sunroof MITSUBISHI LANCER EVOLUTION VI 1999 Workshop Manual

REAR AXLE – Hydraulic Unit 27-40
REMOVAL SERVICE POINTS
AHYDRAULIC UNIT REMOVAL
Should the hydraulic unit be discarded, drill a hole in the
accumulator at the illustrated position beforehand in order
to release the inside gas.
Caution
(1) The hydraulic unit has its accumulator filled with a
high pressure gas. Never throw it into a fire. Also,
never attempt to disassemble, press, weld or melt
it.
(2) When drilling a hole in the accumulator, be sure to
wear safety goggles since drill chips may blow out
together with the gas.
INSTALLATION SERVICE POINTS
AGROMMET INSTALLATION
On the vehicle mounted with a sunroof, mount the drain pipe
to the grommet as illustrated.
BSUCTION HOSE / RETURN HOSE INSTALLATION
Fit the suction hose and return hose to the nipple of hydraulic
unit as illustrated.
CHYDRAULIC UNIT AND BRACKET ASSEMBLY
INSTALLATION
Hook the hydraulic unit bracket hook to the rear floor side
member and install the hydraulic unit and bracket assembly
mounting bolt.Grommet
Drain pipe
25 ± 5 mm
Nipple
Suction hose and
return hose15 mm
Hook
Rear floor side member

42-1
BODY
CONTENTS
GENERAL 2. . . . . . . . . . . . . . . . . . . . . . . . . .
OUTLINE OF CHANGE 2. . . . . . . . . . . . . . . . . .
KEYLESS ENTRY SYSTEM 2. . . . . . . . . .
SPECIAL TOOL 2. . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 2. . . . . . . . . . . . . . . . . . . .
KEYLESS ENTRY SYSTEM 7. . . . . . . . . . . . . .
TRANSMITTER 7. . . . . . . . . . . . . . . . . . . . . . . . . .
SUNROOF 9. . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE SPECIFICATIONS 9. . . . . . . . . . . . . .
SEALANT 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 9. . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE 13. . . . . . . . . . . . . . . .
Water Test 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sunroof Fit Adjustment 13. . . . . . . . . . . . . . . . . . .
SUNROOF 14. . . . . . . . . . . . . . . . . . . . . . . . . . . .

BODY – SunroofBODY – Sunroof42-9
SUNROOF
SERVICE SPECIFICATIONS
ItemsStandard value
Roof lid glass operating current A (at 20C)7 or less
Sunroof motor clutch slippage torque Nm4.7 – 6.2
SEALANT
ItemSpecified sealant
Rail cover assembly3M ATD Part No.8531 or 3M Part No.8646 or equivalent
TROUBLESHOOTING
INSPECTION CHART FOR TROUBLE SYMPTOMS
Trouble symptomInspection procedureReference page
The sunroof can not be operated when the ignition switch is in
ON position.142-9
The motor does not reverse its direction when a load of 140 N
or more is applied while the sunroof is closing.242-11
The timer does not operate for 30 seconds after the ignition
switch is turned to OFF.342-11
Opening or closing of the sunroof is possible for 30 seconds
after turning the ignition switch to OFF, but the timer function
is not extended when the driver’s side door is opened within this
period.442-11
INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS
Inspection Procedure 1
The sunroof can not be operated when the ignition switch
is in ON position.
Probable cause
One of the following items may be defective.

Sunroof switch

Sunroof motor

Sunroof-ECU power supply circuit

Earth circuit
Malfunction of sunroof switch

Malfunction of sunroof motor

Malfunction of sunroof-ECU

Malfunction of wiring harness or connector

BODY – Sunroof42-10
OK
Check trouble symptoms.
NG
Check the harness wire between igni-
tion switch (IG1) and sunroof-ECU, and
repair if necessary.
(2) NG
Check the following connectors:
B-44, B-76, B-73, D-10NG
Repair
OK
Check trouble symptoms.
NG
Check the harness wire between fusible
link No.1 and sunroof-ECU, and repair
if necessary.
(3) NG
Check the following connectors:
B-44, D-10NG
Repair
OK
Check trouble symptoms.
NG
Check the harness wire between sunroof-ECU and
the earth, and repair if necessary.
OK
Check sunroof switch continuity (Refer to P.42-17.)NG
Repair
OK
Measure at the sunroof-ECU connector D-10.

Disconnect the connector and measure at the harness side.

Continuity between 2 and body earth
OK:Continuity present when UP sunroof switch is on

Continuity between 3 and body earth
OK:Continuity present when CLOSE/DOWN sunroof switch
is on

Continuity between 4 and body earth
OK:Continuity present when OPEN sunroof switch is onNGCheck the following connectors:
D-10, D-07NG
Repair
OK
Check trouble symptoms.
NG
Check the harness wire between sun-
roof-ECU and sunroof switch, between
sunroof switch and the earth, and repair
if necessary.
OK
Check the sunroof motor. (Refer to P.42-17.)
Check limit switch continuity. (Refer to P.42-17.)NG
Replace
OK
Measure at the sunroof motor connector D-12.

Disconnect the connector and measure at the harness side.

Continuity between 4 and body earth
OK:ContinuityNGCheck the following connectors:
B-44, D-12NG
Repair
OK
Check trouble symptoms.
NG
Check the harness wire between sun-
roof motor and the earth, and repair
if necessary.
OK
Check the following connectors:
D-12, D-10NG
Repair
OK
Check trouble symptoms.NGCheck the harness wire between sun-
roof-ECU and sunroof motor.NG
Repair
OK
Replace the sunroof-ECU.
Measure at the sunroof-ECU connector D-10.

Disconnect the connector and measure at the harness side.

Ignition switch: ON
(1) Voltage between 5 and body earth
OK:System voltage
(2) Voltage between 7 and body earth
OK:System voltage
(3) Continuity between 18 and body earth
OK:Continuity(1) NGCheck the following connectors:
B-44, B-74, B-76, D-10NG
Repair

BODY – Sunroof42-11
Inspection Procedure 2
The motor does not reverse its direction when a load of
140 N or more is applied while the sunroof is closing.
Probable cause
The sunroof-ECU monitors the load conditions from the amount of current flowing
to the motor. If more than the constant amount of current is flowing, the direction
of motor operation is reversed to prevent jamming.
If the motor does not reverse direction even when an excessive load is being applied,
the cause may be a malfunction of the sunroof-ECU.
Malfunction of sunroof-ECU
Replace the sunroof-ECU.
Inspection Procedure 3
The timer does not operate for 30 seconds after the
ignition switch is turned to OFF.
Probable cause
The sunroof-ECU has a timer function which operates for 30 seconds after the ignition
switch is turned to OFF. If the timer does not operate, the cause may be a malfunction
of the sunroof-ECU or of the wiring harness or connector.
Malfunction of sunroof-ECU

Malfunction of wiring harness or connector
Measure at the sunroof-ECU connector
D-10.

Disconnect the connector and
measure at the harness side.

Voltage between 7 and body earth
OK:System voltageNGCheck the following connectors:
B-44, B-76, B-73NG
Repair
OK
Check trouble symptoms.
OK
Replace the sunroof-ECU.
Check the harness wire between fusible
link No.1 and sunroof-ECU, and repair
if necessary. NG
Inspection Procedure 4
Opening or closing of the sunroof is possible for 30
seconds after turning the ignition switch to OFF, but the
timer function is not extended when the driver’s side door
is opened within this period.
Probable cause
The sunroof timer operation period is extended when an on signal is output from
the driver’s-side door switch. Because of this, if the timer operation period is not
extended, the cause may be a malfunction of the door switch input circuit.
Malfunction of the front door switch (driver’s side)

Malfunction of sunroof-ECU

Malfunction of wiring harness or connector
Check front door switch (driver’s side)
continuity.NG
Replace
OK
Check the following connectors:
B-44, D-03, D-10NG
Repair
OK
Check trouble symptoms.NGCheck the harness wire between front
door switch (driver’s side) and sunroof-
ECU.NG
Repair
OK
Replace the sunroof-ECU.

BODY – Sunroof42-12
TERMINAL VOLTAGE CHART
Terminal No.Check ItemCheck ConditionNormal Condition
1Door switch inputDriver’s door switchON0 V
OFFSystem voltage
2Sunroof switch (up) inputSunroof switch
(up position)
ON0 V
(up position)
OFFSystem voltage
3Sunroof switch (close or
down) input
Sunroof switch (close
position or down position)
ON0 V
down) inputposition or down position)
OFFSystem voltage
4Sunroof switch (open
input)
Sunroof switch
(open position)
ON0 V
input)(open position)
OFFSystem voltage
5ECU power supplyIgnition switch: ONSystem voltage
6Motor output (When
sunroof is opening)While sunroof is opening or moving
downSystem voltage
Other than the above0 V
7Timer operation power
supplyAlwaysSystem voltage
8Motor output (When
sunroofis closing)
While sunroof is closing or moving upSystem voltage
sunroof is closing)
Other than the above0 V
9Limit switch 3 inputIn tilt up condition and fully-open
condition0 V
Other than the aboveSystem voltage
10Limit switch 1 inputIn tilt up conditionSystem voltage
In fully-closed and fully-open conditions0 V
In slide-closing condition0 V → System voltage →
0V.
12Limit switch 2 inputIn tilt up condition and fully-closed
conditionSystem voltage
Other than the above0 V
18EarthAlways0 V

BODY – Sunroof42-13
ON-VEHICLE SERVICE
WATER TEST
Check if there are any leaks in the sunroof by the following
procedure.
1. Fully close the roof lid glass.
2. Adjust the water pressure so that water comes out of
the hose to a height of approximately 50 cm when the
hose is held vertically facing upwards.
3. Hold the end of the hose approximatery 30 cm above
the roof and let the water run onto the weatherstrip for
5 minutes or more.
4. While doing this, check if any water leaks through into
the passenger compartment from around the roof lid glass.
SUNROOF FIT ADJUSTMENT
1. Fully close the roof lid glass.
2. Fully open the sunshade.
3. Remove the side decoration cover.
4. To adjust the forward, backward and sideways position
of the roof lid glass, loosen the six roof lid glass assembly
mounting nuts and then adjust the glass forward,
backward or sideways.
NOTE
If the adjustment cannot be made by loosening the
adjustment nuts, the fully closed position of the roof lid
glass may not match that of the motor. If so, adust them
to match their fully closed positions.
5. To adjust the height of the roof lid glass, loosen the four
guide (A) assembly mounting screws and then move the
roof lid glass assembly along the slot in the guide (A)
assembly.
6. After adjustment, check to be sure that the sunroof
operates smoothly.
Hose
Apporox. 30cm
Clip
Side decoration cover

BODY – Sunroof42-14
SUNROOF
REMOVAL AND INSTALLATION
Post-installation Operation


Sunroof Water Test (Refer to P.42-13.)

Sunroof Fit Adjustment (Refer to P.42-13.)
1 2
3
456
9 10
11 128
NOTE
:Clip position
7
6
Roof lid glass assembly removal
steps
A1. Side decoration cover
2. Roof lid glass assembly
Sunroof switch removal steps
3. Sunroof switch cover
4. Sunroof switch
Drain hose removal steps

Splash shield (Front drain hose)
5. Headlining
BB6. Drain hoseSunroof-ECU removal steps
5. Headlining
7. Sunroof-ECU
Sunroof motor removal steps
5. Headlining
CA8. Sunroof motor
Sunroof assembly removal steps
5. Headlining
6. Drain hose connection
9. Room lamp bracket
10. Sunroof switch bracket
11. Set bracket
12. Sunroof assembly

BODY – Sunroof42-15
REMOVAL SERVICE POINTS
ASIDE DECORATION COVER REMOVAL
Remove the clips, and then remove the side decoration cover.
BDRAIN HOSE REMOVAL
Tie a cord to the end of the drain hose, and wind tape around
the tie until it is smooth. Then pull the drain hose out from
the passenger compartment.
CSUNROOF MOTOR REMOVAL
Caution
Always close the roof lid glass fully before removing
the sunroof motor. If the fully-closed positions of the roof
lid glass and the sunroof motor are not the same, the
sunroof will not operate properly.
INSTALLATION SERVICE POINTS
ASUNROOF MOTOR INSTALLATION
If the fully-closed position of the sunroof motor is incorrect,
set the motor to the fully-closed position by the procedure
given below before installing the motor.
1. Connect a circuit analyser between terminals (4) and (6)
of the motor connector.
2. Operate the motor until the position is reached at which
continuity switches from on to off or from off to on, and
then install the motor.
BDRAIN HOSE INSTALLATION
1. Tie the cord that was used during removal to the end
of the drain hose, and wind tape around it so that there
is no unevenness.
2. Pull the cord to pass through the drain hose
Clip
Side decoration cover
Drain hose
Cord
Cord
Drain hose

BODY – Sunroof42-16
3. Make the drain hose protrusion from the grommet as
shown in the illustration.
INSPECTION
ROOF LID GLASS OPERATION CURRENT CHECK
1. Remove the sunroof fuse and connect a circuit analyser
as shown in the illustration.
2. Press the sunroof switch to the ON position, and then
measure the operation current in the intervals between
the points when the sunroof starts to operate, when it
is fully open, when it is fully closed and when it is fully
tilted up.
Standard value: 7 A or less (at 20C)
3. If the operation current is outside the standard value,
check the following points.

Installation condition, warping or jamming of sunroof
assembly

Sticking of drive cable

Tilt of roof lid glass
Grommet
20–30 mm