1999 MITSUBISHI LANCER EVOLUTION VI clock

STEERING – Power Steering Gear Box37A-10
DISASSEMBLY SERVICE POINTS
ARACK SUPPORT COVER REMOVAL
Use the special tool to remove the rack support cover from
the gear box.
BOIL SEAL / PINION AND VALVE ASSEMBLY
REMOVAL
Using a plastic hammer, gently tap the pinion to remove it.
CSEAL RING REMOVAL
Cut the seal ring and remove it from the pinion and valve
assembly and the rack.
Caution
When cutting the seal ring, be careful not to damage
the pinion and valve assembly or the rack.
DBALL BEARING / OIL SEAL REMOVAL
Use a socket, remove the oil seal and the ball bearing from
the valve housing assembly simultaneously.
ECIRCLIP REMOVAL
1. Turn the rack stopper clockwise until the end of the circlip
comes out of the slot in the rack housing.
2. Turn the rack stopper anticlockwise to remove the circlip.
Caution
Note that if the rack stopper is first turned
anticlockwise, the circlip will get caught in the slot
in the housing and the rack stopper will not turn.
MB990607
Socket
Rack stopper
Rack
Circlip

STEERING – Power Steering Gear Box37A-13
2. Cover rack serrations with special tool.
3. Apply the specified fluid on the special tool.
Specified fluid:
Automatic transmission fluid
DEXRON or DEXRON II
4. Match the oil seal centre with rack to prevent retainer
spring from slipping and slowly insert rack from power
cylinder side.
EOIL SEAL / RACK BUSHING INSTALLATION
1. Apply the specified fluid to the outer surface of the oil
seal. Press-fit the oil seal using the special tool until it
is flush with the bushing end face.
Specified fluid:
Automatic transmission fluid
DEXRON or DEXRON II
2. Apply the specified fluid to the oil seal inner surface and
the O-ring.
Specified fluid:
Automatic transmission fluid
DEXRON or DEXRON II
3. Wrap the rack end with plastic tape, and push the rack
bushing onto the rack.
FCIRCLIP INSTALLATION
Insert the circlip to the rack stopper hole through the cylinder
hole. Turn the rack stopper clockwise and insert the circlip
firmly.
Caution
Insert the circlip to the rack stopper hole while turning
the rack stopper clockwise.
GOIL SEAL / BALL BEARING INSTALLATION
1. Apply a coating of the specified fluid to the outside of
the oil seal. Using the special tools, press the oil seal
into the valve housing.
Specified fluid:
Automatic transmission fluid
DEXRON or DEXRON II
MB991214
Oil seal
Oil seal
MB990927
Rack
bushingO-ring
Rack bushingPlastic tape
Circlip
SlotCirclip
Slot
Oil sealMB990938
MB991203

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

52B-1
SUPPLEMENTAL
RESTRAINT
SYSTEM (SRS)
CONTENTS
GENERAL INFORMATION 2. . . . . . . . . . . . . . . .
SRS SERVICE PRECAUTIONS 3. . . . . . . . . . .
SPECIAL TOOLS 5. . . . . . . . . . . . . . . . . . . . . . . .
TEST EQUIPMENT 5. . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 6. . . . . . . . . . . . . . . . . . . .
SRS MAINTENANCE 15. . . . . . . . . . . . . . . . . . .
POST-COLLISION DIAGNOSIS 19. . . . . . . . .
INDIVIDUAL COMPONENT SERVICE 22. . . WARNING/CAUTION LABELS 23. . . . . . . . . .
SRS AIR BAG CONTROL UNIT
(SRS-ECU) 24. . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR BAG MODULES AND CLOCK
SPRING 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR BAG MODULE DISPOSAL
PROCEDURES 32. . . . . . . . . . . . . . . . . . . . . . . .
Undeployed Air Bag Module Disposal
Procedures 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Deployed Air Bag Module Disposal
Procedures 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAUTION

Carefully read and observe the information in the SERVICE PRECAUTIONS (P.52B-3.) prior to any service.

For information concerning troubleshooting or maintenance, always observe the procedures in the Troubleshooting
(P.52B-6.) section.

If any SRS components are removed or replaced in connection with any service procedures, be sure to follow the
procedures in the INDIVIDUAL COMPONENT SERVICE section (P.52B-22.) for the components involved.

If you have any questions about the SRS, please contact your local distributor.

SRS – General Information52B-2
GENERAL INFORMATION
To improve safety, the SRS is available as optional
part.
The SRS consists of two air bag modules, SRS
air bag control unit (SRS-ECU), SRS warning lamp
and clock spring. One air bag is located in the
centre of the steering wheel and another above
the glove box. Each air bag has a folded air bag
and an inflator unit. The control unit under the floor
console monitors the system and has a safing G
sensor and an analog G sensor. The warning lamp
on the instrument panel indicates the operationalstatus of the SRS. The clock spring is installed
in the steering column.
Only authorized service personnel should do work
on or around the SRS components. Those service
personnel should read this manual carefully before
staring any such work. Extreme care must be used
when servicing the SRS to avoid injury to the service
personnel (by inadvertent deployment of the air
bags) or the driver (by rendering the SRS
inoperative).
Air bag module
(Driver’s side)Clock springAir bag module
(Front passenger’s side)
Diagnosis
connector
SRS-ECU
SRS warning lamp

SRS – SRS Service Precautions52B-3
SRS SERVICE PRECAUTIONS
1. In order to avoid injury to yourself or others
from accidental deployment of the air bag during
servicing, read and carefully follow all the
precautions and procedures described in this
manual.
2. Do not use any electrical test equipment on
or near SRS components, except those
specified on P.52B-5.
3. Never Attempt to Repair the Following
Components:

SRS air bag control unit (SRS-ECU)

Clock Spring

Air Bag Module
(Driver‘s side or front passenger’s side*)NOTE
*: Vehicles with front passenger’s air bag
If any of these components are diagnosed as
faulty, they should only be replaced, in
accordance with the INDIVIDUAL COM-
PONENT SERVICE procedures in this manual,
starting at page 52B-22.
4. After disconnecting the battery cable, wait 60 seconds
or more before proceeding with the following work.
The SRS system is designed to retain enough voltage
to deploy the air bag for a short time even after the
battery has been disconnected, so serious injury may
result from unintended air bag deployment if work
is done on the SRS system immediately after the
battery cables are disconnected.
5. Do not attempt to repair the wiring harness connectors
of the SRS. If any of the connectors are diagnosed as
faulty, replace the wiring harness. If the wires are
diagnosed as faulty, replace or repair the wiring harness
according to the following table.
Battery Insulating tape
SRS-ECU connector

SRS – SRS Service Precautions52B-4
SRS-ECU
terminal No.Harness connector
(No. of terminals,
colour)Destination of harnessCorrective action
1 to 421 pins, yellow––
5Body wiring harness → Clock spring → Air bag
module (Driver’s side)
Correct or replace each
wiring harness Replace
6
module (Driver’s side)wiring harness. Replace
clock spring.
7*Body wiring harness → Air bag module (Front
passenger’s side)
Correct or replace each
wiring harness
8*
passenger’s side)wiring harness.
9,10––
11Body wiring harness → Diagnosis connectorCorrect or replace each
wiring harness.
12––
13Body wiring harness → Junction block (fuse No.2)Correct or replace each
wiring harness
14Body wiring harness → Junction block (fuse No.4)
wiring harness.
15Body wiring harness → SRS warning lamp
16 to 19––
20Body wiring harness → EarthCorrect or replace each
wiring harness.
21––
NOTE
*: Vehicles with front passenger’s air bag
6. SRS components should not be subjected to hear over 93C, so remove the SRS-ECU, air bag
module and clock spring before drying or baking the vehicle after painting.
7. Whenever you finish servicing the SRS, check warning lamp operation to make sure that the system
functions properly. (Refer to P.52B-14.)
8. Make certain that the ignition switch is LOCK (OFF) position when the MUT-II is connected or
disconnected.
9. If you have any questions about the SRS, please contact your local distributor.
NOTE
SERIOUS INJURY CAN RESULT FROM UNINTENDED AIR BAG DEPLOYMENT, SO USE ONLY
THE PROCEDURES AND EQUIPMENT SPECIFIED IN THIS MANUAL.

SRS – Troubleshooting52B-8
Code No.21, 22, 61 or 62 Driver’s side air bag module
(squib) systemProbable cause
These diagnosis codes are output if there is abnormal resistance between the input
terminals of the driver’s side air bag module (squib).
The trouble causes for each diagnosis code No. are as follows.
Malfunction of clock spring

Partial disconnection due to incorrect clock spring
neutral position

Malfunction of wiring harnesses or connectors

Malfunction of driver’s side air bag module (squib)

Malfunction of SRS-ECU
Code No.Trouble symptom
21
Short in driver’s side air bag module (squib) or harness short

Short in clock spring

Malfunction of connector*
22
Open circuit in driver’s side air bag module (squib) or open harness

Open circuit in clock spring

Malfunction of connector contact
61
Short in driver’s side air bag module (squib) harness leading to the power supply
62
Short in driver’s side air bag module (squib) harness leading to the earth
NOTE
*: The connector in the squib circuit has a built-in short bar which short-circuits between plus (+) lead and minus
(–) lead of the squib circuit when the connector is not being connected to prevent an accidental air bag deployment
possibly caused by static electricity, etc. Therefore, malfunction of the connector can also be caused by this
short bar which fails to be released even when the connector is reconnected if it is damaged.
MUT-II Self-diag code

Disconnect clock spring
connector B-82.

Connect SRS check har-
ness connector (1).

Erase diagnosis code
memory.
Are code Nos.21, 22, 61 or
62 output?Ye sCheck the following
connectors:
B-82, B-51NG
Repair
OK
Check trouble symptoms.
NG
Check the harness wire
between the SRS-ECU
and clock spring.NG
Repair
OK
Replace the SRS-ECU.
No
Check the clock spring. (Refer to P.52B-30.)NG
Repair
OK
Replace the driver’s side air bag module.
SRS check harness
(MB991613)
Body wiring
harness
Clock spring
1