sensor MITSUBISHI LANCER EVOLUTION IV 1998 Repair Manual

REAR AXLE – On-vehicle Service <Vehicles with AYC>27-31
7. SPEED SENSOR OUTPUT VOLTAGE
MEASUREMENT <VEHICLES WITHOUT
ABS>
(1) Lift up the vehicle and release the parking brake.
(2) Disconnect the AYC-ECU harness connector and take
measurements on the harness side connector.
Caution
Insert the probe from the harness side with the double
lock of the connector unlocked. Inserting it to the
terminal side could result in poor contact.
(3) Turn the wheel to be tested at about 1/2 to one
revolution/sec. and check for the output voltage using
a circuit tester (AC mV range) or oscilloscope.
Terminal nos.
Front LHFront RHRear LHRear RH
7698
20192221
Output voltage:
When circuit tester is used: 70 mV or more
When oscilloscope is used: 200 mVp-p or more
(4) If the output voltage is lower than the above value, it
is probably attributable to the following faults. Check or
replace the speed sensor as necessary.
Excessive clearance between the pole piece and rotor
of the speed sensor
Defective speed sensor
Waveform Check Using Oscilloscope
Check the harness and connector of the speed sensor for
connection. Then, use an oscilloscope to check for output
voltage waveform of each speed sensor as follows.
Start the engine and monitor the sensor by turning the wheel;
for a driving wheel, let it turn by shifting into the 1st gear
and for a driven wheel turn it manually at a constant speed.
NOTE
(1) Waveform may be observed by actually running the
vehicle.
(2) The output voltage is low when the wheel speed remains
low and builds up as the wheel speed increases.
AYC-ECU connector harness side
When turned manually
At idle (5 to 6 km/h)
1st gear

REAR AXLE – On-vehicle Service <Vehicles with AYC>27-32
Waveform Observation Points
SymptomProbable causeAction
Waveform amplitude is too small, or no
waveform.Defective speed sensorReplace sensor.
Waveform amplitude varies greatly. (No
problem ifthe smallest amplitude is 100
Excessive axle hub lateral and radial runoutReplace hub.
problem if the smallest amplitude is 100
mV or more)Poor AYC-ECU groundingRepair.
Noise on waveform or disturbed
waveform
Open-circuited sensorReplace sensor.
waveform
Open-circuited harnessRepair harness.
Improperly mounted speed sensorCorrect sensor installation.
Missing or collapsed rotor toothReplace rotor.
Caution
Since the speed sensor cable follows the movement of the front or rear suspension, it may be
open-circuited only when the vehicle is run on rough roads and not on ordinary road. The speed
sensor output voltage waveform should therefore be checked also by rocking the sensor harness
so that driving on rough roads may be simulated.
8. ACTION WHEN BATTERY RUNS OUT
When the engine is started using a booster cable where the
battery has completely run down and you attempt to start
the vehicle without waiting for the battery to recover a certain
charge, the engine can misfire and you just cannot start to
move it. In such cases, charge the battery sufficiently; or,
remove the AYC fusible link from the engine compartment
relay box to make AYC inactive before attempting to start
the vehicle. When the fusible link is removed, the AYC warning
lamp lights up. After the battery has been recharged, fit the
fusible link back again and start the engine to ensure that
the AYC warning lamp is off.AYC fusible link

REAR AXLE – Knuckle27-35
KNUCKLE
REMOVAL AND INSTALLATION
Pre-removal Operation
Rear Hub Assembly and Backing Plate Removal
(Refer to P.27-33.)Post-installation Operation
(1) Check Each Ball Joint Dust Cover for Cracks or
Damage by Pushing It with Finger.
(2) Rear Hub Assembly and Backing Plate Installation
(Refer to P.27-33.)
1
23 45
6
Unit: Nm {kgf
m}
25 {2.6}
74 – 87
{7.5 – 8.9}
74 – 87
{7.5 – 8.9}*74 – 87
{7.5 – 8.9}
88 {9.0}*
Removal steps
1. Rear speed sensor connection
<Vehicles with AYC>
A2. Trailing arm connection
3. Lower arm connection
A4. Toe control arm connection
A5. Upper arm connection
6. KnuckleCaution
*: Indicates parts which should be temporarily
tightened, and then fully tightened with the
vehicle on the ground in the unladen condition.
REMOVAL SERVICE POINT
ATRAILING ARM / TOE CONTROL ARM / UPPER
ARM DISCONNECTION
Caution
(1) Use the special tool to loosen the nut only; do not
remove it from the ball joint.
(2) Tie the special tool with a cord not to let it fall off.
MB990635,
MB991113 or
MB991406
NutCord
Ball joint

REAR AXLE – Drive Shaft27-36
DRIVE SHAFT
REMOVAL AND INSTALLATION
Pre-removal Operation
(1) Gear Oil Draining (Refer to P.27-28.)
(2) Center Exhaust Pipe Removal
(Refer to GROUP 15.)Post-installation Operation
(1) Checking Each Ball Joint Dust Cover for Cracks
and Damages by Pressing Dust Cover with Finger
(2) Center Exhaust Pipe Installation
(Refer to GROUP 15.)
(3) Gear Oil Filling (Refer to P.27-28.)
(4) Parking Brake Lever Stroke Check and Adjustment
(Refer to GROUP 36 – On-vehicle Service.)
(5) Wheel Alignment Check and Adjustment
(Refer to GROUP 34 – On-vehicle Service.)
1
2 3
4
56 7
89 10 11
Unit: Nm {kgf
m}
25 {2.6}
74 – 87 {7.5 – 8.9}
74 – 87
{7.5 – 8.9}*88 {9.0}* 49 – 59 {5.0 – 6.0}
196 – 255 {20.0 – 26.0}
Removal steps
1. Caliper assembly
(Refer to P.27-33.)
2. Brake disc
3. Shoe & lining assembly (Refer to
GROUP 36 – Parking Brake.)
4. Clip
5. Parking brake cable connection
AB6. Drive shaft nut
7. Rear speed sensor coupling
<vehicles with AYC>
8. Trailing arm coupling
9. Lower arm coupling
10. Toe control arm coupling
BA11. Drive shaftCaution
(1) With the part marked with *, first temporarily
tighten it, then ground the vehicle and tighten
it to specification in unloaded condition.
(2) When removing the drive shaft from, and
reinstalling it to, a vehicle with AYC, use care
not to damage the rotor mounted on the BJ outer
race.

REAR AXLE – Sensor Relay <Vehicles with AYC>27-52
SENSOR RELAY <VEHICLES WITH AYC>
REMOVAL AND INSTALLATION
12
3
4
Steer sensor removal steps
Steering wheel and column cover
(Refer to GROUP 37 – Steering Wheel
and Shaft.)
A1. Steer sensorAcceleration sensor and AYC relay
removal
2. Longitudinal acceleration sensor
3. Lateral acceleration sensor
4. AYC relay
NOTE
For the wheel speed sensor, refer to GROUP 35B.
REMOVAL SERVICE POINT
ASTEER SENSOR REMOVAL
Remove the steer sensor from the column switch.
Caution
(1) A photocoupler is used as the steer sensor. Use care
not to allow dust or grease to be on the sensor.
(2) Do not bend or dirty with grease the slit plate on
the column switch side.Slit plate
Steer sensor

REAR AXLE – Sensor Relay <Vehicles with AYC> / AYC-ECU27-53
INSPECTION
1. LONGITUDINAL AND LATERAL ACCELERATION
SENSOR CHECK
Refer to GROUP 35B – Acceleration Sensor.
2. AYC RELAY CONTINUITY CHECK
Battery voltageTerminal No.
1345
When not energized
When energized
AYC-ECU
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
Front Floor Console Removal and Installation
Unit: Nm {kgf
m}
5 {0.5}
AYC-ECU
5 {0.5}

FRONT SUSPENSION – Strut Assembly33A-4
STRUT ASSEMBLY
REMOVAL AND INSTALLATION
Post-installation Operation
Front Wheel Alignment Adjustment
(Refer to P.33A-3.)
12 3
4
5
6 7
Unit: Nm {kgfm}
44 {4.5}
108 – 127
{11.0 – 13.0}
Removal steps
1. Brake hose clamp
2. Front speed sensor bracket
<Vehicles with ABS>
3. Flange nut4. Strut tower bar
5. Plain washer
A6. Bolts
7. Strut assembly
REMOVAL SERVICE POINT
ABOLTS REMOVAL
(1) Suspend the lower arm from the vehicle with wire.
(2) Remove the strut and knuckle connection.

REAR SUSPENSION – Rear Suspension Assembly34-4
REAR SUSPENSION ASSEMBLY
REMOVAL AND INSTALLATION
Pre-removal Operation
(1) Center Exhaust Pipe Removal
(Refer to GROUP 15.)
(2) Trunk Room Side Trim Removal <GSR>
(3) AYC Fluid Draining
(Refer to GROUP 27 – On-vehicle Service.)Post-installation Operation
(1) AYC Fluid Refilling and Bleeding
(Refer to GROUP 27 – On-vehicle Service.)
(2) Center Exhaust Pipe Installation
(Refer to GROUP 15.)
(3) AYC Operation Check
(4) Parking Brake Cable Stroke Check
(Refer to GROUP 36 – On-vehicle Service.)
(5) Wheel Alignment Check and Adjustment
(Refer to P.34-3.)
1
34
5
6
7 9 10
1112
1314
15 1617
Unit: Nm {kgf
m}
44 {4.5}
108 – 127 {11.0 – 13.0}
54 {5.5}
88 {9.0}
93 {9.5}*88 {9.0}
158 2
15
29 – 34
{3.0 – 3.5}
25 {2.6}34 {3.5}25 {2.5}
69
{7.0} Toe control bar
EVOLUTION-V RS
137 – 156 {14.0 – 16.0}*59 – 68 {6.0 – 7.0}*
Removal steps
1. Fuel filler cap
2. Bolt
3. Filler neck protector
4. Cap
5. Shock absorber mounting nut
A6. Brake caliper assembly
7. Rear speed sensor <vehicles with
AYC>
8. Brake disc
9. Parking brake cable end (Refer to
GROUP 36.)
10. AYC fluid line connection <vehicles
with AYC>BB11. Propeller shaft connection
12. Upper arm mounting bolt
13. Trailing arm mounting bolt
14. Toe control arm mounting bolt
CA15. Crossmember mounting bolt
16. Differential support assembly
mounting bolt
17. Rear suspension assembly
Caution
The parts marked with * should be first temporarily
tightened, then torqued to specification with the
vehicle on the ground in unloaded condition.

BASIC BRAKE SYSTEM – Master Cylinder and Brake Booster35A-5
MASTER CYLINDER AND BRAKE BOOSTER
<L.H. DRIVE VEHICLES>
REMOVAL AND INSTALLATION
Pre-removal Operation

Brake Fluid Draining

Air Intake Hose RemovalPost-installation Operation

Brake Fluid Supplying

Brake Line Bleeding

Brake Pedal Adjustment (Refer to P.35A-2.)

Air Intake Hose Installation
15–18 Nm 15 Nm
Sealant: 3M ATD Part No.
8661 or equivalent
6
7 3
14
2
8
5
4
14 Nm
5 9
1
10 Nm
Removal steps
1. Brake pipe connection
2. Brake fluid level sensor connector
3. Master cylinder assembly
B
Clearance adjustment between brake
booster push rod and primary piston
A4. Vacuum hose
(With built-in check valve)5. Fitting
6. Snap pin
7. Clevis pin assembly
8. Brake booster
9. Sealer

BASIC BRAKE SYSTEM – Master Cylinder and Brake Booster35A-7
MASTER CYLINDER
DISASSEMBLY AND REASSEMBLY
Master cylinder kit
11
14
1312
141315 1
4 2
3
6
8
9 5
7
10
12
15
13
14Brake fluid: DOT3 or DOT4
11
Disassembly steps
1. Reservoir cap assembly
2. Reservoir cap
3. Diaphragm
4. Filter
5. Brake fluid level sensor
6. Float
7. Reservoir stopper bolt8. Reservoir tank
9. Reservoir seal
A10. Piston stopper bolt
11. Gasket
B12. Piston stopper ring
13. Primary piston assembly
14. Secondary piston assembly
15. Master cylinder body