front MITSUBISHI LANCER EVOLUTION VI 1999 Service Manual

BASIC BRAKE SYSTEM – General / On-vehicle Service35A-2
GENERAL
OUTLINE OF CHANGE

The service procedures for left-hand drive vehicles have been established as described below.

The service procedures for the front and rear disc brakes have been changed since they had been
replaced by a different type.
ON-VEHICLE SERVICE
BRAKE PEDAL CHECK AND ADJUSTMENT

1. Turn up the carpet, etc under the brake pedal.
2. Measure the brake pedal height as illustrated. If the brake
pedal height is not within the standard value, follow the
procedure below.
Standard value: 163.5 –166.5 mm
(1) Disconnect the stop lamp switch connector.
(2) Adjust the brake pedal height by turning the operating
rod with pliers (with the operating rod lock nut
loosened), until the correct brake pedal height is
obtained.
(3) Secure by tightening the lock nut of the operating
rod.
(4) Push the stop lamp switch in the direction of the
pedal stroke until it stops. (The switch will slide if
it is pushed firmly.)
(5) Lift up the pedal until the operating rod is fully
extended, and then slide the stop lamp switch back
to the required position. Adjust the position of the
switch by turning it until the distance shown in the
illustration is correct.
(6) Connect the connector of the stop lamp switch.
(7) Check that the stop lamp is not illuminated with the
brake pedal unpressed.
3. With the engine stopped, depress the brake pedal two
or three times. After eliminating the vacuum in the power
brake booster, press the pedal down by hand, and confirm
that the amount of movement before resistance is met
(the free play) is within the standard value range.
Standard value: 3 – 8 mmOperating
rod
Operating
rod lock nutStop lamp
switch
Pedal down
Pedal up
Lock nut
Lock nut
Outer case
0.5 – 1.0 mm

BASIC BRAKE SYSTEM – Disc Brake35A-9
DISC BRAKE

DISASSEMBLY AND REASSEMBLY
Front Brake
Seal & boot kit Shim set
Clip set Pad set
Brake caliper kit
1 23 4 5
6
7
8 9
10
1
23
43 41
2 56
55
7 9
9 7 9 7
8 6 6
10
21
Disassembly steps
1. Pin
2. Cross spring
3. Pad & wear indicator assembly
4. Pad assembly
5. Shim6. Air bleeder screw
7. Piston boot
8. Piston
9. Piston seal
10. Caliper body

STEERING – Power Steering Gear Box37A-5
POWER STEERING GEAR BOX
REMOVAL AND INSTALLATION
CAUTION: SRS
For vehicles with SRS, before removal of steering gear box, refer to GROUP 52B, centre front wheels and
remove ignition key. Failure to do so may damage SRS clock spring and render SRS system inoperative,
risking serious driver injury.
Pre-removal Operation

Power Steering Fluid Draining

Center Member Removal

Front Exhaust Pipe RemovalPost-installation Operation

Front Exhaust Pipe Installation

Center Member Installation

Power Steering Fluid Supplying

Power Steering Fluid Line Bleeding

Steering Wheel Position Check with Wheels Straight
Ahead

Front Wheel Alignment Adjustment

Dust Cover Check for Cracks or Damage by
Pushing it with Finger.
15 Nm 15–33 Nm
69 Nm17 Nm
5 Nm
15–33 Nm
789
3
45 1 2
611 Nm
Removal steps
1. Steering shaft assembly and gear
box connecting bolt
2. Band
3. Split pin
A4. Tie-rod end and knuckle connection5. Return tube connection
6. Pressure tube connection
7. Cylinder clamp
B8. Gear box assembly
9. Steering cover assembly

BODY – Keyless Entry System42-7
KEYLESS ENTRY SYSTEM
REMOVAL AND INSTALLATION
1
2
Keyless entry receiver removal
steps

Front seat assembly (driver’s side)
1. Keyless entry receiverETACS-ECU removal
2. ETACS-ECU
TRANSMITTER
DISASSEMBLY AND REASSEMBLY
Post-assembly Operation

Transmitter operation check
1
2
34
Disassembly steps
1. Screw
2. TapeA3. Battery
4. Master key assembly

BODY – Sunroof42-11
Inspection Procedure 2
The motor does not reverse its direction when a load of
140 N or more is applied while the sunroof is closing.
Probable cause
The sunroof-ECU monitors the load conditions from the amount of current flowing
to the motor. If more than the constant amount of current is flowing, the direction
of motor operation is reversed to prevent jamming.
If the motor does not reverse direction even when an excessive load is being applied,
the cause may be a malfunction of the sunroof-ECU.
Malfunction of sunroof-ECU
Replace the sunroof-ECU.
Inspection Procedure 3
The timer does not operate for 30 seconds after the
ignition switch is turned to OFF.
Probable cause
The sunroof-ECU has a timer function which operates for 30 seconds after the ignition
switch is turned to OFF. If the timer does not operate, the cause may be a malfunction
of the sunroof-ECU or of the wiring harness or connector.
Malfunction of sunroof-ECU

Malfunction of wiring harness or connector
Measure at the sunroof-ECU connector
D-10.

Disconnect the connector and
measure at the harness side.

Voltage between 7 and body earth
OK:System voltageNGCheck the following connectors:
B-44, B-76, B-73NG
Repair
OK
Check trouble symptoms.
OK
Replace the sunroof-ECU.
Check the harness wire between fusible
link No.1 and sunroof-ECU, and repair
if necessary. NG
Inspection Procedure 4
Opening or closing of the sunroof is possible for 30
seconds after turning the ignition switch to OFF, but the
timer function is not extended when the driver’s side door
is opened within this period.
Probable cause
The sunroof timer operation period is extended when an on signal is output from
the driver’s-side door switch. Because of this, if the timer operation period is not
extended, the cause may be a malfunction of the door switch input circuit.
Malfunction of the front door switch (driver’s side)

Malfunction of sunroof-ECU

Malfunction of wiring harness or connector
Check front door switch (driver’s side)
continuity.NG
Replace
OK
Check the following connectors:
B-44, D-03, D-10NG
Repair
OK
Check trouble symptoms.NGCheck the harness wire between front
door switch (driver’s side) and sunroof-
ECU.NG
Repair
OK
Replace the sunroof-ECU.

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

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