Hot and bothered down under...new owner of a Galant VR4 1997

[babasvr4]

Well I did it, at the age of 50 got myself a little beast!
Been servicing it slowly over the last month with no major issues
other than ambiguous errors that I just can't get help with.

The car drives for about 100 meters and then the AYC light comes on.
On checking the error codes the TCL light flashes 77 and the AYC 82.

Tried evoscan software and a 1.3R cable but I dont think it works, one day
I get DTC 24, 25 not what the lights are saying...
I assume my AYC is not working but it holds in the wet and dry like nothing I've driven before.

Being a 1997 I would have thought it was MUTII / OBD2

So confused, any help would be greatly apprciated guys...

[Nick Mann]

Trust the flashes, not the diagnostic codes. It is not obd2 compatible but it is mut2.
My best guess for the ayc issue is that the pump is not making enough pressure to activate the pressure switch found at the pump assembly. It is also possible that the pressure switch has failed. The best solution is to fit an adjustable pressure switch, this can solve either problem for at least the short term.
Hope you keep having fun!

[babasvr4]

Wow, something that makes sense! Will investigate shortly, just waiting for this latest heat wave to pass..only about 40 degrees outside. Much appreciated Cheers!

[WOODY72]

Where in Aus are you John?

[babasvr4]

Melbourne, Aspendale Gardens 3195, you local too?

[kiwigalant]

Welcome to Club VR-4 John. Woah 40 degrees there, and here I am complaining about it being hot and google says its only 27c here. I lived in Melton for a few years, love Melbourne, looks like you're in a cool place next to the water.

[babasvr4]

Yep, we had 5 straight days about 2 weeks ago above 40..I work in Aged Care and I can tell you it was just bearable inside. Great yo be here, already getting help with my toy!

[babasvr4]

Spent a lot of time years ago in Melton on hares and quail! It's all flattened now, turned into more suburbia...

[Trotty]

Welcome. I was born in sunshine and lived in melton myself. Now in Sydney. Can be damn hot here to. Ha our fair share of 40deg days.

[babasvr4]

Managed to sneak in some VR4 time over the last week between the hot days.
Tackled code 77 TCL by locating and testing the 2 solenoids, Vacuum and Ventilation control
located about mid-way on the firewall up high.
Had to first tackle the grease or whatever was in the connectors! It seemed white in color but there
was so much of it I was concerned it was causing connection problems, it had to go.
Wrapped each connector in a large rag and sprayed them with WD-40 then high pressure air...what came
out onto the rag was horrendous!
Each solenoid pushes out towards the drivers side and with a quick 12v test I discovered both had failed.
The ventilation control solenoid has a single output line and seems "vented" up near the connector. No audible
clicking sound and no change in state. Same applied for the vacuum control solenoid, this has 2 output lines
but again no change with 12v applied.
As with most of the car the parts looked as new, car has about 80k kms only.
Using the long nozzle on the WD-40 I hit both of them and gave them a few taps on a wooden bench, low and behold
they where alive!
I did initially test them with a multimeter and they checked out good at 40 Ohms approx, I was hoping that they
where simply stuck as solenoids sometimes get.
So, next up is the AYC hydraulic pump!
Have already check the oil, level is good , oil is a clear red color.
Had a peak at the unit and it looks clean with only some dust around it so hoping for a connector
issue but happy to run a kit through it and and modify the case that holds it to avoid any dirt and water getting to it again.
Will be looking at the pressure switch as suggested by Nick Mann if it's not connectors or solenoids...


Another 40 degree day in Melbourne!
66468

[babasvr4]

Eek!
Had to brave the outdoors, it's like an itch you have to scratch!
AYC pump out, quite simple. All solenoids and electric motor test fine, there was some coffee colored
fluid that came out when the pump was free and on the bench, I assume through lack of operation.
Looks like the pressure switch could be the culprit here, I have no way to test it but if it fails there is no
operation whatsoever.

Where do I find one, can I test mine?

Cheers guys!
66469

[Gly]

its not the switch, the pumps are well known for failing.

putting an adjustable switch in is just a cover up. allowing it to trigger with lower pressure,

there is someone on ozvr4.com offering a rebuild/exchange service if you want it fixed properly,

or you can ditch the ayc altogether and do a evo LSD conversion.

[Trotty]

Rebuild kit is about $140 delivered. That coffee looking fluid that came sounds like it has been exposed to water and the internal parts have rusted. I have the kit already to go into mine. The seccond packet is injector seals kit.

http://img.tapatalk.com/d/14/02/08/na8y2azy.jpg

[babasvr4]

its not the switch, the pumps are well known for failing.

putting an adjustable switch in is just a cover up. allowing it to trigger with lower pressure,

there is someone on ozvr4.com offering a rebuild/exchange service if you want it fixed properly,

or you can ditch the ayc altogether and do a evo LSD conversion.

Thanks for that.
I did run the pump and solenoids first to test them.
The car has been sitting around for 4 years maybe driven every 2 weeks, the driver lost his life
overseas in a stupid accident and his mum couldnt let go of the car until her daughter convinced it had to go.
I can verify this by the amount of spiders and cobwebs inside and out, surface rust on the rotors and so on.
Dont get me wrong, its out and for $140 I'd love to strip it.

[kiteman]

Good thread this, glad to see you guys are exchanging info and hopefully getting this sorted.
As for the 40 degree weather, we feel so sorry for you guys. ( thats me being sarcastic)

[babasvr4]

Haha..its 10:30 am about to turn southerly so we get some cool time!
Pulled the pump apart, without exaggeration it looks new inside, o rings perfect, no oxidizing anywhere.
Will post pictures soon, but quite sure I need the pressure switch.
Cheers!

[babasvr4]

Just to clarify, after cleaning up the pump assay I primed the unit in an etch primer and painted it with a rust guard satin black.
When the pump goes back in I will be sealing up the underside with a lanolin spray which eventually turns to a wax consistency and
using a self adhesive roofing tape to stop the entry or dirt and water into the carrier section..
6647766478

[Gly]

i would not seal it in, the airflow helps keep it cool during operation,

also handy vid if you do the rebuild.

http://www.youtube.com/watch?v=ZrYjQat4KGE

[babasvr4]

i would not seal it in, the airflow helps keep it cool during operation,

also handy vid if you do the rebuild.

http://www.youtube.com/watch?v=ZrYjQat4KGE

Right! Good call, I'll make sure to allow for this, I may just add a fine mesh under the carrier to keep out the water and dirt.

Cheers,
babasvr4

[babasvr4]

Wah!!!
Well got out into the AYC pump bright and early, went through the rigmarole of carefully removing the
unit, lowered down onto a support and removed the switch. Installed the new one, topped up the reservoir
and with some wood took off for a trial...

Exactly the same as before, first corner fine, ayc lights up on turning at speed and then the AYC light comes on.
Stop start the same again.
Wondering what else could be throwing it out.

[Nick Mann]

Is the new switch adjustable? If so then back it off 2 or 3 full turns and see what happens.

[babasvr4]

Hi Nick, I believe it is, sent kindly by Malc....
It does have a centre slotted screw head so I'll get back out there tomorrow, when I stop sobbing,
and give it say 2 turns out.

Cheers!

[Nick Mann]

Malc sends them out pre adjusted to the right pressure, so keep track of how much you adjust it and then you can put it back as and when required.

[babasvr4]

Managed to get it turned out without too much fuss, same story.
Have a feeling there is something else throwing it out, will do another code check.

Ta da!
Not the switch or pump...corn-hole relay next to the battery.
I have just set the adjustment back again by 2 turns, as supplied by Malc.
Remembered the colors coming of the relay next to the battery, looked at the schematic and
yanked it out.
Functionally the relay did operate but the contacts were heavily pitted and "sticky". Slightly misaligned also.
Some 600 wet n dry paper till the copper or brass contacts shined up and back in.

Ooh that feeling, looking at the road, at the cluster, some more road, lots of cluster and no red AYC light!
You guys are great, thanks so much for your help and input!

Hope I can give back to the forum somehow!

[kiwigalant]

Functionally the relay did operate but the contacts were heavily pitted and "sticky". Slightly misaligned also.
Some 600 wet n dry paper till the copper or brass contacts shined up and back in.

Haha similar problem here - my stereo and central locking stopped working today after trying to solve something else electrical. Checked the fuse and it looked fine. Popped another one in and it works straight away, guess it was the contacts being dirty. Really gives false negatives huh.

[babasvr4]

As a kid I worked on pinball machines and all the early arcade machines. I was taught to never
trust a contact. File it and polish it with fine wet & dry!
The AYC ECU senses the drop in pressure , even temporarily, through the pressure switch and disables the circuit.
To be honest, in normal driving I don't really feel the AYC system helping out, no doubt it may be different
in more aggressive driving conditions.

[Bender]

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