column switch (column ECU) Probable Cause There may be a problem in the column switch (column ECU) • Fault in column switch power supply circuit system. • Fault in harness or connectors If there is a problem in the harness of the ECU battery power supply circuit (column switch terminal No.1), then the ignition switch (IG1) power supply circuit (column switch terminal...
Page 254: No Communication With Etacs-Ecu
54B-28 SWS – TROUBLESHOOTING Inspection Procedure A-3 No communication with ETACS-ECU Probable Cause There may be an abnormality in the power supply circuit of the ETACS- • Fault in ETACS-ECU ECU or a problem in the harness or connectors between the SWS monitor •...
Page 255: No Communication With Front Ecu
SWS – TROUBLESHOOTING 54B-29 Inspection Procedure A-4 No communication with front ECU Probable Cause There may be an abnormality in the front ECU power supply circuit system, or a • Fault in front ECU problem the harness and connectors between the SWS monitor and the front •...
Page 256 54B-30 SWS – TROUBLESHOOTING Inspection Procedure A-5 No communication with electric window main switch (electric window Probable Cause module) There may be an abnormality in the power supply circuit system of the • Fault in electric window main switch electric window main switch (electric window relay drive circuit system), or •...
Page 257: No Communication With Sunroof Motor Assembly
SWS – TROUBLESHOOTING 54B-31 Inspection Procedure A-6 No communication with sunroof motor assembly Probable Cause There may be an abnormality in the communications circuit system or the power • Fault in sunroof motor assembly supply circuit system of the sunroof motor assembly •...
Page 258: No Communication With Multi-Centre Display
54B-32 SWS – TROUBLESHOOTING Inspection Procedure A-7 No communication with multi-centre display Probable Cause There may be an abnormality in the communications circuit system or the • Fault in multi-centre display power supply circuit system of the multi-centre display • Fault in harness or connectors SWS monitor ECU check To Inspection procedure A-2 No communication with •...
Page 259 SWS – TROUBLESHOOTING 54B-33 Inspection Procedure B-1 Ignition key left in reminder function not working correctly Probable Cause This function is operated by determining the following input signals in the • Fault in key reminder switch ETACS-ECU. • Fault in driver’s door switch •...
Page 260 54B-34 SWS – TROUBLESHOOTING Inspection Procedure B-2 Lights left on reminder function not working correctly Probable Cause This function is operated by determining the following input signals in the • Fault in key reminder switch ETACS-ECU. • Fault in driver’s door switch •...
Page 261: Door Ajar Warning Function Not Working Correctly
SWS – TROUBLESHOOTING 54B-35 Inspection Procedure B-3 Door ajar warning function not working correctly Probable Cause This function is operated by determining the following input signals in the • Fault in all door switch ETACS-ECU. • Fault in ETACS-ECU • All door switch •...
Page 262: Turn Indicator Light Operating Noise Not Working Correctly
54B-36 SWS – TROUBLESHOOTING nspection Procedure B-4 Turn indicator light operating noise not working correctly Probable Cause This function is operated by determining the following input signals in the • Fault in column switch ETACS-ECU. • Fault in ETACS-ECU • Turn indicator light switch •...
Page 263 SWS – TROUBLESHOOTING 54B-37 Inspection Procedure B-5 Multi-centre display operating noise function not working correctly Probable Cause A buzzer sounds when the ETACS-ECU receives a sound request signal • Fault in multi-centre display from the multi-centre display. • Fault in ETACS-ECU If this function does not work correctly, then this is probably due to an •...
Page 264 54B-38 SWS – TROUBLESHOOTING Inspection Procedure C-1 Central door locking not working at all Probable Cause The ETACS-ECU locks or unlocks all the doors by activating all of the door • Fault in driver’s door lock actuator lock actuators, when there is a change in the input signal from the driver’s door •...
Page 265 SWS – TROUBLESHOOTING 54B-39 Inspection Procedure C-2 Some doors not operating, even when lock or unlock is performed Probable Cause There is probably a fault in the door lock actuator of the door(s) which are not • Fault in door lock actuator working.
Page 266 54B-40 SWS – TROUBLESHOOTING Inspection Procedure D-1 None of electric windows working Probable Cause This is probably due to a fault in the electric window relay, a fault in the electric • Fault in electric window main switch window main switch or a fault in the ETACS-ECU. •...
Page 267: Driver's Electric Window Not Responding To Electric Window Main
SWS – TROUBLESHOOTING 54B-41 Inspection Procedure D-2 Driver’s electric window not responding to electric window main Probable Cause switch There is probably a fault in the electric window main switch or the driver’s • Fault in electric window main switch electric window motor.
Page 268: Front Passenger's Or Rear Passenger's Electric Windows Not
54B-42 SWS – TROUBLESHOOTING Inspection Procedure D-3 Front passenger’s or rear passenger’s electric windows not Probable Cause responding to their respective switches There is probably a fault in the electric window sub switch or the front or • Fault in electric window sub switch rear passenger electric window motor.
Page 269 SWS – TROUBLESHOOTING 54B-43 From previous page NG (3) NG (2) Repair Check connector E-102 Check the electric window sub switch (rear : Replace RH) (see Chap. 42 Doors *) NG (1) Check connectors C-210, D-03 Measure at Electric window sub switch (rear : RH) connector E-102 •...
Page 270 54B-44 SWS – TROUBLESHOOTING From previous page Check connectors E-104 Measure at Electric window motor (rear : Check connector D-13 LH) connector E-104 • Detach the connector and measure at the Repair harness side • Ignition switch : ON Check the harness between the electric window motor (1) Connectivity between 5 &...
Page 271: Front And/Or Rear Passenger Electric Window Not Responding To
SWS – TROUBLESHOOTING 54B-45 Inspection procedure D-4 Front and/or rear passenger electric window not Probable Cause responding to electric window main switch There is probably a fault in the electric window main switch or • Fault in electric window main switch the front or rear passenger electric window sub switch •...
Page 272: Electric Window Timer Function Not Working Correctly
54B-46 SWS – TROUBLESHOOTING Inspection procedure D-5 Electric window timer function not working correctly Probable Cause This function is operated by determining the following input • Fault in driver’s door switch signals in the ETACS-ECU • Fault in electric window main switch •...
Page 273: While The Window Is Winding Up, It Automatically Starts To Come
SWS – TROUBLESHOOTING 54B-47 Inspection procedure D-6 While the window is winding up, it automatically starts to Probable Cause come down again If there is a large resistance to the movement of the window • Error in adjustment of window glass glass when the electric window is being raised, then it is •...
Page 274 54B-48 SWS – TROUBLESHOOTING Inspection procedure D-7 Electric window trapping prevention function not working correctly Probable Cause There is probably a fault in the rotation detector sensor in the electric window motor • Fault in electric window motor assembly Check the electric window operating current (See Adjust and replace door window fault (See Chap.
Page 275 SWS – TROUBLESHOOTING 54B-49 From previous page NG (4) NG (3) Repair Check connector E-101 Measure at the Electric window motor (rear: Check connector D-03 RH) connector E-101 • Detach the connector and measure at the Repair harness side • Connectivity between 5 and body earth Check the harness between the electric window main OK: Connectivity switch (rear: RH) and the body earth, and repair...
Page 276 54B-50 SWS – TROUBLESHOOTING Inspection procedure E-1 Keyless entry system not working at all Probable Cause This function is operated by determining the following input • Fault in key reminder switch signals in the ETACS-ECU. • Fault in door switch •...
Page 277: Answerback Function Not Working Correctly
SWS – TROUBLESHOOTING 54B-51 Inspection procedure E-2 Keyless entry hazard answerback function or interior light Probable Cause answerback function not working correctly If the hazard lights and interior light are working normally, then • Fault in turn indicator lights there is probably a fault in the ETACS-ECU. •...
Page 278: Encrypted Code Cannot Be Registered
54B-52 SWS – TROUBLESHOOTING Inspection procedure E-3 Encrypted code cannot be registered Probable Cause If the system cannot be set to encrypted code registration • Fault in keyless entry transmitter mode, then there is probably a problem in the input circuit •...
Page 279: Multi-Mode Keyless Entry Function Not Working At All
SWS – TROUBLESHOOTING 54B-53 Inspection procedure E-4 Multi-mode keyless entry function not working at all Probable Cause If the electric windows, sunroof, and motorized door mirrors • Fault in ETACS-ECU are all working normally, then there is probably a fault in the •...
Page 280: Electric Windows Not Working Correctly With Multi-Mode Keyless
54B-54 SWS – TROUBLESHOOTING Inspection procedure E-5 Electric windows not working correctly with multi-mode Probable Cause keyless entry function If the electric windows are working correctly in normal • Fault in ETACS-ECU operation, then there is probably a fault in the ETACS-ECU. •...
Page 281: Sunroof Close Operation Not Working Correctly With Multi-Mode
SWS – TROUBLESHOOTING 54B-55 Inspection procedure E-6 Sunroof close operation not working correctly with multi-mode Probable Cause keyless entry function If the sunroof is working correctly in normal operation, then • Fault in ETACS-ECU there is probably a fault in the ETACS-ECU. •...
Page 282 54B-56 SWS – TROUBLESHOOTING Inspection Procedure F-1 Sunroof not working at all Probable Cause There is probably a fault in the sunroof switch, a problem in • Fault in sunroof switch the sunroof motor assembly power circuit, or a fault in the •...
Page 283: Particular Sunroof Functions Not Working
SWS – TROUBLESHOOTING 54B-57 Inspection procedure F-2 Sunroof timer function not working Probable Cause This function is operated by determining the ignition switch • Fault in sunroof motor assembly (IG1) signal from the ignition switch (IG2) circuit of the sunroof •...
Page 284 54B-58 SWS – TROUBLESHOOTING Inspection procedure G-1 Windscreen wipers not working at all Probable Cause There is probably a fault in the windscreen wipers, a fault in • Fault in column switch the column ECU or a fault in the front ECU. •...
Page 285 SWS – TROUBLESHOOTING 54B-59 Inspection procedure G-2 Windscreen wipers do not work at INT, washer or mist Probable Cause positions, and operate at low speed in both Lo & Hi positions. The failsafe has probably engaged, due to a fault in the SWS •...
Page 286 54B-60 SWS – TROUBLESHOOTING Inspection procedure G-4 Windscreen wipers cannot be operated normally Probable Cause There is probably a fault in the windscreen wiper motor, a fault • Fault in column switch in the column ECU, or a fault in the front ECU •...
Page 287 SWS – TROUBLESHOOTING 54B-61 From previous page Measure at Windscreen wiper motor connector B-12 Confirm the trouble symptoms • Detach the connector and measure at the harness side • Windscreen wiper switch: HI • Voltage between 2 & body earth Transient problem Replace the windscreen OK: Battery voltage...
Page 288 54B-62 SWS – TROUBLESHOOTING Inspection procedure G-6 Intermittent time interval of windscreen wipers does not Probable Cause change with vehicle speed There is probably a fault in the front ECU or the ETACS-ECU. • Fault in front ECU • Fault in ETACS-ECU •...
Page 289 SWS – TROUBLESHOOTING 54B-63 Inspection procedure G-7 Windscreen washer not working correctly Probable Cause There is probably a fault in the windscreen washer motor, a • Fault in column switch fault in the column ECU, or a fault in the front ECU •...
Page 290 54B-64 SWS – TROUBLESHOOTING Inspection procedure H-1 Rear wiper not working at all Probable Cause The rear wiper is operated by determining the following input • Fault in rear wiper motor signals in the ETACS-ECU. • Fault in column switch •...
Page 291 SWS – TROUBLESHOOTING 54B-65 Inspection procedure H-2 Rear wiper does not stop in correct position Probable Cause There is probably a fault in the rear wiper motor or a fault in • Fault in rear wiper motor the ETACS-ECU • Fault in ETACS-ECU •...
Page 292 54B-66 SWS – TROUBLESHOOTING Inspection procedure H-3 Rear wiper does not operate continuously, even when Probable Cause shift is set to R position There is probably a malfunction in the reversing light switch • Fault in reverse light switch input circuit system, or a fault in the ETACS-ECU. •...
Page 293 SWS – TROUBLESHOOTING 54B-67 Inspection procedure H-4 Rear washer does not work Probable Cause There is probably an abnormality in the rear washer switch • Fault in rear washer motor input circuit system, a fault in the rear washer motor, or a fault •...
Page 294 54B-68 SWS – TROUBLESHOOTING Inspection procedure I-1 Motorised retractable door mirrors not working at all Probable Cause The motorised retractable door mirrors are operated by • Fault in motorised remote control mirror switch determining the following input signals in the ETACS-ECU. •...
Page 295 SWS – TROUBLESHOOTING 54B-69 Inspection procedure I-2 Motorised retractable door mirror timer function not working Probable Cause If the mirrors can be operated (folded in or out) using the motorised • Fault in ETACS-ECU remote control mirror switch (fold / return switch), then there is probably a fault in the ETACS-ECU.
Page 296 54B-70 SWS – TROUBLESHOOTING Inspection procedure I-4 Motorised retractable door mirror automatic return Probable Cause function (ignition driven function) does not work correctly This function is operated by determining the following input • Fault in ETACS-ECU signals in the ETACS-ECU. •...
Page 297 SWS – TROUBLESHOOTING 54B-71 Inspection procedure I-5 Motorised retractable door mirror automatic return Probable Cause function (keyless driven function) does not work correctly This function is operated by determining the following input • Fault in keyless entry transmitter signals in the ETACS-ECU. •...
Page 298 54B-72 SWS – TROUBLESHOOTING Inspection procedure I-6 One of the motorised retractable door mirrors is not working. Probable Cause The motorised retractable door mirrors are operated by • Fault in mirror assembly determining the following input signals in the ETACS-ECU. •...
Page 299 SWS – TROUBLESHOOTING 54B-73 Inspection procedure J-1 Ignition key cylinder illumination light does not light up Probable Cause and switch off correctly (Vehicle not fitted with keyless entry) • Fault in key reminder switch The ignition key cylinder illumination light is switched on by •...
Page 300 54B-74 SWS – TROUBLESHOOTING (Vehicle not fitted with keyless entry) To Inspection procedure A-3 No communication with SWS monitor ECU check ETACS-ECU (p.54B-28) • Ignition switch: OFF ETACS-ECU OK: “OK” is displayed NG (a) To Inspection procedure R-2 Ignition switch (IG1) SWS monitor service data signal not input (p.54B-96) (Communications data) ETACS-ECU...
Page 301 SWS – TROUBLESHOOTING 54B-75 (Vehicle fitted with keyless entry) Does the interior light switch on normally? To Inspection procedure N-1 Interior light does not light up or switch off correctly (p.54B-76) SWS monitor ECU check To Inspection procedure A-3 No communication with •...
Page 302 54B-76 SWS – TROUBLESHOOTING Inspection procedure K-1 Head lights do not light up when passing switch is on. Low beam Probable Cause lights up (cannot be changed using dimmer switch) If the low beam turns on, regardless of the position of the headlight •...
Page 303 SWS – TROUBLESHOOTING 54B-77 Inspection procedure K-3 Head lights (low beam) do not light up Probable Cause If neither of the head lights (low beam) lights up properly, then • Fault in column switch there is probably a malfunction in the head light switch input •...
Page 304 54B-78 SWS – TROUBLESHOOTING Inspection procedure K-4 Head lights (high beam) do not light up Probable Cause If neither of the head lights (high beam) lights up properly, • Fault in column switch then there is probably a problem in the dimmer switch input •...
Page 305 SWS – TROUBLESHOOTING 54B-79 Inspection procedure K-5 Head lights (low beam and high beam) do not light up Probable Cause when passing switch is ON If neither of the head lights (low beam and high beam) lights • Fault in column switch up properly, then there is probably a problem in the passing •...
Page 306 54B-80 SWS – TROUBLESHOOTING Inspection procedure K-6 Head light automatic cut-off function not working correctly Probable Cause This function is operated by determining input signals from the • Fault in driver’s door switch ignition switch (IG1) and the driver’s door switch in the ETACS- •...
Page 307 SWS – TROUBLESHOOTING 54B-81 Inspection procedure K-7 One of the head lights does not light up (including high Probable Cause beam indicator light) If any one of the head lights does not light up correctly, then • Fault in headlight bulb there is probably a fault in the harness connectors, or a fault •...
Page 308 54B-82 SWS – TROUBLESHOOTING Inspection procedure K-8 One of the tail lights, position lights, or licence plate Probable Cause lights does not light up If any one of the tail lights, position lights or licence plate • Fault in tail light bulb lights does not light up correctly, then there is probably a fault •...
Page 309 SWS – TROUBLESHOOTING 54B-83 Inspection procedure L-1 Fog lights do not light up correctly Probable Cause If any one of the fog lights does not light up correctly, but the • Fault in fog light switch tail lights and head lights are working normally, then there is •...
Page 310 54B-84 SWS – TROUBLESHOOTING Inspection procedure L-2 One of the fog lights does not light up (including fog light indicator light) Probable Cause If any one of the fog lights does not light up normally, then there is probably a •...
Page 311 SWS – TROUBLESHOOTING 54B-85 Inspection procedure M-1 Turn indicator lights do not light up Probable Cause If none of the turn indicator lights is working, then there is • Fault in column switch probably a problem in the ignition switch (IG1) or turn •...
Page 312 54B-86 SWS – TROUBLESHOOTING Inspection procedure M-2 Hazard lights do not light up Probable Cause If the hazard lights do not light up, then there is probably a • Fault in hazard light switch problem in the hazard light switch input circuit system, or a •...
Page 313 SWS – TROUBLESHOOTING 54B-87 Inspection procedure M-3 One of the turn indicator lights does not light up Probable Cause If one of the turn indicator lights is not working correctly, then • Fault in turn indicator light bulb there is probably a fault in the harness/connector, or a fault in •...
Page 314 54B-88 SWS – TROUBLESHOOTING Inspection procedure N-1 Front interior light and/or rear interior light does not light up or Probable Cause switch off correctly (vehicle not fitted with sunroof) (Vehicle not fitted with keyless entry) • Fault in key reminder switch The front interior light and/or rear interior light (in vehicles not fitted •...
Page 315 SWS – TROUBLESHOOTING 54B-89 (Vehicle not fitted with keyless entry) Is the interior light delay switch off time period set to “7.5 Use the adjustment function to set the interior light delay seconds”, “15 seconds”, “30 seconds” or “60 seconds”? switch off time period to “7.5 seconds”, “15 seconds”, “30 seconds”...
Page 316 54B-90 SWS – TROUBLESHOOTING (Vehicle fitted with keyless entry) Use the adjustment function to set the interior light delay Is the interior light delay switch off time period set to “7.5 switch off time period to “7.5 seconds”, “15 seconds”, “30 seconds”, “15 seconds”, “30 seconds”...
Page 317 SWS – TROUBLESHOOTING 54B-91 Inspection procedure N-2 Interior light automatic cut-off function not working correctly (cars Probable Cause fitted with keyless entry system) The interior light automatic cut-off function is operated by determining • Fault in all door switch the following input signals in the ETACS-ECU. •...
Page 318 54B-92 SWS – TROUBLESHOOTING Inspection procedure O-1 Door ajar indicator light does not light up or switch off correctly Probable Cause The door ajar indicator light is lit up by determining the following input • Fault in all door switch signals in the ETACS-ECU.
Page 319 SWS – TROUBLESHOOTING 54B-93 Inspection procedure P-1 Security alarm does not enter warning state Probable Cause This function is operated by determining the following input • Fault in keyless entry transmitter signals in the ETACS-ECU. • Fault in key reminder switch •...
Page 320 54B-94 SWS – TROUBLESHOOTING Inspection procedure P-2 Interior warning does not operate correctly when security alarm operates Probable Cause This function is operated by determining the all door switch input signal in the • Fault in all door switch ETACS-ECU. •...
Page 321 SWS – TROUBLESHOOTING 54B-95 Inspection procedure P-4 Horn does not sound when security alarm operates Probable Cause This function is operated by the ETACS-ECU. • Fault in ETACS-ECU If the horn does not sound, then there is probably a fault in •...
Page 322 54B-96 SWS – TROUBLESHOOTING Inspection procedure R-1 Ignition switch (ACC) signal not input Probable Cause If there is a problem in the ignition switch (ACC) input signal, • Fault in ETACS-ECU then the ignition switch (ACC) signal will cease to be output to •...
Page 323 SWS – TROUBLESHOOTING 54B-97 Inspection procedure R-3 Reversing light switch signal not input Probable Cause If there is a problem in the reversing light switch input signal, • Fault in the reversing light then the reversing light switch signal will cease to be output to •...
Page 324 54B-98 SWS – TROUBLESHOOTING Inspection procedure R-4 Driver’s door switch signal not input Probable Cause If there is a problem in the input signal for the driver’s door • Fault in driver’s door switch switch, then this driver’s door switch signal will cease to be •...
Page 325 SWS – TROUBLESHOOTING 54B-99 Inspection procedure R-5 Column switches Probable Cause • Tail light switch signal not input • Headlight switch signal not input • Dimmer switch signal not input • Passing switch signal not input • LH turn indicator light switch signal not input •...
Page 326 54B-100 SWS – TROUBLESHOOTING Inspection procedure R-6 Column switches Probable Cause • Windscreen mist wiper switch signal not input • Windscreen intermittent wiper switch signal not input • Windscreen low speed wiper switch signal not input • Windscreen high speed wiper switch signal not input •...
Page 327 SWS – TROUBLESHOOTING 54B-101 Inspection procedure R-7 Windscreen intermittent wiper volume signal not input Probable Cause from column switch If there is a problem in the input signal for the intermittent • Fault in column switch windscreen wiper volume, then the intermittent wiper interval •...
Page 328 54B-102 SWS – TROUBLESHOOTING Inspection procedure R-9 Respective switch signals not input for sunroof Probable Cause If there is a problem in the sunroof switch input signal, then • Fault in sunroof motor assembly the sunroof input check response signal will cease to be •...
Page 329 SWS – TROUBLESHOOTING 54B-103 Inspection procedure R-10 Respective switch signals not input for multi-centre display Probable Cause If there is a problem in the multi-centre display, then the multi- • Fault in multi-centre display centre display input check response signal will cease to be •...
Page 330 54B-104 SWS – TROUBLESHOOTING Inspection procedure R-12 Motorised remote control mirror switch (retract / return switch) Probable Cause signal not input The input signal of the motorised remote control mirror switch ∑ Fault in motorised remote control mirror switch (retract / return) switch is used to determine the operation of ∑...
Page 331 SWS – TROUBLESHOOTING 54B-105 Inspection procedure R-13 Hazard light switch signal not input Probable Cause The hazard light switch input signal is used to determine the • Fault in hazard light switch operation of the hazard lights, and therefore, if there is a •...
Page 332 54B-106 SWS – TROUBLESHOOTING Inspection procedure R-14 All door switch signals not input (except driver’s door) Probable Cause Because the input signals from all the door switches are used • Fault in door switch to determine the operation of the following functions, these •...
Page 333 SWS – TROUBLESHOOTING 54B-107 Inspection procedure R-15 Driver’s door lock actuator signal not input Probable Cause Because the driver’s door actuator input signal is used to • Fault in driver’s door lock actuator determine the operation of the following functions, these •...
Page 334 54B-108 SWS – TROUBLESHOOTING Inspection procedure R-16 Vehicle speed signal not input Probable Cause Because the vehicle speed signal is used to determine the • Fault in vehicle speed sensor operation of the following functions, these functions will not • Fault in ETACS-ECU work correctly if there is an error in the input signal.
Page 335 SWS – TROUBLESHOOTING 54B-109 Inspection procedure R-17 Various switch signals of keyless entry transmitter not input Probable Cause The keyless entry transmitter input signal is used to determine the • Fault in keyless entry transmitter operation of the keyless entry system, and if there is a problem with •...
Page 336 54B-110 SWS – TROUBLESHOOTING Inspection procedure R-18 Fog light switch signal not input Probable Cause The fog light switch input signal is used to determine the • Fault in fog light switch operation of the fog lights, so any problem in this signal will •...
Page 337 SWS – TROUBLESHOOTING 54B-111 Inspection procedure R-19 Generic fuse No.17 load use signal not detected Probable Cause The generic fuse No.17 load signal is used to determine the • Fault in ETACS-ECU interior light cut-off function, and if there is a problem in this •...
Page 338: Chart Of Terminal Voltages
54B-112 SWS – TROUBLESHOOTING 11. Chart of terminal voltages 11-1 ETACS-ECU Note : Terminals No. 1 to 20 cannot be measured as the ETACS-ECU is installed directly on the junction box, and they are listed for reference. Terminal Check Item Check Conditions Normal State Electric window relay output...
Page 339 SWS – TROUBLESHOOTING 54B-113 Terminal Check Item Check Conditions Normal State 32 – 34 Driver’s door lock actuator (lock switch) Driver’s door lock: when locked input Driver’s door lock actuator (unlock switch) Driver’s door lock: when unlocked input 37, 38 Reversing light switch input Shift lever : R Battery voltage...
Page 340 54B-114 SWS – TROUBLESHOOTING 11-2 Column switch Terminal Check Item Check Conditions Normal State Battery power supply Battery voltage SWS request signal input 0 – 12 V (pulse signal) SWS communications line 0 – 12 V (pulse signal) Earth Intermittent windscreen wiper volume Ignition switch : ACC 2.5V output...
Page 341 SWS – TROUBLESHOOTING 54B-115 Terminal Check Item Check Conditions Normal State Earth Ignition switch (IG2) power supply Ignition switch : ON Battery voltage Earth 11-4 Electric window main switch Terminal Check Item Check Conditions Normal State Electric window motor output Earth SWS communications line (with ETACS- 0 –...
Page 342 54B-116 SWS – TROUBLESHOOTING 11-6 Sunroof motor assembly Terminal Check Item Check Conditions Normal State Battery voltage (for motor) Battery voltage Ignition switch (IG2) power supply Ignition switch : ON Battery voltage 3, 4 Earth Sunroof switch (close / open) input Sunroof switch : Close / Open Sunroof switch (up) input Sunroof switch : Up...
Page 343: On-Vehicle Servicing
SWS – ON VEHICLE SERVICING 54B-117 On Vehicle Servicing Adjustment function (User Mode) By setting the various switches to match the conditions for entering adjustment mode, you can switch the security alarm function on and off, or adjust the warning output. Any adjustments made are saved, even when the battery is disconnected.
Page 344: Adjustment Function (Dealer Mode)
54B-118 SWS – ON VEHICLE SERVICING Adjustment function (Dealer mode) The following functions can be adjusted from the MUT-II/III. Any adjustments made will be saved, even if the battery is disconnected. • Door ajar warning. If any one of the doors, including the boot, is open whilst the vehicle is travelling, then this function warns the driver that a door is open by sounding a buzzer and causing a door ajar indicator light to flash on the combination meter..
Page 345 SWS – ON VEHICLE SERVICING 54B-119 • Interior light automatic cut-off function This function automatically switches off the interior lights after a specified time delay if they have been left on with the ignition switch in the LOCK (OFF) position. •...
Page 346 54B-120 SWS – ON VEHICLE SERVICING Item MUT item Item MUT adjustment display Details of adjustment display Keyless (P/W) Multi-mode Open and close Both close and open keyless entry operations (open operation for system: Electric windows only) window and Close only Close operation only (initial sunroof operation setting)
Page 347 SWS – ON VEHICLE SERVICING 54B-121 Note 1. * 1 optional: Can only be adjusted when the smart entry system is fitted. After fitting the smart entry system, a list of adjustable functions will be displayed when the entry system is operated for the first time. If all the functions are initialised, then the adjusted items will be deleted, but by activating the smart entry system, the list of adjusted functions will be displayed again.

Mitsubishi MOTORS Lancer Evolution-VIII Workshop Manual

Lancer

Srs Airbags - General, On-Vehicle Service Points 52B-1 Section 52B Srs Airbags

Section 54A Chassis Electrical

54B-1 Section 54B Smart Wiring System (Sws)

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