MITSUBISHI LANCER EVOLUTION IV 1998 Workshop Manual

EXTERIOR – Intercooler & Radiator Water Spray System <EVOLUTION-V>51-13
INTERCOOLER & RADIATOR WATER SPRAY SYSTEM
<EVOLUTION-V>
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation

Front Bumper Removal and Installation
(Refer to P.51-4.)
12 3
4
567
89
Unit: Nm {kgf
m}
2.5 {0.25}
2.5 {0.25}
1 5
55
5 5
54
4
22
1
4
45
4 4
4 4
5
3
1
2
1. Clamp
2. Water spray nozzle
3. Water spray nozzle bracket
A4. Water spray hose
5. Joint
A6. ClipWater spray motor removal steps
7. Washer tank
8. Water spray hose
9. Water spray motor
NOTE
The conventional service procedures apply for the water
spray switch.

EXTERIOR – Intercooler & Radiator Water Spray System <EVOLUTION-V>51-14
INSTALLATION SERVICE POINT
ACLIP / WATER SPRAY HOSE INSTALLATION
(1) Tape clips as illustrated.
(2) Tape the water spray hose as illustrated.
(3) Insert the clips positively into the mounting holes.
Washer
tank side
TapeConnect to radiator nozzle (RH).
Tape (secures three water hoses together)
Tape
Tape
Tape Tape so that the
clip faces toward
the front of vehicle.Connect to intercooler
nozzle (RH).
Connect to intercooler
nozzle (LH).
Tape so that the clip faces
toward the front of vehicle.Connect to radiator
nozzle (LH).
Section A – A Section B – B
Tape and secure so that the two
thin water spray hoses are located
above the thick water spray hose.Tape and secure so that the thin
water spray hose is located above
the thick water spray hose.
To intercooler
nozzle (RH)To intercooler
nozzle (LH)
<Top view>
Unit: mm
Fixing rangeFixing range
330 ± 550 ± 5+10
060
+10
050
60 ± 5

EXTERIOR – Mark <EVOLUTION-V>51-15
MARK <EVOLUTION-V>
REMOVAL AND INSTALLATION
3
2 1
A1. EVOLUTION-V mark (side)
A2. brembo mark
A3. EVOLUTION-V mark (rear)NOTE
The mark “brembo” represents an Italian disc brake
maker, whose disc brakes are used both in front and rear
on EVOLUTION-V.
INSTALLATION SERVICE POINT
AMARK INSTALLATION
Installation positions
The dimension up to the cutout in decal (A in fig.) is the same as the dimension from the mounting
reference line (A’ in fig.). Use this dimension as a guideline to determine the mounting position. (A =
A’)
1. EVOLUTION-V MARK (SIDE)
Body press lineApplication tape edge
Rear door garnish edge line
Rear door opening line 176 mm

EXTERIOR – Mark <EVOLUTION-V>51-16
2. brembo MARK
Application tape edge
Rear bumper lineTrunk lid opening line
3. EVOLUTION-V MARK (REAR)
Trunk lid opening line
Rear bumper line
(2) Installation procedure
1. Using unleaded gasoline, degrease the surface of the body on which the marks are mounted.
2. Peel off the release paper from the back side of the mark and affix the mark, ensuring the specified
dimensions are met.
Caution
(1) Perform the procedure in a dust-free place with an ambient temperature ranging from
20 to 38C.
(2) If the ambient temperature is below 20C, heat the mark and mounting position to 20
to 30C.
(3) Be sure to press each mark positively, as a low pressure results in the mark being
separated easily.

54-1
CHASSIS
ELECTRICAL
CONTENTS
GENERAL 3. . . . . . . . . . . . . . . . . . . . . . . . . .
BATTERY 3. . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE SPECIFICATION 3. . . . . . . . . . . . . . .
ON-VEHICLE SERVICE 3. . . . . . . . . . . . . . . . . .
IGNITION SWITCH <EXCEPT
EVOLUTION-VI WITH IMMOBILIZER
SYSTEM> 6. . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOL 6. . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 6. . . . . . . . . . . . . . . . . . . .
IGNITION SWITCH 11. . . . . . . . . . . . . . . . . . . . . .
IGNITION SWITCH AND IMMOBILIZER
SYSTEM <EVOLUTION-VI WITH
IMMOBILIZER SYSTEM> 13. . . . . . . . . . .
SPECIAL TOOL 13. . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 13. . . . . . . . . . . . . . . . . .
IGNITION SWITCH AND IMMOBILIZER
SYSTEM 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COMBINATION METERS 22. . . . . . . . . . . .
SERVICE SPECIFICATIONS 22. . . . . . . . . . . .
SEALANT 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 23. . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 24. . . . . . . . . . . . . . . . . .
CONTINUED ON NEXT PAGE
WARNINGS REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM (SRS) EQUIPPED VEHICLES
WARNING!
(1) The service personnel must thoroughly review this manual, and especially its GROUP 52B – Supplemental Restraint
System (SRS) before beginning any service or maintenance of any component of the SRS or any SRS-related
component.
(2) When removing or installing the components indicated in the table of contents by an astarisk (*), use utmost care so
as not to apply any strong shock to SRS components.
NOTE
The SRS includes the following components: SRS-ECU, SRS warning lamp, air bag module, clock spring and interconnecting
wiring. Other SRS-related components (that may have to be removed/installed in connection with SRS service or maintenance) are
indicated in the table of contents by an asterisk (*).

54-2
ON-VEHICLE SERVICE 27. . . . . . . . . . . . . . . .
COMBINATION METERS 30. . . . . . . . . . . . . . .
HEADLAMP 32. . . . . . . . . . . . . . . . . . . . . . . .
SERVICE SPECIFICATIONS 32. . . . . . . . . . . .
SPECIAL TOOLS 32. . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 33. . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE 34. . . . . . . . . . . . . . . .
HEADLAMP AND FRONT TURN-SIGNAL
LAMP* 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT FOG LAMP 39. . . . . . . . . . . . . . . .
SERVICE SPECIFICATIONS 39. . . . . . . . . . . .
ON-VEHICLE SERVICE 39. . . . . . . . . . . . . . . .
FOG LAMP 41. . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR COMBINATION LAMP* 42. . . . . . .
TROUBLESHOOTING 42. . . . . . . . . . . . . . . . . .
REAR COMBINATION LAMP* 42. . . . . . . . . .
SIDE TURN-SIGNAL LAMP 43. . . . . . . . .
SPECIAL TOOL 43. . . . . . . . . . . . . . . . . . . . . . . SIDE TURN-SIGNAL LAMP 43. . . . . . . . . . . .
HAZARD WARNING LAMP
SWITCH, CLOCK 44. . . . . . . . . . . . . . . . . . .
SPECIAL TOOL 44. . . . . . . . . . . . . . . . . . . . . . .
HAZARD WARNING LAMP SWITCH 44. . . .
RADIO AND TAPE PLAYER 45. . . . . . . .
TROUBLESHOOTING 45. . . . . . . . . . . . . . . . . .
RADIO AND TAPE PLAYER 47. . . . . . . . . . . .
SPEAKER 47. . . . . . . . . . . . . . . . . . . . . . . . .
ANTENNA 48. . . . . . . . . . . . . . . . . . . . . . . . .
POLE ANTENNA 48. . . . . . . . . . . . . . . . . . . . . .
REAR WINDOW ANTENNA AND GLASS
DIVERSITY ANTENNA 49. . . . . . . . . . . . . . . . .
REAR WINDOW DEFOGGER 50. . . . . . .
TROUBLESHOOTING <VEHICLES WITH
AUTOMATIC A/C> 50. . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE 50. . . . . . . . . . . . . . . .
REAR WINDOW DEFOGGER SWITCH
<VEHICLES WITH AUTOMATIC A/C> 51. . .

CHASSIS ELECTRICAL – General / Battery54-3
GENERAL
Outline of Change

The following service procedures have been incorporated.
BATTERY
SERVICE SPECIFICATION
ItemSpecification
Specific gravity of the battery fluid1.220 – 1.290 [20C]
ON-VEHICLE SERVICE
FLUID LEVEL AND SPECIFIC GRAVITY CHECK
1. Inspect whether or not the battery fluid is between the
UPPER LEVEL and LOWER LEVEL marks.
2. Use a hydrometer and thermometer to check the specific
gravity of the battery fluid.
Standard value: 1.220–1.290 [20C]
The specific gravity of the battery fluid varies with the
temperature, so use the following formula to calculate
the specific gravity for 20C. Use the calculated value
to determine whether or not the specific gravity is
satisfactory.
D
20=Dt+0.0007 (t–20)
D
20: Specific gravity of the battery fluid calculated
for 20C.
Dt: Actually measured specific gravity
t: Actually measured temperature
Ther-
mometer
HydrometerGood

CHASSIS ELECTRICAL – Battery54-4
CHARGING
1. When charging a battery while still installed in the vehicle,
disconnect the battery cables to prevent damage to
electrical parts.
2. The current normally used for charging a battery should
be approximately 1/10th of the battery capacity.
3. When performing a quick-charging due to lack of time,
etc., the charging current should never exceed the battery
capacity as indicated in amperes.
4. Determining if charging is completed.
(1) If the specific gravity of the battery fluid reaches
1.250–1.290 and remains constant for at least one
hour.
(2) If the voltage of each cell reaches 2.5–2.8 V and
remains constant for at least one hour.
Caution
1. Be careful since the battery fluid level may rise
during charging.
2. Keep all sources of fire away while charging
because there is a danger of explosion.
3. Be careful not to do anything that could generate
sparks while charging.
4. When charging is completed, replace the battery
caps, pour clean water over the battery to remove
any sulfuric acid and dry.

CHASSIS ELECTRICAL – Battery54-5
BATTERY TESTING PROCEDURE
TEST STEP
(1) Turn headlamps on for 15 seconds.
(2) Turn headlamps off for 2 minutes to allow battery voltage to
stabilize.
(3) Disconnect cables.
Read open circuit voltage.
OK:Open circuit voltage is more than 12.4 VNGCharge battery at 5 amps. (see LOAD TEST RATE CHART)
RetestOK
(1) Connect a load tester to the battery.
(2) Load the battery at the recommended discharge rate (see LOAD
TEST RATE CHART).
(3) Read voltage after 15 seconds, then remove load.
(4) Compare the measured value with the minimum voltage (see
LOAD TEST CHART).
OK:Higher than minimum voltageNG
Replace battery
OK
Normal
LOAD TEST RATE CHART
Battery type28B19L34B19L44B20L95D31L55D23L55B24L
Charging time when fully discharged h
[5-amp rated current charging]56713108
Load test (Amps)120130160310170170
LOAD TEST CHART
Temperature C21 and
above16 to
2010 to
154 to 9–1 to 3–7 to
–2–12 to
–8–18 to
–13
Minimum voltage V9.69.59.49.39.18.98.78.5

CHASSIS ELECTRICAL – Ignition SwitchCHASSIS ELECTRICAL – Ignition Switch54-6
IGNITION SWITCH <EXCEPT EVOLUTION-VI WITH
IMMOBILIZER SYSTEM>
SPECIAL TOOL
ToolNumberNameUse
MB991502MUT-II sub
assemblyETACS-ECU input signal checking
TROUBLESHOOTING
DIAGNOSIS FUNCTION
INPUT SIGNAL INSPECTION POINTS <VEHICLES
WITH ETACS-ECU>
Refer to Group 00 – How to Use Troubleshooting / Inspection
Service Points.
INSPECTION CHART FOR TROUBLE SYMPTOMS
Trouble symptomsInspection
procedureReference page
Communication with
MUTIIis impossible
Key hole illumination lamp remains illuminated.154-7
MUT-II is impossible.
Even if driver’s side door is opened, key hole
illumination lamp does not illuminate.254-7
While key hole illumination lamp is illuminated,
ignition key is turned to the ON position but key hole
illumination lamp does not switch off. (However, it
switch off after 10 seconds.)354-8
Key reminder warning
buzzer systemWhile the key reminder warning buzzer is sounding,
the ignition key is turned to the ON position but the
sound dose not stop. (However, it stops when the
driver’s side door is closed.)354-8
The key reminder warning buzzer dose not stop
sounding even if the key is removed. (However, it
stops when the driver’s side door is closed.)454-9
The key reminder warning buzzer does not sound
ever if the driver’s side door is opened while the key
is still inserted. (However, the ignition key should be
in the OFF position.)554-10
NOTE
If every input signal can not be checked with the MUT-II, a diagnosis circuit system failure is probably
the cause. <Vehicles with ETACS-ECU>