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Mitsubishi Lancer Evolution VI User Manual
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WORKSHOP MANUAL
Pub. No. S9806CNCP9-A
EVOLUTION-VI
Pub. No. S9806CNCP9-A
EVOLUTION-VI
Pub. No. S9806CNCP9-A
Mar
. ’99 Printed in Japan
WORKSHOP MANUAL
2
Table of Contents
21 Evolution-VI
2
Table of Contents
2
How to Use this Manual
5
Scope of Maintenance, Repair and Servicing Explanations
5
Definition of Terms
5
Indication of Tightening Torque
5
General
6
Explanation of Manual Contents
6
How to Use
8
Points
8
Troubleshooting Contents
8
Diagnosis Function
9
How to Use the Inspection Procedures
12
Connector Measurement Service Points
13
Connector Inspection
14
Inspection Service Points for a Blown Fuse
15
Points to Note for Intermittent Malfunctions
15
Models
16
Precautions before Service
17
Support Locations for Lifting and Jacking
20
Garage Jack
20
Axle Stands
21
Single-Post and Double-Post Lift
21
Special Handling Instruments for Towing
22
Brake Test
23
Tightening Torque
24
Engine
25
General Information
26
Specifications
27
Service Specifications
27
Torque Specifications
29
New Tightening Method by Use of Bolts to be Tightened in Plastic Area
33
Sealants
33
Form-In-Place Gasket
34
Special Tools
35
Alternator and Ignition System
38
Timing Belt
39
Fuel and Emission Control Parts
51
Secondary Air System and Intake Manifold
53
Exhaust Manifold
55
Water Pump and Water Hose
58
Rocker Arms and Camshaft
61
Cylinder Head and Valves
67
Front Case, Counterbalance Shaft and Oil Pan
75
Piston and Connecting Rod
83
Crankshaft and Flywheel
91
Throttle Body
97
Turbocharger
99
Alternator
103
Starter Motor
107
Multipoint Injection (Mpi)
112
General
113
Multipoint Injection (Mpi)
113
Outline of Change
113
Sealant
115
Service Specifications
115
Special Tools
116
Troubleshooting
117
Inspection Chart for Trouble Symptoms
129
Communication with All Systems Is Impossible
131
Inspection Procedure
132
No Initial Combustion (Starting Impossible)
133
Initial Combustion but no Complete Combustion
134
Starting Impossible
134
Long Time to Start (Improper Starting)
135
Unstable Idling (Rough Idling, Hunting)
136
Engine
137
Idling Speed Is High. (Improper Idling Speed)
137
Idling Speed Is Low. (Improper Idling Speed)
138
When the Engine Is Cold, It Stalls at Idling. (die Out)
139
When the Engine Is Hot, It Stalls at Idling. (die Out)
140
The Engine Stalls When Starting the Car. (Pass Out)
141
The Engine Stalls When Decelerating
141
Hesitation, Sag or Stumble
142
The Feeling of Impact or Vibration When Accelerating
142
The Feeling of Impact or Vibration When Decelerating
143
Poor Acceleration
143
Too High Co and Hc Concentration When Idling
145
Low Alternator Output Voltage (Approx. 12.3 V)
146
Fuel Pump System
147
Fuel
172
On-Vehicle Service
179
Fuel Pump Resistor Check
179
Continuity Check
179
Engine Control Relay and Fuel Pump Relay Continuity Check
179
Fuel Supply
180
General
180
Outline of Change
180
Clutch
181
On-Vehicle Service
182
Clutch Pedal Inspection and Adjustment
182
Bleeding
183
Outline of Change
182
General
182
Clutch Pedal
184
Clutch Control
185
Removal and Installation
185
Clutch Master Cylinder
186
Clutch
187
Manual Transmission
187
Clutch Housing
191
Reverse Idler Gear
192
Front Axle
193
Rear Axle
195
Lubricants
195
Service Specifications
196
Rear Axle
197
Lubricant
196
General
196
Outline of Change
196
Special Tools
197
Vehicles with Ayc
225
Rear Axle Total Backlash Check
225
Gear Oil Level Check
225
Gear Oil Change
226
Fluid Level Check
227
Bleeding
228
AYC Operation Check
228
Hydraulic Pressure Check
229
Differential Carrier Oil Seal Replacement
230
Wheel Speed Sensor Output Voltage Measurement <Vehicles Without ABS
231
Action When Battery Runs out
232
Troubleshooting
225
On-Vehicle Service
225
Hydraulic Unit
233
Vehicles with Ayc
233
Sensor Relay <Vehicles with Ayc
235
Ayc-Ecu
236
Rear Axle
237
Front Suspension
237
Basic Brake System
238
General
239
Outline of Change
239
On-Vehicle Service
239
Brake Pedal Check and Adjustment
239
Brake Pedal
241
Master Cylinder and Brake Booster
242
Steering
244
Body
244
Master Cylinder
244
Disc Brake
246
General/Keyless Entry System
265
Keyless Entry System
266
Special Tool
266
Troubleshooting
266
Keyless Entry System
271
Transmitter
271
Sealant
273
Service Specifications
273
General
266
Outline of Change
266
Sunroof
273
Troubleshooting
273
On-Vehicle Service
277
Water Test
277
Sunroof Fit Adjustment
277
Sunroof
278
Exterior
283
Front Bumper
284
General
284
Outline of Change
284
Special Tool
284
Aero Parts
286
Washer Tank and Hoses
288
Intercooler & Radiator Water Spray System
289
Marks
290
Supplemental Restraint System (Srs)
292
General Information
293
Srs Service Precautions
294
Special Tools
296
Test Equipment
296
Troubleshooting
297
Srs Maintenance
306
Post-Collision Diagnosis
310
Individual Component Service
313
Warning/Caution Labels
314
Srs Air Bag Control Unit
315
Srs-Ecu
315
Air Bag Modules and Clock Spring
316
Air Bag Module Disposal Procedures
323
Undeployed Air Bag Module Disposal Procedures
323
Deployed Air Bag Module Disposal Procedures
331
Chassis Electrical
333
Battery
335
Service Specification
335
On-Vehicle Service
335
Battery Testing Procedure
337
General
335
Immobilizer System
338
Chassis Electrical
339
Ignition Switch
339
Special Tool
345
Troubleshooting
345
Ignition Switch and Immobilizer System
345
Ignition Switch <Except Evolution-VI with Immobilizer System
338
Special Tool
338
Troubleshooting
338
Ignition Switch
338
Combination Meters
354
Service Specifications
354
Sealant
355
Special Tools
355
Troubleshooting
356
On-Vehicle Service
359
Combination Meters
362
Headlamp
364
Service Specifications
364
Special Tools
364
Troubleshooting
365
On-Vehicle Service
366
Headlamp and Front Turn-Signal Lamp
368
Front Fog Lamp
371
Service Specifications
371
On-Vehicle Service
371
Fog Lamp
373
Rear Combination Lamp
374
Troubleshooting
374
Side Turn-Signal Lamp
375
Special Tool
375
Hazard Warning Lamp Switch, Clock
376
Special Tool
376
Hazard Warning Lamp Switch
376
Radio and Tape Player
377
Troubleshooting
377
Radio and Tape Player
379
Speaker
379
Antenna
380
Pole Antenna
380
Rear Window Antenna and Glass Diversity Antenna
381
Rear Window Defogger
382
Troubleshooting <Vehicles with
382
Automatic A/C
382
On-Vehicle Service
382
Rear Window Defogger Switch
383
Vehicles with Automatic A/C
383
Heater, Air Conditioner and Ventilation
384
Heater and Manual Air Conditioner
386
General
386
Outline of Change
386
Service Specifications
386
Lubricants
386
Special Tools
386
On-Vehicle Service
389
Refrigerant Charging
389
Refrigerant Charging Amount Check
392
Replenishing System
393
Discharging System
394
Performance Test
394
Dual Pressure Switch Simple Check
396
Power Relay Check
396
Idle-Up Operation Check
397
Heater Control Assembly and A/Cswitch
398
Heater Unit and Blower Unit <Vehicles Without Air Conditioner
401
Heater Unit, Cooling and Blower Unit <Vehicles with Air Conditioner
402
Blower Motor Assembly, Resistor and Evaporator
403
Compressor and Tension Pulley
406
Condenser and Condenser Fan
411
Refrigerant Line
413
Ducts
414
Full-Automatic Air Conditioner
416
General
416
Outline of Change
416
Service Specifications
416
Lubricants
416
Special Tools
416
On-Vehicle Service
439
Refrigerant Charging, Level Check, Addition and Removal, Performance Test, Dual Pressure Switch Simple Check
439
Power Relay Check
440
Idle-Up Operation Check
440
And Power Transistor
441
Damper Control Motor Assembly
441
Photo Sensor
444
Outside Air Temperature
445
Sensor
445
Heater Water Temperature
446
Other Maintenance Service Points
447
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Mitsubishi Lancer Evolution VI Specifications
General
Brand
Mitsubishi
Model
Lancer Evolution VI
Category
Automobile Parts
Language
English
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