Diff MITSUBISHI LANCER EVOLUTION VI 1999 Workshop Manual

GENERAL – How to Use Troubleshooting/Inspection Service Points00-6
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE
POINTS
Troubleshooting of electronic control systems for which the MUT-II can be used follows the basic outline
described below. Furthermore, even in systems for which the MUT-II cannot be used, part of these systems
still follow this outline.
TROUBLESHOOTING CONTENTS
1. STANDARD FLOW OF DIAGNOSIS TROUBLESHOOTING
The troubleshooting sections follow the basic diagnosis flow which is given below. If the diagnosis
flow is different from that given below, or if additional explanation is required, the details of such
differences or additions will also be listed.
Diagnosis method
Gathering information
from the customer.
Check trouble symptom.
Reoccurs Does not reoccur.
Read the diagnosis code
No diagnosis code
or communication
with MUT-II not
possible
Refer to the INSPECTION
CHART FOR TROUBLE
SYMPTOMS (Refer to
applicable group.)Diagnosis code
displayed.
Read the diagnosis code
Diagnosis code
displayed.No diagnosis
code
After taking note of the
malfunction code, erase
the diagnosis code
memory
Recheck trouble symptom.
Diagnosis code
displayed.
Read the diagnosis codes.
No diagnosis
code
Refer to the INSPECTION CHART FOR DIAGNOSIS
CODES (Refer to applicable group.)INTERMITTENT MALFUNCTIONS (Refer to P.00-13.)
2. SYSTEM OPERATION AND SYMPTOM VERIFICATION TESTS
If verification of the trouble symptoms is difficult, procedures for checking operation and verifying
trouble symptoms are shown.
3. DIAGNOSIS FUNCTION
Details which are different from those in the “Diagnosis Function” section on the next page are listed.

GENERAL – How to Use Troubleshooting/Inspection Service Points00-13
INSPECTION SERVICE POINTS FOR A BLOWN
FUSE
Remove the fuse and measure the resistance between the
load side of the fuse and the earth. Set the switches of all
circuits which are connected to this fuse to a condition of
continuity. If the resistance is almost 0 Ω at this time, there
is a short somewhere between these switches and the load.
If the resistance is not 0 Ω, there is no short at the present
time, but a momentary short has probably caused the fuse
to blow.
The main causes of a short circuit are the following.
Harness being clamped by the vehicle body
Damage to the outer casing of the harness due to wear
or heat
Water getting into the connector or circuitry
Human error (mistakenly shorting a circuit, etc.)
POINTS TO NOTE FOR INTERMITTENT
MALFUNCTIONS
Intermittent malfunctions often occur under certain conditions,
and if these conditions can be ascertained, determining the
cause becomes simple. In order to ascertain the conditions
under which an intermittent malfunction occurs, first ask the
customer for details about the driving conditions, weather
conditions, frequency of occurrence and trouble symptoms,
and then try to recreate the trouble symptoms. Next, ascertain
whether the reason why the trouble symptom occurred under
these conditions is due to vibration, temperature or some
other factor. If vibration is thought to be the cause, carry
out the following checks with the connectors and components
to confirm whether the trouble symptom occurs.
The objects to be checked are connectors and components
which are indicated by inspection procedures or given as
probable causes (which generates diagnosis codes or trouble
symptoms.)
Gently shake the connector up, down and to the left and
right.
Gently shake the wiring harness up, down and to the
left and right.
Gently rock each sensor and relay, etc. by hand.
Gently shake the wiring harness at suspensions and other
moving parts.
NOTE
If determining the cause is difficult, the flight recorder function
of the MUT-II can also be used.
Battery
Fuse
Load
switch
LoadConnector
inspection0 Ω

ENGINE – Specifications11-9
NEW TIGHTENING METHOD – BY USE OF BOLTS TO BE TIGHTENED IN
PLASTIC AREA
A new type of bolts, to be tightened in plastic area, is currently used some parts of the engine. The
tightening method for the bolts is different from the conventional one. Be sure to observe the method
described in the text when tightening the bolts.
Service limits are provided for the bolts. Make sure that the service limits described in the text are strictly
observed.

Areas where the bolts are in use:
(1) Cylinder head bolts
(2) Main bearing cap bolts
(3) Connecting rod cap bolts

Tightening method
After tightening the bolts to the specified torque, tighten them another 90° or 180° (twice 90°). The
tightening method varies on different areas. Observe the tightening method described in the text.
SEALANTS
ItemSpecified sealantQuantity
Engine support bracket bolt3MTM AAD Part No. 8672 or equivalentAs required
Semi-circular packing3MTM AAD Part No. 8672 or equivalentAs required
Rocker cover3MTM AAD Part No. 8672 or equivalentAs required
Oil return pipe gasket3MTM AAD Part No. 8731 or equivalentAs required
Thermostat housingMitsubishi Genuine Part No. MD970389 or
equivalentAs required
Water outlet fittingMitsubishi Genuine Part No. MD970389 or
equivalentAs required
Engine coolant temperature gauge unit3MTM AAD Part No. 8672 or equivalentAs required
Engine coolant temperature sensor3MTM AAD Part No. 8731 or equivalentAs required
Cam position sensor supportMitsubishi Genuine Part No. MD970389 or
equivalentAs required
Oil pressure switch3MTM AAD Part No. 8672 or equivalentAs required
Oil panMitsubishi Genuine Part No. MD970389 or
equivalentAs required
Oil seal caseMitsubishi Genuine Part No. MD970389 or
equivalentAs required

ENGINE – Specifications11-10
FORM-IN-PLACE GASKET
The engine has several areas where the form-in-place gasket (FIPG) is in use. To ensure that the gasket
fully serves its purpose, it is necessary to observe some precautions when applying the gasket. Bead
size, continuity and location are of paramount importance. Too thin a bead could cause leaks. Too thick
a bead, on the other hand, could be squeezed out of location, causing blocking or narrowing of the
fluid feed line. To eliminate the possibility of leaks from a joint, therefore, it is absolutely necessary to
apply the gasket evenly without a break, while observing the correct bead size.
The FIPG used in the engine is a room temperature vulcanisation (RTV) type and is supplied in a 100-gram
tube (Part No. MD970389). Since the RTV hardens as it reacts with the moisture in the atmospheric
air, it is normally used in the metallic flange areas. The FIPG, Part No. MD970389, can be used for
sealing both engine oil and coolant, while Part No. MD997110 can only be used for engine oil sealing.
Disassembly
The parts assembled with the FIPG can be easily disassembled without use of a special method. In
some cases, however, the sealant between the joined surfaces may have to be broken by lightly striking
with a mallet or similar tool. A flat and thin gasket scraper may be lightly hammered in between the
joined surfaces. In this case, however, care must be taken to prevent damage to the joined surfaces.
For removal of the oil pan, the special tool “Oil Pan Remover” (MD998727) is available. Be sure to use
the special tool to remove the oil pan.
Surface Preparation
Thoroughly remove all substances deposited on the gasket application surfaces, using a gasket scraper
or wire brush. Check to ensure that the surfaces to which the FIPG is to be applied is flat. Make sure
that there are no oils, greases and foreign substances deposited on the application surfaces. Do not
forget to remove the old sealant remained in the bolt holes.
Form-in-Place Gasket Application
When assembling parts with the FIPG, you must observe some precautions, but the procedures is very
simple as in the case of a conventional precut gasket.
Applied FIPG bead should be of the specified size and without breaks. Also be sure to encircle the
bolt hole circumference with a completely continuous bead. The FIPG can be wiped away unless it is
hardened. While the FIPG is still moist (in less than 15 minutes), mount the parts in position. When
the parts are mounted, make sure that the gasket is applied to the required area only. In addition, do
not apply any oil or water to the sealing locations or start the engine until a sufficient amount of time
(about one hour) has passed after installation is completed.
The FIPG application procedure may vary on different areas. Observe the procedure described in the
text when applying the FIPG.

ENGINE – Timing Belt11-16
REMOVAL SERVICE POINTS
ATIMING BELT REMOVAL
(1) If the timing belt is to be reused, chalk an arrow mark
on the back surface of the belt so that the belt can be
reinstalled in the same direction.
(2) Place the exhaust camshaft sprocket in a position where
the timing mark for No. 1 cylinder is positioned about
one tooth before the top dead center of the compression
stroke.
Caution
The camshaft sprocket on the exhaust side can turn
very easily because of the valve spring tension. Use
care not to allow your fingers to get caught by the
sprocket.
(3) Loosen the lock nut of the tensioner pulley, then remove
the timing belt.
BOIL PUMP SPROCKET REMOVAL
(1) Remove the plug on the left side of cylinder block.
(2) Insert a screwdriver (shank diameter 8 mm) to block the
counterbalance shaft.
(3) Remove the nut.
(4) Remove the oil pump sprocket.
CCRANKSHAFT BOLT LOOSENING
(1) Hold the drive plate with the special tool as shown.
(2) Remove the crankshaft bolt.
DCRANKSHAFT SPROCKET REMOVAL
If it is difficult to remove the sprocket, use the special tool.
Timing mark

ENGINE – Timing BeltENGINE – Timing Belt11-17
ETIMING BELT “B” REMOVAL
Make a mark on the back of the timing belt indicating the
direction of rotation so it may be reassembled in the same
direction if it is to be reused.
NOTE
(1) Water or oil on the belt shortens its life drastically, so
the removed timing belt, sprocket, and tensioner must
be free from oil and water. These parts should not be
washed. Replace parts if seriously contaminated.
(2) If there is oil or water on each part check front case
oil seals, camshaft oil seal and water pump for leaks.
FCOUNTERBALANCE SHAFT SPROCKET
REMOVAL
(1) Set the special tool as shown to prevent the
counterbalance shaft sprocket from turning together.
(2) Loosen the bolt and remove the sprocket.
GCRANKSHAFT SPROCKET “B” REMOVAL
If it is difficult to remove the sprocket, use the special tool.
HCAMSHAFT SPROCKET BOLT LOOSENING
Use a wrench to hold the hexagonal part of the camshaft,
and then remove the camshaft sprocket mounting bolt.
INSTALLATION SERVICE POINTS
ACAMSHAFT SPROCKET BOLT TIGHTENING
Using a wrench, hold the camshaft at its hexagon and tighten
the bolt to the specification.
6EN1322
MD998785

ENGINE – Cylinder Head and Valves11-50
VALVE GUIDE REPLACEMENT PROCEDURE
(1) Force the valve guide out toward the cylinder block using
a press.
(2) Machine the valve guide hole in the cylinder head to
the size of the oversize valve guide to be installed.
Caution
Do not use the valve guide of the same size as the
removed one.
Valve gauge hole diameters in cylinder head
ItemStandard value mm
0.05 O.S.12.05 – 12.07
0.25 O.S.12.25 – 12.27
0.50 O.S.12.50 – 12.52
(3) Press-fit the valve guide until it protrude specified value
19.5 mm as shown in the illustration.
Caution
1. Press the valve guide from the cylinder head top
surface.
2. Valve guide for intake valve and that for exhaust
valve are different in length. (45.5 mm for intake
valve; 50.5 mm for exhaust valve)
(4) After the valve guide has been installed, insert a new
valve to check for smooth sliding motion.
1EN0106
Protrusion

ENGINE – Front Case, Counterbalance Shaft and Oil Pan11-56
(2) Secure the oil pump driven gear onto the left
counterbalance shaft by tightening the flange bolt to
specified torque.
KPLUG INSTALLATION
(1) Install a new O-ring to the groove of the front case.
(2) Install the plug to the front case.
(3) Fit the special tool MD998162 on the plug, and then
hold it in position with special tool MD998783.
(4) Tighten the plug to the specified torque.
(5) Remove the special tools MD998783 and MD998162.
LOIL PAN INSTALLATION
(1) Clean both mating surfaces of oil pan and cylinder block.
(2) Apply a 4 mm wide bead of sealant to the entire
circumference of the oil pan flange.
Specified sealant:
Mitsubishi Genuine Part No. MD970389 or
equivalent
NOTE
1. Be sure to install the oil pan quickly while the sealant
is wet (within 15 minutes).
2. After installation, keep the sealed area away from
the oil and coolant for approx. one hour.
(3) Note the difference in bolt lengths at the location shown.
MD998162
MD998783
6EN0213
Bolt hole
portionGroove
portion

MPI – General13-2
MULTIPOINT INJECTION (MPI)
GENERAL
OUTLINE OF CHANGE

The descriptions of the troubleshooting using an MUT-II tester have been added.

The fuel system and its management of EVOLUTION-VI are different from those of EVOLUTION-V
in the following items. Accordingly, the service procedures for these items are described herein. The
service procedures for the remaining item are the same as those for EVOLUTION-V.

Fan motor control

Fuel pump drive control

Fuel pump relay No.2

Fuel pump resistor

Actuator test function of MUT-II (The test of the following items has been made possible.)
a) Item No.36: Secondary air control solenoid valve
b) Item No.37: Air conditioner condenser fan (High)
c) Item No.38: Air conditioner condenser fan (Low)

MPI – Troubleshooting13-24
INSPECTION PROCEDURE 7
Long time to start (Improper starting)
Probable cause
In cases such as the above, the cause is probably that the spark is weak and ignition
is difficult, the initial mixture for starting is not appropriate, or sufficient compression
pressure is not being obtained.
Malfunction of the ignition system

Malfunction of the injector system

Inappropriate gasoline use

Poor compression
Check system voltage when cranking
OK:8 V or higherNGCheck the battery.
OK
MUT-II: Check if uncomplete combustion occurs.
(Refer to P.13-48, INSPECTION PROCEDURE 39.)
OK
Can any sound be heard from the injectors when cranking (check
using a soundscope)?NGCheck the injector system. (Refer to P.13-15, INSPECTION PRO-
CEDURE FOR DIAGNOSIS CODE 41.)
OK
Check the ignition timing when cranking.
OK:Approx. 5BTDCNGCheck that the crank angle sensor and the timing belt cover are
installed properly.
OK
Check the following items.

Check the ignition coil, spark plugs, spark plug cables.

Check the injectors for clogging and leakage.

Check the compression pressure.

Check if foreign materials (water, alcohol, etc.) got into fuel.