front axle 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 . . . . . . . . . . . . . . . . . . . . .
.

FRONT AXLE – General / Axle Hub and Knuckle 26-1
GROUP 26
FRONT AXLE
GENERAL
OUTLINE OF CHANGE

The installation method of the ball joint between the knuckle and the lower arm has been changed,
and accordingly the removal and installation procedures of the axle hub and the knuckle have been
revised.
AXLE HUB AND KNUCKLE
REMOVAL AND INSTALLATION
Caution
(1) For vehicles with AYC, be careful when handling the pole piece at the tip of the speed sensor so as
not to damage it by striking against other parts.
(2) For vehicles with AYC, be careful not to damage the rotors installed to B.J. outer race during removal
and installation of the drive shaft.
Post-installation Operation

Check the Dust Cover for Cracks or Damage by
Pushing it with Finger.
1
23
4 5 6 7
8
12 1415
1388 Nm 108 – 127 Nm
90 – 110 Nm
15 – 33 Nm177 – 275 Nm 25 Nm
25 Nm
9 Nm
103 Nm
74 –87
Nm
11 910
1610
11
Ball joint kit
Removal steps
1. Front speed sensor AYC>
A2. Caliper assembly
3. Brake disc
4. Split pin
BA5. Drive shaft nut
6. Front hub assembly
7. Dust shield
8. Connection for lower arm ball joint
9. Connection bolt for lower arm joint10. Lower arm ball joint
11. Dust cover
12. Split pin
C13. Connection for tie rod end
D14. Front drive shaft
15. Front strut mounting bolt
16. Knuckle
NOTE
Follow the conventional procedures for removal
and installation service points.

FRONT AXLE – Axle Hub and Knuckle 26-2
INSPECTION
LOWER ARM BALL JOINT ROTATION STARTING
TORQUE CHECK
(1) After shaking the ball joint stud several times, install the
nut to the stud and use the special tool to measure the
rotation starting torque of the ball joint.
Standard value: 1.0 – 3.4 Nm
(2) When the measured value exceeds the standard value,
replace the ball joint assembly.
(3) When the measured value is lower than the standard
value, check that the ball joint turns smoothly without
excessive play. If so, it is possible to use that ball joint.
LOWER ARM BALL JOINT DUST COVER
REPLACEMENT
When the dust cover is damaged during service work or grease
leaks out from the dust cover, replace the dust cover in the
conventional procedure. After replacement, check the dust
cover for cracks or damage by pushing it with finger.
MB990326

REAR AXLE – Troubleshooting 27-7

OK
Check the wheel bearing.
NG
Check and repair the harness between
wheel speed sensor and AYC-ECU.
NG
Replace AYC-ECU.
OK
Check the trouble symptom.
OK
Check the following connector:
B-95NG
Repair
OK
Check the trouble symptom.
OK
Check the following connectors:
B-95, B-52, B-17, A-26, A-50, D-04,
D-14, D-19NG
Repair
OK
Measure at B-95 AYC-ECU connector.

Disconnect the connector and
measure at the harness side.

Resistance across 7-20 (front, LH),
6-19 (front, RH), 9-22 (rear, LH),
and 8-21 (rear, RH).
OK:1.4 – 1.8 kΩ.NGCheck the wheel speed sensor. (Refer
to Group 35B.)
Check the installation of wheel speed
sensor.NG
Repair
OK
Check the wheel speed sensor output
voltage. (Refer to P.27-37)NGCheck the wheel speed sensor and
ABS rotor. (Refer to Group 35B.)NG
Replace
NG
Replace

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 27-30
LISTING OF RESISTANCE AND CONTINUITY ACROSS CONNECTOR TERMINALS ON HARNESS
SIDE

Measure the resistance and check for continuity with the ignition switch in the “OFF” position and
AYC-ECU connector disconnected.

Measure the resistance and check for continuity across terminals listed below.

Fig. below shows the arrangement of terminals.
Terminal No.Signal nameNormally
2 – body groundLongitudinal acceleration sensor ground, lateral acceleration sensor groundConducting
26 – body groundECU groundConducting
35 – body groundAYC motor relayConducting
37 – body groundDirectional control valve (right)15.4 – 16.4 Ω
38 – body groundProportioning valve3.4 – 4.0 Ω
45 – body groundDirectional control valve (left)15.4 – 16.4 Ω
46 – body groundECU groundConducting
6 – 19*2Speed sensor (front, RH)1.4 – 1.8 kΩ
7 – 20*2Speed sensor (front, LH)1.4 – 1.8 kΩ
8 – 21*2Speed sensor (rear, RH)1.4 – 1.8 kΩ
9 – 22*2Speed sensor (rear, LH)1.4 – 1.8 kΩ
NOTE
*2: Indicates the vehicles without ABS.

REAR AXLE – On-vehicle Service 27-37
WHEEL SPEED SENSOR OUTPUT VOLTAGE
MEASUREMENT
1. Lift up the vehicle and release the parking brake.
2. Disconnect the AYC-ECU harness connector and take
measurements on the harness side connector.
Caution
Insert the probe from the harness side with the double
lock of the connector unlocked. Inserting it to the
terminal side could result in poor contact.
3. Turn the wheel to be tested at about 1/2 to one
revolution/sec. and check for the output voltage using
a circuit tester (AC mV range) or oscilloscope.
Terminal nos.
Front LHFront RHRear LHRear RH
7698
20192221
Output voltage:
When circuit tester is used: 70 mV or more
When oscilloscope is used: 200 mVp-p or more
(4) If the output voltage is lower than the above value, it
is probably attributable to the following faults. Check or
replace the wheel speed sensor as necessary.

Excessive clearance between the pole piece and rotor
of the wheel speed sensor

Defective wheel speed sensor
Waveform Check Using Oscilloscope
Check the harness and connector of the wheel speed sensor
for connection. Then, use an oscilloscope to check for output
voltage waveform of each sensor as follows.
Start the engine and monitor the sensor by turning the wheel;
for a driving wheel, let it turn by shifting into the 1st gear
and for a driven wheel turn it manually at a constant speed.
NOTE
(1) Waveform may be observed by actually running the
vehicle.
(2) The output voltage is low when the wheel speed remains
low and builds up as the wheel speed increases.
AYC-ECU connector harness side
When turned manually
At idle (5 to 6 km/h)
1st gear

REAR AXLE – On-vehicle Service 27-38
Waveform Observation Points
SymptomProbable causeAction
Waveform amplitude is too small, or no
waveform.Defective wheel speed sensorReplace sensor.
Waveform amplitude varies greatly. (No
problem ifthe smallest amplitude is 100
Excessive axle hub lateral and radial runoutReplace hub.
problem if the smallest amplitude is 100
mV or more)Poor AYC-ECU groundingRepair.
Noise on waveform or disturbed
waveform
Open-circuited sensorReplace sensor.
waveform
Open-circuited harnessRepair harness.
Improperly mounted wheel speed sensorCorrect sensor installation.
Missing or collapsed ABS rotor toothReplace ABS rotor.
Caution
Since the wheel speed sensor cable follows the movement of the front or rear suspension, it
may be open-circuited only when the vehicle is run on rough roads and not on ordinary road.
The wheel speed sensor output voltage waveform should therefore be checked also by rocking
the sensor harness so that driving on rough roads may be simulated.
ACTION WHEN BATTERY RUNS OUT
When the engine is started using a booster cable where the
battery has completely run down and you attempt to start
the vehicle without waiting for the battery to recover a certain
charge, the engine can misfire and you just cannot start to
move it. In such cases, charge the battery sufficiently; or,
remove the AYC fusible link from the engine compartment
relay box to make AYC inactive before attempting to start
the vehicle. When the fusible link is removed, the AYC warning
lamp lights up. After the battery has been recharged, fit the
fusible link back again and start the engine to ensure that
the AYC warning lamp is off.AYC fusible link

REAR AXLE – Sensor Relay / AYC-ECU27-42
INSPECTION
1. LONGITUDINAL AND LATERAL ACCELERATION
SENSOR CHECK
Refer to GROUP 35B – Acceleration Sensor.
2. AYC RELAY CONTINUITY CHECK
Battery voltageTerminal No.
1345
When not energized
When energized
AYC-ECU
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation

Front Floor Console Removal and Installation
5 Nm
AYC-ECU
5 Nm