1999 MITSUBISHI LANCER EVOLUTION VI cooling

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 – Front Case, Counterbalance Shaft and Oil Pan11-58
COUNTERBALANCE SHAFT
(1) Check oil holes for clogging.
(2) Check journals for seizure, damage and contact with
bearing. If there is anything wrong with the journal, replace
the counterbalance shaft, bearing or front case assembly.
OIL COOLER BY-PASS VALVE (ENGINE WITH AIR
COOLING TYPE OIL COOLER)
(1) Make sure that the valve moves smoothly.
(2) Ensure that the dimension (L) measures the standard
valve under normal temperature and humidity.
Standard value (L): 34.5 mm
(3) The dimension must be the standard value when
measured after the valve has been dipped in 100°C oil.
Standard value (L): 40 mm or more
OIL PUMP
(1) Assemble the oil pump gear to the front case and rotate
it to ensure smooth rotation with no looseness.
(2) Ensure that there is no ridge wear on the contact surface
between the front case and the gear surface of the oil
pump cover.
(3) Check the side clearance.
Standard value:
Drive gear 0.08 – 0.14 mm
Driven gear 0.06 – 0.12 mm
Valve

MPI – Troubleshooting13-56
DATA LIST REFERENCE TABLE
Item
No.Inspection
itemInspection contentsNormal conditionInspection
procedure
No.Reference
page
11Oxygen
sensorEngine:After having
warmed up
Air/fuel mixture is
made leaner when de-
When at 4,000 r/min,
engine is suddenly
decelerated200 mV or lessProcedure
No. 3113-42
made leaner when de-
celerating, and is made
richer when racing.
When engine is
suddenly raced600 – 1,000 mV
Engine:After having
warmed up
The oxygen sensor
si
gnal is used to check
Engine is idling400 mV or less
(Changes)
signal is used to check
the air/fuel mixture
ratio, and control
condition is also
checked by the ECU.2,500 r/min600 – 1,000 mV
12Air flow
sensor*
Engine coolant
tem
perature: 80 –
Engine is idling17 – 43 Hz––
sensor
TION-IV>temperature: 80
95C

Lamps, electric
li f d ll
2,500 r/min46 – 86 Hzp
cooling fan and all
accessories: OFF

Transmission:
Neutral (A/T:
P range)Engine is racedFrequency
increases in
response to
racing
12Air flow
sensor*
Engine coolant
tem
perature: 80 –
Engine is idling12 – 38 Hz––
sensor
TION-V, VI>temperature: 80
95C

Lamps, electric
li f d ll
2,500 r/min36 – 76 Hzp
cooling fan and all
accessories: OFF

Transmission:
Neutral (A/T:
P range)Engine is racedFrequency
increases in
response to
racing
13Intake air
temperature
sensor
Ignition switch: ON or
with engine runningWhen intake air
temperature is –20C–20CCode No.
1313-9
sensorWhen intake air
temperature is 0C0C
When intake air
temperature is 20C20C
When intake air
temperature is 40C40C
When intake air
temperature is 80C80C
NOTE
*: In a new vehicle [driven approximately 500 km or less], the air flow sensor output frequency is sometimes
10% higher than the standard frequency.

MPI – Troubleshooting13-59
Item
No.Inspection
itemInspection contentsNormal conditionInspection
procedure
No.Reference
page
41Injectors*1
TION-IV>Engine: CrankingWhen engine
coolant temperature
is 0C (injection is
carried out for all
cylinders
simultaneously)27 – 41 ms––
When engine
coolant temperature
is 20C14 – 22 ms
When engine
coolant temperature
is 80C3.9 – 5.9 ms
Injectors*2
TION-IV>

Engine coolant
temperature:
80–95C
Engine is idling1.2 – 2.4 ms
TION-IV>80–95C

Lamps, electric
cooling fan and all
accessories: OFF
2,500 r/min1.0 – 2.2 ms
accessories: OFF

Transmission:
Neutral (A/T :
P range)When engine is
suddenly racedIncreases
41Injectors*1
TION-V, VI>Engine: CrankingWhen engine
coolant temperature
is 0C27 – 40 ms––
When engine
coolant temperature
is 20C14.5 – 21.7 ms
When engine
coolant temperature
is 80C3.8 – 5.6 ms
Injectors*2
TION-V VI>

Engine coolant
temperature:
80–95C
Engine is idling0.9 – 2.1 ms
TION-V, VI>80–95C

Lamps, electric
cooling fan and all
accessories: OFF
2,500 r/min0.7 – 1.9 ms
accessories: OFF

Transmission:
Neutral (A/T :
P range)When engine is
suddenly racedIncreases
NOTE
*1: The injector drive time represents the time when the cranking speed is at 250 r/min or below when
the power supply voltage is 11 V.
*
2: In a new vehicle [driven approximately 500 km or less], the injector drive time is sometimes 10%
longer than the standard time.

MPI – Troubleshooting13-60
Item
No.Inspection
itemInspection contentsNormal conditionInspection
procedure
No.Reference
page
44Ignition coils
and power
transistors
having warmed up

Timing lamp is set.
(The timing lampEngine is idling3ATDC –
13BTDC––
TION-IV>
(tgp
is set in order to
check actual
ignition timing.)2,500 r/min24 – 44BTDC
44Ignition coils
and power
transistors

Engine: After
having warmed up

Timing lamp is set
Engine is idling0 – 13BTDC––
transistors
TION-V, VI>
Timing lamp is set.
2,500 r/min24 – 44BTDC
45ISC
(stepper)
motor
position *

Engine coolant
temperature: 80 –
90C

Lam
ps, electric
A/C switch: OFF2 – 25 steps––
position
Lamps, electric
cooling fan and all
accessories: OFF

Transmission:
Neutral (A/T :
P range)
Idl iti
A/C switch:
OFF → ONIncreases by
10 – 70 steps
g)

Idle position
switch: ON

Engine: Idling

When A/C switch
is ON, A/C
compressor should
be operating
A/C switch: OFF

Select lever:
N range →
D rangeIncreases by
5 – 50 steps
49A/C relayEngine: After having
warmed up/Engine is
idlingA/C switch: OFFOFF (Compressor
clutch is not
operating)Procedure
No. 2913-39
A/C switch: ONON (Compressor
clutch is
operating)
NOTE
*: In a new vehicle [driven approximately 500 km or less], the stepper motor has sometimes 30 steps
greater than the standard value.
Caution
When shifting the select lever to D range, the brakes should be applied so that the vehicle does
not move forward.

55-1
HEATER,
AIR CONDITIONER
AND VENTILATION
CONTENTS
HEATER AND MANUAL AIR
CONDITIONER 3. . . . . . . . . . . . . . . . . . . . . .
GENERAL 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outline of Change 3. . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE SPECIFICATIONS 3. . . . . . . . . . . . . .
LUBRICANTS 3. . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 3. . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 4. . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE 6. . . . . . . . . . . . . . . . . .
Refrigerant Charging 6. . . . . . . . . . . . . . . . . . . . . . .
Refrigerant Charging Amount Check 9. . . . . . . .
Replenishing System 10. . . . . . . . . . . . . . . . . . . . .
Discharging System 11. . . . . . . . . . . . . . . . . . . . . .
Performance Test 11. . . . . . . . . . . . . . . . . . . . . . . .
Dual Pressure Switch Simple Check 13. . . . . . .
Power Relay Check 13. . . . . . . . . . . . . . . . . . . . . .
Idle-up Operation Check 14. . . . . . . . . . . . . . . . . .
HEATER CONTROL ASSEMBLY AND A/C
SWITCH 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HEATER UNIT AND BLOWER UNIT
AIR CONDITIONER> 18. . . . . . . . . . . . . . . . . . .
HEATER UNIT, COOLING AND BLOWER
UNIT CONDITIONER> 19. . . . . . . . . . . . . . . . . . . . . . .
BLOWER MOTOR ASSEMBLY, RESISTOR
AND EVAPORATOR 20. . . . . . . . . . . . . . . . . . .
COMPRESSOR AND TENSION
PULLEY 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONDENSER AND CONDENSER FAN 28. .
REFRIGERANT LINE 30. . . . . . . . . . . . . . . . . .
DUCTS 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTINUED ON NEXT PAGE

HEATER AND MANUAL AIR CONDITIONER – On-vehicle Service55-12
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. Start the engine.
6. Set the blower switch to HI (Fast) position
7. Set the A/C switch to ON position
8. Set the temperature control to Max. cooling position
9. Set the mode selection to Face position
10. Set the air selection to Recirculation position
11. Fix engine speed to 1,500 r/min.
12. Check that the high-pressure side pressure is 1,667 –
1,765 kPa.
NOTE
If the pressure is not within this range, adjust it as follows;
cool down the condenser using a cooling fan if the
pressure is higher, and cover the condenser to protect
it from ventilation air if it is lower.
13. Set a dry-bulb/wet-bulb thermometer at the air inlet, and
set a dry-bulb thermometer at the air outlet.
Caution
(1) Set the dry-bulb thermometer at a position where
the temperature sensing section can be directly
blown with cooled air.
(2) Place the dry-bulb/wet-bulb thermometer at a
position where it is not exposed to cooled air
blown out.
14. After the temperature of the air blown out from the air
outlet has been stabilized (10 – 15 minutes after starting),
read the dry-bulb thermometer set at the air outlet and
the wet-valve thermometer set at the air inlet.
15. The air conditioning system is considered in good
condition if the intersecting point of the measurements
obtained in Step (14) is below the performance evaluation
reference line on the graph.
Caution
Do not remove the quick joint immediately after the
performance test has been completed. Stop the engine
and wait until the high-pressure side pressure of the
gauge manifold has been lowered sufficiently.
Dry-bulb ther-
mometer
Dry-bulb/wet-bulb
thermometer
Reading of wet-bulb thermometer
set at air inlet (°C)
Performance
evaluation
reference line
In order
Not in order
0Reading of dry-bulb
thermometer set at air outlet
(°C)
15 20 25 30 5 10 15 20 25

– Heater Unit, Cooling and Blower Unit HEATER AND MANUAL
AIR CONDITIONER55-19
HEATER UNIT, COOLING AND BLOWER UNIT

REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation

Engine Coolant Draining and Refilling

Discharging and Charging of Refrigerant
(Refer to P.55-6.)

Air Cleaner Cover and Hose Removal and
Installation

Floor Console and Instrument Panel Removal and
Installation

Rear Seat Heater Duct Removal and Installation
(Refer to P.55-31.)
1
34
5 6
2 7
8 9
10 1112
Piping connection
O-ring
A/C Compressor oil: SUN PAG 56
Removal steps
1. Center reinforcement RH
2. Heater control assembly
3. Center reinforcement LH
4. Center ventilation duct
5. Foot distribution duct
6. Drain hose
A7. Connection between cooling unit
and refrigerant line8. Cooling and blower unit
9. Heater hose
10. Heater unit
11. Heater core support
12. Heater core
REMOVAL SERVICE POINT
AREMOVAL OF REFRIGERANT LINE FROM
COOLING UNIT
Plug the open end of the removed hose and the opening
in the cooling unit to prevent entry of dust and foreign
substances.
Caution
Compressor oil and the receiver are highly
moisture-absorptive.
Do not use plugs allowing ventilation.