Mitsubishi Lancer Evolution Forum banner

WARNING: Fuel Pump Relay

257K views 639 replies 205 participants last post by  it_manager  
#1 · (Edited)
I am writing this as a warning to those who own an Evo X. There has been a couple of threads on Evom about Evo Xs that are running lean on the stock tune at WOT. I have not encountered that until recently. I was baselining SpunkySandoval's Evo X for a tune and the car was running unusually lean. The car had an exhaust and an HKS drop-in filter. Here is the way the AFR looked on the stock tune:

Image


I have never seen such a lean AFR on the stock tune. The lean AFR and the advanced stock timing made the car register 10-14 counts of knock by redline. The owner and I surmised that this was a fuel related problem. The car was not getting the needed fuel during WOT operation.

Luckily SpunkySandoval is an expert electrical trouble shooter. With the help of the service manual he discovered that:

…the fuel delivery system on the Evo X has two voltage operation states. One state is at low load and it supplies the fuel pump with a low voltage that goes through a resistor circuit to drop the voltage prior to going to the fuel pump. The second fuel pump voltage state occurs at high load conditions, not necessarily WOT, but high load. I don't know what the various determinants the ECU uses or what strategy Mitsu used to initiate the high voltage state, but I do know that the ECM powers up fuel pump relay #1 during higher load running conditions.
Image


Using a multi-meter and a power source he tested the resistance on the fuel pump relay and he discovered that it was OL, which mean that it was Out of Limits, which mean the circuit stayed open. He then tested the horn relay (green trace on picture and same type as the fuel pump relay) and found that it was working fine. So he determined that it was a faulty fuel pump relay.

A couple of days later he came to my place and we swapped the high beam lamp relay (blue trace in the picture) with the fuel pump relay; the high beam lamp relay being the same type as that of the fuel pump. He then turned the high beams on with the fuel pump relay in place. A few seconds later, the high beams shut off, indicating that the fuel pump relay was faulty.

We kept the high beam relay in the fuel pump relay slot, hooked up my logging equipment, and went logging on the stock tune. The car ran pig rich. This is the first time I was happy to see an Evo X running rich
Image
Here are the stock runs with the functioning relay:

Image


I just want to warn everyone with an Evo X about this. This is very serious and can blow your engine. The relay that Mistu used for the fuel pump is weak and it is failing. This is my first encounter with this problem, but I am sure it is not going to be my last.
 
#7 ·
Awesome info. BTW what program are you using? I love tables like that when data logging.
I log in Evoscan and I then use a Macro to move the data into a template that can be read by Logworks ver 2. Logworks is freeware from Innovate. It is used to read Innovate logs. It cannot read Evoscan logs w/o the macro template.
 
#8 ·
If the stock relay is weak, is there any better ones out there that we can swap in so we dont have to worry about it failing?
 
#9 ·
As SpunkySandoval explained it to me, Mitsu should have used a solid state relay (don't ask me what that means). I do not know if there are solid state relays that can work in place of the stock one.

Hopefully, SpunkySandoval will chime in one this.

I hope this gets to Mitsu's attention. While there have not been a lot of documented cases, it is entirely possible that some cars have this problem and the owners do not know about it. Afterall, how many owners have a wideband on their cars and actively log AFR???
 
#12 ·
we did this on rockstars car and it did not fix anything.....

he was leaning out under WOT..

he got a dealer reflash and was good to go.
 
#27 ·
^interesting.

Now I wonder if it is map-related or electrical failure.
 
#32 ·
I've heard of this problem before.

The interesting take away is this - if you're too cheap for a tune, get a faulty relay in there and lean it out a little bit for more power! lol.
I know your kidding and I hope others know that. The leaness combined with the ridiculously advanced timing made the car knock like crazy. It would have knocked worse had the weather been hot when we were logging.

The bottom line though - This is why all performance cars need a wideband gauge.
I 100% agree with that. I will also add a high quality boost gauge to this mix. A boost gauge attached to a MAP sensor is what I am talking about. Do not get the mechanical ones, they are usually off by at 2 psi.
 
#33 ·
correction on our findings...

when i earlier stated that the dealrship reflashed the car and it corrected the error..

it only "Masked" the error. The stock duty cycle was 120% on the injectors and and the car was only running 25 psi and put down 300whp.

We found this out by datalogging the car, finally, and once we did this relay switch, the car was running well into the 8's AFR's. We were able to adjust and tuen like car FORREAL!

Thank you Lo0ney!
 
#46 ·
You need to arrange your ECUflash log coulmns in the same order as the macro columns. Do not touch the LogID, LogEntryDate, LogEntryTime, LogEntrySeconds, and LogNotes in the ECUlfash log. Remove the Mode23Enable columns.

Open the Macro. Go back to the ECUflash log and from the Tools tab select Macro and run it. The macro will move the columns from ECUflash into a Logworks format.

Save the log in dif format and open it in Logworks2. I have not tried Logworks3. You will have to adjust the channels in Logworks to read in the same units as the macro. Use the Configure tab for that.
 
#43 ·
We hit 108% IDC when trying to tune the car with the defective relay. Boost was 23.5 psi tapering to 18.5 by redline. The AFR was scary lean @ 12.5:1 by redline. I tried to richen up the AFR from the fuel map, but the car did not respond.

Once we swapped the relay from the high beam, the car became pig rich at 9.8:1 AFR by redline. My meter read 9.3:1 at one point.

This is a serious problem and it will get worse as the miles accumulate on these Evo Xs. The higher the mileage, the more the likelihood of the relay failing.