MITSUBISHI LANCER EVOLUTION VI 1999 Workshop Manual

BODY – Sunroof42-13
ON-VEHICLE SERVICE
WATER TEST
Check if there are any leaks in the sunroof by the following
procedure.
1. Fully close the roof lid glass.
2. Adjust the water pressure so that water comes out of
the hose to a height of approximately 50 cm when the
hose is held vertically facing upwards.
3. Hold the end of the hose approximatery 30 cm above
the roof and let the water run onto the weatherstrip for
5 minutes or more.
4. While doing this, check if any water leaks through into
the passenger compartment from around the roof lid glass.
SUNROOF FIT ADJUSTMENT
1. Fully close the roof lid glass.
2. Fully open the sunshade.
3. Remove the side decoration cover.
4. To adjust the forward, backward and sideways position
of the roof lid glass, loosen the six roof lid glass assembly
mounting nuts and then adjust the glass forward,
backward or sideways.
NOTE
If the adjustment cannot be made by loosening the
adjustment nuts, the fully closed position of the roof lid
glass may not match that of the motor. If so, adust them
to match their fully closed positions.
5. To adjust the height of the roof lid glass, loosen the four
guide (A) assembly mounting screws and then move the
roof lid glass assembly along the slot in the guide (A)
assembly.
6. After adjustment, check to be sure that the sunroof
operates smoothly.
Hose
Apporox. 30cm
Clip
Side decoration cover

BODY – Sunroof42-14
SUNROOF
REMOVAL AND INSTALLATION
Post-installation Operation


Sunroof Water Test (Refer to P.42-13.)

Sunroof Fit Adjustment (Refer to P.42-13.)
1 2
3
456
9 10
11 128
NOTE
:Clip position
7
6
Roof lid glass assembly removal
steps
A1. Side decoration cover
2. Roof lid glass assembly
Sunroof switch removal steps
3. Sunroof switch cover
4. Sunroof switch
Drain hose removal steps

Splash shield (Front drain hose)
5. Headlining
BB6. Drain hoseSunroof-ECU removal steps
5. Headlining
7. Sunroof-ECU
Sunroof motor removal steps
5. Headlining
CA8. Sunroof motor
Sunroof assembly removal steps
5. Headlining
6. Drain hose connection
9. Room lamp bracket
10. Sunroof switch bracket
11. Set bracket
12. Sunroof assembly

BODY – Sunroof42-15
REMOVAL SERVICE POINTS
ASIDE DECORATION COVER REMOVAL
Remove the clips, and then remove the side decoration cover.
BDRAIN HOSE REMOVAL
Tie a cord to the end of the drain hose, and wind tape around
the tie until it is smooth. Then pull the drain hose out from
the passenger compartment.
CSUNROOF MOTOR REMOVAL
Caution
Always close the roof lid glass fully before removing
the sunroof motor. If the fully-closed positions of the roof
lid glass and the sunroof motor are not the same, the
sunroof will not operate properly.
INSTALLATION SERVICE POINTS
ASUNROOF MOTOR INSTALLATION
If the fully-closed position of the sunroof motor is incorrect,
set the motor to the fully-closed position by the procedure
given below before installing the motor.
1. Connect a circuit analyser between terminals (4) and (6)
of the motor connector.
2. Operate the motor until the position is reached at which
continuity switches from on to off or from off to on, and
then install the motor.
BDRAIN HOSE INSTALLATION
1. Tie the cord that was used during removal to the end
of the drain hose, and wind tape around it so that there
is no unevenness.
2. Pull the cord to pass through the drain hose
Clip
Side decoration cover
Drain hose
Cord
Cord
Drain hose

BODY – Sunroof42-16
3. Make the drain hose protrusion from the grommet as
shown in the illustration.
INSPECTION
ROOF LID GLASS OPERATION CURRENT CHECK
1. Remove the sunroof fuse and connect a circuit analyser
as shown in the illustration.
2. Press the sunroof switch to the ON position, and then
measure the operation current in the intervals between
the points when the sunroof starts to operate, when it
is fully open, when it is fully closed and when it is fully
tilted up.
Standard value: 7 A or less (at 20C)
3. If the operation current is outside the standard value,
check the following points.

Installation condition, warping or jamming of sunroof
assembly

Sticking of drive cable

Tilt of roof lid glass
Grommet
20–30 mm

BODY – Sunroof42-17
SUNROOF MOTOR CHECK
Check the direction of rotation of the drive gear when the
battery is connected to the connector.
Battery connection terminalDrive gear rotation
di ti12direction
Left
Right
LIMIT SWITCH CONTINUITY CHECK
1. Remove the limit switches from the sunroof motor, and
then check the operation of the limit switches.
Switch positionTerminal No.
4567
Limit switch 1ON
OFF
Limit switch 2ON
OFF
Limit switch 3ON
OFF
2. Check the identification colours. Then install the limit
switches as shown in the illustration.
SUNROOF SWITCH CONTINUITY CHECK
Switch positionTerminal No.
3456
Slide open
Off
Tilt up
Slide close, Tilt down
Left rotationDrive gear
Right rotation
(Red)(White)Limit switch 2, 3
ON
OFF
(Black)
(Black)(Blue)
Limit switch 1

BODY – Sunroof42-18
DISASSEMBLY AND REASSEMBLY
Sealant:
3M ATD Part No.8531 or 3M Part
No.8646, or equivalent
1 2
3 4
5
67
89 10
11
12
1110
NOTE
:Clip position
Disassembly steps
1. Side decoration cover
(Refer to P.42-15.)
2. Roof lid glass assembly
3. Sunroof motor
4. Drip rail assembly
5. Sunshade assembly
6. Cushion (B) assembly7. Drive unit assembly
8. Decoration link
9. Guide (A) assembly
10. Slider assembly
11. Rail cover assembly
12. Frame sub assembly

51-1
EXTERIOR
CONTENTS
GENERAL 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outline of Change 2. . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOL 2. . . . . . . . . . . . . . . . . . . . . . . . .
FRONT BUMPER 2. . . . . . . . . . . . . . . . . . . . . . . .
AERO PARTS 4. . . . . . . . . . . . . . . . . . . . . . . . . . . WASHER TANK AND HOSES 6. . . . . . . . . . . .
INTERCOOLER & RADIATOR WATER
SPRAY SYSTEM 7. . . . . . . . . . . . . . . . . . . . . . . .
MARKS 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EXTERIOR – General / Special Tool / Front Bumper51-2
GENERAL
OUTLINE OF CHANGE
As the following changes had been made, the service procedures for the relating components have
been newly established.

Front bumper and aero parts changed

Front and rear window washer tank relocated to the luggage compartment

Intercooler & radiator water spray system changed

Marks changed
SPECIAL TOOL
ToolNumberNameUse
B990784
MB990784Ornament removerRemoval of front bumper
FRONT BUMPER
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operations

Front Turn Signal Lamp Removal and Installation
Front bumper assembly

EXTERIOR – Front Bumper51-3
DISASSEMBLY AND REASSEMBLY
2 13
56
8910 12
11
1315 14
16
1719 1874
185 74
Disassembly steps

Front airdam (Refer to P.51-4)
1. Licence plate bracket
2. Licence plate garnish
3. Three-diamond mark
4. Front fog lamp cover
5. Front fog lamp plate
6. Oil cooler duct
7. Bumper side stay
8. Air outlet garnish (R.H. side only)
9. Bumper side net
10. Bumper bolt plateA11. Clip
12. Bumper upper reinforcement
assembly
13. Bumper lower reinforcement
14. Bumper reinforcement
15. Bumper center net
16. Water spray hose assembly
17. Water spray nozzle
18. Air blow duct
19. Bumper face

EXTERIOR – Front Bumper / Aero Parts51-4
DISASSEMBLY SERVICE POINT
ACLIP REMOVAL
1. Use the special tool to pull up the center pin in the clip.
2. Remove the clip.
AERO PARTS
REMOVAL AND INSTALLATION
21
Front airdam removal steps
1. Air blow duct
AA2. Front airdam
NOTE
The removal and installation service points for the new model
are the same as those for the preceding models.
PinClip
MB990784MB990784