brake MITSUBISHI LANCER EVOLUTION VI 1999 Owner's Manual

BASIC BRAKE SYSTEM – Brake Pedal35A-4
BRAKE PEDAL <L.H. DRIVE VEHICLES>
REMOVAL AND INSTALLATION
Pre-removal Operation

Instrument Under Cover Removal

Steering Column Assembly Removal
(Refer to GROUP 37A – Steering Wheel and Shaft.)

Accelerator Pedal RemovalPost-installation Operation

Accelerator Pedal Installation

Steering Column Assembly Installation
(Refer to GROUP 37A – Steering Wheel and Shaft.)

Instrument Under Cover Installation

Brake Pedal Adjustment (Refer to P.35A-2.)
29 Nm
12 Nm
14 Nm
1 2
3
4 5
67 813 Nm
11
910
8 9
Removal steps
1. Stop lamp switch connector
2. Stop lamp switch
3. Snap pin
4. Clevis pin
5. Brake pedal shaft bolt
6. Brake pedal7. Brake pedal pad
8. Brake pedal return spring
9. Bushing
10. Pipe
11. Pedal support member

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-6
INSTALLATION SERVICE POINTS
AVACUUM HOSE CONNECTION
Insert securely and completely until the vacuum hose at the
engine side contacts the edge of the hexagonal part of the
fitting, and then secure by using the hose clip.
BCLEARANCE ADJUSTMENT BETWEEN BRAKE
BOOSTER PUSH ROD AND PRIMARY PISTON
Calculate clearance A from the B, C and D measurements.
A = B – C – D
Standard value: 0.65–0.85 mm
If the clearance is not within the standard value range, adjust
by changing the push rod length by turning the screw of
the push rod.
Measuring
distance BMeasuring
distance D
Block
gaugeB
AC
D

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

BASIC BRAKE SYSTEM – Master Cylinder and Brake Booster35A-8
DISASSEMBLY SERVICE POINTS
APISTON STOPPER BOLT DISASSEMBLY
Remove the piston stopper bolt, while depressing the piston.
BPISTON STOPPER RING DISASSEMBLY
Remove the piston stopper ring, while depressing the piston.
INSPECTION

Check the inner surface of master cylinder body for rust
or pitting.

Check the primary and secondary pistons for rust, scoring,
wear, damage or wear.

Check the diaphragm for cracks and wear.

BASIC BRAKE SYSTEM – Disc Brake35A-9
DISC BRAKE
<EVOLUTION-VI WITH BREMBO BRAKING SYSTEM>
DISASSEMBLY AND REASSEMBLY
Front Brake
Seal & boot kit Shim set
Clip set Pad set
Brake caliper kit
1 23 4 5
6
7
8 9
10
1
23
43 41
2 56
55
7 9
9 7 9 7
8 6 6
10
21
Disassembly steps
1. Pin
2. Cross spring
3. Pad & wear indicator assembly
4. Pad assembly
5. Shim6. Air bleeder screw
7. Piston boot
8. Piston
9. Piston seal
10. Caliper body

BASIC BRAKE SYSTEM – Disc Brake35A-10
Rear Brake
Seal & boot kit Shim set
Clip set Pad setBrake caliper kit
1
23 4 5
6
7 8
910
2
6
16
7
8 910 2
1
7
9 7 9
3
4
3 4
2
1
65
5
5
Disassembly steps
1. Pin
2. Cross spring
3. Pad & wear indicator assembly
4. Pad assembly
5. Shim6. Air bleeder screw
7. Piston boot
8. Piston
9. Piston seal
10. Caliper body

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

C-2
STOP LAMP 51. . . . . . . . . . . . . . . . . . . . . . . . . .
BACK-UP LAMP 52. . . . . . . . . . . . . . . . . . . . . . .
METER AND GAUGE 54. . . . . . . . . . . . . . . . . .
FUEL WARNING LAMP 56. . . . . . . . . . . . . . . .
BRAKE WARNING LAMP 56. . . . . . . . . . . . . .
OIL PRESSURE WARNING LAMP 57. . . . . .
SEAT BELT WARNING LAMP 57. . . . . . . . . .
CENTRAL DOOR LOCKING SYSTEM 58. .
Without Keyless Entry System 58. . . . . . . . . . . .
With Keyless Entry System 60. . . . . . . . . . . . . . .
HEATER AND AIR CONDITIONER 64. . . . . .
FULL-AUTO AIR CONDITIONER 70. . . . . . . .
WINDSHIELD WIPER AND WASHER 78. .
With Intermittent Wiper 78. . . . . . . . . . . . . . . . . . .
REAR WIPER AND WASHER 79. . . . . . . . . .
DEFOGGER AND DOOR MIRROR
HEATER 80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Without Full-Auto Air Conditioner 80. . . . . . . . . .
With Full-Auto Air Conditioner 82. . . . . . . . . . . . .
RADIO 84. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Radio Spare Circuit 84. . . . . . . . . . . . . . . . . . . . . .
4 Speaker, 6 Speaker 86. . . . . . . . . . . . . . . . . . . .
KEY REMINDER BUZZER 89. . . . . . . . . . . . . .
ANTI-SKID BRAKING SYSTEM (ABS) 90. .
SUPPLEMENTAL RESTRAINT SYSTEM
(SRS) 96. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ACTIVE YAW CONTROL SYSTEM (AYC) 98
INTERCOOLER AND RADIATOR WATER
SPRAY SYSTEM 104. . . . . . . . . . . . . . . . . . . . .

– Engine Compartment WIRING HARNESS
CONFIGURATION DIAGRAMS
Connector
symbol
–01
thru
–50
A
Earth cable
C-4
WIRING HARNESS CONFIGURATION DIAGRAMS
ENGINE COMPARTMENT
A-01 (2-B) Brake fluid level switch
A-03 (1-B) Noise condenser
A-04 (1) Alternator
A-05 (4-GR) Alternator
A-09 (1-B) Starter
A-10 (1) Starter
A-12 (2-B) Fuel pressure solenoid valve
A-16 (4-B) Throttle position sensor
A-18 (6-B) Idle speed control servo
A-19 (3-B) Vehicle speed sensorA-20 (4-B) Windshield wiper motor
A-21 (8-B) Hydraulic unit <vehicles with ABS>
A-22 (2-B) Hydraulic unit <vehicles with ABS>
A-23 (2-B) Waste gate solenoid valve
A-25 (7-B) Air flow sensor
A-26 (2-B) Front speed sensor (LH) <vehicles with
ABS>
A-28 (10-B) Control harness and front harness
combination