heater MITSUBISHI LANCER EVOLUTION VI 1999 Workshop Manual

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General . . . . . . . . . . . . . . . . . . . . . . . .
Engine . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch . . . . . . . . . . . . . . . . . . . . . . . . .
Manual Transmission . . . . . . . . . . .
Front Axle . . . . . . . . . . . . . . . . . . . . . .
Rear Axle . . . . . . . . . . . . . . . . . . . . . .
Front Suspension . . . . . . . . . . . . . . .
Service Brakes . . . . . . . . . . . . . . . . .
Steering . . . . . . . . . . . . . . . . . . . . . . . .
Body . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exterior . . . . . . . . . . . . . . . . . . . . . . . .
Chassis Electrical . . . . . . . . . . . . . .
Electrical Wiring . . . . . . . . . . . . . . . .
WORKSHOP MANUAL
SUPPLEMENT
FOREWORD
This Workshop Manual contains procedures for
service mechanics, including removal, disassembly,
inspection, adjustment, reassembly and
installation. Use the following manuals in
combination with this manual as required.
TECHNICAL INFORMATION MANUAL
N9806CNCP9
N9806CNCP9-A
WORKSHOP MANUAL
S9806CNCP9
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.
The EVOLUTION -VI is sold exclusively through
RALLIART Inc. Since the EVOLUTION-VI is a rally-
based model, it will not be warranted and will not be
homologated for general production. Therefore, any
service matters on the EVOLUTION-VI should be
inquired to RALLIART Inc. as usual.
EVOLUTION-VI

Mitsubishi Motors Corporation March 1999
Interior and Supplemental
Restraint System (SRS) . . . . . . . . .
.
Heater, Air Conditioner and
Ventilation . . . . . . . . . . . . . . . . . . . . .
.

MPI – Troubleshooting13-65
Terminal
No.Normal condition Check condition (Engine condition) Check item
41Alternator FR terminal
Engine: 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)System voltage
60Oxygen sensor heater
<EVOLUTION V VI>
Engine: Idling0 – 3 V
<EVOLUTION-V, VI>
Engine speed: 5,000 r/minSystem voltage
71Ignition switch-STEngine: Cranking8 V or more
72Intake air temperature
sensorIgnition switch: ONWhen intake air tempera-
ture is 0C3.2 – 3.8 V
When intake air tempera-
ture is 20C2.3 – 2.9 V
When intake air tempera-
ture is 40C1.5 – 2.1 V
When intake air tempera-
ture is 80C0.4 – 1.0 V
76Oxygen sensorEngine: Running at 2,000 r/min after having been
warmed up (Check using a digital type voltmeter)0 ↔ 0.8 V
(Changes repeatedly)
80Backup power supplyIgnition switch: OFFSystem voltage
81Sensor impressed
voltageIgnition switch: ON4.5 – 5.5 V
82Ignition switch-IGIgnition switch: ONSystem voltage
83Engine coolant
temperature sensorIgnition switch: ONWhen engine coolant
temperature is 0C3.2 – 3.8 V
When engine coolant
temperature is 20C2.3 – 2.9 V
When engine coolant
temperature is 40C1.3 – 1.9 V
When engine coolant
temperature is 80C0.3 – 0.9 V
84Throttle position sensorIgnition switch: ONSet throttle valve to idle
position0.3 – 1.0 V
Fully open throttle valve4.5 – 5.5 V
85Barometric pressure
sensor
Ignition switch: ONWhen altitude is 0 m3.7 – 4.3 V
sensor
When altitude is 1,200 m3.2 – 3.8 V
86Vehicle speed sensor
Ignition switch: ON

Move the vehicle slowly forward0 ↔ 5 V
(Changes repeatedly)

MPI – Troubleshooting13-67
RESISTANCE AND CONTINUITY BETWEEN HARNESS SIDE CONNECTORS AND TERMINALS
Engine-ECU Harness Side Connector Terminal Arrangement
Terminal No.Inspection itemNormal condition (Check condition)
1 – 12No.1 injector2 – 3 Ω (At 20C)
14 – 12No.2 injector
2 – 12No.3 injector
15 – 12No.4 injector
3 – 12Fuel pressure control valve28 – 36 Ω (At 20C)
4 – 12Stepper motor coil (A1)28 – 33 Ω (At 20C)
17 – 12Stepper motor coil (A2)
5 – 12Stepper motor coil (B1)
18 – 12Stepper motor coil (B2)
6 – 12Secondary air control solenoid valve28 – 36 Ω (At 20C)
11 – 12Wastegate solenoid valve62 – 74 Ω (At 20C)
60 – 12Oxygen sensor heater
<EVOLUTION-V, VI>11 – 18 Ω (at 20C)
13 – Body earthEngine-ECU earthContinuity established (0 Ω)
26 – Body earth
72 – 92Intake air temperature sensor5.3 – 6.7 kΩ (When intake air temperature is 0C)
2.3 – 3.0 kΩ (When intake air temperature is 20C)
1.0 – 1.5 kΩ (When intake air temperature is 40C)
0.30 – 0.42 kΩ (When intake air temperature is 80C)
74 – 77High temperature sensor3 Ω or less
83 – 92Engine coolant temperature sensor5.1 – 6.5 kΩ (When coolant temperature is 0C)
2.1 – 2.7 kΩ (When coolant temperature is 20C)
0.9 – 1.3 kΩ (When coolant temperature is 40C)
0.26 – 0.36 kΩ (When coolant temperature is 80C)
87 – 92Idle position switchContinuity established (when throttle valve is at idle
position)
No continuity (when throttle valve is slightly open)
91 – Body earth–Continuity established

CHASSIS ELECTRICAL – Ignition Switch and Immobilizer System54-19
IGNITION SWITCH AND IMMOBILIZER SYSTEM
Caution: SRS
Before removal of air bag module and clock spring, refer to GROUP 52B – SRS Service Precautions
and Air Bag Module and Clock Spring.
REMOVAL AND INSTALLATION
4
58 6
109 7
2
13
<L.H. drive vehicles>
<R.H. drive vehicles>
3 4
Immobilizer-ECU removal steps
1. Hood lock release handle
2. Driver‘s side lower cover

Radio and tape player <R.H drive
vehicles>

Heater control assembly <R.H. drive
vehicles>
3. Immobilizer-ECUIgnition switch and ignition key
ring antenna removal steps
1. Hood lock release handle
2. Driver‘s side lower cover
4. Steering wheel
5. Column cover, lower
6. Column cover, upper
7. Column switch
8. Ignition key ring antenna
A9. Steering lock cylinder
10. Ignition switch

CHASSIS ELECTRICAL – Radio and Tape Player54-45
RADIO AND TAPE PLAYER
TROUBLESHOOTING
There is noise when the engine is running.
Kind of Noise (Parenthe-
sized is how noise
sounds.)SymptomCauseRemedy
AM, FM: Ignition noise
(Popping, snapping,
crackling, buzzing)
Popping sound becomes
faster with the increase
of engine speed.

The noise is lost with
ignition switch turned to
ACC.
Mainly due to the
spark plugs.

Due to noise circula-
tion from elsewhere

Noise from the engineCheck the noise capacitor
and earth cable and
replace if necessary. (See
Fig. 1 and Fig. 2.)
AM, FM: Defogger noise
(1) (Murmuring)Occurs when the defogger
switch is turned to ON and
OFF.Noise produced by spark-
ing when the defogger
switch is turned to ON/
OFF enters the glass
antenna.Check the noise capacitor
and replace if necessary.
(See Fig. 1.)
AM, FM: Defogger noise
(2) (Snapping noise)Occurs when the defogger
switch is turned to ON.Noise produced by current
flowing in the defogger
enters the glass antenna.Check the choke coil and
replace if necessary.
(See Fig. 3.)
AM, FM: Defogger noise
(3) (Scratching, gaggling)Occurs when the defogger
switch is turned to ON with
print heater wire broken.Noise produced by spark-
ing where print heater is
broken enters the glass
antenna.Repair the print heater.
AM, FM: Wiper motor
noise (Humming, wheez-
ing)Sound becomes faster with
the increase of wiper speed
and is lost when the wiper is
stopped.Caused by sparking in
wiper motor brush.Replace the wiper motor.
FM: Mirror motor noise
(Humming, wheezing)Occurs when electric mirror
operates.Caused by sparking in
mirror motor brush.Replace the electric
motor.
Other electrical compo-
nents–Noise is emitted by some
electrical components in
long use.Repair or replace electri-
cal components.
Static electricity (Crack-
ling, crinkling)
Noise is stopped when
the vehicle comes to a
complete stop.

Noise becomes louder
when the clutch is
released.Occurs when parts or
wiring move for some
reason and contact metal
parts of the body.Put parts or wiring into
position.
Various noises are produced
by body parts.Due to electrical detach-
ment of the hood, exhaust
pipe and muffler, suspen-
sion, etc. from the body.Tighten mounting bolts
securely. In many cases,
remedy of one part does
not eliminate the problem
due to incomplete earthing
elsewhere.
Caution
(1) Never let the noise filter contact a high tension cable. The noise filter could break down.
(2) Check that there is no external noise. This check is necessary to prevent misidentification of noise
sources.
(3) Noise prevention should be performed by eliminating noise sources in the descending order of loudness.

CHASSIS ELECTRICAL – Antenna / Rear Window Defogger54-50
REMOVAL SERVICE POINT
AANTENNA AMPLIFIER ASSEMBLY REMOVAL
Take off the left-hand edge of the hand lining and undo the
clips of the antenna amplifier assembly.
REAR WINDOW DEFOGGER
TROUBLESHOOTING <VEHICLES
WITH AUTOMATIC A/C>
Refer to GROUP 55.
ON-VEHICLE SERVICE
PRINTED-HEATER CHECK
1. Run engine at 2,000 r/min. Check heater element with
battery at full.
2. Turn ON rear window defogger switch. Measure heater
element voltage with circuit tester at rear window glass
centre A.
Condition is good if it indicates about 6V.
3. If 12 V is indicated at A, there is a break in the negative
terminals from A.
Move test bar slowly to negative terminal to detect where
voltage changes suddenly (0V).
4. If 0 V is indicated at A, there is a break in the positive
terminals from A. Defect where the voltage changes
suddenly (12 V) in the same method described above.
DEFOGGER RELAY CONTINUITY CHECK
Battery voltageTerminal No.Battery voltage1325
Power is not supplied
Power is supplied
Normal characteristic curve
Voltage
A (Centre point)
approx. 6 V
Positive
terminal
Printed heater lineNegative
terminal
Abnormal characteristic curve
Voltage
Open-circuit
point
Positive
terminal
Printed heater lineNegative
terminal
Junction block
Defogger relay

CHASSIS ELECTRICAL – Rear Window Defogger
ILL
IND
ILL
54-51
REAR WINDOW DEFOGGER SWITCH
<VEHICLES WITH AUTOMATIC A/C>
REMOVAL AND INSTALLATION
Refer to GROUP – Heater Control Assembly.
INSPECTION
DEFOGGER SWITCH CONTINUITY CHECK
Switch
iti
Terminal No.
position12–34–6
OFF
ON
OFF ←→ON

55-1
HEATER,
AIR CONDITIONER
AND VENTILATION
CONTENTS
HEATER AND MANUAL AIR
CONDITIONER 3. . . . . . . . . . . . . . . . . . . . . .
GENERAL 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outline of Change 3. . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE SPECIFICATIONS 3. . . . . . . . . . . . . .
LUBRICANTS 3. . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 3. . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 4. . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE 6. . . . . . . . . . . . . . . . . .
Refrigerant Charging 6. . . . . . . . . . . . . . . . . . . . . . .
Refrigerant Charging Amount Check 9. . . . . . . .
Replenishing System 10. . . . . . . . . . . . . . . . . . . . .
Discharging System 11. . . . . . . . . . . . . . . . . . . . . .
Performance Test 11. . . . . . . . . . . . . . . . . . . . . . . .
Dual Pressure Switch Simple Check 13. . . . . . .
Power Relay Check 13. . . . . . . . . . . . . . . . . . . . . .
Idle-up Operation Check 14. . . . . . . . . . . . . . . . . .
HEATER CONTROL ASSEMBLY AND A/C
SWITCH 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HEATER UNIT AND BLOWER UNIT
<VEHICLES WITHOUT
AIR CONDITIONER> 18. . . . . . . . . . . . . . . . . . .
HEATER UNIT, COOLING AND BLOWER
UNIT <VEHICLES WITH AIR
CONDITIONER> 19. . . . . . . . . . . . . . . . . . . . . . .
BLOWER MOTOR ASSEMBLY, RESISTOR
AND EVAPORATOR 20. . . . . . . . . . . . . . . . . . .
COMPRESSOR AND TENSION
PULLEY 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONDENSER AND CONDENSER FAN 28. .
REFRIGERANT LINE 30. . . . . . . . . . . . . . . . . .
DUCTS 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTINUED ON NEXT PAGE

55-2
FULL-AUTOMATIC AIR
CONDITIONER 33. . . . . . . . . . . . . . . . . . . . .
GENERAL 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outline of Change 33. . . . . . . . . . . . . . . . . . . . . . . .
SERVICE SPECIFICATIONS 33. . . . . . . . . . . .
LUBRICANTS 33. . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 33. . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 34. . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE 56. . . . . . . . . . . . . . . .
Refrigerant Charging, Level Check, Addition
and Removal, Performance Test, Dual
Pressure Switch Simple Check 56. . . . . . . . . . . .
Power Relay Check 57. . . . . . . . . . . . . . . . . . . . . .
Idle-up Operation Check 57. . . . . . . . . . . . . . . . . .
DAMPER CONTROL MOTOR ASSEMBLY
AND POWER TRANSISTOR 58. . . . . . . . . . . .
PHOTO SENSOR 61. . . . . . . . . . . . . . . . . . . . . .
OUTSIDE AIR TEMPERATURE
SENSOR 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HEATER WATER TEMPERATURE
SENSOR 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OTHER MAINTENANCE SERVICE
POINTS 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General / Service Specifications /
Lubricants / Special Tools HEATER AND MANUAL
AIR CONDITIONER –55-3
HEATER AND MANUAL AIR CONDITIONER
GENERAL
OUTLINE OF CHANGE

The following service procedures have been established.
SERVICE SPECIFICATIONS
ItemsStandard value
Idle speed r/min700 ± 50
Idle up speed r/min850 ± 50
Resistor (for blower motor) ΩHI – LO (between terminals 3 and 2)2.81 ± 10%
HI – ML (between terminals 3 and 4)1.28 ± 10%
HI – MH (between terminals 3 and 1)0.33 ± 10%
Air gap (Compressor) mm0.4 – 0.6
LUBRICANTS
ItemsSpecified lubricantsQuantity
Compressor oil m
SUN PAG 56120 – 140
Pipe jointSUN PAG 56As required
Refrigerant gR134a (HFC-134a)555 – 595
SPECIAL TOOLS
ToolNumberNameUse
MB991367Special spannerRemoval and installation of armature mounting
nut of compressor
MB991386Pin