1999 MITSUBISHI LANCER EVOLUTION VI Workshop Manual

ENGINE – Crankshaft and Flywheel11-72
(5) Using cylinder gauge, measure the cylinder bore and
cylindricity. If worn badly, correct cylinder to an oversize
and replace piston and piston rings. Measure at the points
shown in illustration.
Standard value:
Cylinder I.D. 85.00 – 85.03 mm
Cylindricity 0.01 mm or less
BORING CYLINDER
(1) Oversize pistons to be used should be determined on
the basis of the largest bore cylinder.
Piston size identification
SizeIdentification mark
0.50 O.S.50
1.00 O.S.100
NOTE
Size mark is stamped on the piston top.
(2) Measure outside diameter of piston to be used. Measure
it in thrust direction as shown.
(3) Based on the measured piston O.D. calculate boring finish
dimension.
Boring finish dimension = Piston O.D. + (clearance
between piston O.D. and cylinder) – 0.02 mm
(honing margin)
(4) Bore all cylinders to the calculated boring finish dimension.
Caution
To prevent distortion that may result from temperature
rise during honing, bore cylinders, working from No.
2, No. 4, No. 1 to No. 3.
(5) Hone to final finish dimension (piston O.D. + clearance
between piston O.D. and cylinder).
(6) Check clearance between piston and cylinder.
Clearance between piston and cylinder:
0.02 – 0.04 mm
NOTE
When boring cylinders, finish all of four cylinders to same
oversize. Do not bore only one cylinder to an oversize.

ENGINE – Throttle Body11-73
THROTTLE BODY
DISASSEMBLY AND REASSEMBLY
1
2
34
5 6
73.5 Nm
3.5 Nm
Disassembly steps
AA1. Throttle position sensor (with built-
in closed throttle position switch)
2. Idle speed control body assembly
3. O-ring
B4. Throttle body
5. Fixed SAS
6. Speed adjusting screw
8. O-ringNOTE
1. The fixed SAS and the speed adjusting screw are
correctly adjusted at the factory and should not be
removed.
2. If the fixed SAS should happen to have been
removed, carry out fixed SAS adjustment.
3. If the speed adjusting screw should happen to have
been removed, carry out speed adjusting screw
adjustment.

ENGINE – Throttle Body11-74
DISASSEMBLY SERVICE POINTS
ATHROTTLE POSITION SENSOR AND IDLE AIR
CONTROL MOTOR REMOVAL
(1) Do not disassemble the sensor and motor.
(2) Do not immerse solvent to clean the sensor and motor.
Clean then with shop towel.
BTHROTTLE BODY REMOVAL
(1) Do not remove the throttle body.
(2) Check if the vacuum port or passage is clogged. Use
compressed air to clean the vacuum passage.
REASSEMBLY SERVICE POINT
ATHROTTLE POSITION SENSOR INSTALLATION
(1) Install the throttle position sensor to the throttle body
as shown in the diagram.
(2) Turn throttle position sensor 90° clockwise to set it, and
tighten screws.
(3) Check the continuity between terminal No. 3 (Idle throttle
position switch) and No. 4 (Earth).
Throttle valve conditionContinuity
Fully closedConductive
Fully openNo conductive
If there is no continuity with the throttle valve fully closed,
turn the throttle position sensor counterclockwise, and
then check again.
Throttle position sensor
Earth TPS power supply
TPS outputIdle position switch

ENGINE – Turbocharger11-75
TURBOCHARGER
DISASSEMBLY AND REASSEMBLY
1 2 3
4567
8
11 Nm
Disassembly steps
F
Inspection of turbocharger waste gate
actuator operation
1. Snap pin
2. Waste gate actuator
E3. CouplingD4. Turbine housing
AC5. Snap ring
BB6. Turbine wheel assembly
7. Compressor cover
A8. O-ring

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 – Turbocharger11-77
CSNAP RING INSTALLATION
Lay the assembly with the compressor cover facing down
and fit the snap ring.
Caution
Fit the snap ring with its chamfered side facing up.
DTURBINE HOUSING INSTALLATION
Install the turbine housing in relation to the dowel pin.
Caution
Use care not to damage the blades of turbine wheel.
ECOUPLING INSTALLATION
Install the coupling and tighten to the specified torque.
FWASTE GATE ACTUATOR OPERATION CHECK
Using a tester, apply a pressure of approx. 100.0 kPa to
the actuator and make sure that the rod moves.
Caution
Do not apply a pressure of more than 113.3 kPa to the
actuator. Otherwise, diaphragm may be damaged. Never
attempt to adjust the waste gate valve.
INSPECTION
TURBINE HOUSING
(1) Check the housing for traces of contact with the turbine
wheel, cracks due to overheating, pitching, deformation
and other damage. Replace with a new turbine housing
if cracked.
(2) Operate the waste gate valve lever manually to check
that the gate can be operated and closed smoothly.
Compressor
cover
Turbine wheel
assembly
Chamfered
edge
Snap ring
Dowel pin
Dowel pin hole
Coupling
Traces of contact

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

ENGINE – Alternator11-79
ALTERNATOR
DISASSEMBLY AND REASSEMBLY
1
234
5
6
7
8910
11 12
1314
Disassembly steps
A1. Front bracket assembly
B2. Alternator pulley
B3. Rotor
4. Rear bearing
5. Bearing retainer
6. Front bearing
7. Front bracketC8. Stator
9. Plate
CA10. Regulator assembly
11. Brush
12. Slinger
13. Rectifier
14. Rear bracket