1999 MITSUBISHI LANCER EVOLUTION VI front

ENGINE – Piston and Connecting Rod11-60
REMOVAL SERVICE POINTS
ACONNECTING ROD CAP REMOVAL
(1) Mark the cylinder number on the side of the connecting
rod big end for correct reassembly.
(2) Keep the removed connecting rods, caps, and bearings
in order according to the cylinder number.
BPISTON PIN REMOVAL
(1) Insert the special tool, Push Rod, into the piston from
the side on which the front mark is stamped in the piston
head, and attach the guide C to the push rod end.
(2) Place the piston and connecting rod assembly on the
special tool, Piston Pin Setting Base, with the front mark
facing upward.
(3) Using a press, remove the piston pin.
NOTE
Keep the disassembled pistons, piston pins and
connecting rods in order according to the cylinder number.

ENGINE – Piston and Connecting Rod11-61
INSTALLATION SERVICE POINTS
APISTON PIN INSTALLATION
(1) Measure the following dimensions of the piston, piston
pin and connecting rod.
A: Piston pin insertion hole length
B: Distance between piston bosses
C: Piston pin length
D: Connecting rod small end width
(2) Obtain dimension L (to be used later) from the above
measurements by using by following formula.
L =
(A – C) – (B – D)
2
(3) Insert the special tool, Push Rod, into the piston pin and
attach the guide A to the push rod end.
(4) Assemble the connecting rod in the piston with their front
marks facing the same direction.
(5) Apply engine oil to the entire periphery of the piston pin.
(6) Insert the piston pin, push rod and guide A assembly
having assembled in step (3) from the guide A side into
the piston pin hole on the front marked side.
(7) Screw the guide B into the guide A until the gap between
both guides amounts to the value L obtained in step
(2) plus 3 mm.
(8) Place the piston and connecting rod assembly onto the
piston setting base with the front marks directed upward.
(9) Press-fit the piston pin using a press.
If the press-fitting force required is less than the standard
value, replace the piston and piston pin set or/and the
connecting rod.
Standard value: 7,350 – 17,200 N
3 mm + L

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

ENGINE – Alternator11-80
DISASSEMBLY SERVICE POINTS
AFRONT BRACKET ASSEMBLY REMOVAL
Insert a flat tip screwdrivers or the like in the clearance between
the front bracket assembly and stator core, to pry open and
separate the stator and front bracket.
Caution
Do not insert the screwdriver too far, or the stator coil
gets damaged.
BALTERNATOR PULLEY REMOVAL
Face pulley side upward, fix the rotor with a work bench
and remove the pulley.
Caution
Use care not to damage the rotor.
CSTATOR / REGULATOR ASSEMBLY REMOVAL
(1) Unsolder the stator with a soldering iron (180 to 250
W). Complete this work within four seconds not to transfer
heat to the diode.
(2) When removing rectifier from the regulator assembly,
remove the soldered sections to rectifier.
Caution
1. Use care to make sure that the heat of the soldering
iron is not transmitted to the diodes for a long
period.
2. Use care that no undue force is exerted to the
lead wires of the diodes.
REASSEMBLY SERVICE POINTS
AREGULATOR ASSEMBLY INSTALLATION
After installing the regulator assembly, insert a wire into the
hole provided on the rear bracket while pressing in the brush
to fix the brush.
NOTE
The brush is fixed when a wire is inserted, making rotor
installation easier.
Soldered
Rear bracket
Brush
WireWire

ENGINE – Starter Motor11-83
STARTER MOTOR
DISASSEMBLY AND REASSEMBLY
1 23
4 5
6
789
10 1112 13 14
15
16 17
18 19
202122
23
Disassembly steps
1. Cover
2. Screw
A3. Magnetic switch
4. Screw
5. Through
6. Rear bracket
7. Brush holder
8. Brush
9. Rear bearing
B10. Armature
11. Yoke assembly
B12. Ball13. Packing A
14. Packing B
15. Plate
16. Planetary gear
17. Lever
CA18. Snap ring
CA19. Stop ring
20. Overrunning clutch
21. Internal gear
22. Planetary gear holder
23. Front bracket

ENGINE – Starter Motor11-86
OVERRUNING CLUTCH CHECK
(1) While holding clutch housing, rotate the pinion. Drive
pinion should rotate smoothly in one direction, but should
not rotate in opposite direction. If clutch does not function
properly, replace overrunnig clutch assembly.
(2) Inspect pinion for wear or burrs. If pinion is worn or burred,
replace overrunning clutch assembly. If pinion is damaged,
also inspect ring gear for wear or burrs.
FRONT AND REAR BRACKET BUSHING CHECK
Inspect bushing for wear or burrs. If bushing is worn or burred,
replace front bracket assembly or rear bracket assembly.
BRUSH AND SPRING REPLACEMENT
(1) Brushes that are worn beyond wear limit line, or oil-soaked,
should be replaced.
(2) When replacing ground brush, slide the brush from brush
holder by prying retaining spring back.
ARMATURE TEST
ARMATURE COIL SHORT-CIRCUIT TEST
(1) Place armature in a growler.
(2) Hold a thin steel blade parallel and just above while rotating
armature slowly in growler. A shorted armature will cause
blade to vibrate and be attracted to the core. Replace
shorted armature.
ARMATURE COIL EARTH TEST
Check the insulation between each commutator segment and
armature coil core.
If there is no continuity, the insulation is in order.
Free
Lock
Wear limit line
Growler

MANUAL TRANSMISSION OVERHAUL – Specifications22B-3
SPECIFICATIONS
TRANSMISSION MODEL TABLE

Transmission modelGear ratioSpeedometer gear ratioFinal gear ratioFront LSD
W5M51-1-X6AA29/364.529Not available
W5M51-1-X6A1A29/364.529Available
W5M51-1-X7AA30/364.529Not available
W5M51-1-X7A1A30/364.529Available
W5M51-1-Z6AB29/364.875Not available
W5M51-1-Z6A1B29/364.875Available
W5M51-1-Z7AB30/364.875Not available
W5M51-1-Z7A1B30/364.875Available
W5M51-1-X6A2B29/364.529Not available
W5M51-1-X6A3B29/364.529Available
W5M51-1-X7A2B30/364.529Not available
W5M51-1-X7A3B30/364.529Available

Transmission modelGear ratioSpeedometer gear ratioFinal gear ratioFront LSD
W5M51-2-X6AA29/364.529Not available
W5M51-2-X6A1A29/364.529Available
W5M51-2-Z6AB29/364.875Not available
W5M51-2-X6A2B29/364.529Not available
W5M51-2-Z6A1B29/364.875Available
W5M51-2-X6A3B29/364.529Available

Transmission modelGear ratioSpeedometer gear ratioFinal gear ratioFront LSD
W5M51-2-X6A4A29/364.529Not available
W5M51-2-X6A6B29/364.529Not available
W5M51-2-Z6AB29/364.875Not available
W5M51-2-X6A8A29/364.529Available
W5M51-2-Z6A7B29/364.529Available
W5M51-2-X6A1B29/364.875Available

FRONT AXLE – General / Axle Hub and Knuckle 26-1
GROUP 26
FRONT AXLE
GENERAL
OUTLINE OF CHANGE

The installation method of the ball joint between the knuckle and the lower arm has been changed,
and accordingly the removal and installation procedures of the axle hub and the knuckle have been
revised.
AXLE HUB AND KNUCKLE
REMOVAL AND INSTALLATION
Caution
(1) For vehicles with AYC, be careful when handling the pole piece at the tip of the speed sensor so as
not to damage it by striking against other parts.
(2) For vehicles with AYC, be careful not to damage the rotors installed to B.J. outer race during removal
and installation of the drive shaft.
Post-installation Operation

Check the Dust Cover for Cracks or Damage by
Pushing it with Finger.
1
23
4 5 6 7
8
12 1415
1388 Nm 108 – 127 Nm
90 – 110 Nm
15 – 33 Nm177 – 275 Nm 25 Nm
25 Nm
9 Nm
103 Nm
74 –87
Nm
11 910
1610
11
Ball joint kit
Removal steps
1. Front speed sensor AYC>
A2. Caliper assembly
3. Brake disc
4. Split pin
BA5. Drive shaft nut
6. Front hub assembly
7. Dust shield
8. Connection for lower arm ball joint
9. Connection bolt for lower arm joint10. Lower arm ball joint
11. Dust cover
12. Split pin
C13. Connection for tie rod end
D14. Front drive shaft
15. Front strut mounting bolt
16. Knuckle
NOTE
Follow the conventional procedures for removal
and installation service points.