check oil MITSUBISHI LANCER EVOLUTION VI 1999 Repair Manual

REAR AXLE – Troubleshooting <AYC>27-27
ACTUATOR TEST REFERENCE TABLE
The following items can be tested by driving the corresponding actuator forcibly using the MUT-II.
Item No.Check itemChecking requirementsNormal value
10Air bleedingSupply current to proportioning
valve in accordance with steering
angle to operate directional valve.No air is to be bled from the
bleeder plug on the torque transfer
differential.
11Oil level checkLet the directional valve operate to
left and right 20 times.To be checked by oil level in
reservoir tank.
12Electric pump operationLet the electric pump operate for 5
seconds.Operation sounds of the electric
pump are to be heard.
13Clutch operation (left)Let the directional valve operate to
supply the maximum pressure to the
left clutch.The operation conditions are to be
checked by the speed difference
between left and right rear wheels
with the wheels raised. For details,
refer to AYC Operation Check on
P.27-34.
14Clutch operation (right)Let the directional valve operate to
supply the maximum pressure to the
right clutch.The operation conditions are to be
checked by the speed difference
between left and right rear wheels
with the wheels raised. For details,
refer to AYC Operation Check on
P.27-34.
15Control OFFTurn off the electric pump relay to
deactivate AYC control.During the test run, some
differences are to be recognized in
running behaviors between when
the system is ON and when it is
OFF.
NOTE
(1) The actuator test is feasible only when the following requirements are all satisfied.

All of inputs from four wheel speed sensors show 20 km/h or lower.

No system failure is registered.

The steering angle is within ±30 deg. from the neutral position.
(2) The actuator test comes to an end when either of the following conditions is met since the forced
actuation is canceled.

Either of inputs from four wheel sensors shows higher than 20 km/h (with exception of Item
No.15 “Control OFF”).

Some trouble with the system is registered.

Forced activation time expires.

MUT-II is removed.

The clear key of MUT-II is operated.

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>27-32
TORQUE TRANSFER MECHANISM
1. Remove the filler plug.
2. Check that the gear oil level is up to the bottom end
of the filler plug hole.
3. If the gear oil level is lower than the bottom end of the
filler plug hole, add the specified gear oil up to the bottom
end of the filler plug hole.
Specified gear oil:
MITSUBISHI GENUINE DIA QUEEN SUPER AYC
FLUID
4. Fit the filler plug and tighten it to the specified torque.
GEAR OIL CHANGE
DIFFERENTIAL
1. Remove the drain plug to discharge the gear oil.
2. Fit the drain plug and tighten it to the specified torque.
Tightening torque: 49 Nm
3. Remove the filler plug and 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.
Quantity used: 0.41 ± 0.02

NOTE
10C or more: #90, less than 10C: #80
4. Fit the filler plug and tighten it to the specified torque.
Filler plug
49 Nm
Gear oil
Filler plug
49 Nm
Gear oil
Drain plug

REAR AXLE – On-vehicle Service <Vehicles with AYC>27-33
TORQUE TRANSFER MECHANISM
1. Remove the drain plug to discharge the gear oil.
2. Fit the drain plug and tighten it to the specified torque.
3. Remove the filler plug.
4. Pour the specified gear oil up to the bottom end of the
filler plug hole using an oil syringe (recommended tool)
through the gap between the body and the differential
support arm.
Specified gear oil:
MITSUBISHI GENUINE DIA QUEEN SUPER AYC
FLUID
Quantity used: 0.70
0
0.05

5. Fit the filler plug and tighten it to the specified torque.
FLUID LEVEL CHECK
1. Remove the maintenance lid located in the luggage
compartment.
2.<When MUT-II is not used>
If the vehicle has been run, leave it for 5 min. or more
in an ordinary temperature (10C to 30C) to allow the
accumulator internal pressure to drop.
NOTE
If the ambient temperature is less than 10C or less,
allow more time to leave the vehicle to stand idle.
<When MUT-II is used>
Connect the MUT-II to the 16-pin diagnosis connector.
Turn on the ignition switch. Operate the MUT-II (Item
No.11) to activate the hydraulic unit forcibly for removing
the pressure from inside the accumulator.
Caution
Before connecting or disconnecting the MUT-II,
always turn off the ignition switch.
NOTE
(1) The forced activation (oil level check mode) will be
automatically canceled as soon as the directional
valve in the hydraulic unit is activated to the left and
right 20 times.
It can also be canceled forcibly by operating the clear
key on the MUT-II.
(2) While this function is being disabled by the fail-safe
function, the forced activation of the hydraulic unit
can not be executed.
3. Check that the fluid level in the oil reservoir is in the
range between MAX and MIN.
4. If the fluid level is lower than MIN, add the specified
fluid.
Specified fluid: Dia Queen ATF SP II or equivalent
5. Reinstall the maintenance lid.
Gear oil
Drain plug
49 Nm
Oil syringe
(Recommended tool)
Filler plug
49 Nm

REAR AXLE – On-vehicle Service <Vehicles with AYC>REAR AXLE – On-vehicle Service <Vehicles with AYC>27-34
BLEEDING
1. Lift up the vehicle.
2. Connect the MUT-II to the 16-pin diagnosis connector.
Caution
Before connecting or disconnecting the MUT-II,
always turn off the ignition switch.
3. Turn on the ignition switch.
4. Operate the MUT-II (Item No.10) to activate the hydraulic
unit forcibly.
NOTE
(1) The forced activation (air bleeding mode) will be
automatically canceled after 5 minutes operation. It
can also be canceled forcibly by operating the clear
key on the MUT-II.
(2) While this function is being disabled by the fail-safe
function, the forced activation of the hydraulic unit
can not be executed.
5. Remove the cap of the left bleeder screw on the torque
transfer differential and connect a vinyl hose.
6. Gradually turn the steering wheel clockwise from the
straight-ahead position. At this time, loosen the left bleeder
screw and check that fluid is discharged with air.
7. After air has been completely discharged, tighten the
bleeder screw.
Caution
While the system is being bled of air, add fluid as
necessary to ensure that it is left in the oil reservoir
during the entire procedure.
8. Repeat steps (6) and (7) two to three times until no air
bubbles are recognized in the fluid that comes out. Then,
tighten the bleeder screw to the specified torque.
Tightening torque: 9 Nm
9. Perform steps (5) through (8) for the right bleeder screw.
Note, however, that the steering wheel should be turned
counterclockwise.
10. After the system has been completely bled of air, check
for the fluid level. (Refer to P.27-33.)
Caution
If the system is not completely bled of air, the hydraulic
unit could generate noise, degrading pump durability.
AYC OPERATION CHECK
1. Lift up the vehicle.
2. Connect the MUT-II to the 16-pin diagnosis connector.
Caution
Before connecting or disconnecting the MUT-II, always
turn off the ignition switch.
3. Start the engine.
4. Operate the MUT-II with the transmission in 2nd or a
higher gear and check to ensure that the vehicle speed
is higher than 10 km/h using the Data List (Item 10).
Bleeder
screws Vinyl hose

REAR AXLE – On-vehicle Service <Vehicles with AYC>27-36
(2) While this function is being disabled by the fail-safe
function, the forced activation of the hydraulic unit
can not be executed.
6. Check to ensure that the hydraulic pressure generated
by the hydraulic unit conforms to the standard value.
Standard value: 1.0 – 1.6 MPa
NOTE
During checking the hydraulic pressure, occasionally
replenish the oil reservoir with fluid so that it does not
become empty.
7. Check the hydraulic pressure of the clutch right side by
repeating the steps (4) through (6). At this time, however,
the special tool must be connected to the R port and
the blind plug or the R port of the removed hydraulic
unit hose assembly must be attached to the L port. Further,
the MUT-II must be operated in the forced activation mode
Item No. 14 (clutch right side operation check mode).
8. If the measured value exceeds the standard value, replace
the hydraulic unit.
9. Connect the hydraulic unit hose assembly to the hydraulic
unit and to the torque transfer differential and tighten
the flare nuts to the specified torque.
Specified torque: 34 Nm
10. Pour the specified fluid in the oil reservoir up to the MAX
mark. Then, bleed the system.
Specified fluid: Dia Queen ATF SP II or equivalent
Fluid amount used: Approx. 1

DIFFERENTIAL CARRIER OIL SEAL
REPLACEMENT
DIFFERENTIAL
1. Remove the drive shaft.
2. Remove the oil seal from the differential carrier.
3. Using the special tool, drive a new oil seal all the way
into position.
4. Coat the oil seal lips and the drive shaft surface in contact
with the oil seal with multi-purpose grease.
5. Replace the drive shaft circlip with a new one and mount
the drive shaft to the differential carrier.
6. Check for correct wheel alignment.
TORQUE TRANSFER MECHANISM
1. Remove the drive shaft.
2. Remove the oil seal from the differential carrier.
3. Using the special tool, drive a new oil seal all the way
into position.
4. Coat the oil seal lips and the drive shaft surface in contact
with the oil seal with the specified grease.
Specified grease: Vaseline
5. Replace the drive shaft circlip with a new one and mount
the drive shaft to the differential carrier.
6. Check for correct wheel alignment.
MB990938
MB991115
MD998829
MD998812
MD998813

STEERING – Power Steering Gear Box37A-17
INSPECTION
RACK CHECK

Check the rack tooth surfaces for damage or wear.

Check the oil seal contact surfaces for uneven wear.

Check the rack for bends.
PINION AND VALVE ASSEMBLY CHECK

Check the pinion gear tooth surfaces for damage or wear.

Check for worn or defective seal ring.
BEARING CHECK

Check for roughness or abnormal noise during bearing
operation.

Check the bearing for play.

Check the needle roller bearing for roller slip-off.
OTHER CHECK

Check the cylinder inner surface of the rack housing for
damage.

Check the boots for damage, cracking or deterioration.

Check the rack support for uneven wear or dents.

Check the rack bushing for uneven wear or damage.

SRS – SRS-ECU / Air Bag Modules and Clock Spring52B-25
INSTALLATION SERVICE POINTS
ASRS-ECU INSTALLATION
Caution
The SRS may not activate if SRS-ECU is not installed
properly, which could result in serious injury or death
to the vehicle’s driver or front passenger.
BPOST-INSTALLATION INSPECTION
1. Reconnect the negative battery terminal.
2. Turn the ignition key to the “ON” position.
3. Does the “SRS” warning lamp illuminate for about 7
seconds, and then remain extinguished for at least 5
seconds after turning OFF?
4. If yes, SRS system is functioning properly.
If no, consult page 52B-6.
INSPECTION

Check the SRS-ECU and brackets for dents, cracks or
deformation.

Check connector for damage, and terminals for
deformation.
Caution
If a dent, crack, deformation or rust is discovered,
replace the SRS-ECU with a new one.
NOTE
For checking of the SRS-ECU other than described above,
refer to the section concerning troubleshooting. (Refer
to P.52B-6.)
AIR BAG MODULES AND CLOCK SPRING
Caution
1. Disconnect the battery (–) terminal and wait
for 60 seconds or more before starting work.
Furthermore, the disconnected battery
terminal should be covered with tape to
insulate it. (Refer to P.52B-3.)
2. Never attempt to disassemble or repair the
air bag modules or clock spring.
If faulty, replace it.
3. Do not drop the air bag modules or clock
spring or allow contact with water, grease
or oil.
Replace it if a dent, crack, deformation or
rust is detected.
4. The air bag modules should be stored on
a flat surface and placed so that the pad
surface is facing upward.
Do not place anything on top of it.5. Do not expose the air bag modules to
temperatures over 93C.
6. Both driver’s side and front passenger’s
side air bag modules should be replaced
with new ones once the respective air bags
were deployed. The clock springs should
also be checked and replaced with new ones
if considered abnormal.
7. Wear gloves and safety glasses when
handling air bags that have already
deployed.
8. An undeployed air bag module should only
be disposed of in accordance with the
procedures (Refer to P.52B-32.)
SRS warning lamp

SRS – Air Bag Module Disposal ProceduresSRS – Air Bag Module Disposal Procedures52B-40
(5) Place three old tyres, without wheels, on top of the
tyre secured to the air bag module, and secure all
tyres with ropes (4 locations).
NOTE
The front passenger’s side air bag is larger in capacity
than the driver’s side air bag when deployed. For
this reason, it is necessary to tie up all tyres together
with rope.
(6) At a location as far away from the air bag module
as possible, and from a shielded position, disconnect
the two connected wires from each other, and connect
them to the two terminals of the battery (which has
been removed from the vehicle) to deploy the air
bag.
Caution
1) Before deployment, check carefully to be sure
that no one is nearby.
2) The inflator will be quite hot immediately
following the deployment, so wait at least 30
minutes to allow it to cool before attempting
to handle it. Although not poisonous, do not
inhale gas from air bag deployment. See
Deployed Air Bag Module Disposal
Procedures (P.52B-40) for post-deployment
handling instructions.
3) If the air bag fails to deploy when the
procedures above are followed, do not go near
the module. Contact your local distributor.
(7) After deployment, dispose of the air bag module
according to the Deployed Air Bag Module Disposal
Procedures.
DEPLOYED AIR BAG MODULE DISPOSAL
PROCEDURES
After deployment, the air bag module should be disposed
of in the same manner as any other scrap parts, adhering
to local laws and/or legislation that may be in force except
that the following points should be carefully noted during
disposal.
1. The inflator will be quite hot immediately following
deployment, so wait at least 30 minutes to allow it cool
before attempting to handle it.
2. Do not put water or oil on the air bag after deployment.
Tyres without wheels
Deployment wire
harness
Deployment wire
harness

CHASSIS ELECTRICAL – Combination Meters54-25
Inspection Procedure 2
Tachometer does not work.
Probable cause
The ignition signal may not be input from the engine, or there may be a malfunction
in the power supply or earth circuit.
Malfunction of tachometer

Malfunction of harness or connector
Disconnect the combination meter con-
nector B-08 and measure at the harness
sides.
1. Measure the voltage between
terminal No.33 and earth.
OK: 5 V
2. Continuity between the terminal
No.34 and earth
OK: Continuity
3. Voltage between the terminal No.42
and earth
OK: System voltage1. NGCheck the following connectors.
B-08, A-36, B-61, B-64, A-41, A-109NG
Repair
OK
Check trouble symptom.NGCheck the harness between the engine-
ECU and combination meter, and repair
if necessary.
2. NGCheck the following connectors.
B-08, B-50, B-64, A-41NG
Repair
OK
Check trouble symptom.NGCheck the harness between the com-
bination meter and the body earth, and
repair if necessary. OK
Replace the tachometer.
3. NG
Check the following connectors.
B-08, B-75, B-76NG
Repair
OK
Check trouble symptom.NGCheck the harness between the power
supply and combination meter, and
repair if necessary.
YESRefer to Group 13 – Troubleshooting,
No. 44 Ignition coils and power
transistors.
OK
MUT-II Self-Diag code
Is the diagnosis code 44 relating to MPI
system output?