1999 MITSUBISHI LANCER EVOLUTION VI Workshop Manual

STEERING – Power Steering Gear Box37A-15
3. 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
(1) When adjusting, set the standard value at its
highest value.
(2) Assure no ratcheting or catching when operating
the rack towards the shaft direction.
NOTE
When it cannot be adjusted within the specified return
angle, check or replace the rack support cover
components.
4. After adjusting, lock the rack support cover with lock nut.
LTAB WASHER / TIE-ROD INSTALLATION
After installing the tie-rod to the rack, fold the tab washer
end (2 locations) to the tie-rod notch.
MBELLOWS BAND INSTALLATION
1. Turn the adjusting bolt of the special tool to adjust the
opening dimension (W) to the standard value.
Standard value (W): 2.9 mm

Screw in the adjusting bolt.

Loosen the adjusting bolt.
NOTE
(1) The dimension (W) is adjusted by approx. 0.7 mm
per one turn.
(2) Do not turn the adjusting bolt more than one turn.
MB991006
MB991561
Stopper
Adjusting bolt W

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

STEERING – Power Steering Gear Box37A-17
INSPECTION
RACK CHECK

Check the rack tooth surfaces for damage or wear.

Check the oil seal contact surfaces for uneven wear.

Check the rack for bends.
PINION AND VALVE ASSEMBLY CHECK

Check the pinion gear tooth surfaces for damage or wear.

Check for worn or defective seal ring.
BEARING CHECK

Check for roughness or abnormal noise during bearing
operation.

Check the bearing for play.

Check the needle roller bearing for roller slip-off.
OTHER CHECK

Check the cylinder inner surface of the rack housing for
damage.

Check the boots for damage, cracking or deterioration.

Check the rack support for uneven wear or dents.

Check the rack bushing for uneven wear or damage.

NOTES

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 – 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.

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
From previous page

BODY – Keyless Entry System42-4
INSPECTION PROCEDURE 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.)
Probable cause
If the room lamp operates normally when the doors are opened and closed, the cause
of the problem may be a malfunction of the receiver or a malfunction of the harness
between the room lamp the receiver.
Malfunction of receiver

Malfunction of connector or wiring harness
NG
Repair
NG
Check the harness wire between room lamp and receiver, and
repair if necessary.
OK
Replace the receiver.
OK
Check trouble symptoms.
Measure at the receiver connector D-01.

Disconnect the connector, and measure at the harness side.

Voltage between 11 and body earth
OK:System voltageNGCheck the following connectors:
B-80, D-01
INSPECTION PROCEDURE 3
Secret codes cannot be registered.
Probable cause
The cause may be a malfunction of the diagnosis connector, a malfunction of the
power supply or earth circuit of the receiver, a malfunction of the earth circuit or
a malfunction of the diagnosis output circuit.
Malfunction of receiver

Malfunction of MUT-II

Malfunction of connector or wiring harness
NG
Repair
NG
Check the harness wire, and repair if necessary.

Between receiver and diagnosis connector
NG
Repair
NG
Check the harness wire, and repair if necessary.

Between fusible link No.1 and diagnosis connector
OK
Check trouble symptoms.NGCheck the harness wire, and repair if necessary.

Between diagnosis connector and earth
Ye s
To next page
NG
Check the following
connectors:
B-22, B-50NG
Repair
OK
Measure at the diagnosis
connector B-22.

Continuity between 4
and body earth

Continuity between 5
and body earth
OK:ContinuityOKReplace MUT-II.
OK
Check trouble symptoms.
No
Measure at the diagnosis
connector B-22

Voltage between 16
and body earth
OK:System voltageNGCheck the following connectors:
B-22, B-49, B-75
OK
Can the MUT-II communicate with other systems?
OK
Check trouble symptoms.
Measure at the diagnosis connector B-22 and the receiver connector
D-01.

Disconnect the connector, and measure at harness side.

Continuity between following terminals:
OK:Continuity
7 – 1 NGCheck the following connectors:
B-22, D-01