brake MITSUBISHI LANCER EVOLUTION VI 1999 User Guide

CLUTCH –
General / Service Specifications /
Lubricants / On-vehicle Service21A-2
GENERAL
OUTLINE OF CHANGE

The service procedures for left-hand drive vehicles have been established as described below.
SERVICE SPECIFICATIONS <L.H. DRIVE VEHICLES>
ItemsStandard value
Clutch pedal height mm163.5–166.5
Clutch pedal clevis pin play mm1–3
Clutch pedal free play mm6–13
Distance between the clutch pedal and the toeboard when
the clutch is disengaged mm85 or more
LUBRICANTS <L.H. DRIVE VEHICLES>
ItemsSpecified lubricantsQuantity
Clutch fluidBrake fluid DOT 3 or DOT 4As required
Push rod assemblyRubber grease
Boot
Release cylinder push rodMITSUBISHI genuine grease
Part No. 0101011
ON-VEHICLE SERVICE
<L.H. DRIVE VEHICLES>
CLUTCH PEDAL INSPECTION AND
ADJUSTMENT
1. Turn up the carpet, etc. under the clutch pedal.
2. Measure the clutch pedal height.
Standard value (A): 163.5 – 166.5 mm
3. If the height of the clutch pedal is outside the standard
value, loosen the locking nut and adjust the pedal height
to the standard value using the adjusting bolt or push
rod.
Clutch pedal height
A
Setting nutAdjusting bolt
Locking
nut
13 Nm

CLUTCH – On-vehicle Service21A-3
4. Measure the clutch pedal play.
Standard value (B): 1 – 3 mm
5. If the clutch pedal play is not within the standard value,
loosen the setting nut and move the push rod to adjust.
Caution
Do not push in the master cylinder push rod at this
time.
6. After completing the adjustments, confirm that the clutch
pedal free play (measured at the face of the pedal pad)
and the distance between the clutch pedal (the face of
the pedal pad) and the toeboard when the clutch is
disengaged are within the standard value ranges.
Standard value (C): 6–13 mm
Standard value (D): 85 mm or more
7. If the clutch pedal free play and the distance between
the clutch pedal and the toeboard when the clutch is
disengaged do not agree with the standard values, it
is probably the result of either air in the hydraulic system
or a faulty master cylinder or clutch. Bleed the air, or
disassembly and inspect the master cylinder or clutch.
8. Turn back the carpet, etc.
BLEEDING
Specified fluid: Brake fluid DOT 3 or DOT 4
Caution
Use the specified brake fluid. Avoid using a mixture of
the specified fluid and other fluid.
Clutch pedal clevis pin play
B
Clutch pedal free play
Distance between the clutch pedal and the
toeboard when the clutch is disengagedC
D

CLUTCH – Clutch Control21A-6
DISASSEMBLY AND REASSEMBLY
CLUTCH MASTER CYLINDER
13 Nm
6 7
3
1
2
Piston repair kitClutch fluid:
Brake fluid DOT3 or DOT4
Grease: Rubber grease
2 5
4
413
44 8
Disassembly steps
1. Piston stopper ring
A2. Push rod assembly
3. Boot
4. Piston assembly
5. Reservoir cap
6. Spring pin
7. Reservoir tank
8. Clutch master cylinder bodyCaution
Do not disassemble piston assembly.
INSTALLATION SERVICE POINT
APUSH ROD ASSEMBLY INSTALLATION
Set the length of the push rod assembly to the shown
dimension to make the adjustment of the clutch pedal easier.
122.5 mm

FRONT AXLE – General / Axle Hub and Knuckle <EVOLUTION-VI>26-1
GROUP 26
FRONT AXLE
GENERAL
OUTLINE OF CHANGE

The installation method of the ball joint between the knuckle and the lower arm has been changed,
and accordingly the removal and installation procedures of the axle hub and the knuckle have been
revised. <EVOLUTION-VI>
AXLE HUB AND KNUCKLE <EVOLUTION-VI>
REMOVAL AND INSTALLATION
Caution
(1) For vehicles with AYC, be careful when handling the pole piece at the tip of the speed sensor so as
not to damage it by striking against other parts.
(2) For vehicles with AYC, be careful not to damage the rotors installed to B.J. outer race during removal
and installation of the drive shaft.
Post-installation Operation

Check the Dust Cover for Cracks or Damage by
Pushing it with Finger.
1
23
4 5 6 7
8
12 1415
1388 Nm 108 – 127 Nm
90 – 110 Nm
15 – 33 Nm177 – 275 Nm 25 Nm
25 Nm
9 Nm
103 Nm
74 –87
Nm
11 910
1610
11
Ball joint kit
Removal steps
1. Front speed sensor<Vehicles with
AYC>
A2. Caliper assembly
3. Brake disc
4. Split pin
BA5. Drive shaft nut
6. Front hub assembly
7. Dust shield
8. Connection for lower arm ball joint
9. Connection bolt for lower arm joint10. Lower arm ball joint
11. Dust cover
12. Split pin
C13. Connection for tie rod end
D14. Front drive shaft
15. Front strut mounting bolt
16. Knuckle
NOTE
Follow the conventional procedures for removal
and installation service points.

REAR AXLE – Troubleshooting <AYC>27-13
Code No. 52: Longitudinal acceleration sensor systemProbable cause
This code is output when the longitudinal acceleration exceeds a predetermined value
while the vehicle is running with both ABS and brakes being inactive.
Defective longitudinal acceleration sensor

Defective harness or connector

Defective AYC-ECU
NG
Check and repair the harness between
longitudinal acceleration sensor and
AYC-ECU.
OK
Check the trouble symptom.
NG
Replace AYC-ECU.
OK
Check the trouble symptom.
OK
Check the following connector:
B-95NG
Repair
OK
Measure at B-95 AYC-ECU connector.

Connector connected

Ignition switch: ON

Voltage across 3 and body ground
OK:2.4 V to 2.6 V (where vehicle
in horizontal position)NGCheck the following connectors:
B-95, B-52, D-20
Check the acceleration sensor.
(Refer to P.27-42.)NG
Replace
NG
Repair
Code No. 61: Stop lamp switch systemProbable cause
This code is output under either of the following conditions:

Stop lamp switch remains ON for 15 min. or more.

There is an open-circuit in the harness between AYC-ECU and stop lamp switch.
Defective stop lamp switch

Defective harness or connector

Defective AYC-ECU
NG
Replace AYC-ECU.
OK
Check the trouble symptom.
OK
Check the following connector:
B-95NG
Repair
OK
Measure at the B-95 AYC-ECU con-
nector.

Disconnect the connector and
measure at the harness side.

Voltage across 11 and body ground

Brake pedal not depressed.
OK:1 V or lessNGCheck and repair the harness between
AYC-ECU and stop lamp switch.
Check the stop lamp switch.NG
Replace

REAR AXLE – On-vehicle Service <Vehicles with AYC>27-31
ON-VEHICLE SERVICE
<VEHICLES WITH AYC>
REAR AXLE TOTAL BACKLASH CHECK
If the drive system roars or the vehicle vibrates, use the
following procedure to measure total backlash in the rear
axle. Based on the measurement taken, determine whether
the differential carrier assembly needs to be removed or not.
1. Place the shift lever in the neutral position and operate
the parking brake.
2. Turn the propeller shaft fully clockwise and make an
alignment mark on the companion flange dust cover and
gear carrier.
3. Turn the propeller shaft fully counterclockwise and
measure the deviation between the alignment marks.
Limit: 5 mm
4. If the backlash exceeds the limit, replace the differential
carrier assembly.
GEAR OIL LEVEL CHECK
DIFFERENTIAL
1. Remove the filler plug.
2. Check that the gear oil level is within the specified range
from the bottom end of the filler plug hole.
Standard value (A): 6 mm
3. If the gear oil level exceeds the standard value, add the
specified gear oil up to the bottom end of the filler plug
hole.
Specified gear oil:
Hypoid gear oil API classification GL-5 or higher
SAE viscosity Number 90, 80W.
NOTE
10C or more: #90, less than 10C: #80
4. Fit the filler plug and tighten it to the specified torque.
Alignment marks
Filler plug
49 Nm
Gear oil
Upper
limit
Lower
limit

REAR AXLE – On-vehicle Service <Vehicles with AYC>27-37
WHEEL 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 wheel speed sensor as necessary.

Excessive clearance between the pole piece and rotor
of the wheel speed sensor

Defective wheel speed sensor
Waveform Check Using Oscilloscope
Check the harness and connector of the wheel speed sensor
for connection. Then, use an oscilloscope to check for output
voltage waveform of each 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

35A-1
BASIC BRAKE
SYSTEM
CONTENTS
GENERAL 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outline of Change 2. . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE 2. . . . . . . . . . . . . . . . . .
Brake Pedal Check and Adjustment 2. . . . . . . .
BRAKE PEDAL 4. . . . . . . . . . . . . . . . . . . . . . . . . . MASTER CYLINDER AND BRAKE
BOOSTER 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Master Cylinder 7. . . . . . . . . . . . . . . . . . . . . . . . . . .
DISC BRAKE 9. . . . . . . . . . . . . . . . . . . . . . . . . . . .

BASIC BRAKE SYSTEM – General / On-vehicle Service35A-2
GENERAL
OUTLINE OF CHANGE

The service procedures for left-hand drive vehicles have been established as described below.

The service procedures for the front and rear disc brakes have been changed since they had been
replaced by a different type. <EVOLUTION-VI with BREMBO braking system>
ON-VEHICLE SERVICE
BRAKE PEDAL CHECK AND ADJUSTMENT
<L.H. DRIVE VEHICLES>
1. Turn up the carpet, etc under the brake pedal.
2. Measure the brake pedal height as illustrated. If the brake
pedal height is not within the standard value, follow the
procedure below.
Standard value: 163.5 –166.5 mm
(1) Disconnect the stop lamp switch connector.
(2) Adjust the brake pedal height by turning the operating
rod with pliers (with the operating rod lock nut
loosened), until the correct brake pedal height is
obtained.
(3) Secure by tightening the lock nut of the operating
rod.
(4) Push the stop lamp switch in the direction of the
pedal stroke until it stops. (The switch will slide if
it is pushed firmly.)
(5) Lift up the pedal until the operating rod is fully
extended, and then slide the stop lamp switch back
to the required position. Adjust the position of the
switch by turning it until the distance shown in the
illustration is correct.
(6) Connect the connector of the stop lamp switch.
(7) Check that the stop lamp is not illuminated with the
brake pedal unpressed.
3. With the engine stopped, depress the brake pedal two
or three times. After eliminating the vacuum in the power
brake booster, press the pedal down by hand, and confirm
that the amount of movement before resistance is met
(the free play) is within the standard value range.
Standard value: 3 – 8 mmOperating
rod
Operating
rod lock nutStop lamp
switch
Pedal down
Pedal up
Lock nut
Lock nut
Outer case
0.5 – 1.0 mm

BASIC BRAKE SYSTEM – On-vehicle Service35A-3
If the free play exceeds the standard value, it is probably
due to excessive play between the retaining ring bolt
and brake pedal arm.
Check for excessive clearance and replace faulty parts
as required.
4. Start the engine, depress the brake pedal with
approximately 490 N of force, and measure the clearance
between the brake pedal and the floorboard.
Standard value: 80 mm or more
If the clearance is outside the standard value, check for
air trapped in the brake line, clearance between the lining
and the drum and dragging in the parking brake.
Adjust and replace defective parts as required.
5. Turn back the carpet, etc.