MITSUBISHI LANCER EVOLUTION IV 1998 Workshop Manual

CHASSIS ELECTRICAL – Combination MetersCHASSIS ELECTRICAL – Combination Meters54-27
ON-VEHICLE SERVICE
SPEEDOMETER CHECK
1. Adjust the pressure of the tyres to the specified level.
2. Set the vehicle onto a speedometer tester and use wheel
chocks to hold the rear wheels.
3. Pull the parking brake lever firmly.
4. To prevent the front wheel from moving from side to side,
attach tension bars to the tie-down hook, and secure
both ends to anchor plates.
5. To prevent the vehicles from starting, attach a chain or
wire to the rear towing hook, and secure the other end
of the chain or wire firmly to an unmovable body.
6. Check if the speedometer indication range is within the
standard values and if the pointer fluctuation is within
the limits.
Caution
Do not operate the clutch suddenly. Do not
increase/decrease speed rapidly while testing.
Standard values:
Vehicle speed km/hSpeedometer indication
allowable errors km/h
4037 – 45
8075 – 88
120113 – 132
160150 – 176
Limit: Pointer fluctuation
(at vehicle speeds of higher than 35 km/h) ±3 km/h
TACHOMETER CHECK
1. Insert a paper clip in the engine speed detection connector
from the harness side, and attach the engine
speedometer.
2. Compare the readings of the engine speedometer and
the tachometer at every engine speed, and check if the
variations are within the standard values.
Standard values:
700 r/min : ±100 r/min
3,000
*1 r/min : ±150 r/min
3,000*2 r/min : +225 to –100 r/min
5,000*1 r/min : ±250 r/min
5,000*2 r/min : +325 to –125 r/min
6,000*1 r/min : ±300 r/min
7,000*2 r/min : +400 to –100 r/min
8,000*3 r/min : +400 to 0 r/min
NOTE
*1: Tachometer measurable up to 8,000 r/min
*2: Tachometer measurable up to 9,000 r/min and one measurable up to 10,000 r/min
*3: Tachometer measureble up to 10,000 r/min
Wheel chocks
Tension bar
Tie-down hook
Front
Anchor plate
Engine speed detection
connector

CHASSIS ELECTRICAL – Combination Meters54-28
FUEL GAUGE SIMPLE CHECK
Remove the fuel gauge unit connector.
Use the special tool to connect a test
lamp (12 V – 3.4 W) to the harness
connector. (Refer to Fig.1)
When the ignition switch is turned to
ON, the test lamp illuminates.OKThe needle of the fuel gauge moves.OKReplace the fuel gauge unit.
NG
Replace the fuel gauge.NG
Repair the harness.
FUEL GAUGE UNIT CHECK
Remove the fuel gauge unit from the fuel tank.
FUEL GAUGE UNIT RESISTANCE
1. Check that resistance value between the fuel gauge unit
terminal and earth terminal is at standard value when
fuel gauge unit float is at point F and point E.
Standard value:
Float positionMainSub
Point F1.8 ±1.2 Ω1.2 ±0.8 Ω
Point E65.2 ±4 Ω44.8 ±8 Ω
2. Check that resistance value changes smoothly when float
moves slowly between point F and point E.
Test lamp
(12V–3.4W)
Earth
Fuel gaugeMB991219
Fig: 1EarthFuel gauge
Fuel gauge unit
Earth
Earth Fuel gauge unit
Main fuel gauge unitSub fuel gauge unit

CHASSIS ELECTRICAL – Combination Meters54-29
FUEL GAUGE UNIT FLOAT HEIGHT
Move float and measure the height at point F (A) and at
point E (B) with float arm touching stopper.
Standard value:
Float positionMainSub
Point F16.417.5
Point E122.6134.6
FUEL LEVEL SENSOR (THERMISTOR)
1. Connect a test lamp (12V – 3.4W) to the fuel gauge
unit connector terminal and apply the battery voltage.
2. Condition is good if lamp goes off when the thermistor
is immersed in water and goes on when it is taken out
of water.
ENGINE COOLANT TEMPERATURE GAUGE SIMPLE CHECK
Remove the engine coolant tempara-
ture gauge unit connector.
Connect a test lamp (12 V – 3.4 W)
between the harness side connector
and the earth.
When the ignition switch is turned to
ON, the test lamp illuminates.OKThe needle of the engine coolant tem-
perature gauge moves.NGReplace the engine coolant tempera-
ture gauge.
OK
Replace the engine coolant tempera-
ture gauge unit.
NG
Repair the harness.
Point F
Point E
A
B Stopper
Stopper
Test lamp
(12V – 3.4 W)
Earth
Thermistor
Thermistor
Lamp goes on
Lamp goes off

CHASSIS ELECTRICAL – Combination Meters54-30
ENGINE COOLANT TEMPERATURE GAUGE UNIT
CHECK
1. Bleed the engine coolant.
2. Remove the engine coolant temperature gauge unit.
3. Immerse the unit in 70C water to measure the resistance.
Standard value: 104 ±13.5 Ω
4. After checking, apply the specified adhesive around the
thread of engine coolant temperature gauge unit. Then,
tighten the unit to the specified torque.
Specified sealant:
3M Adhesive Nut Locking No. 4171 or equivalent
5. Add engine coolant.
COMBINATION METERS
REMOVAL AND INSTALLATION
2 1
3
Vehicle speed sensor removal
steps

Battery and battery tray

Air cleaner assembly
1. Vehicle speed sensorCombination meter removal steps
2. Meter bezel
3. Combination meter
ThermometerCircuit tester
10 – 12 Nm

CHASSIS ELECTRICAL – Combination MetersCHASSIS ELECTRICAL – Combination MetersCHASSIS ELECTRICAL – Combination Meters54-31
INSPECTION
FUEL GAUGE RESISTANCE CHECK
1. Remove the power supply tightening screw.
2. Use a circuit tester to measure the resistance value
between the terminals.
Standard value: Unit: Ω
Measurement terminalResistance value
Power supply – Earth192±19.2
Power supply – Fuel gauge89±8.9
Fuel gauge – Earth103±10.3
Caution
When inserting the testing probe into the power supply
terminal, be careful not to touch the printed board.
ENGINE COOLANT TEMPERATURE GAUGE
RESISTANCE CHECK
1. Remove the power supply tightening screw.
2. Use a circuit tester to measure the resistance value
between the terminals.
Standard value: Unit: Ω
Measurement terminalResistance value
Power supply – Earth187±18.7
Power supply – Engine coolant
temperature gauge90±4.5
Engine coolant temperature
gauge – Earth247±24.7
Caution
When inserting the testing probe into the power supply
terminal, be careful not to touch the printed board.
VEHICLE SPEED SENSOR CHECK
1. Connect a 3 – 10 kΩ resistance as shown in the illustration.
2. Turn the shaft of the vehicle speed sensor one turn and
check that voltage changes are caused when measured
between terminals 2 and 3 using a circuit tester. (1 turn
= 4 pulses)
Fuel gauge
Power
supply
Earth
Earth
Power
supply
Engine
coolant
temperature
gauge
TurnShaft
Circuit testerResistance
3 – 10 kΩ Vehicle
speed
sensor Terminal No.
16R0273
Battery

CHASSIS ELECTRICAL – Headlamp54-32
HEADLAMP
SERVICE SPECIFICATIONS
ItemsStandard valueLimit
Headlamp
aiming
High
beam
Vertical direction25’ (22 mm) below horizontal line–
aiming
[Parenthe-
sized are
allowable
beam
Horizontal
directionLeft head-
lampParallel to direction of vehicle travel–
allowable
beam axis
deviations 3
m ahead of
Right head-
lamp15’ (13 mm) leftward from vertical line (V)–
m ahead of
headlamp.]Low
beam
Vertical direction25’ (22 mm) below horizontal line–p]beam
Horizontal directionPosition where 15* rising section intersects
vertical line (V)–
Headlamp intensity cd (Center of high-beam high intensity
zone)–15,000 or
more per
light
Cautions in Handling Headlamp Assembly
Each headlamp assembly has a plastic outer lens on. Observe the do’s and don’ts below when
handling the headlamps.

Do not leave the headlamps lit for longer than 3 minutes with a protective cover on.

Do not mask the outer lens surface by taping or in any other way.

Do not scrub the outer lens surface with a pointed tool.

Use the designated wax remover for cleaning the outer lens surface. Rinse it thoroughly.

Use the designated genuine bulbs.
SPECIAL TOOLS
ToolNumberNameUse
MB991502MUT-II sub as-
semblyETACS-ECU input signal checking

CHASSIS ELECTRICAL – Headlamp54-33
TROUBLESHOOTING
DIAGNOSIS FUNCTION
INPUT SIGNAL INSPECTION POINTS <VEHICLES WITH ETACS-ECU>
Refer to Group 00 – How to Use Troubleshooting / Inspection Service Points.
The lighting monitor buzzer does not sound even when
the ignition key is removed with the tail lamps or
headlamps ON and the driver’s side door open. [However,
the key reminder warning buzzer sounds when inserting
the key into the ignition key cylinder.
Probable cause
The cause is probably a malfunction of the lighting switch input circuit system or
a malfunction of ETACS-ECU or buzzer ECU. When the key reminder warning buzzer
is sounding, the lighting monitor warning buzzer does not sound even if the tail lamps
or headlamps are lit.
Malfunction of harness or connector

Malfunction of ETACS-ECU

Malfunction of buzzer ECU
<Vehicles with ETACS-ECU>
MUT-II Pulse check
OK:MUT-II buzzer sounds once
when the lighting switch is
turned from OFF to TAIL or
HEAD.NG
Check the following connectors.
B-79Repair
OK
Check trouble symptom.NGOK
Replace the ETACS-ECU.
<Vehicles with buzzer ECU>
NG
Check the harness in the junction block.NG
Replace the ETACS-ECU or the buzzer
ECU.OKRepair NG

CHASSIS ELECTRICAL – Headlamp54-34
ON-VEHICLE SERVICE
HEADLAMP AIMING
Bring the vehicle in the following conditions before aiming
the headlamp.

Check the tires for inflation pressure. Pump them up if
necessary to the labeled pressure level.

Set the vehicle unladen on a level floor.

Place one person (approximately 55 kg) on the driver’s
seat.
1. Position the tester so that its converging lens faces the
high-beam lamp ( marked) center to center at a distance
of 3 m from each other.
2. Aim the headlamps to appropriate standard values using
the aiming adjustment screw.
Face the face 3 m apart from each other
Lamp center
16M0001
Horizontal adjustment
Vertical
adjust-
ment

CHASSIS ELECTRICAL – Headlamp54-35
Standard values:
Vertical direction25’ (22 mm) below hori-
zontal line (H)
Horizontal
directionLeft headlampParallel to direction of
vehicle travel
Right head-
lamp15’ (13 mm) leftward
from vertical line (V)
Caution:
(1) Perform aiming adjustments, one light at a time,
with the other headlamp disconnected so as not
to be lit unless circumstances compel otherwise.
When reconnecting the headlamps, be careful not
to upset their aim. Do not leave the headlamps
on for any longer than 3 minutes if their outer
lenses are covered with a surface covering
impervious to light.
(2) Do not mask the outer lenses by taping or in any
other way.
(3) Aiming adjustment must be completed with the
aiming adjustment screws turned in the tightening
direction.
INTENSITY MEASUREMENT
1. Position the tester so that its light sensor faces each
headlamp center to center at the appropriate distance
shown.
2. Maintain an engine speed of 2,000 r/minto keep the battery
in the charged condition.
3. Check that the high-beam headlamp intensity at the center
of the high intensity zone satisfies the limit value.
Limit: 15,000 cd or more per headlamp
Caution
(1) Perform intensity measurement, one headlamp at
a time, with the low-beam lamp and the other
headlamp disconnected from the battery unless
circumstances compel otherwise. Do not leave
the headlamps on for any longer than 3 minutes
if their outer lenses are covered with a surface
covering impervious to light.
(2) Do not mask the outer lens surfaces by taping
or in any other way.
HEADLAMP BULB REPLACEMENT
1. Disconnect the connector.
2. Remove the socket cover.
3. Unhook the spring which secures the bulb, and then
remove the bulb.
Caution
Do not touch the surface of the bulb with hands or
dirty gloves. If the surface does become dirty, clean
it with alcohol or thinner, and let it dry thoroughly
before installing.
<Left headlamp>
Lamp center
Vertical direction
Vertical direction High
intensity
zone
center
(optical
axis)
High
intensity
zone
center
(optical
axis)High intensity zone
High intensity zoneLamp center <Right headlamp>V
H
V
H
Screen type tester: 3 m Converging
lens type tester: 1 m
Spring

CHASSIS ELECTRICAL – HeadlampCHASSIS ELECTRICAL – Headlamp54-36
4. After the bulb is replaced, reinstall the socket cover with
the TOP mark facing upward.
NOTE
To prevent the clouding of lens and ingress of water into
the lamp unit, install the socket cover correctly.
POSITION LAMP BULB REPLACEMENT
Remove the position lamp by turning it together with the lamp
socket, then replace its bulb.
HEADLAMP AND FRONT TURN-SIGNAL LAMP
REMOVAL AND INSTALLATION
CAUTION: SRS
Before removal of air bag module and clock spring, refer to GROUP 52B – SRS Service Precautions and Air
Bag Module and Clock Spring.
5 Nm
2 3
4
5 Nm
1
1. Column switchRemoval steps
A2. Front turn-signal lamp
3. Radiator grille
A4. Headlamp
Position lamp connector