power steering MITSUBISHI LANCER EVOLUTION IV 1998 Workshop Manual

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General . . . . . . . . . . . . . . . . . . . . . . . .
Engine . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Lubrication . . . . . . . . . . . . .
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Cooling . . . . . . . . . . . . . . . . .
Intake and Exhaust . . . . . . . . . . . .
Engine Electrical . . . . . . . . . . . . . . .
Engine and Emission Control . . . .
Clutch . . . . . . . . . . . . . . . . . . . . . . . . .
Manual Transmission . . . . . . . . . . .
Front Axle . . . . . . . . . . . . . . . . . . . . . .
Rear Axle . . . . . . . . . . . . . . . . . . . . . .
Power Plant Mount . . . . . . . . . . . . . .
Front Suspension . . . . . . . . . . . . . . .
Rear Suspension . . . . . . . . . . . . . . .
Service Brakes . . . . . . . . . . . . . . . . .
Parking Brakes . . . . . . . . . . . . . . . . .
Steering . . . . . . . . . . . . . . . . . . . . . . . .
Body . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exterior . . . . . . . . . . . . . . . . . . . . . . . .
Chassis Electrical . . . . . . . . . . . . . .
Electrical Wiring . . . . . . . . . . . . . . . .
WORKSHOP MANUAL
FOREWORD
This Workshop Manual contains procedures for
service mechanics, including removal, disassembly,
inspection, adjustment, reassembly and
installation. Figures taken from registration
documents are given in metric units only. All other
figures are given in SI units with metric units in
brackets. Use the following manuals in combination
with this manual as required.
TECHNICAL INFORMATION MANUAL
N9806CNCP9
All information, illustrations and product
descriptions contained in this manual are current
as at the time of publication. We, however, reserve
the right to make changes at any time without prior
notice or obligation.
July 1998
EVOLUTION-IV
EVOLUTION-V

ENGINE – Engine Assembly11- 33
25
27 2819
20 21
22 23
24
26
Unit: Nm {kgf
m}
98 {10.0}*
29
57 {5.8}
22
12 {1.2} 39 {4.0}
9 {0.9}
19. Solenoid valve connector
20. Vacuum tank/solenoid valve/vacuum hose assembly
21. Oil pressure switch connector
22. Alternator connector  Drive belt tension inspection
(Refer to P.11-4.)
 A 23. Drive belt
 B 24. A/C compressor
 C 25. Power steering oil pump
 Transmission assembly 26. A/C relay box
27. A/C receiver bracket mounting bolt
28. Oil pressure hose mounting bolt
 C B 29. Engine mount bracket
 E A 30. Engine assembly
Caution
Mounting locations marked by * should be
provisionally tightened, and then fully tightened after
placing the vehicle horizontally and loading the full
weight of the engine on the vehicle body.

ENGINE – Engine Assembly 11- 34
REMOVAL SERVICE POINTS
 A DRIVE BELT REMOVAL
(1) Align the hole in the auto tensioner bracket with that in the arm and insert a screwdriver into the holes.
(2) Remove the drive belt.
 B POWER STEERING OIL PUMP REMOVAL
Remove the power steering oil pump from the bracket with
the hose attached.
NOTE
Place the removed power steering oil pump in a place where
it will not be a hindrance when removing and installing the
engine assembly, and tie it with a cord.
 C A/C COMPRESSOR REMOVAL
Disconnect the A/C compressor connector and remove the
compressor from the compressor bracket with the hose still
attached.
NOTE
Place the removed A/C compressor where it will not be a
hindrance when removing and installing the engine assembly,
and tie it with a cord.
 D ENGINE MOUNT BRACKET REMOVAL
(1) Support the engine with a garage jack.
(2) Remove the special tools which was attached when the transmission assembly was removed.
(3) Hold the engine assembly with a chain block or similar tool.
(4) Place a garage jack against the engine oil pan with a piece of wood in between, jack up the engine so that
the weight of the engine is no longer being applied to
the engine mount bracket, and then remove the engine
mount bracket.
Phillips
screwdriver
Hole in arm
Auto tensioner
Hole in bracket
MZ203826 or MZ203827
MB991453

MPI – General Information13-2
MULTIPOINT INJECTION (MPI)
GENERAL INFORMATION
OMPI System Diagram

1 Injector

2 ISC servo

3 Fuel pressure control valve

4 Waste gate solenoid valve

5 Secondary air control solenoid valve
Control relay
Fuel pump relay
A/C relay
Ignition coil
Exhaust temperature warning lamp
Engine warning lamp
Diagnosis output
Alternator G terminal
Fan motor relay
Tachometer
Fuel pump relay No.2 1 Oxygen sensor
2 Air flow sensor
3 Intake air temperature sensor
4 Throttle position sensor
5 Idle switch
6 Camshaft position sensor
7 Crank angle sensor
8 Barometric pressure sensor
9 High temperature sensor
10 Engine coolant temperature sensor
11 Detonation sensor
Power supply voltage
Ignition switch-IG
Ignition switch-ST
Vehicle speed sensor
A/C switch
Power steering fluid pressure switch
Alternator FR signalEngine ECU
1 Oxygen sensor
2 Air flow sensor3
Intake air tem-
perature sensor
4,
5
6 Camshaft position
sensor
7 Crank angle sensor 8 Barometric
pressure sensor
9 High temperature
sensor 10 Coolant temperature sensor
11 Detonation sensor
1 Injector
2 ISC servo

3 Fuel pressure
control valve

4 Waste gate
solenoid valve
5 Secondary air
control solenoid
valveCanister
Check valveFrom
fuel
tank
Throttle position
sensor (with a
built-in
idle
switch)
Secondary
air valve
AirTo fuel
tankFuel
pressure
regulatorFrom
fuel
pump
Waste gate
actuator
Catalytic converter
Given above is the MPI system diagram for EVOLUTION-IV. The MPI system for EVOLUTION-V is different
from this in the following point;
Oxygen sensor with a heater is adopted.
The diagnosis connector power supply circuit is different.
The high temperature sensor is no longer used.

MPI – Troubleshooting13-19
Item
No.Inspection
itemInspection contentsNormal condition
21Engine
coolant
temperature
Ignition switch: ON or with engine
runningWhen engine coolant temper-
ature is –20C–20C
temperature
sensorWhen engine coolant temper-
ature is 0C0C
When engine coolant temper-
ature is 20C20C
When engine coolant temper-
ature is 40C40C
When engine coolant temper-
ature is 80C80C
22Crank angle
sensorEngine: Idling
Idle position switch: ONWhen engine coolant temper-
ature is –20C1,300 – 1,500 rpm
When engine coolant temper-
ature is 0C1,300 – 1,500 rpm
When engine coolant temper-
ature is 20C1,300 – 1,500 rpm
When engine coolant temper-
ature is 40C1,150 – 1,350 rpm
When engine coolant temper-
ature is 80C750 – 950 rpm
25Barometric
pressure
Ignition switch: ONAt altitude of 0 m101 kPa
pressure
sensor
At altitude of 600 m95 kPa
At altitude of 1,200 m88 kPa
At altitude of 1,800 m81 kPa
26Idle position
switchIgnition switch: ON
(Check by operating accelerator
dl tdl )
Throttle valve: Set to idle
positionON
pedal repeatedly.)Throttle valve: Slightly openOFF*1
27Power
steering fluidEngine: IdlingSteering wheel stationaryOFF
tg
pressure
switchSteering wheel turningON
28A/C switchEngine: Idling
(when A/C switch is ON A/C
A/C switch: OFFOFF
(when A/C switch is ON, A/C
compressor should be operating.)A/C switch: ONON

MPI – Troubleshooting13-23
Terminal
No.Normal condition Check condition (Engine condition) Check item
21Fan motor relay (LOW)Fan not operating (coolant temperature: 90C or
below)Battery voltage
Fan at low speed (coolant temperature: 90 – 100C)0 – 3 V
22A/C relayEngine: Idling
A/C switch: OFF to ON (Compressor is being
driven.)Battery voltage, or 6 V
or more instanta-
neously to 0 – 3 V
33Alternator G terminalEngine: Warm, idle (radiator fan: OFF)
Headlamp: OFF to ON
Brake lamp: OFF to ON
Rear defogger switch: OFF to ONVoltage rises by 0.2 –
3.5 V.
36Engine warning lampIgnition switch: OFF → ON0 – 3 V → Battery
voltage (After several
seconds have
elapsed)
37Power steering fluid
pressure switchEngine: Idling after
warming upWhen steering wheel is
stationaryBattery voltage
When steering wheel is
turned0 – 3 V
38Control relayIgnition switch: OFFBattery voltage
Ignition switch: ON0 – 3 V
39Fuel pump relay No.2While engine is idling, suddenly depress the
accelerator pedal.Momentarily rises
slightly from 0 to 3 V.
40Exhaust temperature
warning lampIgnition switch: OFF to ON0 – 3 V to battery
voltage (After several
seconds have
elapsed)
41Alternator FR terminalEngine: Warm, idle (radiator fan: OFF)
Headlamp: OFF to ON
Brake lamp: OFF to ON
Rear defogger switch: OFF to ONVoltage drops by 0.2 –
3.5 V.
45A/C switchEngine: Idle speedTurn the A/C switch OFF0 – 3 V
Turn the A/C switch ON
(A/C compressor is oper-
ating)Battery voltage
60Oxygen sensor heater
(Evolution V only)
Engine: Idling0 – 3 V
(Evolution-V only)
Engine speed: 5,000 r/minBattery voltage
71Ignition switch-STEngine: Cranking8 V or more

MPI – On-vehicle Service13-31
5. MPI SYSTEM COMPONENTS LAYOUT
NameSymbolNameSymbol
A/C switchQExhaust temperature warning lampS
A/C relayHFuel pressure control valveA
Air flow sensor (with a built-in intake air temperaturesensor and barometric pressure sensor)FIgnition coil and power transistor unitLsensor and barometric pressure sensor)InjectorB
Camshaft position sensorMISC servoD
Control relay and fuel pump relayPOxygen sensorK
Coolant temperature sensorEPower steering fluid pressure switchI
Crank angle sensorJSecondary air control solenoid valveN
Detonation sensorCThrottle position sensor (with a built-in idle switch)D
Diagnosis connectorR
Engine ECUOVehicle speed sensorT
Engine warning lampSWastegate solenoid valveG

ENGINE ELECTRICAL – Charging System16-2
CHARGING SYSTEM
ALTERNATOR
REMOVAL AND INSTALLATION
Pre-removal Operation
(1) Under Cover Removal
(2) Engine Mount Removal
(3) Strut Tower Bar RemovalPost-installation Operation
(1) Strut Tower Bar Installation
(2) Engine Mount Installation
(3) Under Cover Installation
(4) Drive Belt Tension Adjustment
(Refer to GROUP 11 – On-vehicle Service.)
Unit: Nm {kgf
m}
44 {4.5}
7 3
2
6
15 4
24 {2.4} 22 {2.2} 9 {0.9}12 – 15
{1.2 – 1.5}10 – 13
{1.0 – 1.3}
12 {1.2}
Removal steps

A1. Drive belt (Power steering, A/C)

B2. Delivery pipe, injector and pressure
regulator assembly
3. Oil level gauge guide4. Pressure hose connection

C5. Alternator
6. Water pump pulley
7. Alternator brace

ENGINE ELECTRICAL – Charging System16-3
REMOVAL SERVICE POINTS

APOWER STEERING, A/C COMPRESSOR, AND
ALTERNATOR DRIVE BELT REMOVAL
(1) Align the hole in the auto tensioner bracket with that
in the arm and insert a screwdriver into the holes.
(2) Remove the drive belt.

BDELIVERY PIPE, INJECTOR, AND PRESSURE
REGULATOR ASSEMBLY REMOVAL
After the mounting points have been loosened, slightly move
the corresponding part to allow for a space for removal of
the alternator.

CALTERNATOR REMOVAL
Push the engine all the way up with a garage jack and remove
the alternator upward the engine compartment.
Phillips
screwdriver
Hole in arm
Auto tensioner
Hole in bracket

ENGINE ELECTRICAL – Ignition System16-5
CAMSHAFT POSITION SENSOR AND CRANK ANGLE SENSOR
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
Timing Belt Removal and Installation
(Refer to GROUP 11.)
Unit: Nm {kgf
m}
49 {5.0}
5
9 {0.9}9 {0.9}
9 {0.9} 39 {4.0} 3 {0.3}
2
3
41
Removal steps
1. Camshaft position sensor
2. Center cover

A3. Power steering oil pump4. Power steering oil pump bracket
5. Crank angle sensor
REMOVAL SERVICE POINT

APOWER STEERING OIL PUMP REMOVAL
Remove the power steering oil pump with hose from the power
steering oil pump bracket.
NOTE
String up the oil pump which has been removed onto a location
that does not hamper removal and installation of the power
steering oil pump bracket.