light MITSUBISHI LANCER EVOLUTION VI 1999 Workshop Manual

GENERAL – How to Use Troubleshooting/Inspection Service Points00-13
INSPECTION SERVICE POINTS FOR A BLOWN
FUSE
Remove the fuse and measure the resistance between the
load side of the fuse and the earth. Set the switches of all
circuits which are connected to this fuse to a condition of
continuity. If the resistance is almost 0 Ω at this time, there
is a short somewhere between these switches and the load.
If the resistance is not 0 Ω, there is no short at the present
time, but a momentary short has probably caused the fuse
to blow.
The main causes of a short circuit are the following.
Harness being clamped by the vehicle body
Damage to the outer casing of the harness due to wear
or heat
Water getting into the connector or circuitry
Human error (mistakenly shorting a circuit, etc.)
POINTS TO NOTE FOR INTERMITTENT
MALFUNCTIONS
Intermittent malfunctions often occur under certain conditions,
and if these conditions can be ascertained, determining the
cause becomes simple. In order to ascertain the conditions
under which an intermittent malfunction occurs, first ask the
customer for details about the driving conditions, weather
conditions, frequency of occurrence and trouble symptoms,
and then try to recreate the trouble symptoms. Next, ascertain
whether the reason why the trouble symptom occurred under
these conditions is due to vibration, temperature or some
other factor. If vibration is thought to be the cause, carry
out the following checks with the connectors and components
to confirm whether the trouble symptom occurs.
The objects to be checked are connectors and components
which are indicated by inspection procedures or given as
probable causes (which generates diagnosis codes or trouble
symptoms.)
Gently shake the connector up, down and to the left and
right.
Gently shake the wiring harness up, down and to the
left and right.
Gently rock each sensor and relay, etc. by hand.
Gently shake the wiring harness at suspensions and other
moving parts.
NOTE
If determining the cause is difficult, the flight recorder function
of the MUT-II can also be used.
Battery
Fuse
Load
switch
LoadConnector
inspection0 Ω

GENERAL – Precautions Before Service00-16
SERVICING THE ELECTRICAL SYSTEM
Before replacing a component related to the electrical system
and before undertaking any repair procedures involving the
electrical system, be sure to first disconnect the negative
(–) cable from the battery in order to avoid damage caused
by short-circuiting.
Caution
Before connecting or disconnecting the negative (–) cable,
be sure to turn off the ignition switch and the lighting
switch.
(If this is not done, there is the possibility of
semiconductor parts being damaged.)
APPLICATION OF ANTI-CORROSION AGENTS
AND UNDERCOATS
If oil or grease gets onto the oxygen sensor, it will cause
a drop in the performance of the sensor.
Cover the oxygen sensor with a protective cover when applying
anti-corrosion agents and undercoats.
PRE-INSPECTION CONDITION
“Pre-inspection condition” refers to the condition that the
vehicle must be in before proper engine inspection can be
carried out. If you see the words “Set the vehicle to the
pre-inspection condition.” in this manual, it means to set the
vehicle to the following condition.
Engine coolant temperature: 80–90C
Lamps, electric cooling fan and all accessories: OFF
M/T: Neutral
VEHICLE WASHING
If high-pressure car-washing equipment or steam car-washing
equipment is used to wash the vehicle, be sure to note the
following information in order to avoid damage to plastic
components, etc.
Spray nozzle distance: Approx. 40 cm or more
Spray pressure: 3,900 kPa or less
Spray temperature: 82C or less
Time of concentrated spray to one point: within 30 sec.
Approx.
40 cm

ENGINE – Specifications11-10
FORM-IN-PLACE GASKET
The engine has several areas where the form-in-place gasket (FIPG) is in use. To ensure that the gasket
fully serves its purpose, it is necessary to observe some precautions when applying the gasket. Bead
size, continuity and location are of paramount importance. Too thin a bead could cause leaks. Too thick
a bead, on the other hand, could be squeezed out of location, causing blocking or narrowing of the
fluid feed line. To eliminate the possibility of leaks from a joint, therefore, it is absolutely necessary to
apply the gasket evenly without a break, while observing the correct bead size.
The FIPG used in the engine is a room temperature vulcanisation (RTV) type and is supplied in a 100-gram
tube (Part No. MD970389). Since the RTV hardens as it reacts with the moisture in the atmospheric
air, it is normally used in the metallic flange areas. The FIPG, Part No. MD970389, can be used for
sealing both engine oil and coolant, while Part No. MD997110 can only be used for engine oil sealing.
Disassembly
The parts assembled with the FIPG can be easily disassembled without use of a special method. In
some cases, however, the sealant between the joined surfaces may have to be broken by lightly striking
with a mallet or similar tool. A flat and thin gasket scraper may be lightly hammered in between the
joined surfaces. In this case, however, care must be taken to prevent damage to the joined surfaces.
For removal of the oil pan, the special tool “Oil Pan Remover” (MD998727) is available. Be sure to use
the special tool to remove the oil pan.
Surface Preparation
Thoroughly remove all substances deposited on the gasket application surfaces, using a gasket scraper
or wire brush. Check to ensure that the surfaces to which the FIPG is to be applied is flat. Make sure
that there are no oils, greases and foreign substances deposited on the application surfaces. Do not
forget to remove the old sealant remained in the bolt holes.
Form-in-Place Gasket Application
When assembling parts with the FIPG, you must observe some precautions, but the procedures is very
simple as in the case of a conventional precut gasket.
Applied FIPG bead should be of the specified size and without breaks. Also be sure to encircle the
bolt hole circumference with a completely continuous bead. The FIPG can be wiped away unless it is
hardened. While the FIPG is still moist (in less than 15 minutes), mount the parts in position. When
the parts are mounted, make sure that the gasket is applied to the required area only. In addition, do
not apply any oil or water to the sealing locations or start the engine until a sufficient amount of time
(about one hour) has passed after installation is completed.
The FIPG application procedure may vary on different areas. Observe the procedure described in the
text when applying the FIPG.

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 – Turbocharger11-76
DISASSEMBLY SERVICE POINTS
ASNAP RING REMOVAL
Lay the unit with the compressor cover side facing down
and using snap ring pliers, remove the compressor cover
attaching snap ring.
Caution
When removing the snap ring, hold it with fingers to
prevent it from springing away.
BTURBINE WHEEL ASSEMBLY REMOVAL
Remove the turbine wheel assembly, striking the
circumference of the compressor cover with a plastic hammer.
The turbine wheel assembly may be a little hard to remove
due to an O-ring put on the outer circumference.
CLEANING
(1) Use a clean cleaning oil commercially available. Do not
use corrosive cleaning oils as they could damage to some
parts.
(2) Use a plastic scraper or hard brush to clean aluminum
parts.
REASSEMBLY SERVICE POINTS
AO-RING INSTALLATION
Apply a light coat of engine oil to a new O-ring and fit in
the turbine wheel assembly groove.
Caution
When installing the O-ring, use care not to damage it.
A damaged O-ring causes oil leaks.
BTURBINE WHEEL ASSEMBLY
(1) Apply a light coat of engine oil to the periphery of the
O-ring.
(2) Install the turbine wheel assembly to the compressor cover
in relation to the dowel pin.
Caution
Use care not to damage the blades of turbine wheel
and compressor wheel.
Snap ring
Turbine
wheel
assembly
O-ring
Dowel pin hole
Dowel pin

ENGINE – Turbocharger11-78
COMPRESSOR COVER
Check the compressor cover for traces of contact with the
compressor wheel and other damage.
TURBINE WHEEL ASSEMBLY
(1) Check the turbine and compressor wheel blades for bend,
burr, damage, corrosion and traces of contact on the
back side and replace if defective.
(2) Check the oil passage of the turbine wheel assembly
for deposit and clogging.
(3) In the case of water cooled type, check also the water
passage for deposit and clogging.
(4) Check the turbine wheel and compressor wheel for light
and smooth turning.Oil passage
Turbine wheel
Compressor
wheelWater passage

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 – Troubleshooting13-23
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 – Troubleshooting13-47
INSPECTION PROCEDURE 37
MUT-II: Inspection of no initial combustion
MUT-II Data list
16 engine-ECU power supply voltage (Refer to P.13-57.)NGCheck the power supply and ignition switch-IG system.
(Refer to P.13-35, INSPECTION PROCEDURE 24.)
OK
Does the camshaft rotate at the engine cranking?
(When oil filler cap is removed.)NoCheck timing belt for breakage.
Ye s
MUT-II Self-Diag code
Are diagnosis codes displayed?Ye sRefer to P.13-8, INSPECTION CHART FOR DIAGNOSIS CODES.
No
MUT-II Data list
22 Crank angle sensor
OK:Cranking speed is displayed.NGCheck the crank angle sensor system.
(Refer to P.13-11, INSPECTION PROCEDURE FOR DIAGNOSIS
CODE 22.)
OK
MUT-II Actuator test
07 Fuel pump (Refer to P.13-61.)NGCheck the fuel pump system.
(Refer to P.13-36, INSPECTION PROCEDURE 25.)
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.)
INSPECTION PROCEDURE 38
Ignition system: Inspection of no initial combustion.
OK
Check the ignition timing when cranking.
OK:Approx. 5BTDCNGCheck that the crank angle sensor and the timing belt cover are
installed properly.
NGCheck the ignition circuit system.
(Refer to P.13-44, INSPECTION PROCEDURE 32.)Check by connecting a timing light to the spark plug cable.
OK:Timing light flashes during cranking.