1999 MITSUBISHI LANCER EVOLUTION VI ad blue

ENGINE – Crankshaft and Flywheel11-69
Crankshaft journal outside diameterCylinder block bearing boreCrankshaft bearing
Identification colorSize mmIdentification markIdentification mark or color
Yellow56.994 – 57.00000 or Black
11 or Green
22 or Yellow
None56.988 – 56.99401 or Green
12 or Yellow
23 or None
White56.982 – 56.98802 or Yellow
13 or None
24 or Blue
For example, if the crankshaft journal outside diameter
ID color is “yellow” and cylinder block bearing bore ID
mark is “1”, select a bearing whose ID mark is “1”.
If there is no ID color paint on the crankshaft, measure
the journal outside diameter and select a bearing
appropriate for the measured value.
(2) Install the bearings having an oil groove to the cylinder
block.
(3) Install the bearings having no oil groove to the bearing
cap.
CBEARING CAP / BEARING CAP BOLT
INSTALLATION
(1) Install the bearing caps so the arrow points to the timing
belt side.
(2) Before installing the bearing cap bolts, check that the
shank length of each bolt meets the limit. If the limit is
exceeded, replace the bolt.
Limit: Max. 71.1 mm
(3) Apply engine oil to the threaded portion and bearing
surface of the bolt.Crankshaft bearing size
identification mark or color
Identification
mark or color
UpperGroove
Lower
9EN0477
Shank length

MPI – Troubleshooting13-17
Code No. 64 Alternator FR terminal systemProbable cause
Range of Check

Engine speed is approx. 50 r/min or more
Set Conditions

The input voltage from the alternator FR terminal is higher than 4.5 V for 20 seconds.
Open circuit in alternator FR terminal circuit

Malfunction of the engine-ECU
Measure at the alternator connector A-05.

Connect the connector. (Use the test harness: MB991519.)

Voltage between 4 (blue clip) and earth
(Engine: Idling)
(Radiator fan: Stopped)
(Headlamp: OFF → ON)
(Brake lamp: OFF → ON)
(Rear window defogger switch: OFF → ON)
OK:Voltage drops 0.2 to 3.5 VOKReplace the engine-ECU.
NG
Measure at the alternator connector A-05.

Disconnect the connector, and measure at the harness side.

Voltage between 4 and earth
(Ignition switch: ON)
OK:4.8 – 5.2 VNGCheck the following
connectors: B-60, A-88NG
Repair
OK
Check trouble symptom.
NG
Check the harness wire
between the engine-ECU
and the alternator con-
nector.NG
Repair
OK
Replace the engine-ECU.
OK
Check the following connector: A-05NG
Repair
OK
Check trouble symptom.
NG
Check the harness wire between the engine-ECU and the alternator
connector.NG
Repair
OK
Replace the alternator.

BODY – Sunroof42-17
SUNROOF MOTOR CHECK
Check the direction of rotation of the drive gear when the
battery is connected to the connector.
Battery connection terminalDrive gear rotation
di ti12direction
Left
Right
LIMIT SWITCH CONTINUITY CHECK
1. Remove the limit switches from the sunroof motor, and
then check the operation of the limit switches.
Switch positionTerminal No.
4567
Limit switch 1ON
OFF
Limit switch 2ON
OFF
Limit switch 3ON
OFF
2. Check the identification colours. Then install the limit
switches as shown in the illustration.
SUNROOF SWITCH CONTINUITY CHECK
Switch positionTerminal No.
3456
Slide open
Off
Tilt up
Slide close, Tilt down
Left rotationDrive gear
Right rotation
(Red)(White)Limit switch 2, 3
ON
OFF
(Black)
(Black)(Blue)
Limit switch 1

HEATER AND MANUAL AIR CONDITIONER –
Troubleshooting /
On-vehicle Service55-6
INSPECTION AT THE AUTOMATIC COMPRESSOR-ECU TERMINAL
Terminal
No.Check itemChecking requirementsNormal condition
1Output from ECU to A/C compressor
relay
A/C compressor relay: OFFSystem voltage
relay
A/C compressor relay: ON0 V
2Input from A/C switch to ECUA/C switch: OFF0 V
A/C switch: ONSystem voltage
3EarthAlways0 V
ON-VEHICLE SERVICE
REFRIGERANT CHARGING
Caution
The refrigerant generates toxic gases when it is expored
to a heat source such as fire. Keep flames away from
the refrigerant. Perform refrigerant charging at a
well-ventilated place.
1. Recommended charging tools
The following commercially available tools are recommended
for discharging and charging refrigerant.

Gas charging set [No. EA95 (R134a)]

Gas charging set case [No. EA101CS-2]

Gauge manifold [No. EA101N-1]

Charging valve [No. EA108N]

Adapter valve [No. EA104AD-3]
NOTE
The adapter valve opens when the handle is turned
clockwise and closes when it is turned counter-clockwise.

Quick joint (for low pressure) [No. EA413L]

Quick joint (for high pressure) [No. EA413H]

Charging hose (red) [No. EA104N-1]

Charging hose (blue) [No. EA104N-2]

Charging hose (yellow) [No. EA104N-3]

Vacuum pump [No. EA112A]

Vacuum pump adaptor [No. EA112X]
Gauge manifold
Adapter valve
(for low pressure)
Charging hoseVacuum
pump adaptor
Quick joint
(for low pressure)Charging valve
Quick joint
(for high pressure)
Vacuum pump

HEATER AND MANUAL AIR CONDITIONER – On-vehicle Service55-7
2. Charging
1. Open the low-pressure valve of the gauge manifold. Keep
the high-pressure valve closed.
2. With the handles turned back all the way (valve closed),
install the adaptor valve to the low-pressure side of the
gauge manifold.
3. Connect the charging hose (blue) to the adaptor valve
1.
4. Connect the quick joint 2 to the charging hose (blue).
5. Connect the quick joint 2 to the low pressure service
valve.
NOTE
The low-pressure service valve is provided on the suction
pipe.
Caution
(1) To install the quick joint, press section “A” firmly
against the service valve until a click is heard.
(2) When connecting, run your hand along the hose
while pressing to ensure that there are no bends
in the hose.
6. Connect the charging hose (yellow) to the valve 3 of
the gauge manifold.
7. Install the vacuum pump adaptor to the vacuum pump.
Caution
To supply the power, connect the power supply plug
of the vacuum pump to the vacuum pump adapter
and then the power supply plug of the vacuum pump
adapter to a 100 V power outlet.
8. Connect the charging hose (yellow) to the R134a
connection port of the vacuum pump adaptor.
9. Tighten the adaptor valve 1 handle (valve closed).
10. Turn the power switch of the vacuum pump to the ON
position.
NOTE
Even if the vacuum pump power switch is turned ON,
the vacuum pump will not operate because of the power
supply connection in step (7).
11. Turn the vacuum pump adaptor switch to the R134a side
to start the vacuum pump.
Low-
pressure
valveHigh-
pressure
valve
Gauge
manifold
Adapter
valve (for low
pressure)
Charging hose (yellow)
Charging hose
(blue)
To 100 V
power
outletSwitchR134a
connec-
tion port
Vacuum
pump
adaptor
Vacuum
pump
Power
supply
plug Quick joint
(for low
pressure)
Low-
pressure
service
valve
Sleeve
Low-
pressure
gaugeHigh-
pressure
gauge
Valve
High-
pressure
service
valve
Air
condi-
tioning
system
A
Power
supply
plug
Switch

HEATER AND MANUAL AIR CONDITIONER – On-vehicle Service55-8
12. Evacuate to a vacuum reading of 100 kPa or higher (takes
approx. 10 minutes).
Start evacuation
Approx. for 10 minutes up to
100 kPa
Stop evacuation
Refrigerant charging
(until saturated pressure is reached)
Wait for 5 minutes
Air-tight checkIf faulty
Refrigerant charging
Gas leak check*If faultyRetighten connections
*: If the leaking point cannot be located even after
performing a gas leak check, ask an expert for
checking the system.
13. Return the handle of the adapter valve 1 to the original
position (valve closed), turn off the vacuum pump adapter
switch and leave as it is for 5 minutes.
14. Carry out a leak test. (Good if the negative pressure
does not drop.)
15. With the handle turned back all the way (valve open),
install the charging valve to the service can.
16. Remove the adaptor valve 1 from the gauge manifold
and install the service can.
17. Tighten the handle of the charging valve (valve closed)
and puncture the service can.
18. Turn the handle of the charging valve back (valve open)
and tighten the handle of the adaptor valve 1 (valve open)
to charge the system with refrigerant.
19. If the refrigerant is not drawn in, turn the handle of the
adaptor valve 1 back all the way (valve closed).
20. Check for gas leaks using a leak detector.
Caution
The leak detector for R134a should be used.
21. Start the engine.
22. Operate the A/C and set to the lowest temperature (MAX.
COOL).
23. Fix the engine speed at 1,500 r/min.
24. Tighten the handle of the adaptor valve 1 (valve open)
to charge the required volume of refrigerant.
Caution
If the service can is inverted, liquid refrigerant may
be drawn into the compressor damaging it by liquid
compression. Keep the service can upright to ensure
that refrigerant is charged in gas state.
25. After charging with refrigerant, turn the handle of the
adaptor valve 1 back all the way (valve closed).
26. Tighten the charging valve handle (valve closed).
Charging
valveAdapter valve
(for low pressure)
Charging hose
(blue)
R134a
Service
can
Quick joint
(for low pressure)
Low-
pressure
service
valveHigh-
pressure
service
valve
Air conditioning system

HEATER AND MANUAL AIR CONDITIONER – On-vehicle Service55-10
REPLENISHING SYSTEM
1. Connect the charging hose (blue) to the adapter valve
1 with the handle fully turned back (valve closed).
2. Connect the charging hose (blue) to the quick joint 2
and to the low pressure service valve.
Caution
Never connect to the high-pressure side since
otherwise the refrigerant could flow back.
3. Open and close the valve by operating the handle of
the adapter valve 1 to bleed air from inside the charging
hose.
4. With the handle turned back all the way (valve open),
install the charging valve to the service van.
5. Tighten the handle of the charging valve (valve closed)
and puncture the service can.
6. Install the charging valve to the adapter valve 1 and turn
back the handle all the way (valve open).
7. Start the engine.
8. Operate the A/C and set to the lowest temperature (MAX.
COOL).
9. Fix the engine speed at 1,500 r/min.
10. Tighten the handle of the adapter valve 1 (valve open).
Replenish the system with refrigerant while checking the
level through the sight glass.
After charging with refrigerant, turn the handles of the
charging valve and the adapter valve 1 all the way back
(valve closed), then remove the quick joint 2.
NOTE
If the service can is not emptied completely, keep the
handles of the charging valve and adaptor valve closed
for the next charging.Charging
valveAdapter valve
(for low pressure)
Charging hose
(blue)
R134a
Service
can
Quick joint
(for low pressure)
Low-
pressure
service
valveHigh-
pressure
service
valve
Air conditioning system

HEATER AND MANUAL AIR CONDITIONER – On-vehicle Service55-11
DISCHARGING SYSTEM
1. Run the engine at an engine speed of 1,200–1,500 r/min
for approximately 5 minutes with the A/C operating to
return to the oil.
NOTE
Returning the oil will be more effective if it is done while
driving.
2. Stop the engine.
3. Connect the charging hose (blue) to the adaptor valve
1 with its handle turned back all the way (valve closed).
4. Connect the quick joint 2 to the charging hose (blue),
and install the quick joint to the low-pressure service valve.
NOTE
The low-pressure service valve is provided on the suction
pipe.
Caution
(1) To connect the quick joint, press section “A” firmly
against the service valve until a click is heard.
(2) When connecting, run your hand along the hose
while pressing to ensure that there are no bends
in the hose.
5. Place the adaptor valve 1 inside the container and
discharge the refrigerant by opening the handle gradually
so that oil does not gush out.
NOTE
Any oil remaining in the container should be returned
to the A/C system.
PERFORMANCE TEST
1. The vehicle to be tested should be placed in a place
that is not exposed to direct sunlight.
2. The ambient condition should be 16 – 30 °C in temperature
and 60 – 100 % in relative humidity.
3. Open all the doors so that the air condition inside the
passenger compartment may be identical to that of the
outside.
4. With the high-pressure side of the gauge manifold closed,
connect the charging hose (red) to the gauge manifold
high-pressure side. Attach the quick joint for high-pressure
to the charging hose (red) and install it to the high-pressure
service valve on the vehicle side.
NOTE
The high-pressure service valve is found on liquid pipe
B.
Sleeve
Low-
pressure
service
valveHigh-
pressure
service
valve
Air conditioning system Adapter
valve (for low
pressure)Charging hose
(blue)
Quick joint (for
low pressure)Air conditioning
compressor oilA
Low-pressure
valve
Gauge manifold
Charging hose (red)
Quick joint
(for high pressure)
Low-
pressure
service
valve
Sleeve
Low-pressure
gaugeHigh-pressure
gauge
High-
pressure
service
valve
Air conditioning system
A
High-
pressure
valve