clock MITSUBISHI LANCER EVOLUTION VI 1999 Workshop Manual

WARNING!
(1) Improper service or maintenance of any component of the SRS, or any SRS-related component,
can lead to personal injury or death to service personnel (from inadvertent firing of the air
bag) or to the driver and passenger (from rendering the SRS inoperative).
(2) SRS components should not be subjected to heat over 93C, so remove the SRS-ECU, air
bag module and clock spring before drying or baking the vehicle after painting.
(3) Service or maintenance of any SRS component or SRS-related component must be performed
only at an authorized MITSUBISHI dealer.
(4) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP
52B – Supplemental Restraint System (SRS), before beginning any service or maintenance
of any component of the SRS or any SRS-related component.
NOTE
Section titles with asterisks (*) in the table of contents in each group indicate operations requiring warnings.

GENERAL – Precautions Before Service00-15
PRECAUTIONS BEFORE SERVICE
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
1. Items to follow when servicing SRS
(1) Be sure to read GROUP 52B – Supplemental Restraint System (SRS).
For safe operations, please follow the directions and heed all warnings.
(2) Always use the designated special tools and test equipment.
(3) Wait at least 60 seconds after disconnecting the battery cable before doing any further work.
The SRS system is designed to retain enough voltage to deploy the air bag even after the battery
has been disconnected. Serious injury may result from unintended air bag deployment if work
is done on the SRS system immediately after the battery cable is disconnected.
(4) Never attempt to disassemble or repair the SRS components. (SRS air bag control unit, air bag
module and clock spring.) If faulty, replace it.
(5) Warnings labels must be needed when servicing and handling SRS components. Warning labels
are located in the following locations.
Sun visor
Glove box
SRS air bag control unit
Steering wheel
Steering gear and linkage
Air bag module
Clock spring
(6) Store components removed from the SRS in a clean and dry place.
The air bag module should be stored on a flat surface and placed so that the pad surface is
facing upwards.
(7) Be sure to deploy the air bag before disposing of air bag module or disposing of a vehicle equipped
with an air bag. (Refer to GROUP 52B – Air Bag Module Disposal Procedures.)
(8) Whenever you finish servicing the SRS, check the SRS warning lamp operation to make sure
that the system functions properly.
2. Observe the following when carrying out operations on place where SRS components are installed,
including operations not directly related to the SRS air bag.
(1) When removing or installing parts do not allow any impact or shock to the SRS components.
(2) SRS components should not be subjected to heat over 93C, so remove the SRS components
before drying or baking the vehicle after painting.
After re-installing them, check the SRS warning lamp operation to make sure that the system
functions properly.

ENGINE – Timing Belt11-22
LTIMING BELT INSTALLATION
(1) Place the exhaust side camshaft sprocket in a position
where its timing mark is one tooth offset from the timing
mark on the rocker cover in the counterclockwise direction.
NOTE
Even if the timing marks on the sprocket and the rocker
cover are brought into alignment, the exhaust camshaft
is forced back by the valve spring tension. It is stabilized
at a position one tooth before the timing mark.
(2) Align the timing mark on the intake side camshaft sprocket
with that on the rocker cover.
NOTE
Even if the timing marks on the sprocket and the cover
are brought into alignment, the intake camshaft is forced
to turn one tooth in the clockwise direction by the valve
spring tension and stabilized there.
(3) Place the timing mark on the crankshaft sprocket one
tooth this side from the mated timing mark as in the case
of the camshaft sprocket.
(4) Align the timing mark on oil pump sprocket with its mating
mark.
(5) Remove the plug on cylinder block and insert a Phillips
screwdriver (shank diameter 8 mm) through the hole
(Engine with counterbalance shafts).
If it can be inserted as deep as 60 mm or more, the
timing marks are correctly aligned. If the inserted depth
is only 20 – 25 mm, turn the oil pump sprocket one turn
and realign timing marks. Then check to ensure that the
screwdriver can be inserted 60 mm or more. Keep the
screwdriver inserted until installation of timing belt is
finished.
Timing mark
Timing mark
6EN1327
Oil pump
sprocket
timing marks
Screwdriver
6EN1026
Plug

ENGINE – Timing Belt11-23
(6) Remove the Phillips screwdriver. Place the oil pump
sprocket in a position where its timing mark is one tooth
offset from the mated timing mark in the counterclockwise
direction.
(7) Fit the timing belt over the exhaust side camshaft sprocket,
and secure it at the illustrated position using a paper
clip.
(8) Turn the intake side camshaft sprocket as shown to a
position where its timing mark is one tooth offset from
the mated timing mark in the counterclockwise direction.
Then, fit the timing belt over the sprocket and secure
it with a paper clip.
NOTE
The intake camshaft will be turned a little clockwise by
the valve spring tension and stabilized in position even
if the belt is clipped at one tooth offset position.
(9) Check to ensure that the timing marks on the intake
camshaft sprocket side are in alignment when the exhaust
camshaft sprocket is turned clockwise to align the timing
marks.
NOTE
The timing belt span between the intake and exhaust
sprockets will have 17 cogs.
(10)Fit the timing belt over the idler pulley, oil pump sprocket
and crankshaft sprocket in this order.
NOTE
Be careful that the belt does not become slack.
Timing mark
6EN1327
Timing mark
Crankshaft
sprocketOil pump
sprocket

ENGINE – Timing Belt11-24
(11) Fit the timing belt over the tensioner pulley.
NOTE
When fitting the timing belt over the tensioner pulley,
turn the intake side camshaft sprocket a little
counterclockwise, as this will facilitate the work.
(12)Turn the crankshaft pulley a little in the illustrated direction
to pull up the timing belt at the idler pulley side.
(13)Check to ensure that the timing marks on the crankshaft
sprocket, oil pump sprocket and exhaust camshaft
sprocket are all offset one tooth from the corresponding
timing marks in the counterclockwise direction.
(14)Using the special tool, turn the tensioner pulley in the
illustrated direction to strain the timing belt. Then, secure
the tensioner temporarily by tightening the retaining bolt
lightly.
NOTE
There must be no slack in the timing belt between the
intake and exhaust camshafts.
(15)Turn the crankshaft to align the timing mark with the mark
for No. 1 cylinder top dead center in the compression
stroke.
(16)Set the special tool as shown and screw it in up to the
position where the wire inserted in the auto-tensioner
when installing it can be moved lightly.
Crankshaft
sprocket
MD998767
MD998738

ENGINE – Timing Belt11-25
(17)Loosen the retaining bolt of the tensioner pulley.
Caution
Loosening the retaining bolt can cause the intake
and exhaust camshafts to turn, resulting in slackened
timing belt. Use care that the timing belt does not
come off the sprockets at this time.
(18)Pull up the slack of the timing belt by turning the tensioner
in illustrated direction using the special tool and a torque
wrench (0 – 5 Nm).
(19)From this position, turn back the tensioner until the torque
wrench reading becomes 3.5 Nm, then secure it by
tightening the retaining bolt.
(20)Remove the special tool attached in step (16).
(21)Rotate the crankshaft clockwise 2 turns. Then, leave it
intact 15 minutes.
(22)Check to see that the wire inserted when installing the
auto-tensioner can be pulled out lightly. If it can be pulled
out lightly, the timing belt is being tensioned properly.
If so, remove the wire. In addition, check that the rod
protrusion from the auto-tensioner meets the standard
value, which is also an indication of properly tensioned
timing belt.
Standard value: 3.8 – 4.5 mm
(23)If the wire cannot be removed with a light force, repeat
steps (16) through (21) until the proper belt tensioner
is obtained.
INSPECTION
TIMING BELT
Replace belt if any of the following conditions exist.
(1) Hardening of back rubber.
Back side is glossy without resilience and leaves no indent
when pressed with fingernail.
(2) Cracks on rubber back.
(3) Cracks or peeling of canvas.
(4) Cracks on rib root.
(5) Cracks on belt sides.
MD998767

ENGINE – Throttle Body11-74
DISASSEMBLY SERVICE POINTS
ATHROTTLE POSITION SENSOR AND IDLE AIR
CONTROL MOTOR REMOVAL
(1) Do not disassemble the sensor and motor.
(2) Do not immerse solvent to clean the sensor and motor.
Clean then with shop towel.
BTHROTTLE BODY REMOVAL
(1) Do not remove the throttle body.
(2) Check if the vacuum port or passage is clogged. Use
compressed air to clean the vacuum passage.
REASSEMBLY SERVICE POINT
ATHROTTLE POSITION SENSOR INSTALLATION
(1) Install the throttle position sensor to the throttle body
as shown in the diagram.
(2) Turn throttle position sensor 90° clockwise to set it, and
tighten screws.
(3) Check the continuity between terminal No. 3 (Idle throttle
position switch) and No. 4 (Earth).
Throttle valve conditionContinuity
Fully closedConductive
Fully openNo conductive
If there is no continuity with the throttle valve fully closed,
turn the throttle position sensor counterclockwise, and
then check again.
Throttle position sensor
Earth TPS power supply
TPS outputIdle position switch

REAR AXLE – Troubleshooting 27-25
DATA LIST REFERENCE TABLE
The following items can be read by t01he MUT-

from the ECU input data.
Item No.
Check itemChecking requirementsNormal value
01Front-right wheel speedPerform a test run.Vehicle speeds
displayed on the
02Front-left wheel speed
displayed on the
speedometer and
MUTIIare identi03Rear-right wheel speedMUT-II are identi-
cal.
04Rear-left wheel speed
05Front-right wheel speed
(0.2 km/h)
06Front-left wheel speed (0.2
km/h)
07Rear-right wheel speed
(0.2 km/h)
08Rear-left wheel speed (0.2
km/h)
10Vehicle speed
11System voltageIgnition switch: ONBattery voltage
15TPS openingAccelerator pedal position/Igni-
tion switch: ON
Fully closed300 – 1000mV
tion switch: ON
Partially openGradually increases
from the above val-
ue.
Fully open4500 – 5000mV
19Longitudinal acceleration
sensor
Vehicle stands on level ground2.4 – 2.6V
sensor
Perform a test run.Reading fluctuates
up or down with 2.5V
as its center.
20Lateral acceleration sensorVehicle stands on level ground2.4 – 2.6V
Perform a test run.Reading fluctuates
up or down with 2.5V
as its center.
22Steering wheel operationSteering wheel turning direction
Ignition switch: ON90 deg. clock-
wiseR90 deg
90 deg counter-
clockwiseL90 deg
23Steering wheel turning
angular velocity
Steering wheel position
Ignition switch: ON
Not turned0 deg/s
angular velocityIgnition switch: ON
TurnedReading varies ac-
cording to turning
speeds.
45Idle position switchAccelerator pedal position
Ignition position: ON
Not depressedON
Ignition position: ON
DepressedOFF

REAR AXLE – Troubleshooting 27-26
Item No.Normal value Checking requirements Check item
46Steer sensor (ST-N)Steering wheel position
Ignition switch: ON
Neutral positionON
Ignition switch: ON
90 deg. turned
from neutral
positionOFF
47Steer sensor (ST-1)Steering wheel position: Turn slowly counterclock-
wise.
Ignition switch: ONON and OFF are
indicated alternate-
ly.
48Steer sensor (ST-2)Steering wheel position: Turn slowly clockwise.
Ignition switch: ONON and OFF are
indicated alternate-
ly.
50Stop lamp switchAccelerator pedal position
Ignition switch: ON
DepressedON
Ignition switch: ON
ReleasedOFF
56Pressure switchForced activation No.13 or
No.14 is being executed.Electric pump in
operationLow
Electric pump
not in operationHigh
59ABS monitorABS monitorON
ABS not in operationOFF

REAR AXLE – On-vehicle Service 27-31
ON-VEHICLE SERVICE

REAR AXLE TOTAL BACKLASH CHECK
If the drive system roars or the vehicle vibrates, use the
following procedure to measure total backlash in the rear
axle. Based on the measurement taken, determine whether
the differential carrier assembly needs to be removed or not.
1. Place the shift lever in the neutral position and operate
the parking brake.
2. Turn the propeller shaft fully clockwise and make an
alignment mark on the companion flange dust cover and
gear carrier.
3. Turn the propeller shaft fully counterclockwise and
measure the deviation between the alignment marks.
Limit: 5 mm
4. If the backlash exceeds the limit, replace the differential
carrier assembly.
GEAR OIL LEVEL CHECK
DIFFERENTIAL
1. Remove the filler plug.
2. Check that the gear oil level is within the specified range
from the bottom end of the filler plug hole.
Standard value (A): 6 mm
3. If the gear oil level exceeds the standard value, add the
specified gear oil up to the bottom end of the filler plug
hole.
Specified gear oil:
Hypoid gear oil API classification GL-5 or higher
SAE viscosity Number 90, 80W.
NOTE
10C or more: #90, less than 10C: #80
4. Fit the filler plug and tighten it to the specified torque.
Alignment marks
Filler plug
49 Nm
Gear oil
Upper
limit
Lower
limit