Evo 7 workshop manual MITSUBISHI LANCER EVOLUTION VI 1999 Workshop Manual

WORKSHOP MANUAL
Pub. No. S9806CNCP9-A
EVOLUTION-VI
Pub. No. S9806CNCP9-A
EVOLUTION-VI
Pub. No. S9806CNCP9-A
Mar. ’99 Printed in Japan
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 – Troubleshooting13-9
Code No. 13 Intake air temperature sensor systemProbable cause
Range of Check

Ignition switch: ON

Excluding 60 seconds after the ignition switch is turned to ON or immediately
after the engine starts.
Set conditions

Sensor output voltage is 4.6 V or more (corresponding to an intake air temperature
of –45C or less) for 4 seconds.
or

Sensor output voltage is 0.2V or less (corresponding to an intake air temperature
of 125C or more) for 4 seconds.
Malfunction of the intake air temperature sensor

Improper connector contact, open or short-circuited
harness wire of the intake air temperature sensor circuit

Malfunction of the engine-ECU
Check the intake air temperature
sensor. (Refer to P.13-32.)*NG
OK
Measure at the air flow sensor con-
nector A-25.

Disconnect the connector, and
measure at the harness side.

Voltage between 6 and earth
(Ignition switch: ON)
OK:4.5–4.9 V

Continuity between 5 and earth
OK:ContinuityNGCheck the following connector:
B-62NG
Repair
OK
Check trouble symptom.
NG
Check the harness wire between
the engine-ECU and the intake air
temperature sensor connector.NG
Repair
OK
Replace the engine-ECU. OK
Check the following connector:
A-25NG
Repair
OK
Check trouble symptom.NGReplace the engine-ECU.
Replace the air flow sensor.
NOTE
*: Refer to Workshop Manual for LANCER EVOLUTION-IV and EVOLUTION-V (Pub. No. S9806CNCP9).
Code No. 14 Throttle position sensor system
Probable cause
Range of Check

Ignition switch: ON

Excluding 60 seconds after the ignition switch is turned to ON or immediately
after the engine starts.
Set conditions

The sensor output voltage is 0.2 V or less for 4 seconds.
Malfunction of the throttle position sensor

Improper connector contact, open or short-circuited
harness wire of the throttle position sensor circuit

Improper “ON” state of idle position switch

Short circuit of the idle position switch signal line

Malfunction of the engine-ECU
MUT-II Data list
26 Idle position switch system
OK:With the throttle valve at the
idle position: ON
With the throttle valve slight-
ly open: OFFNGCheck the idle position switch system.
(Refer to P.13-38, INSPECTION PRO-
CEDURE 26.)
OK
Check the throttle position sensor.NG
Replace
OK
Measure at the throttle position sensor
connector A-16.

Disconnect the connector, and
measure at the harness side.

Voltage between 1 and earth
(Ignition switch: ON)
OK:4.8–5.2 V

Continuity between 4 and earth
OK:ContinuityNGCheck the following connector:
B-62NG
Repair
OK
Check trouble symptom.
NG
Check the harness wire between the
engine-ECU and the throttle position
sensor connector.NG
Repair
OK
Replace the engine-ECU. OK
Check the throttle position sensor out-
put circuit. (Refer to P.13-55, INSPEC-
TION PROCEDURE 49.)

MPI – Troubleshooting13-10
Code No. 21 Engine coolant temperature sensor systemProbable cause
Range of Check

Ignition switch: ON

Excluding 60 seconds after the ignition switch is turned to ON or immediately
after the engine starts.
Set conditions

Sensor output voltage is 4.6 V or more (corresponding to an engine coolant
temperature of –45C or less) for 4 seconds.
or

Sensor output voltage is 0.1 V or less (corresponding to an engine coolant
temperature of 140C or more) for 4 seconds.
Malfunction of the engine coolant temperature sensor

Improper connector contact, open or short-circuited
harness wire of the engine coolant temperature sensor
circuit

Malfunction of the engine-ECU
Range of Check

Ignition switch: ON

Engine speed is approx. 50 r/min or more
Set conditions

The sensor output voltage increases from 1.6 V or less (corresponding to an
engine coolant temperature of 40C or more) to 1.6 V or more (corresponding
to an engine coolant temperature of 40C or less).

After this, the sensor output voltage is 1.6 V or more for 5 minutes.
Check the engine coolant temperature
sensor. (Refer to P.13-32.)*NG
Replace
OK
Measure at the engine coolant temper-
ature sensor connector A-38.

Disconnect the connector, and
measure at the harness side.

Voltage between 1 and earth
(Ignition switch: ON)
OK:4.5–4.9 V

Continuity between 2 and earth
OK:ContinuityNGCheck the following connector:
B-62NG
Repair
OK
Check trouble symptom.
NG
Check the harness wire between the
engine-ECU and the engine coolant
temperature sensor connector.NG
Repair
OK
Replace the engine-ECU.
Check the following connector:
A-38OKCheck trouble symptom.
NG
Replace the engine-ECU.
NG
RepairOK
NOTE
*: Refer to Workshop Manual for LANCER EVOLUTION-IV and EVOLUTION-V (Pub. No. S9806CNCP9).

MPI – Troubleshooting13-15
Code No. 31 Detonation sensor systemProbable cause
Range of Check

Ignition switch: ON

Excluding 60 seconds after the ignition switch is turned to ON or immediately
after the engine starts.

Engine speed is approx. 5,000 r/min or more

Set conditions

The change in the detonation sensor output voltage (detonation sensor peak voltage
at each 1/2 revolution of the crankshaft) is less than 0.06 V for 200 times in
succession.
Malfunction of the detonation sensor

Improper connector contact, open or short-circuited
harness wire of the detonation sensor circuit

Malfunction of the engine-ECU
Measure at the detonation sensor con-
nector A-96.

Disconnect the connector and
measure at the harness side.

Continuity between 2 and earth
OK:ContinuityOKCheck the following connector:
B-62NG
Repair
OK
Check trouble symptom.
NG
Check the harness wire between the
engine-ECU and the detonation sensor
connector.OKReplace the detonation sensor.
Check trouble symptom.
NG
Replace the engine-ECU.
NG
Repair
NG
Check the harness wire between the
detonation sensor and earth, and repair
if necessary.
Code No. 41 Injector systemProbable cause
Range of Check

Engine speed is approx. 50–1,000 r/min

The throttle position sensor output voltage is 1.15 V or less.

Actuator test by MUT-II is not carried out.
Set conditions

Surge voltage of injector coil is not detected for 4 seconds.
Malfunction of the injector

Improper connector contact, open or short-circuited
harness wire of the injector circuit

Malfunction of the engine-ECU
OK
Check trouble symptom.NGCheck the harness wire between the
resistor and the injector connector, and
repair if necessary.
Check the injector control circuit.
(Refer to P.13-55, INSPECTION PRO-
CEDURE 50.)OK
OK
Measure at the injector connectors
A-53, A-54, A-55, A-56

Disconnect the connector, and
measure at the harness side.

Voltage between 1 and earth
(Ignition switch: ON)
OK:System voltageNGCheck the following connector:
A-125NG
Repair
OK
Measure at the resistor connector
A-125.

Disconnect the connector, and
measure at the harness side.

Voltage between 3 and earth
(Ignition switch: ON)
OK:System voltageNGCheck the harness wire between the
control relay and the resistor connector,
and repair if necessary.
Check the injector. (Refer to P.13-34.)*
Check the resistor. (Refer to P.13-34.)*NG
Replace
NOTE
*: Refer to Workshop Manual for LANCER EVOLUTION-IV and EVOLUTION-V (Pub. No. S9806CNCP9).

MPI – Troubleshooting13-23
INSPECTION PROCEDURE 6
Initial combustion but no complete combustion
(starting impossible)
Probable cause
In such cases as the above, the cause is probably that the spark plugs are generating
sparks but the sparks are weak, or the initial mixture for starting is not appropriate.
Malfunction of the ignition system

Malfunction of the injector system

Foreign materials in fuel

Poor compression

Malfunction of the engine-ECU
Check system voltage when cranking.
OK:8 V or higherNGCheck the battery.
OK
MUT-II: Check if uncompleted combustion occurs.
(Refer to P.13-48, INSPECTION PROCEDURE 39.)
OK
Can any sound be heard from the injectors when cranking (check
using a soundscope)?NGCheck the injector system, (Refer to P.13-15, INSPECTION PRO-
CEDURE FOR DIAGNOSIS CODE 41.)
OK
Is starting good if the engine is cranked with the accelerator pedal
slightly depressed?Ye sCheck ISC servo for op-
eration sound. NGCheck the ISC servo sys-
tem. (Refer to P.13-44, IN-
SPECTION PROCE-
DURE 33.)
OK

Clean the throttle valve area.

Adjust the fixed SAS. (Refer to P.13-30.)*
No
Check the ignition timing when cranking.
OK:Approx. 5BTDCNGCheck that the crank angle sensor and the timing belt cover are
installed properly.
OK
Check the following items.

Check the ignition coil, spark plugs, spark plug cables.

Check the injectors for clogging and leakage.

Check the compression pressure.

Check fuel lines for clogging.

Check if foreign materials (water, alcohol, etc.) got into fuel.
NOTE
*: Refer to Workshop Manual for LANCER EVOLUTION-IV and EVOLUTION-V (Pub. No. S9806CNCP9).

MPI – Troubleshooting13-25
INSPECTION PROCEDURE 8
Unstable idling (Rough idling, hunting)
Probable cause
In cases as the above, the cause is probably that the ignition system, air/fuel mixture,
idle speed control (ISC) or compression pressure is defective.
Because the range of possible causes is broad, inspection is narrowed down to simple
items.
Malfunction of the ignition system

Malfunction of air-fuel ratio control system

Malfunction of the ISC servo system

Poor compression

Drawing air into exhaust system

Secondary air backflow to the intake system
Were the battery terminals disconnected recently?Ye sAfter warming-up, let the engine run at idling for about 10 minutes.
No
MUT-II Self-Diag code
Are diagnosis codes displayed?Ye sRefer to P.13-8, INSPECTION CHART FOR DIAGNOSIS CODES.
No
Does idling speed fluctuate excessively?Ye sCheck if hunting occurs.
(Refer to P.13-48, INSPECTION PROCEDURE 40.)
No
Check the ISC servo for operation sound.NGCheck the ISC servo system.
(Refer to P.13-44, INSPECTION PROCEDURE 33.)
OK
Check the injector for operation.NGCheck the injector system. (Refer to P.13-15, INSPECTION PRO-
CEDURE FOR DIAGNOSIS CODE 41.)
OK
MUT-II: Check if idling speed is unstable.
(Refer to P.13-49, INSPECTION PROCEDURE 41.)
OK
Check the ignition timing.
(Refer to GROUP 11 – Engine Adjustment.)*NGCheck that the crank angle sensor and the timing belt cover are
installed properly.
OK
Check the following items.

Check the ignition coil, spark plugs, spark plug cables.

Check the secondary air supply system. (Ensure that there is no back flow of secondary air into the intake system.)

Check the compression pressure.

Check if foreign materials (water, alcohol, etc.) got into fuel.
NOTE
*: Refer to Workshop Manual for LANCER EVOLUTION-IV and EVOLUTION-V (Pub. No. S9806CNCP9).

MPI – Troubleshooting13-26
INSPECTION PROCEDURE 9
Idling speed is high. (Improper idling speed)
Probable cause
In such cases as the above, the cause is probably that the intake air volume during
idling is too great.
Malfunction of the ISC servo system

Malfunction of the throttle body
OK
MUT-II Data list
26 Idle position switch (Refer to P.13-58.)NGCheck the idle position switch system.
(Refer to P.13-38, INSPECTION PROCEDURE 26.)
No
Check the ISC servo for operation sound.NGCheck the ISC servo system.
(Refer to P.13-44, INSPECTION PROCEDURE 33.)
OK
MUT-II Data list
21 Engine coolant temperature sensor (Refer to P.13-57.)NGCheck the engine coolant temperature sensor system.
(Refer to P.13-10, INSPECTION PROCEDURE FOR DIAGNOSIS
CODE 21.)
OK
MUT-II Data list
28 A/C switch (Refer to P.13-58.)NGCheck the A/C switch and A/C relay system.
(Refer to P.13-39, INSPECTION PROCEDURE 29.)
OK
Basic idle speed adjustment (Refer to P.13-30.)*
Check trouble symptom.NGClean the throttle valve area.
Adjust the fixed SAS. (Refer to P.13-30.)*
MUT-II Self-Diag code
Are diagnosis codes displayed?Ye sRefer to P.13-8, INSPECTION CHART FOR DIAGNOSIS CODES.
NOTE
*: Refer to Workshop Manual for LANCER EVOLUTION-IV and EVOLUTION-V (Pub. No. S9806CNCP9).

MPI – Troubleshooting13-27
INSPECTION PROCEDURE 10
Idling speed is low. (Improper idling speed)
Probable cause
In cases such as the above, the cause is probably that the intake air volume during
idling is too small.
Malfunction of the ISC servo system

Malfunction of the throttle body
MUT-II Self-Diag code
Are diagnosis codes displayed?Ye sRefer to P.13-8, INSPECTION CHART FOR DIAGNOSIS CODES.
No
Check the ISC servo for operation sound.NGCheck the ISC servo system.
(Refer to P.13-44, INSPECTION PROCEDURE 33.)
OK
MUT-II Data list
26 Idle position switch (Refer to P.13-58.)NGCheck the idle position switch system.
(Refer to P.13-38, INSPECTION PROCEDURE 26.)
OK
MUT-II Data list
21 Engine coolant temperature sensor (Refer to P.13-57.)NGCheck the engine coolant temperature sensor system.
(Refer to P.13-10, INSPECTION PROCEDURE FOR DIAGNOSIS
CODE 21.)
OK
Basic idle speed adjustment (Refer to P.13-30.)*
Check trouble symptom.NGClean the throttle valve area.
Adjust the fixed SAS. (Refer to P.13-30.)*
NOTE
*: Refer to Workshop Manual for LANCER EVOLUTION-IV and EVOLUTION-V (Pub. No. S9806CNCP9).

MPI – Troubleshooting13-28
INSPECTION PROCEDURE 11
When the engine is cold, it stalls at idling. (Die out)
Probable cause
In such cases as the above, the cause is probably that the air/fuel mixture is inappropriate
when the engine is cold, or that the intake air volume is insufficient.
Malfunction of the ISC servo system

Malfunction of the throttle body

Malfunction of the injector system

Malfunction of the ignition system
Were the battery terminals disconnected recently?Ye sAfter warming-up, let the engine run at idling for about 10 minutes.
No
MUT-II Self-Diag code
Are diagnosis codes displayed?Ye sRefer to P.13-8, INSPECTION CHART FOR DIAGNOSIS CODES.
OK
Check the fuel pressure. (Refer to P.13-30.)*
OK
Check the ignition timing.
(Refer to GROUP 11 – Engine Adjustments.)*NGCheck that the crank angle sensor and the timing belt cover are
installed properly.
OK
Check the following items.

Check the ignition coil, spark plugs, spark plug cables.

Check the compression pressure.

Check the engine oil viscosity.
OK
MUT-II Data list
26 Idle position switch (Refer to P.13-58.)NGCheck the idle position switch system.
(Refer to P.13-38, INSPECTION PROCEDURE 26.)
OK
Check the injector for operation sound.NGCheck the injector system. (Refer to P.13-15, INSPECTION PRO-
CEDURE FOR DIAGNOSIS CODE 41.)
Ye s
Check the ISC servo for operation sound.NGCheck the ISC servo system.
(Refer to P.13-44, INSPECTION PROCEDURE 33.)
No
Is engine-idling stable after the warming-up?NoCheck for unstable idling (Rough idling, hunting).
(Refer to P.13-25, INSPECTION PROCEDURE 8.)
No
Does the engine stall right after the accelerator pedal is released?Ye sClean the throttle valve
area.Adjust the fixed SAS.
(Refer to P.13-30.)*
OK
MUT-II Data list
21 Engine coolant temperature sensor (Refer to P.13-57.)NGCheck the engine coolant temperature sensor system.
(Refer to P.13-10, INSPECTION PROCEDURE FOR DIAGNOSIS
CODE 21.)
NOTE
*: Refer to Workshop Manual for LANCER EVOLUTION-IV and EVOLUTION-V (Pub. No. S9806CNCP9).