1999 MITSUBISHI LANCER EVOLUTION VI ECU
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BASIC BRAKE SYSTEM – General / On-vehicle Service35A-2
GENERAL
OUTLINE OF CHANGE
The service procedures for left-hand drive vehicles have been established as described below.
The service procedures for the front and rear disc brakes have been changed since they had been
replaced by a different type.
ON-VEHICLE SERVICE
BRAKE PEDAL CHECK AND ADJUSTMENT
1. Turn up the carpet, etc under the brake pedal.
2. Measure the brake pedal height as illustrated. If the brake
pedal height is not within the standard value, follow the
procedure below.
Standard value: 163.5 –166.5 mm
(1) Disconnect the stop lamp switch connector.
(2) Adjust the brake pedal height by turning the operating
rod with pliers (with the operating rod lock nut
loosened), until the correct brake pedal height is
obtained.
(3) Secure by tightening the lock nut of the operating
rod.
(4) Push the stop lamp switch in the direction of the
pedal stroke until it stops. (The switch will slide if
it is pushed firmly.)
(5) Lift up the pedal until the operating rod is fully
extended, and then slide the stop lamp switch back
to the required position. Adjust the position of the
switch by turning it until the distance shown in the
illustration is correct.
(6) Connect the connector of the stop lamp switch.
(7) Check that the stop lamp is not illuminated with the
brake pedal unpressed.
3. With the engine stopped, depress the brake pedal two
or three times. After eliminating the vacuum in the power
brake booster, press the pedal down by hand, and confirm
that the amount of movement before resistance is met
(the free play) is within the standard value range.
Standard value: 3 – 8 mmOperating
rod
Operating
rod lock nutStop lamp
switch
Pedal down
Pedal up
Lock nut
Lock nut
Outer case
0.5 – 1.0 mm
Page 246 of 558
BASIC BRAKE SYSTEM – Master Cylinder and Brake Booster35A-6
INSTALLATION SERVICE POINTS
AVACUUM HOSE CONNECTION
Insert securely and completely until the vacuum hose at the
engine side contacts the edge of the hexagonal part of the
fitting, and then secure by using the hose clip.
BCLEARANCE ADJUSTMENT BETWEEN BRAKE
BOOSTER PUSH ROD AND PRIMARY PISTON
Calculate clearance A from the B, C and D measurements.
A = B – C – D
Standard value: 0.65–0.85 mm
If the clearance is not within the standard value range, adjust
by changing the push rod length by turning the screw of
the push rod.
Measuring
distance BMeasuring
distance D
Block
gaugeB
AC
D
Page 251 of 558
37A-1
STEERING
CONTENTS
GENERAL 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outline of Change 2. . . . . . . . . . . . . . . . . . . . . . . . .
STEERING WHEEL AND SHAFT* 2. . . . . . . .
POWER STEERING GEAR BOX* 5. . . . . . . . .
WARNINGS REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM (SRS) EQUIPPED VEHICLES
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) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized
MITSUBISHI dealer.
(3) 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
The SRS includes the following components: SRS-ECU, SRS warning lamp, air bag module, clock spring and interconnecting
wiring. Other SRS-related components (that may have to be removed/installed in connection with SRS service or maintenance) are
indicated in the table of contents by an asterisk (*).
Page 256 of 558
STEERING – Power Steering Gear Box37A-6
REMOVAL SERVICE POINTS
ATIE-ROD END AND KNUCKLE DISCONNECTION
Caution
1. In order not to damage the ball joint thread, the tie
rod end mounting nut must be only loosened but not
removed from the ball joint. Be sure to use the special
tool.
2. Tie the special tool with a cord so as not to fall off.
BGEAR BOX ASSEMBLY REMOVAL
Caution
Do not damage the bellows and the tie-rod end dust cover
when removing the gear box assembly.
INSPECTION
Check the rubber parts for cracks and breakage.
GEAR BOX TOTAL PINION TORQUE
Using the special tools, rotate the pinion gear at the rate
of one rotation in approximately 4 to 6 seconds to check
the total pinion torque.
Standard value: 0.9 – 1.7 Nm
[Change in torque: 0.4 Nm]
Caution
When holding the steering gear box assembly in a vice,
secure its mounting positions. If it is secured in any other
places, the gear housing may become deformed or
damaged.
NOTE
When measuring, remove the bellows from the rack housing.
Measure the pinion torque through the whole stroke of the
rack.
If the measured value is not within the standard range, first
adjust the rack support cover, and then check the total pinion
starting torque again.
Cord
Ball joint
NutMB990635 or
MB991113
MB991006
Page 264 of 558
STEERING – Power Steering Gear Box37A-14
2. Apply a coating of the specified fluid to the outside of
the ball bearing. Using the special tools, press the ball
bearing into the valve housing.
Specified fluid:
Automatic transmission fluid
DEXRON or DEXRON II
HSEAL RING INSTALLATION
1. Kneed the seal ring to soften it.
2. Apply the specified fluid to the seal ring, and install to
the rack groove.
Specified fluid:
Automatic transmission fluid
DEXRON or DEXRON II
3. Insert the tapered side of the special tool from the pinion
gear side, and compress the seal ring.
IOIL SEAL INSTALLATION
Use the special tool to press the oil seal into the valve housing.
The upper surface of the oil seal should project outwards
approx. 1 mm from the housing edge surface.
Caution
If the oil seal is flush with or lower than the housing
edge, it will cause oil leaks and require reassembly.
JEND PLUG INSTALLATION
1. Apply the specified sealant to the threaded part of the
end plug.
Specified sealant:
3M ATD Part No.8661 or equivalent
2. Secure the threaded portion of the end plug at two places
by using a punch.
KTOTAL PINION TORQUE ADJUSTMENT
1. Position the rack at its centre. Tighten the rack support
cover to 15 Nm.
2. In neutral position, rotate the pinion shaft clockwise one
turn/4 – 6 seconds with the special tool. Return the rack
support cover 30 – 60 and adjust torque to the standard
value.
Ball bearingMB990938
MB991203
Pinion gearMB991317
Tapered side
Approx. 1 mmMB990941
End plug
SealantEnd plug
MB991006
Page 266 of 558
STEERING – Power Steering Gear Box37A-16
2. Use the special tool to crimp the bellows band.
Caution
(1) Hold the rack housing, and use the special tool
to crimp the bellows band securely.
(2) Crimp the bellows band until the special tool
touches the stopper.
3. Check that the crimped width (A) is within the standard
value.
Standard value (A): 2.4 – 2.8 mm
Readjust the dimension (W) of step (1) to the value
calculated by the following equation, and repeat
step (2).
W = 5.5 mm – A [Example: If (A) is 2.9 mm, (W)
is 2.6 mm.]
Remove the bellows band, readjust the dimension
(W) of step (1) to the value calculated by the
following equation, and use a new bellows band
to repeat steps (2) to (3).
W = 5.5 mm – A [Example: If (A) is 2.3 mm, (W)
is 3.2 mm.]
NTIE-ROD END / TIE-ROD END LOCKING NUT
INSTALLATION
Screw in the tie-rod end until the dimension shown is achieved.
Then, temporarily tighten with the locking nut.
NOTE
The locking nut must be tightened securely only after the
power steering gear box and linkage are installed to the vehicle
and toe-in is adjusted.
TIE-ROD END BALL JOINT DUST COVER
REPLACEMENT
Only when the dust cover is damaged accidentally during
service work, replace the dust cover as follows:
1. Apply grease inside a new dust cover.
2. Using the special tool, press in the dust cover to the
tie rod end.
3. Check the dust cover for cracks or damage by pushing
it with finger.
MB991561
A
212 mm Edge of bellows
assembly grooveLock nut
MB990776
Page 270 of 558
BODY – General / Keyless Entry System42-2
GENERAL
OUTLINE OF CHANGE
The descriptions of the troubleshooting using on MUT-II tester have been incorporated.
KEYLESS ENTRY SYSTEM
SPECIAL TOOL
ToolNumberNameUse
MB991502MUT-II sub assemblyRecording secret codes
TROUBLESHOOTING
INSPECTION CHART FOR TROUBLE SYMPTOMS
Trouble symptomInspection procedure No.Reference page
None of the doors can be locked or unlocked using the transmitter.142-2
All of the doors can be locked and unlocked using the transmitter,
but the room lamp does not flash or illuminate. (However, the room
lamp operates normally when the doors are opened and closed.)242-4
Secret codes cannot be registered.342-4
INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS
INSPECTION PROCEDURE 1
None of the doors can be locked or unlocked using the
transmitter.
Probable cause
The cause may be a malfunction of the transmitter, a malfunction of the receiver
or the lock and unlock signals are not being input to the ETACS-ECU.Malfunction of transmitter
Malfunction of receiver
Malfunction of ETACS-ECU
Malfunction of wiring harness or connector
Malfunction of key reminder switch
Malfunction of door switch
NG
To next page
OK
Replace the transmitter battery. (Refer to P.42-7.)
Ye s
Has the secret code been registered properly? *NGRe-register the secret code. (Refer to P.42-8.)
Can the doors be locked and unlocked by the driver’s-side door
key cylinder and lock knob?NoCheck the centre door lock system.
NOTE
*: This should be done if a transmitter or receiver has been replaced, and if a secret code has not
been registered properly.
Page 271 of 558
BODY – Keyless Entry System42-3
NG
Repair
NG
Check the harness wire, and repair if necessary.
Between receiver and earth
NG
Repair
OK
Replace the ETACS-
ECU.
NG
Repair
OK
Replace the transmitter.NGReplace the receiver.
NG
Check the harness wire.
Between key reminder switch and receiver
Between key reminder switch and earthNG
Repair
OK
Check trouble symptoms.
OK
Check the following connectors:
B-50, B-84, D-01NG
Repair
OK
Key reminder switch continuity check (Refer to GROUP 54 – Ignition
Switch.)NG
Replace
NG
Check the harness wire.
Between receiver and door switchNG
Repair
OK
Check trouble symptoms.
OK
Check the following connectors:
D-01, D-03, D-06, D-17, F-12, F-26NG
Repair
NG
Check the harness wire.
Between ETACS-ECU and receiver
OK
Door switch continuity checkNG
Replace
OK
Check trouble symptoms.
OK
Measure at the receiver connector D-01.
Disconnect the connector, and measure at harness side.
Voltage between 12 and body earth
Voltage between 14 and body earth
OK:System voltageNGCheck the connectors:
B-77, D-01
OK
Check trouble symptoms.
OK
Measure at the receiver connector D-01.
Disconnect the connector, and measure at the harness side.
Continuity between 20 and body earth
OK:ContinuityNGCheck the following connectors:
B-50, D-01
NG
Repair
NG
Check the harness wire, and repair if necessary.
Between ignition switch and receiver
Between fusible link No.1 and receiver
OK
Check trouble symptoms.
Measure at the receiver connector D-01.
Disconnect the connector, and measure at the harness side.
Voltage between 9 and body earth
Voltage between 10 and body earth
OK:System voltageNGCheck the following connectors:
B-49, B-73, B-75, B-76
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