1999 MITSUBISHI LANCER EVOLUTION VI air condition

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General . . . . . . . . . . . . . . . . . . . . . . . .
Engine . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch . . . . . . . . . . . . . . . . . . . . . . . . .
Manual Transmission . . . . . . . . . . .
Front Axle . . . . . . . . . . . . . . . . . . . . . .
Rear Axle . . . . . . . . . . . . . . . . . . . . . .
Front Suspension . . . . . . . . . . . . . . .
Service Brakes . . . . . . . . . . . . . . . . .
Steering . . . . . . . . . . . . . . . . . . . . . . . .
Body . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exterior . . . . . . . . . . . . . . . . . . . . . . . .
Chassis Electrical . . . . . . . . . . . . . .
Electrical Wiring . . . . . . . . . . . . . . . .
WORKSHOP MANUAL
SUPPLEMENT
FOREWORD
This Workshop Manual contains procedures for
service mechanics, including removal, disassembly,
inspection, adjustment, reassembly and
installation. Use the following manuals in
combination with this manual as required.
TECHNICAL INFORMATION MANUAL
N9806CNCP9
N9806CNCP9-A
WORKSHOP MANUAL
S9806CNCP9
All information, illustrations and product
descriptions contained in this manual are current
as at the time of publication. We, however, reserve
the right to make changes at any time without prior
notice or obligation.
The EVOLUTION -VI is sold exclusively through
RALLIART Inc. Since the EVOLUTION-VI is a rally-
based model, it will not be warranted and will not be
homologated for general production. Therefore, any
service matters on the EVOLUTION-VI should be
inquired to RALLIART Inc. as usual.
EVOLUTION-VI

Mitsubishi Motors Corporation March 1999
Interior and Supplemental
Restraint System (SRS) . . . . . . . . .
.
Heater, Air Conditioner and
Ventilation . . . . . . . . . . . . . . . . . . . . .
.

GENERAL – How to Use This Manual00-4
EXPLANATION OF MANUAL CONTENTS
Indicates procedures to be performed
before the work in that section is started,
and procedures to be performed after
the work in that section is finished.
Indicates (by symbols) where lubrica-
tion is necessary.
Maintenance and Servicing Procedures
The numbers provided within the diagram indi-
cate the sequence for maintenance and servic-
ing procedures.
Removal steps:
The part designation number corresponds
to the number in the illustration to indicate
removal steps.
Disassembly steps:
The part designation number corresponds
to the number in the illustration to indicate
disassembly steps.Installation steps:
Specified in case installation is impossible
in reverse order of removal steps. Omitted
if installation is possible in reverse order of
removal steps.
Reassembly steps:
Specified in case reassembly is impossible
in reverse order of disassembly steps.
Omitted if reassemby is possible in reverse
order of disassembly steps.
Classifications of Major Maintenance/Service Points
When there are major points relative to maintenance and servicing procedures
(such as essential maintenance and service points, maintenance and service stan-
dard values, information regarding the use of special tools, etc.), these are ar-
ranged together as major maintenance and service points and explained in detail.
A: Indicates that there are essential points for removal or disassembly.
A: Indicates that there are essential points for installation or reassembly.
Symbols for Lubrication, Sealants and Adhesives
Information concerning the locations for lubrica-
tion and for application of sealants and adhe-
sives is provided, by using symbols, in the dia-
gram of component parts or on the page follow-
ing the component parts page, and explained.: Grease
(multipurpose grease unless there is a
brand or type specified)
: Sealant or adhesive
: Brake fluid or automatic transmission fluid
: Engine oil, gear oil or air conditioner com-
pressor oil
: Adhesive tape or butyl rubber tape
Component Diagram
A diagram of the component parts is
provided near the front of each section
in order to give a reader a better under-
standing of the installed condition of
component parts.

GENERAL – How to Use Troubleshooting/Inspection Service Points00-8
WHEN USING THE WARNING LAMP
1. Use the special tool to earth No.1 terminal (diagnosis
control terminal) of the diagnosis connector.
2. To check ABS system, remove the valve relay.
NOTE
That is because the valve relay is off and the warning
lamp remains illuminated if there is a fault in the ABS
system.
3. Turn on the ignition switch.
4. Read out a diagnosis code by observing how the warning
lamp flashes.
Applicable systems
System nameWarning lamp name
MPIEngine warning lamp
AY CAYC warning lamp
ABSABS warning lamp
Indication of diagnosis code by warning lamp
When the diagnosis code No.24 is outputWhen no diagnosis code is output*
On
Off
1.5 secs.0.5 sec.0.5 sec.
Pause
time 3
secs.Tens
signalPlace
division
2 secs.Units
signal
On
Off
0.5 sec.
NOTE
*: Even if the ABS system is normal, removing the valve relay causes the diagnosis code No.52 to
be output.
WHEN USING THE VOLTMETER
Use the special tool to connect the diagnosis output terminals
and the earth terminal of the diagnosis connector to a voltmeter
and take a reading of the diagnosis codes from the movement
of the needle.
Voltmeter connection terminals
System namePositive connection
terminalNegative connec-
tion terminal
Full-auto air
conditioner114 or 5
Diagnosis connector
MB991529
Earth terminal
Full-auto air con-
ditioner terminal
MB991529

GENERAL – How to Use Troubleshooting/Inspection Service Points00-10
HOW TO USE THE INSPECTION PROCEDURES
The causes of a high frequency of problems occurring in electronic circuitry are generally the connectors,
components, the ECU and the harnesses between connectors, in that order. These inspection procedures
follow this order, and they first try to discover a problem with a connector or a defective component.
Indicator does not turn on or off even if control
mode switch is pressed.
Indicator switch should not be illuminated is
illuminated.Probable cause
OK
OK
OK
Measure at switch connector A-44
Disconnect the connector, and measure at the harness
side.
Voltage between terminal 6 – earth and terminal 8 –
earth
OK:Approx. 5V
OK
NG
Check the following connector. A-44
Repair
OK
Check trouble symptom.
Replace the ECS-ECU.
In the above cases, the ECS switch circuit is defective or the indicator
circuit is defective.
CHECKING PROCEDURE 4
2. Indicates inspection carried out using the
MUT-II.
Indicates the operation and inspection proce-
dures.
Indicates the OK judgement conditions.
3. Detailed inspection procedures (methods)
such as component inspection and circuit
inspection are listed on a separate page, and
are given here for reference.
5. Inspect the contact condition at each connector terminal.
(Refer to Connector Inspection Service Points.)
The connector position can be located in the wiring diagram in the
electrical wiring manual by means of this symbol.
Caution
After carrying out connector inspection, always be sure to
reconnect the connector as it was before.
6. Confirm that there are trouble symptoms. If trouble symptoms have
disappeared, the connector may have been inserted incorrectly and the
trouble symptom may have disappeared during inspection.
If it seems that trouble symptoms still remain, proceed to the next page of
instructions.
7. If trouble symptoms still remain up to this stage, there is a possibility that there is an
open or short circuit in the harness between the connectors, so check the harness.
Alternatively, the cause may be a defective ECU, so try replacing the ECU and check
if the trouble symptom disappears.
NGECU switch component inspection (Refer to P.3-44.)
NG
1. Comments on the diagnosis code or trouble
symptom above.
MUT-II Data list
17 Control mode selection switch
OK:Voltage changes between approx. 0V → approx.
2.5V → approx. 5V when the switch is operated.
4. Indicates voltage and resistance to be measured at a particular
connector.
(Refer to Connector Measurement Service Points.)
The connector position can be located in the wiring diagram in the
electrical wiring manual by means of this symbol.
Indicates operation and inspection procedures, inspection terminals
and inspection conditions.
Indicates the OK judgement conditions.
HARNESS INSPECTION
Check for an open or short circuit in the harness between the terminals which were defective according
to the connector measurements. Carry out this inspection while referring to the electrical wiring manual.
Here, “Check harness between power supply and terminal xx” also includes checking for blown fuses.
For inspection service points when there is a blown fuse, refer to “Inspection Service Points for a Blown
Fuse.”
MEASURES TO TAKE AFTER REPLACING THE ECU
If the trouble symptoms have not disappeared even after replacing the ECU, repeat the inspection procedure
from the beginning.

GENERAL – Precautions Before Service00-16
SERVICING THE ELECTRICAL SYSTEM
Before replacing a component related to the electrical system
and before undertaking any repair procedures involving the
electrical system, be sure to first disconnect the negative
(–) cable from the battery in order to avoid damage caused
by short-circuiting.
Caution
Before connecting or disconnecting the negative (–) cable,
be sure to turn off the ignition switch and the lighting
switch.
(If this is not done, there is the possibility of
semiconductor parts being damaged.)
APPLICATION OF ANTI-CORROSION AGENTS
AND UNDERCOATS
If oil or grease gets onto the oxygen sensor, it will cause
a drop in the performance of the sensor.
Cover the oxygen sensor with a protective cover when applying
anti-corrosion agents and undercoats.
PRE-INSPECTION CONDITION
“Pre-inspection condition” refers to the condition that the
vehicle must be in before proper engine inspection can be
carried out. If you see the words “Set the vehicle to the
pre-inspection condition.” in this manual, it means to set the
vehicle to the following condition.
Engine coolant temperature: 80–90C
Lamps, electric cooling fan and all accessories: OFF
M/T: Neutral
VEHICLE WASHING
If high-pressure car-washing equipment or steam car-washing
equipment is used to wash the vehicle, be sure to note the
following information in order to avoid damage to plastic
components, etc.
Spray nozzle distance: Approx. 40 cm or more
Spray pressure: 3,900 kPa or less
Spray temperature: 82C or less
Time of concentrated spray to one point: within 30 sec.
Approx.
40 cm

ENGINE – Cylinder Head and Valves11-44
REMOVAL SERVICE POINTS
PRECAUTION FOR REMOVED PARTS
Keep removed parts in order according to the cylinder number
and intake/exhaust.
ACYLINDER HEAD BOLTS REMOVAL
Using the special tool, loosen the cylinder head bolts. Loosen
evenly, little by little.
BRETAINER LOCK REMOVAL
Store removed valves, springs and other parts, tagged to
indicate their cylinder No. and location for reassembly.
CVALVE HANDLING PRECAUTIONS
(1) Sodium reacts violently with water or moisture generation
heat and liberating hydrogen. It must be handled with
utmost care because otherwise the following dangerous
conditions may result:
Loss of eyesight if sodium gets in eyes.
Burns if soduim contact skin.
Fire hazard.
(2) Handling of Soduim-filled Exhaust Valves
Soduim-filled exhaust valves are not dangerous and may
be handled in the same way as ordinary valves unless
they are broken.
Never try to break the valves and expose soduim to the
air. When worn exhaust valves are to be discarded, have
them disposed of by a salvage company equipped with
special disposal system, notifying them that the valves
contain soduim.
Should the exhaust valves be broken, neutralize soduim
using the method described below, and discard the valves
in the same way as ordinary valves.
MB991654
MD998772
MD998735

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

MPI – General13-2
MULTIPOINT INJECTION (MPI)
GENERAL
OUTLINE OF CHANGE

The descriptions of the troubleshooting using an MUT-II tester have been added.

The fuel system and its management of EVOLUTION-VI are different from those of EVOLUTION-V
in the following items. Accordingly, the service procedures for these items are described herein. The
service procedures for the remaining item are the same as those for EVOLUTION-V.

Fan motor control

Fuel pump drive control

Fuel pump relay No.2

Fuel pump resistor

Actuator test function of MUT-II (The test of the following items has been made possible.)
a) Item No.36: Secondary air control solenoid valve
b) Item No.37: Air conditioner condenser fan (High)
c) Item No.38: Air conditioner condenser fan (Low)