heater MITSUBISHI LANCER EVOLUTION IV 1998 Workshop Manual

ENGINE – Cylinder Head Gasket11-18
10 mm
10 mm
10 mm
Semi-drying sealant:
THREEBOND 1207D
29
9 {0.9}
Unit: Nm {kgf
m}
3.4 {0.35}
30 {3.1} 22 {2.2}
9 {0.9}
30 {3.1}
32
33
28
2725
26
2430 23
2122
31
78 → 0 → 20 → +90
→ +90

{8.0 → 0 → 2.0 → +90
→ +90
}
22
22
23
10 mm 10 mm
Removal steps
21. PCV hose connection
22. Rocker cover
23. Semi-circular packing
24. Starter
25. Oil return pipe
C26. Oil return pipe gasket
27. Vacuum tank/solenoid valve/vacuum
hose assembly28. Intake manifold stay
29. Heater hose connection
30. Alternator brace stay mounting bolt
AB31. Cylinder head bolt
32. Cylinder head assembly
A33. Cylinder head gasket

ENGINE – Engine Assembly 11- 32
ENGINE ASSEMBLY
REMOVAL AND INSTALLATION
Pre-removal Operation
(1) Fuel Discharge Prevention
(2) Hood Removal
(3) Strut Tower Bar Removal
(4) Air Hose C Removal
(Refer to GROUP 15 – Intercooler.)
(5) Radiator Assembly Removal (Refer to GROUP 14.)
(6) Under Cover Removal
(7) Front Exhaust Pipe Removal (Refer to GROUP 15.)Post-installation Operation
(1) Front Exhaust Pipe Installation
(Refer to GROUP 15.)
(2) Under Cover Installation
(3) Radiator Assembly Installation (Refer to GROUP 14.)
(4) Accelerator Cable Adjustment
(5) Air Hose C Installation (Refer to GROUP 15 – Intercooler.)
(6) Strut Tower Bar Installation
(7) Hood Installation
O-ring Delivery pipe
1
2
3
4
5
6
7 8
9
10
11
18 12
Engine oil
5 {0.5}
Unit: Nm {kgf

m}
10 – 12
{1.0 – 1.2}
17 1614 13
10
– 12
{1.0 – 1.2}
15
3 {0.3}
17
8
Removal steps1. Center cover
2. Accelerator cable
3. Brake booster vacuum hose connection
4. Vacuum hose connection
5. Throttle position sensor connector
6. Idle speed control motor connector
7. Heater hose connection
8. Ignition coil connector
9. Crank angle sensor connector
10. Oxygen sensor connector 11. Injector connector
12. Cam position sensor connector
13. Coolant temperature sensor con-
nector
14. Coolant temperature gauge unit connector
15. Vacuum pipe/hose assembly
16. Control harness
 C 17. High-pressure fuel hose connection
18. Fuel return hose connection

MPI – General Information13-2
MULTIPOINT INJECTION (MPI)
GENERAL INFORMATION
OMPI System Diagram

1 Injector

2 ISC servo

3 Fuel pressure control valve

4 Waste gate solenoid valve

5 Secondary air control solenoid valve
Control relay
Fuel pump relay
A/C relay
Ignition coil
Exhaust temperature warning lamp
Engine warning lamp
Diagnosis output
Alternator G terminal
Fan motor relay
Tachometer
Fuel pump relay No.2 1 Oxygen sensor
2 Air flow sensor
3 Intake air temperature sensor
4 Throttle position sensor
5 Idle switch
6 Camshaft position sensor
7 Crank angle sensor
8 Barometric pressure sensor
9 High temperature sensor
10 Engine coolant temperature sensor
11 Detonation sensor
Power supply voltage
Ignition switch-IG
Ignition switch-ST
Vehicle speed sensor
A/C switch
Power steering fluid pressure switch
Alternator FR signalEngine ECU
1 Oxygen sensor
2 Air flow sensor3
Intake air tem-
perature sensor
4,
5
6 Camshaft position
sensor
7 Crank angle sensor 8 Barometric
pressure sensor
9 High temperature
sensor 10 Coolant temperature sensor
11 Detonation sensor
1 Injector
2 ISC servo

3 Fuel pressure
control valve

4 Waste gate
solenoid valve
5 Secondary air
control solenoid
valveCanister
Check valveFrom
fuel
tank
Throttle position
sensor (with a
built-in
idle
switch)
Secondary
air valve
AirTo fuel
tankFuel
pressure
regulatorFrom
fuel
pump
Waste gate
actuator
Catalytic converter
Given above is the MPI system diagram for EVOLUTION-IV. The MPI system for EVOLUTION-V is different
from this in the following point;
Oxygen sensor with a heater is adopted.
The diagnosis connector power supply circuit is different.
The high temperature sensor is no longer used.

MPI – Troubleshooting13-23
Terminal
No.Normal condition Check condition (Engine condition) Check item
21Fan motor relay (LOW)Fan not operating (coolant temperature: 90C or
below)Battery voltage
Fan at low speed (coolant temperature: 90 – 100C)0 – 3 V
22A/C relayEngine: Idling
A/C switch: OFF to ON (Compressor is being
driven.)Battery voltage, or 6 V
or more instanta-
neously to 0 – 3 V
33Alternator G terminalEngine: Warm, idle (radiator fan: OFF)
Headlamp: OFF to ON
Brake lamp: OFF to ON
Rear defogger switch: OFF to ONVoltage rises by 0.2 –
3.5 V.
36Engine warning lampIgnition switch: OFF → ON0 – 3 V → Battery
voltage (After several
seconds have
elapsed)
37Power steering fluid
pressure switchEngine: Idling after
warming upWhen steering wheel is
stationaryBattery voltage
When steering wheel is
turned0 – 3 V
38Control relayIgnition switch: OFFBattery voltage
Ignition switch: ON0 – 3 V
39Fuel pump relay No.2While engine is idling, suddenly depress the
accelerator pedal.Momentarily rises
slightly from 0 to 3 V.
40Exhaust temperature
warning lampIgnition switch: OFF to ON0 – 3 V to battery
voltage (After several
seconds have
elapsed)
41Alternator FR terminalEngine: 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)Battery voltage
60Oxygen sensor heater
(Evolution V only)
Engine: Idling0 – 3 V
(Evolution-V only)
Engine speed: 5,000 r/minBattery voltage
71Ignition switch-STEngine: Cranking8 V or more

MPI – Troubleshooting13-25
6-2 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)
13 – Body earthEngine-ECU earthContinuity established (0 Ω)
26 – Body earth
60 – 12Oxygen sensor heater (EVOLUTION-V
only)11 – 18 Ω (at 20C)
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

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

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


3 4
Immobilizer-ECU removal steps
1. Hood lock release handle
2. Driver‘s side lower cover

Radio and tape player vehicles>

Heater control assembly 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 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

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