cooling MITSUBISHI LANCER EVOLUTION IV 1998 Workshop Manual

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General . . . . . . . . . . . . . . . . . . . . . . . .
Engine . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Lubrication . . . . . . . . . . . . .
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Cooling . . . . . . . . . . . . . . . . .
Intake and Exhaust . . . . . . . . . . . .
Engine Electrical . . . . . . . . . . . . . . .
Engine and Emission Control . . . .
Clutch . . . . . . . . . . . . . . . . . . . . . . . . .
Manual Transmission . . . . . . . . . . .
Front Axle . . . . . . . . . . . . . . . . . . . . . .
Rear Axle . . . . . . . . . . . . . . . . . . . . . .
Power Plant Mount . . . . . . . . . . . . . .
Front Suspension . . . . . . . . . . . . . . .
Rear Suspension . . . . . . . . . . . . . . .
Service Brakes . . . . . . . . . . . . . . . . .
Parking Brakes . . . . . . . . . . . . . . . . .
Steering . . . . . . . . . . . . . . . . . . . . . . . .
Body . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exterior . . . . . . . . . . . . . . . . . . . . . . . .
Chassis Electrical . . . . . . . . . . . . . .
Electrical Wiring . . . . . . . . . . . . . . . .
WORKSHOP MANUAL
FOREWORD
This Workshop Manual contains procedures for
service mechanics, including removal, disassembly,
inspection, adjustment, reassembly and
installation. Figures taken from registration
documents are given in metric units only. All other
figures are given in SI units with metric units in
brackets. Use the following manuals in combination
with this manual as required.
TECHNICAL INFORMATION MANUAL
N9806CNCP9
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.
July 1998
EVOLUTION-IV
EVOLUTION-V

MPI – Troubleshooting13-18
5. SERVICE DATA LIST

Item
No.Inspection
itemInspection contentsNormal condition
11Oxygen
sensorEngine: After having been warmed
up
Air/fuel mixture is made leaner when
When at 4,000 r/min, engine is
suddenly decelerated200 mV or less
Air/fuel mixture is made leaner when
decelerating, and is made richer
when racing.
When engine is suddenly
raced600 – 1,000 mV
Engine: After having been warmed
up
The ox
ygen sensor signal is used to
Engine is idling400 mV or less
(Chan
ges)The oxygen sensor signal is used to
check the air/fuel mixture ratio, and
control condition is also checked by
the ECU.2,500 r/min
(Changes)
600 – 1,000 mV
12Air flow
sensor*
Engine coolant temperature:
8095C
Engine is idling17 – 43 Hz
sensor*80 – 95C
Lamps, electric cooling fan and
all accessories: OFF
2,500 r/min46 – 86 Hz
all accessories: OFF
Transmission: NeutralEngine is racedFrequency increases
in response to racing
13Intake air
temperature
sensor
Ignition switch: ON or with engine
runningWhen intake air temperature
is –20C–20C
sensorWhen intake air temperature
is 0C0C
When intake air temperature
is 20C20C
When intake air temperature
is 40C40C
When intake air temperature
is 80C80C
14Throttle
position
Ignition switch: ONSet to idle position300 – 1,000 mV
position
sensor
Gradually openIncreases in proportion
to throttle opening
angle
Open fully4,500 – 5,500 mV
16Power
supply
voltageIgnition switch: ONSystem voltage
18Cranking
signal Ignition switch: ONEngine: StoppedOFF
g
(ignition
switch-ST)Engine: CrankingON
NOTE
*: When the car is new (distance it travelled is less than 500 km), output frequency of the air flow sensor may
become about 10% higher.

MPI – Troubleshooting13-20
Item
No.Normal condition Inspection contents Inspection
item
41Injector
drive time*2Engine: CrankingWhen engine coolant temper-
ature is 0C (injection is
carried out for all cylinders
simultaneously)27 – 41 ms
When engine coolant temper-
ature is 20C14 – 22 ms
When engine coolant temper-
ature is 80C3.9 – 5.9 ms
Injector
drive time*3Engine coolant temperature:
8095C
Engine is idling1.2 – 2.4 ms
drive time*380 – 95C
Lamps, electric cooling fan and
all accessories: OFF
2,500 r/min1.0 – 2.2 ms
all accessories: OFF
Transmission: NeutralWhen engine is suddenly
racedIncreases
44Ignition
advanceEngine: After having been
warmed up
Timing lamp is set (The timing
Engine is idling3 – 13BTDC
Timing lamp is set. (The timing
lamp is set in order to check
actual ignition timing.)2,500 r/min24 – 44BTDC
45ISC
(stepper)
motor
Engine coolant temperature:
80 – 90C
Lamps electric coolingfan and
A/C switch: OFF2 – 25 steps
motor
position *4Lamps, electric cooling fan and
all accessories: OFF
Transmission: Neutral
Idle position switch: ON
Engine: Idling
A/C switch: OFF → ONIncreases by 10 – 70
steps
Engine: Idling
(When A/C switch is ON, A/C
compressor should be operat-
ing.)A/C switch: OFFIncreases by 5 – 50
steps
49A/C relayEngine: After having been warmed
up/Engine is idlingA/C switch: OFFOFF (Compressor
clutch is not operating)
A/C switch: ONON (Compressor
clutch is operating)
NOTE
*1: The idle position switch normally turns off when the voltage of the throttle position sensor is 50 – 100 mV
higher than the voltage at the idle position. If the idle position switch turns back on after the throttle valve
is opened, the idle position switch and the throttle position sensor need to be adjusted.
*2: The injector drive time represents the time when the cranking speed is at 250 r/min or below when the power
supply voltage is 11 V.
*3: In a new vehicle [driven approximately 500 km or less], the injector drive time is sometimes 10% longer than
the standard time.
*4: In a new vehicle [driven approximately 500 km or less], the step of the stepper motor is sometimes 30 steps
greater than the standard value.

MPI – Troubleshooting13-21

Descriptions other than those given below are the same as for the EVOLUTION-IV.
Item
No.Inspection
itemInspection contentsNormal condition
12Air flow
sensor*1Engine coolant temperature:
80–95C
Engine is idling12 – 38 Hz
sensor*180 – 95C
Lamps, electric cooling fan and
all accessories: OFF
2,500 r/min36 – 76 Hz
all accessories: OFF
Transmission: NeutralEngine is racedFrequency increases
in response to racing
41Injector
drive time*2Engine: Cranking*2When engine coolant temper-
ature is 0C27 – 40 ms
When engine coolant temper-
ature is 20C14.5 – 21.7 ms
When engine coolant temper-
ature is 80C3.8 – 5.6 ms
Injector
drive time*3Engine coolant temperature:
8095C
Engine is idling0.9 – 2.1 ms
drive time *380 – 95C
Lamps, electric cooling fan and
all accessories: OFF
2,500 r/min0.7 – 1.9 ms
all accessories: OFF
Transmission: NeutralWhen engine is suddenly
racedIncreases
44Ignition
advance
Engine: After having been
warmed up
Engine is idling0 – 13BTDC
advancewarmed up
Timing lamp is set.2,500 r/min24 – 44BTDC
NOTE
*1: In a new vehicle (driven approximately 500 km or less), the air flow sensor output frequency is sometimes
10 % higher than the standard frequency.
*2: The injector drive time represents the time when the cranking speed is at 250 r/min or below when the power
supply voltage is 11 V.
*3: In a new vehicle (driven approximately 500 km or less), the injector drive time is sometimes 10 % longer than
the standard time.

14-1
ENGINE
COOLING
CONTENTS
SERVICE SPECIFICATIONS 2. . . . . . . . . . . . . .
LUBRICANT 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE 2. . . . . . . . . . . . . . . . . .
Coolant Replacement 2. . . . . . . . . . . . . . . . . . . . . .
THERMOSTAT 3. . . . . . . . . . . . . . . . . . . . . . . . . . .
WATER PUMP 5. . . . . . . . . . . . . . . . . . . . . . . . . . .
WATER HOSE AND WATER PIPE 6. . . . . . . .
RADIATOR 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE COOLING – Service Specifications / Lubricant / On-vehicle Service14-2
SERVICE SPECIFICATIONS
ItemsStandard value
Thermostat valve opening temperature
CWhen open76.5 ± 1.5
When fully open90
Thermostat lift mm8.5 or more
LUBRICANT
ItemsBrandQuantity dm3 {
}
Coolant capacity (in condenser tank)MITSUBISHI GENUINE DIA QUEEN SUPER
LONG LIFE COOLANT6 {6}
ON-VEHICLE SERVICE
COOLANT REPLACEMENT
CYLINDER BLOCK DRAIN PLUG
Unit: Nm {kgfm}
Drying sealant: HELMESEAL H-1M
44 {4.5}
RADIATOR CAP VALVE OPENING PRESSURE
CHECK
On EVOLUTION-V, the radiator cap valve opening pressure
must be as shown below.
Standard value: 93 – 123 kPa {0.95 – 1.25 kgf/cm
2}
Limit: 83 kPa {0.85 kgf/cm
2}

ENGINE COOLING – Thermostat14-3
THERMOSTAT
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
Engine Coolant Draining and Supplying
(Refer to P.14-2.)
Air Intake Hose Assembly Removal and Installation
(Refer to GROUP 15 – Intercooler.)
4 3
5
1
Unit: Nm {kgfm}
13 {1.3}
Removal steps
AB1. Radiator lower hose connection
2. Control wiring harness connection
3. Water inlet fitting
A4. Thermostat
REMOVAL SERVICE POINT
ARADIATOR LOWER HOSE DISCONNECTION
After making mating marks on the radiator hose and the hose
clamp, disconnect the radiator hose.

ENGINE COOLING – Thermostat14-4
INSTALLATION SERVICE POINTS
ATHERMOSTAT INSTALLATION
(1) Install the thermostat so that the jiggle valve is facing
straight up.
Caution
Make absolutely sure that no oil is adhering to the
rubber ring of the thermostat. If the rubber ring is
damaged, replace the thermostat.
(2) When assembling the thermostat, be careful not to fold
over or scratch the rubber ring.
BRADIATOR LOWER HOSE CONNECTION
(1) Insert each hose as far as the projection of the water
inlet fitting.
(2) Align the mating marks on the radiator hose and hose
clamp, and then connect the radiator hose.
INSPECTION
THERMOSTAT CHECK
(1) Immerse the thermostat in water, and heat the water while
stirring. Check the thermostat valve opening temperature.
Standard value: 76.5 ± 1.5
C
(2) Check that the amount of valve lift is at the standard
value when the water is at the full-opening temperature.
Standard value:
Full-opening temperature: 90
C
Amount of valve lift: 8.5 mm or more
NOTE
Measure the valve height when the thermostat is fully
closed, calculate the valve lift by subtracting this
measurement from the valve height when the thermostat
is fully open.
Jiggle valve
Rubber ring
Valve lift

ENGINE COOLING – Water Pump14-5
WATER PUMP
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
Engine Coolant Draining and Supplying
(Refer to P.14-2.)Timing Belt and Timing Belt B Removal and Installation
(Refer to GROUP 11.)
12 – 15 {1.2 – 1.5} 24 {2.4}
8 × 22 8 × 14
Bolt specifications
8 × 24
Screw diameter × length mm
1
2
4
3
2
22 {2.2}
8 × 70
Unit: Nm {kgfm}
Removal steps
1. Alternator brace
2. Water pump
3. Water pump gasket
A4. O-ring
INSTALLATION SERVICE POINT
AO-RING INSTALLATION
Fit the O-ring in the O-ring groove in the water inlet pipe,
and coat the outer circumference of the O-ring or the inside
surface of the water pump with water before inserting the
pipe.
Water pump
O-ring
Water inlet pipe

ENGINE COOLING – Water Hose and Water Pipe14-6
WATER HOSE AND WATER PIPE
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
(1) Coolant Draining and Refilling (Refer to P.14-2.)
(2) Air Hose C Removal and Installation
(Refer to GROUP 15 – INTERCOOLER.)
(3) Air Control Valve Bracket Removal and Installation
(Refer to GROUP 15 – AIR CONTROL VALVE.)
6 2
10
8
Semi-drying sealant:
THREEBOND 1207F
57

3mm
6
9 1 3
Unit: Nm {kgfm}
24 {2.4}
48 {4.9}
10 {1.0}
141112
13 {1.3}
41 {4.2} 13 {1.3} 10 {1.0}24 {2.4}
41 {4.2}
13
4
Removal steps
AC1. Radiator upper hose connection
AC2. Radiator lower hose connection
3. Water hose
4. Water hose
5. Water inlet fitting
B6. Thermostat case assembly
7. Water hose
8. Water hose9. Heater hose connection
A10. O-ring
11. Water inlet pipe
A12. O-ring
Turbocharger (Refer to GROUP 15.)
13. Water pipe assembly A
14. Water pipe assembly B