1999 MITSUBISHI LANCER EVOLUTION VI Workshop Manual

WORKSHOP MANUAL
Pub. No. S9806CNCP9-A
EVOLUTION-VI
Pub. No. S9806CNCP9-A
EVOLUTION-VI
Pub. No. S9806CNCP9-A
Mar. ’99 Printed in Japan
WORKSHOP MANUAL

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26
27
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35
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42
51
52
54
55
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 . . . . . . . . . . . . . . . . . . . . .
.

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.

00-1
GENERAL
CONTENTS
HOW TO USE THIS MANUAL 3. . . . . . . . . . . . . .
Scope of Maintenance, Repair and Servicing
Explanations 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Definition of Terms 3. . . . . . . . . . . . . . . . . . . . . . . . . . .
Indication of Tightening Torque 3. . . . . . . . . . . . . . . .
Explanation of Manual Contents 4. . . . . . . . . . . . . . .
HOW TO USE
TROUBLESHOOTING/INSPECTION SERVICE
POINTS 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Contents 6. . . . . . . . . . . . . . . . . . . . .
Diagnosis Function 7. . . . . . . . . . . . . . . . . . . . . . . . . . .
How to Use the Inspection Procedures 10. . . . . . .
Connector Measurement Service Points 11. . . . . . .
Connector Inspection 12. . . . . . . . . . . . . . . . . . . . . . . .
Inspection Service Points for a Blown Fuse 13. . . Points to Note for Intermittent Malfunctions 13. . . .
MODELS 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRECAUTIONS BEFORE SERVICE 15. . . . . . .
SUPPORT LOCATIONS FOR LIFTING AND
JACKING 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Garage Jack 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axle Stands 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Single-post and Double-post Lift 19. . . . . . . . . . . . . .
SPECIAL HANDLING INSTRUMENTS FOR
TOWING 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE TEST 21. . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE 22. . . . . . . . . . . . . . . . . . .

00-2
NOTES

GENERAL – How to Use This Manual00-3
HOW TO USE THIS MANUAL
SCOPE OF MAINTENANCE, REPAIR
AND SERVICING EXPLANATIONS
This manual provides explanations, etc. concerning
procedures for the inspection, maintenance, repair
and servicing of the subject model. Note, however,
that for engine and transmission-related component
parts, this manual covers only on-vehicle
inspections, adjustments, and the removal and
installation procedures for major components.
For detailed information concerning the inspection,
checking, adjustment, disassembly and reassembly
of the engine, transmission and major components
after they have been removed from the vehicle,
please refer to separate manuals covering the
engine and the transmission.
ON-VEHICLE SERVICE
“On-vehicle Service” is procedures for performing
inspections and adjustments of particularly
important locations with regard to the construction
and for maintenance and servicing, but other
inspection (for looseness, play, cracking, damage,
etc.) must also be performed.
INSPECTION
Under this title are presented inspection and
checking procedures to be performed by using
special tools and measuring instruments and by
feeling, but, for actual maintenance and servicing
procedures, visual inspections should always be
performed as well.
DEFINITION OF TERMS
STANDARD VALUE
Indicates the value used as the standard for judging
the quality of a part or assembly on inspection
or the value to which the part or assembly is
corrected and adjusted. It is given by tolerance.
LIMIT
Shows the standard for judging the quality of a
part or assembly on inspection and means the
maximum or minimum value within which the part
or assembly must be kept functionally or in strength.
It is a value established outside the range of
standard value.
REFERENCE VALUE
Indicates the adjustment value prior to starting the
work (presented in order to facilitate assembly and
adjustment procedures, and so they can be
completed in a shorter time).
CAUTION
Indicates the presentation of information particularly
vital to the worker during the performance of
maintenance and servicing procedures in order to
avoid the possibility of injury to the worker, or
damage to component parts, or a reduction of
component or vehicle function or performance, etc.
INDICATION OF TIGHTENING TORQUE
The tightening torque shown in this manual is a
basic value with a tolerance of ±10% except the
following cases when the upper and lower limits
of tightening torque are given.
(1) The tolerance of the basic value is within ±10%.
(2) Special bolts or the like are in use.
(3) Special tightening methods are used.

GENERAL – How to Use This Manual00-4
EXPLANATION OF MANUAL CONTENTS
Indicates procedures to be performed
before the work in that section is started,
and procedures to be performed after
the work in that section is finished.
Indicates (by symbols) where lubrica-
tion is necessary.
Maintenance and Servicing Procedures
The numbers provided within the diagram indi-
cate the sequence for maintenance and servic-
ing procedures.
Removal steps:
The part designation number corresponds
to the number in the illustration to indicate
removal steps.
Disassembly steps:
The part designation number corresponds
to the number in the illustration to indicate
disassembly steps.Installation steps:
Specified in case installation is impossible
in reverse order of removal steps. Omitted
if installation is possible in reverse order of
removal steps.
Reassembly steps:
Specified in case reassembly is impossible
in reverse order of disassembly steps.
Omitted if reassemby is possible in reverse
order of disassembly steps.
Classifications of Major Maintenance/Service Points
When there are major points relative to maintenance and servicing procedures
(such as essential maintenance and service points, maintenance and service stan-
dard values, information regarding the use of special tools, etc.), these are ar-
ranged together as major maintenance and service points and explained in detail.
A: Indicates that there are essential points for removal or disassembly.
A: Indicates that there are essential points for installation or reassembly.
Symbols for Lubrication, Sealants and Adhesives
Information concerning the locations for lubrica-
tion and for application of sealants and adhe-
sives is provided, by using symbols, in the dia-
gram of component parts or on the page follow-
ing the component parts page, and explained.: Grease
(multipurpose grease unless there is a
brand or type specified)
: Sealant or adhesive
: Brake fluid or automatic transmission fluid
: Engine oil, gear oil or air conditioner com-
pressor oil
: Adhesive tape or butyl rubber tape
Component Diagram
A diagram of the component parts is
provided near the front of each section
in order to give a reader a better under-
standing of the installed condition of
component parts.

GENERAL – How to Use This Manual00-5
Denotes tightening torque.
For bolts and nuts which do not
have a tightening torque listed,
refer to the “Tightening torque”.
indicates that there is
a continuity between the termi-
nals.
indicates terminals to
which battery voltage is applied.
Indicates the
section title.Indicates the
group num-
ber.Indicates the
page number.Indicates the
group title.
Denotes non-reus-
able part.
Repair kit or set parts
are shown. (Only very
frequently used parts
are shown.)
Operating procedures, cau-
tions, etc. on removal, installa-
tion, disassembly and reas-
sembly are described.
The title of the page (following
the page on which the diagram
of component parts is pres-
ented) indicating the locations of
lubrication and sealing proce-
dures.