General -- Lancer Evolution: Diagnosis Mitsubishi Lancer X

TROUBLESHOOTING CONTENTS

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1. STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING Troubleshooting sections are based on the diagnostic flow as below. If the diagnostic flow is different from that given below, or if additional explanation is required, the details of such differences or additions will also be listed. Troubleshooting of electronic control systems for which scan tool MB991958 can be used follows the basic outline described below. Even in systems for which scan tool MB991958 cannot be used, some of these systems still follow this outline. Diagnostic method *1: For how to diagnose CAN bus lines, refer to «CAN BUS LINE DIAGNOSTIC FLOW»(ref-289394-S13849121612008063000000) . *2: For the CAN bus diagnosis chart, refer to «CAN BUS DIAGNOSTICS TABLE»(ref-289394-S27719724372008063000000) . *3: When scan tool MB991958 detects a diagnostic trouble code, its display informs users whether a mechanical problem currently exists or whether it existed before. The message for the former state identifies it as an "Active" and the message for the latter identifies it as a "Stored". *4: For how to treat past trouble, refer to «HOW TO TREAT PAST TROUBLE»(ref-289379-S13606268642008063000000) . *5: For how to cope with intermittent malfunctions, refer to «HOW TO COPE WITH INTERMITTENT MALFUNCTIONS»(ref-289379-S36733983872008063000000) . *6: For coding data, refer to «CODING LIST»(ref-289379-S27431265632008063000000) .
2. SYSTEM OPERATION AND SYMPTOM VERIFICATION TESTS If verification of the symptom(s) is difficult, procedures for checking operation and verifying symptoms are shown.
3. DIAGNOSTIC FUNCTION The following trouble code diagnosis are shown. How to read diagnostic trouble codes How to erase diagnostic trouble codes Input inspection service points
4. DIAGNOSTIC TROUBLE CODE CHART If the scan tool displays a diagnostic trouble code, find the applicable inspection procedure according to this chart.
5. SYMPTOM CHART If there are symptoms, even though the scan tools show that no DTCs are set, inspection procedures for each symptom will be found by using this chart.
6. DIAGNOSTIC TROUBLE CODE PROCEDURES Indicates the inspection procedures corresponding to each diagnostic trouble code. (Refer to «HOW TO USE THE INSPECTION PROCEDURES»(ref-289379-S09569497042008063000000) ).
7. SYMPTOM PROCEDURES Indicates the inspection procedures corresponding to each symptom listed in the Symptom Chart. (Refer to «HOW TO USE THE INSPECTION PROCEDURES»(ref-289379-S09569497042008063000000) ).
8. SERVICE DATA REFERENCE TABLE Inspection items and normal judgment values have been provided in this chart as reference information.
9. CHECK AT ECU TERMINALS Terminal numbers for the ECU connectors, inspection items, and standard values have been provided in this chart as reference information. TERMINAL VOLTAGE CHECKS Connect a needle-nosed wire probe to a voltmeter probe. CAUTION: Short-circuiting the positive (+) probe between a connector terminal and ground could damage the vehicle wiring, the sensor, the ECU, or all three. Use care to prevent this! Insert the needle-nosed wire probe into each of the ECU connector terminals from the wire side, and measure the voltage while referring to the check chart. NOTE: Measure voltage with the ECU connectors connected. You may find it convenient to pull out the ECU to make it easier to reach the connector terminals. Checks don't have to be carried out in the order given in the chart. If voltage readings differ from normal condition values, check related sensors, actuators, and wiring. Replace or repair as needed. After repair or replacement, recheck with the voltmeter to confirm that the repair has corrected the problem. TERMINAL RESISTANCE AND CONTINUITY CHECKS Turn the ignition switch to the "LOCK" (OFF) position. Disconnect the ECU connector. CAUTION: If resistance and continuity checks are performed on the wrong terminals, damage to the vehicle wiring, sensors, ECU, and/or ohmmeter may occur. Use care to prevent this! Measure the resistance and check for continuity between the terminals of the ECU harness-side connector while referring to the check chart. NOTE: Checks don't have to be carried out in the order given in the chart. If the ohmmeter shows any deviation from the Normal Condition value, check the corresponding sensor, actuator and related electrical wiring, then repair or replace. After repair or replacement, recheck with the ohmmeter to confirm that the repair has corrected the problem.
10. INSPECTION PROCEDURES USING AN OSCILLOSCOPE When there are inspection procedures using an oscilloscope, these are listed.

HOW TO USE THE INSPECTION PROCEDURES

The causes of many of the problems occurring in electric circuitry are generally the connectors, components, the ECU, and the harnesses between connectors, in that order. These inspection procedures follow this order. They first try to discover a problem with a connector or a defective component.

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HARNESS INSPECTION

Check for an open or short circuit in the harness between the terminals which were faulty according to the connector measurements. Carry out this inspection while referring to HARNESS CONNECTOR INSPECTION . Here, "Check harness between power supply and terminal xx" also includes checking for blown fuse. For inspection service points when there is a blown fuse, refer to " INSPECTION SERVICE POINTS FOR A BLOWN FUSE ".

IF INSPECTING WITH THE CONNECTOR CONNECTED < WATERPROOF CONNECTORS >

Be sure to use special tool. Never insert a test probe from the harness side, as this will reduce the waterproof performance and result in corrosion.

Scheme 18

IF INSPECTING WITH THE CONNECTOR CONNECTED < ORDINARY (NON-WATERPROOF) CONNECTORS >

Required Special Tool

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1. MB992006: Extra Fine Probe Inspect by inserting a test probe from the harness side. If the connector is too small to insert a test probe (e.g. control unit connector), do not insert it forcibly. Use special tool MB992006 (extra fine probe).

IF INSPECTING WITH THE CONNECTOR DISCONNECTED

< When Inspecting a Female Pin >

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1. From front side of the connector Required Special Tool: MB991219: Inspection Harness (Included in MB991223, Harness Set) The inspection harness for connector pin contact pressure should be used. The test probe should never be forcibly inserted, as it may cause a defective contact.
2. From back side of the connector (SRS-ECU harness side connector) Since the SRS-ECU harness connector is plated to improve conductivity, observe the warning below when checking this connector.

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< When Inspecting a Male Pin >

Touch the pin directly with the test probe.

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1. Connector is disconnected or improperly connected
2. Connector pins are pulled out
3. Stretched an broken wires at terminal section
4. Low contact pressure between male and female terminals
5. Low connection pressure due to rusted terminals or foreign matter lodged in terminals

CONNECTOR PIN INSPECTION

If the connector pin stopper is damaged, the terminal connections (male and female pins) will not be perfect even when the connector body is connected, because the pins may pull out of the back side of the connector. Therefore, gently pull the wires one by one to make sure that no pins pull out of the connector.

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CONNECTOR ENGAGEMENT INSPECTION

Required Special Tool

MB991219: Inspection Harness (contained in MB991223 Test Harness)

Use special tool, MB991219 to inspect the engagement of the male pins and female pins. [Pin drawing force: 1 N (0.2 pound) or more]

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3. USE SIMULATION TEST

Use the simulation tests below to attempt to duplicate the customer's complaint. Determine the most likely circuit(s) and perform the simulation tests on the connectors and parts of that circuit(s). Be sure to use the inspection procedures provided for diagnostic trouble codes and trouble symptoms.

For temperature and/or moisture condition related intermittent malfunctions, try to change the conditions of the suspected circuit components, then use the simulation tests below.

HOW TO TREAT PAST TROUBLE

Since the trouble may still be present even the status is "Stored", set the vehicle to the diagnostic trouble code detection condition and check that the status changes to "Active". If the status does not change from "Stored", carry out the following procedure.

1. Establish from the customer whether a fuse or connector has been replaced or disconnected.
2. If yes, erase the diagnostic trouble code, and then check that no diagnostic code is reset. If no diagnostic trouble code is reset, the diagnosis is complete.
3. If no, follow the applicable Diagnostic Trouble Code Chart. Then check the wiring harness and connector, and refer to " «HOW TO COPE WITH INTERMITTENT MALFUNCTION»(ref-289379-S36733983872008063000000) ".

INSPECTION SERVICE POINTS FOR A BLOWN FUSE

Remove the blown fuse and measure the resistance between the load side of the blown fuse and the ground. Close the switches of all circuits which are connected to this fuse. If the resistance is almost 0 ohms at this time, there is a short somewhere between these switches and the load. If the resistance is not 0 ohms, there is no short at the present time, but a momentary short has probably caused the fuse to blow.

The main causes of a short circuit are the following.

Scheme 26

1. Harness being clamped by the vehicle body
2. Damage to the outer casing of the harness due to wear or heat
3. Water getting into the connector or circuitry
4. Human error (mistakenly shorting a circuit, etc.)

TEST/LIMIT VALUE READOUT

Required Special Tools

1. MB991958: Scan Tool (M.U.T.-III Sub Assembly) MB991824: V. C.I. MB991827: M.U.T.-III USB Cable MB991910: M.U.T.-III Main Harness A

1. After the ignition switch is in "LOCK" (OFF) position, connect scan tool MB991958 to the diagnosis connector.
2. Turn the ignition switch to the "ON" position.
3. Select "MFI" from System select Screen of scan tool MB991958.
4. Select "Special Function" from MFI Screen.
5. Select "Timing chain maintenance" from Special Function Screen.
6. Select "Test/Limit value readout" from Timing chain maintenance Screen.
7. Read the value of percentage (%) shown on the screen. NOTE: The value of percentage (%) shown on the screen is the amount of elongation of the timing chain calculated by the ECM based on the learning value, and thus is not the actual amount. Use this for the reference only.

SCAN TOOL (MULTI USE TESTER { M.U.T.-III } SUB ASSEMBLY)

Note. M.U.T.-III trigger harness is not necessary when pushing V. C.I. ENTER key.

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< WHEN THE SCAN TOOL IS USED >

1. Remove the trunk room side trim lid on the right of the trunk room. CAUTION: Turn the ignition switch to the "LOCK (OFF)" position before connecting or disconnecting the scan tool.
2. Set the scan tool to the 16-pin data link connector. (Refer to «HOW TO CONNECT THE SCAN TOOL (M.U.T.-III)»(ref-289399-S38586115952008063000000) .)
3. Turn the ignition switch to the ON position.
4. Using the scan tool, forcibly activate the hydraulic unit (item No. 03) to reduce the pressure inside the accumulator. (Refer to «ACTUATOR TEST TABLE»(ref-289383-S24170514592008063000000) .) NOTE: With the forced activation (oil level check mode), the hydraulic unit direction valve is operated 20 times to right and left, and then the operation is canceled automatically. Also, using the clear key on the scan tool, the activation can be forcibly canceled. When the functions are suspended by the fail-safe function, the hydraulic unit cannot be forcibly activated.
5. Check that the oil reservoir fluid level is in between MAX and MIN.
6. If the fluid level is not in between MAX and MIN, fill the specified fluid. Specified fluid: DIAMOND ATF-SP III
7. Install the trunk room side trim lid.

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1. Remove the engine room under cover front A (RH). (Refer to «UNDER COVER»(ref-289387-S33328341892008063000000) ) WARNING: When removing the radiator cap, use care to avoid contact with hot coolant or steam. Place a shop towel over the cap and turn the cap counterclockwise a little to let the pressure escape through the vinyl tube. After relieving the steam pressure, remove the cap by slowly turning it counterclockwise.
2. Drain the water from the radiator, heater core and engine after unplugging the radiator drain plug and removing the radiator cap.
3. Remove the engine room under cover front B. (Refer to «UNDER COVER»(ref-289387-S33328341892008063000000) )
4. Remove the air cleaner intake hose. (Refer to «AIR CLEANER»(ref-289375-S31240850732008063000000) )
5. Remove the turbocharger compressor bracket. (Refer to «EXHAUST MANIFOLD AND TURBOCHARGER ASSEMBLY»(ref-289375-S31455216472008063000000) )
6. Disconnect the turbocharger water return hose and drain the coolant in the water jacket.
7. Remove the radiator condenser tank and drain the coolant.
8. Drain the coolant then clean the path of the coolant by injecting water into the radiator from the radiator cap area.
9. Securely tighten the drain plug of the radiator.
10. Reinstall the radiator condenser tank. CAUTION: Do not use alcohol or methanol anti-freeze or any engine coolants mixed with alcohol or methanol anti-freeze. The use of an improper anti-freeze can cause corrosion of the aluminum components.
11. By referring to the article on coolant, select an appropriate concentration for safe operating temperature within the range of 30 to 60%. Use special tool MB991871 to refill the engine coolant up to the top of the radiator port. A convenient mixture is a 50% water and 50% antifreeze solution [freezing point: -31°C (-23.8 °F)]. Recommended antifreeze: Long Life Antifreeze Coolant or an equivalent Quantity: 7.5 dm 3 (7.9 quarts) NOTE: For how to use special tool (MB991871), refer to its manufacturer's instructions.
12. Tighten the radiator cap securely.
13. Remove the radiator condenser tank cap, and add the engine coolant up to the "FULL" line.
14. Turn the A/C switch to OFF position to start the engine and warm up until the cooling fan operates. NOTE: This step opens the thermostat fully.
15. Rev the engine several times and then stop it. Check that there are no coolant leaks.
16. Remove the radiator cap with the engine cool, and then refill the engine coolant up to the top of the radiator port.
17. Tighten the radiator cap securely. CAUTION: Do not overfill the radiator condenser tank.
18. Remove the radiator condenser tank cap, and add the engine coolant up to the "FULL" line.
19. Install the turbocharger compressor bracket. (Refer to «EXHAUST MANIFOLD AND TURBOCHARGER ASSEMBLY»(ref-289375-S31455216472008063000000) )
20. Install the air cleaner intake hose. (Refer to «AIR CLEANER»(ref-289375-S31240850732008063000000) )
21. Remove the engine room under cover front A and engine room under cover front A (RH). (Refer to «UNDER COVER»(ref-289387-S33328341892008063000000) )

16. COOLANT HOSES (RADIATOR HOSE, HEATER HOSE) (INSPECT)

Inspect the surface of radiator hoses and heater hoses for heat and mechanical damage. Hard and brittle rubber, cracking, tears, cuts, abrasions and excessive swelling indicate deterioration of the rubber.

21. SUSPENSION SYSTEM (INSPECT FOR LOOSENESS AND DAMAGE)

Visually inspect the front/rear suspension components for deterioration and damage. Re-tighten the front/rear suspension components retaining bolts to specified torque.

Scheme 30

1. Remove the filler plug.
2. Remove the drain plug and drain oil.
3. Install the drain plug, and tighten it to the specified torque. Tightening torque: 32 ± 2 N.m (23 ± 2 ft-lb)
4. Fill the specified gear oil up to the bottom of the filler plug hole. Specified gear oil: MITSUBISHI Genuine DIA QUEEN Multi gear oil LS Amount to use: 0.55 ± 0.02 dm 3 (0.58 ± 0.02 qt)
5. Install the filler plug, and tighten it to the specified torque. Tightening torque: 49 ± 10 N.m (37 ± 7 ft-lb)

Scheme 31

1. Remove the filler plug.
2. Remove the drain plug and drain oil.
3. Install the drain plug, and tighten it to the specified torque. Tightening torque: 32 ± 2 N.m (23 ± 2 ft-lb)
4. Fill the specified gear oil up to the bottom of the filler plug hole. Specified gear oil: DIAMOND ATF-SP III Amount to use: 0.55 - 0.60 dm 3 (0.58 - 0.63 qt)
5. Install the filler plug, and tighten it to the specified torque. Tightening torque: 49 ± 10 N.m (37 ± 7 ft-lb)