change time MITSUBISHI LANCER EVOLUTION VI 1999 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 – Troubleshooting13-15
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 – Troubleshooting
Vehicle
speedInitial accel-
erator pedal
depression
NormalHesitation
Sag
Time
(Figure 1)(Figure 2)
Normal
Initial accel-
erator pedal
depression
IdlingStumble
TimeVehicle
speed
13-19
PROBLEM SYMPTOMS TABLE (FOR YOUR INFORMATION)
ItemsSymptom
StartingWon’t startThe starter is used to crank the engine, but there is no combustion within the
cylinders, and the engine won’t start.
Fires up and diesThere is combustion within the cylinders, but then the engine soon stalls.
Hard startingEngine starts after cranking a while.
Idling
stability
HuntingEngine speed doesn’t remain constant; changes at idle.
stability
Rough idleUsually, a judgement can be based upon the movement of the tachometer
pointer, and the vibration transmitted to the steering wheel, shift lever, body, etc.
This is called rough idle.
Incorrect idle speedThe engine doesn’t idle at the usual correct speed.
Engine stall
(Die out)The engine stalls when the foot is taken from the accelerator pedal, regardless
of whether the vehicles is moving or not.
Engine stall
(Pass out)The engine stalls when the accelerator pedal is depressed or while it is being
used.
DrivingHesitation, Sag“Hesitation” is the delay in response of the vehicle speed (engine speed) that
occurs when the accelerator is depressed in order to accelerate from the speed
at which the vehicle is now traveling, or a temporary drop in vehicle speed
(engine speed) during such acceleration. Serious hesitation is called “sag”.
(Refer to Figure 1.)
Poor accelerationPoor acceleration is inability to obtain an acceleration corresponding to the
degree of throttle opening, even though acceleration is smooth, or the inability
to reach maximum speed.
StumbleEngine speed increase is delayed when the accelerator pedal is initially
depressed for acceleration. (Refer to Figure 2.)
ShockThe feeling of a comparatively large impact or vibration when the engine is
accelerated or decelerated.
SurgeThis is repeated surging ahead during constant speed travel or during variable
speed travel.
KnockingA sharp sound like a hammer striking the cylinder walls during driving and which
adversely affects driving.
StoppingRun on
(“Dieseling”)The condition in which the engine continues to run after the ignition switch is
turned to OFF. Also called “Dieseling”.

MPI – Troubleshooting13-56
DATA LIST REFERENCE TABLE
Item
No.Inspection
itemInspection contentsNormal conditionInspection
procedure
No.Reference
page
11Oxygen
sensorEngine:After having
warmed up
Air/fuel mixture is
made leaner when de-
When at 4,000 r/min,
engine is suddenly
decelerated200 mV or lessProcedure
No. 3113-42
made leaner when de-
celerating, and is made
richer when racing.
When engine is
suddenly raced600 – 1,000 mV
Engine:After having
warmed up
The oxygen sensor
si
gnal is used to check
Engine is idling400 mV or less
(Changes)
signal is used to check
the air/fuel mixture
ratio, and control
condition is also
checked by the ECU.2,500 r/min600 – 1,000 mV
12Air flow
sensor*
Engine coolant
tem
perature: 80 –
Engine is idling17 – 43 Hz––
sensor
TION-IV>temperature: 80
95C

Lamps, electric
li f d ll
2,500 r/min46 – 86 Hzp
cooling fan and all
accessories: OFF

Transmission:
Neutral (A/T:
P range)Engine is racedFrequency
increases in
response to
racing
12Air flow
sensor*
Engine coolant
tem
perature: 80 –
Engine is idling12 – 38 Hz––
sensor
TION-V, VI>temperature: 80
95C

Lamps, electric
li f d ll
2,500 r/min36 – 76 Hzp
cooling fan and all
accessories: OFF

Transmission:
Neutral (A/T:
P range)Engine is racedFrequency
increases in
response to
racing
13Intake air
temperature
sensor
Ignition switch: ON or
with engine runningWhen intake air
temperature is –20C–20CCode No.
1313-9
sensorWhen intake air
temperature is 0C0C
When intake air
temperature is 20C20C
When intake air
temperature is 40C40C
When intake air
temperature is 80C80C
NOTE
*: In a new vehicle [driven approximately 500 km or less], the air flow sensor output frequency is sometimes
10% higher than the standard frequency.

REAR AXLE – Troubleshooting 27-11
Code No. 33: Steer sensor (ST-N) systemProbable cause
This code is output when the steering wheel is turned 400 or more in the same
direction with ST-N OFF (HIGH voltage).
Defective steer sensor

Defective harness or connector

Defective AYC-ECU
NG
Replace AYC-ECU.
Check the trouble symptom.
OK
Replace the steer sensor.
NG
Check the harness between steer sen-
sor and AYC-ECU.NG
Repair
OK
Replace AYC-ECU.
OK
Check the trouble symptom.
Measure at B-95 AYC-ECU connector.

Connector connected.

Ignition switch: ON

Turn steering wheel about 90 in
either direction from the straight-
ahead position.

Voltage across 17 and body
ground.
OK:The voltage increases from
about 0.5 V or less to about
3 V.NGCheck the following connectors:
B-95, B-65, B-98NG
Repair
Code No. 34: Steer sensor (ST-1, ST-2) systemProbable cause
This code is output if a turning condition is detected for a cumulative period of time
of 15 min. or more, during which there is no change in the steer sensor (ST-1, ST-2)
signals with the wheel speed 15 km/h or more.
Defective steer sensor

Defective harness or connector

Defective AYC-ECU
NG
Replace AYC-ECU.
Check the trouble symptom.
OK
Replace the steer sensor.
NG
Check the harness between steer sen-
sor and AYC-ECU.NG
Repair
OK
Replace AYC-ECU.
OK
Check the trouble symptom.
Measure at B-95 AYC-ECU connector.

Connector connected.

Ignition switch: ON

Voltage across 4/5 and body
ground
OK:The voltage alternates
between about 0.5 V and
about 3 V as the steering
wheel is turned.NGCheck the following connectors:
B-95, B-65, B-98NG
Repair

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

BODY – Keyless Entry System42-5
NG
Repair
NG
Check the harness wire, and repair if necessary.

Between fusible link No.1 and receiver

Between ignition switch and receiver
NG
Repair
NG
Check the harness wire, and repair if necessary.

Between receiver and earth
OK
Replace the receiver.
OK
Check trouble symptoms.
OK
Measure at the receiver connector D-01.

Disconnect the connector, and measure at the harness side.

Between 20 and body earth
OK:ContinuityNGCheck the following connectors:
B-50, D-01
OK
Check trouble symptoms.
Measure at the receiver connector D-01.

Disconnect the connector, and measure at the harness side.

Voltage between 9 and body earth

Voltage between 10 and body earth
OK:System voltageNGCheck the following connectors:
B-49, B-75, D-01
From previous page
INSPECTION OF RECEIVER TERMINAL VOLTAGE
TerminalSignal nameConditionsTerminal voltage
2Door switchOne or more doors are open (Door switch: ON)0 V
All doors are closed (Door switch: OFF)System voltage
6Door lock actuator
switch (driver’s side)
LOCK5 V and pulse output*
switch (driver’s side)
UNLOCK0 V
7Diagnosis changeover
input
When MUT-II is connected0 V
input
When MUT-II is disconnectedSystem voltage
8Key reminder switchOFF (When ignition key is inserted)5 V and pulse output*
ON (When ignition key is removed)0 V
9Ignition switchIgnition switch: ACC or ONSystem voltage
Ignition switch: OFF0 V
10Receiver power supplyAt all timesSystem voltage
11Room lamp outputOne or more door are open (Door switch: ON)0 V
All doors are closed (Door switch: OFF)System voltage

FULL-AUTOMATIC AIR CONDITIONER – Troubleshooting55-54
DATA LIST REFERENCE TABLE
Check itemCheck conditionNormal condition
Inside air temperature sensor

MUT-II (11)Ignition switch: ONInside air temperature and temper-
ature displayed on the MUT-II are
identical.
Outside air temperature sen-
sor

MUT-II (13)Ignition switch: ONOutside air temperature and tem-
perature displayed on the MUT-II
are identical.
Heater water temperature
sensor

MUT-II (15)Ignition switch: ONHeater core surface temperature
and temperature displayed on the
MUT-II are identical.
Air thermo sensor

MUT-II (21)Ignition switch: ONEvaporator surface temperature
and temperature displayed on the
MUT-II are identical.
Photo sensor

MUT-II (25)Ignition switch: ONAmount of incident light is propor-
tional to voltage displayed on the
MUT-II.
Air mix damper potentiometer

MUTII(31)
Ignition switch: ONDamper positionOpening degree (%)

MUT-II (31)MAX. HOTApprox. 100
MAX. COOLApprox. 0
Air outlet changeover damper
potentiometer
Ignition switch: ONDamper positionOpening degree (%)
potentiometer

MUT-II (32)FACEApprox. 0
FOOTApprox. 50
FOOT/DEF.Approx. 75
DEF.Approx. 100
CHECK AT THE A/C-ECU TERMINALS
A/C-ECU
The parenthesized values in “Normal condition” column are for your reference.
Terminal
No.
Check itemCheck conditionNormal condition
1Front power transistor collector outputWhen blower switch is at OFFSystem voltage
When blower switch is at LOApprox. 7 V
When blower switch is at HIAlmost no voltage (0 V)
2Front power transistor base outputWhen blower switch is at OFF0 V
When blower switch is at LOApprox. 1.3 V
When blower switch is at HIApprox. 2.5 V
3BackupAt all timesSystem voltage

FULL-AUTOMATIC AIR CONDITIONER – Troubleshooting55-55
Terminal
No.Normal condition Check condition Check item
4Heater water temperature sensor
inputWhen sensor section temperature is
25C (4 kΩ)2.3 – 2.9 V
5Air mix damper potentiometer inputWhen damper is moved to MAX. HOT
position4.7 – 5.0 V
6Air outlet changeover damper poten-
tiometer inputWhen damper is moved to DEF.
position4.8 – 5.2 V
7Outside air temperature sensor inputWhen sensor section temperature is
25C (4 kΩ)2.3 – 2.9 V
8Air thermo sensor inputWhen sensor section temperature is
25C (4 kΩ)2.3 – 2.9 V
9Photo sensor (–)At luminous intensity of 0 lux0 V
At luminous intensity of 100,000 lux or
more–0.1 – 0.2 V
10Sensor power supplyAt all times4.8 – 5.2 V
12Blower motor HI relay (Exciting circuit)When blower switch is in HI1.5 V or less
When blower switch is in a position
other than HISystem voltage
16Rear defoggerWhen rear defogger switch is ON1.5 V or less
When rear defogger switch is OFFSystem voltage
17Diagnosis date outputWhen ignition switch is ON0 V ↔ 12 V
18Diagnosis control outputWhen ignition switch is ONSystem voltage – 2 V
19Photo sensor (+)At all times0 V
20Sensor earthAt all times0 V
21Air outlet changeover damper motor
(FACE)When damper is moved to FACE
position10 V
When damper is moved to DEF.
positionAlmost no voltage
(0.5 V)
22Air mix damper motor (MAX. COOL)When damper is moved to MAX.
COOL position10 V
When damper is moved to MAX. HOT
positionAlmost no voltage
(0.5 V)
23Inside/outside air changeover damper
motor (Inside)When switch is set to inside air
positionAlmost no voltage
(0.5 V)
When switch is set to outside air
position10 V
24Air outlet changeover damper motor
(DEF.)When damper is moved to FACE
positionAlmost no voltage
(0.5 V)
When damper is moved to DEF.
position10 V

FULL-AUTOMATIC AIR CONDITIONER –
Troubleshooting /
On-vehicle Service55-56
Terminal
No.Normal condition Check condition Check item
25Air mix damper motor (MAX. HOT)When damper is moved to MAX.
COOL positionAlmost no voltage
(0.5 V)
When damper is moved to MAX. HOT
position10 V
26Inside/outside air changeover damper
motor (Outside)When switch is set to inside air
position10 V
When switch is set to outside air
positionAlmost no voltage
(0.5 V)
28IG2 power supplyWhen ignition switch is ONSystem voltage
29EarthAt all timesContinuity
30ILL power supplyWhen lighting switch is at ONSystem voltage
34A/C outputWhen A/C is OFF0 V
When A/C is ONSystem voltage
35EarthAt all timesContinuity
ON-VEHICLE SERVICE
REFRIGERANT CHARGING, LEVEL CHECK,
ADDITION AND REMOVAL, PERFORMANCE
TEST, DUAL PRESSURE SWITCH SIMPLE
CHECK
Follow the same procedures as for the heater and manual
air conditioner. (Refer to P.55-6.)