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Mitsubishi Lancer Evolution-VI Supplement Service Manual – PDF
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Description
Mitsubishi Lancer Evolution-VI Supplement Service Manual S9806CNCP9-A – PDF DOWNLOAD
FILE DETAILS:
Mitsubishi Lancer Evolution-VI Supplement Service Manual S9806CNCP9-A – PDF DOWNLOAD
Language : English
Pages : 712
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
Mitsubishi Lancer Evolution-VI Supplement Service Manual S9806CNCP9-A – PDF DOWNLOAD
GENERAL...................................................................................................................... 4 HOW TO USE THIS MANUAL................................................................................................... 6 SCOPE OF MAINTENANCE, REPAIR AND SERVICING EXPLANATIONS.............................................................. 6 DEFINITION OF TERMS.................................................................................................. 6 INDICATION OF TIGHTENING TORQUE...................................................................................... 6 EXPLANATION OF MANUAL CONTENTS....................................................................................... 7 HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE............................................................................ 9 TROUBLESHOOTING CONTENTS............................................................................................. 9 DIAGNOSIS FUNCTION................................................................................................... 10 HOW TO USE THE INSPECTION PROCEDURES................................................................................. 13 CONNECTOR MEASUREMENT SERVICE POINT.................................................................................. 14 CONNECTOR INSPECTION................................................................................................. 15 INSPECTION SERVICE POINTS FOR A BLOWN FUSE........................................................................... 16 POINTS TO NOTE FOR INTERMITTENT MALFUNCTIONS......................................................................... 16 MODELS................................................................................................................... 17 PRECAUTIONS BEFORE SERVICE............................................................................................... 18 SUPPORT LOCATIONS FOR LIFTING AND JACKING................................................................................ 21 GARAGE JACK.......................................................................................................... 21 AXLE STANDS.......................................................................................................... 22 SINGLE-POST AND DOUBLE-POST LIFT..................................................................................... 22 SPECIAL HANDLING INSTRUMENTS FOR TOWING.............................................................................. 23 BRAKE TEST........................................................................................................... 24 TIGHTENING TORQUE.................................................................................................... 25 ENGINE....................................................................................................................... 26 GENERAL INFORMATION...................................................................................................... 27 SPECIFICATIONS........................................................................................................... 28 SERVICE SPECIFICATIONS............................................................................................... 28 TORQUE SPECIFICATIONS................................................................................................ 30 NEW TIGHTENING METHOD - BY USE OF BOLTS TO BE TIGHTENED IN PLASTIC AREA.............................................. 34 SEALANTS............................................................................................................. 34 FORM-IN-PLACE GASKET................................................................................................. 35 SPECIAL TOOLS............................................................................................................ 36 ALTERNATOR AND IGNITION SYSTEM........................................................................................... 39 TIMING BELT.............................................................................................................. 40 FUEL AND EMISSION CONTROL PARTS.......................................................................................... 52 SECONDARY AIR SYSTEM AND INTAKE MANIFOLD................................................................................. 54 EXHAUST MANIFOLD......................................................................................................... 56 WATER PUMP AND WATER HOSE................................................................................................ 59 ROCKER ARMS AND CAMSHAFT................................................................................................. 62 CYLINDER HEAD AND VALVES................................................................................................. 68 FRONT CASE, COUNTERBALANCE SHAFT AND OIL PAN............................................................................. 76 PISTON AND CONNECTING ROD................................................................................................ 84 CRANKSHAFT AND FLYWHEEL.................................................................................................. 92 THROTTLE BODY............................................................................................................ 98 TURBOCHARGER.............................................................................................................100 ALTERNATOR...............................................................................................................104 STARTER MOTOR............................................................................................................108 FUEL.........................................................................................................................113 MULTIPOINT INJECTION (MPI)...............................................................................................114 GENERAL..............................................................................................................114 OUTLINE OF CHANGE................................................................................................114 SERVICE SPECIFICATIONS...............................................................................................116 SEALANT..............................................................................................................116 SPECIAL TOOLS........................................................................................................117 TROUBLESHOOTING......................................................................................................118 ON-VEHICLE SERVICE...................................................................................................180 FUEL PUMP RESISTOR CHECK <EVOLUTION-VI>..........................................................................180 FUEL PUMP RELAY №2 CONTINUITY CHECK <EVOLUTION-VI>...............................................................180 ENGINE CONTROL RELAY AND FUEL PUMP RELAY CONTINUITY CHECK........................................................180 FUEL SUPPLY..........................................................................................................181 GENERAL..........................................................................................................181 OUTLINE OF CHANGE............................................................................................181 FUEL TANK <EVOLUTION-VI>.........................................................................................181 CLUTCH.......................................................................................................................182 GENERAL..................................................................................................................183 OUTLINE OF CHANGE....................................................................................................183 SERVICE SPECIFICATIONS <L.H. DRIVE VEHICLES>.............................................................................183 LUBRICANTS <L.H. DRIVE VEHICLES>.........................................................................................183 ON-VEHICLE SERVICE <L.H. DRIVE VEHICLES>.................................................................................183 CLUTCH PEDAL INSPECTION AND ADJUSTMENT...............................................................................183 BLEEDING.............................................................................................................184 CLUTCH PEDAL <L.H. DRIVE VEHICLES>.......................................................................................185 CLUTCH CONTROL <L.H. DRIVE VEHICLES>.....................................................................................186 CLUTCH MASTER CYLINDER...............................................................................................187 CLUTCH OVERHAUL..............................................................................................................188 GENERAL..................................................................................................................189 OUTLINE OF CHANGE....................................................................................................189 CLUTCH...................................................................................................................190 CLUTCH RELEASE CYLINDER..................................................................................................196 MANUAL TRANSMISSION OVERHAUL.................................................................................................198 GENERAL..................................................................................................................199 OUTLINE OF CHANGE....................................................................................................199 SPECIFICATIONS...........................................................................................................200 TRANSMISSION.............................................................................................................201 CLUTCH HOUSING...........................................................................................................202 REVERSE IDLER GEAR.......................................................................................................203 REAR AXLE....................................................................................................................206 GENERAL..................................................................................................................207 OUTLINE OF CHANGE....................................................................................................207 SERVICE SPECIFICATIONS...................................................................................................207 LUBRICANT................................................................................................................207 SPECIAL TOOLS............................................................................................................208 TROUBLESHOOTING <AYC>....................................................................................................209 ON-VEHICLE SERVICE <VEHICLES WITH AYC>...................................................................................236 REAR AXLE TOTAL BACKLASH CHECK.......................................................................................236 GEAR OIL LEVEL CHECK.................................................................................................236 GEAR OIL CHANGE......................................................................................................237 FLUID LEVEL CHECK....................................................................................................238 BLEEDING.............................................................................................................239 AYC OPERATION CHECK..................................................................................................239 HYDRAULIC PRESSURE CHECK.............................................................................................240 DIFFERENTIAL CARRIER OIL SEAL REPLACEMENT............................................................................241 WHEEL SPEED SENSOR OUTPUT VOLTAGE MEASUREMENT <VEHICLES WITHOUT ABS>................................................242 ACTION WHEN BATTERY RUNS OUT.........................................................................................243 HYDRAULIC UNIT <VEHICLES WITH AYC>......................................................................................244 SENSOR RELAY <VEHICLES WITH AYC>........................................................................................246 AYC-ECU..................................................................................................................247 BASIC BRAKE SYSTEM...........................................................................................................249 GENERAL..................................................................................................................250 OUTLINE OF CHANGE....................................................................................................250 ON-VEHICLE SERVICE.......................................................................................................250 BRAKE PEDAL CHECK AND ADJUSTMENT.....................................................................................250 BRAKE PEDAL <L.H. DRIVE VEHICLES>........................................................................................252 MASTER CYLINDER AND BRAKE BOOSTER <L.H. DRIVE VEHICLES>..................................................................253 MASTER CYLINDER......................................................................................................255 DISC BRAKE <EVOLUTION-VI WITH BREMBO BRAKING SYSTEM>.....................................................................257 ANTI-SKID BRAKING SYSTEM (ABS)...............................................................................................259 GENERAL..................................................................................................................260 OUTLINE OF CHANGE....................................................................................................260 SERVICE SPECIFICATIONS...................................................................................................260 SPECIAL TOOLS............................................................................................................260 TROUBLESHOOTING..........................................................................................................261 ON-VEHICLE SERVICE.......................................................................................................293 WHEEL SPEED SENSOR OUTPUT VOLTAGE CHECK..............................................................................293 HYDRAULIC UNIT CHECK.................................................................................................295 REMEDY FOR A FLAT BATTERY............................................................................................296 ABS MOTOR CONTINUITY CHECK...........................................................................................297 ABS VALVE RELAY CONTINUITY CHECK.....................................................................................297 MASTER CYLINDER AND BRAKE BOOSTER........................................................................................298 MASTER CYLINDER......................................................................................................298 HYDRAULIC UNIT...........................................................................................................299 WHEEL SPEED SENSOR.......................................................................................................302 ACCELERATION SENSOR......................................................................................................304 ABS-ECU..................................................................................................................305 STEERING.....................................................................................................................306 GENERAL..................................................................................................................307 OUTLINE OF CHANGE....................................................................................................307 STEERING WHEEL AND SHAFT <L.H. DRIVE VEHICLES>...........................................................................307 POWER STEERING GEAR BOX <L.H. DRIVE VEHICLES>............................................................................310 BODY.........................................................................................................................323 GENERAL..................................................................................................................324 OUTLINE OF CHANGE....................................................................................................324 KEYLESS ENTRY SYSTEM.....................................................................................................324 SPECIAL TOOL.........................................................................................................324 TROUBLESHOOTING......................................................................................................324 KEYLESS ENTRY SYSTEM.................................................................................................329 TRANSMITTER..........................................................................................................329 SUNROOF..................................................................................................................331 SERVICE SPECIFICATIONS...............................................................................................331 SEALANT..............................................................................................................331 TROUBLESHOOTING......................................................................................................331 ON-VEHICLE SERVICE...................................................................................................335 WATER TEST.......................................................................................................335 SUNROOF FIT ADJUSTMENT...........................................................................................335 SUNROOF..............................................................................................................336 EXTERIOR.....................................................................................................................341 GENERAL..................................................................................................................342 OUTLINE OF CHANGE....................................................................................................342 SPECIAL TOOL.............................................................................................................342 FRONT BUMPER.............................................................................................................342 AERO PARTS...............................................................................................................344 WASHER TANK AND HOSES....................................................................................................346 INTERCOOLER & RADIATOR WATER SPRAY SYSTEM................................................................................347 MARKS....................................................................................................................348 SUPPLEMENTAL RESTRAINT SYSTEM (SRS)..........................................................................................350 GENERAL INFORMATION......................................................................................................351 SRS SERVICE PRECAUTIONS..................................................................................................352 SPECIAL TOOLS............................................................................................................354 TEST EQUIPMENT...........................................................................................................354 TROUBLESHOOTING..........................................................................................................355 SRS MAINTENANCE..........................................................................................................364 POST-COLLISION DIAGNOSIS.................................................................................................368 INDIVIDUAL COMPONENT SERVICE.............................................................................................371 WARNING/CAUTION LABELS...................................................................................................372 SRS AIR BAG CONTROL UNIT (SRS-ECU).......................................................................................373 AIR BAG MODULES AND CLOCK SPRING.........................................................................................374 AIR BAG MODULE DISPOSAL PROCEDURES.......................................................................................381 UNDEPLOYED AIR BAG MODULE DISPOSAL PROCEDURES............................................................................381 DEPLOYED AIR BAG MODULE DISPOSAL PROCEDURES..............................................................................389 CHASSIS ELECTRICAL...........................................................................................................391 GENERAL..................................................................................................................393 BATTERY..................................................................................................................393 SERVICE SPECIFICATION................................................................................................393 ON-VEHICLE SERVICE...................................................................................................393 IGNITION SWITCH <EXCEPT EVOLUTION-VI WITH IMMOBILIZER SYSTEM>............................................................396 SPECIAL TOOL.........................................................................................................396 TROUBLESHOOTING......................................................................................................396 IGNITION SWITCH......................................................................................................401 IGNITION SWITCH AND IMMOBILIZER SYSTEM <EXCEPT EVOLUTION-VI WITH IMMOBILIZER SYSTEM>....................................403 SPECIAL TOOL.........................................................................................................403 TROUBLESHOOTING......................................................................................................403 IGNITION SWITC AND IMMOBILIZER SYSTEM................................................................................409 COMBINATION METERS.......................................................................................................412 SERVICE SPECIFICATIONS...............................................................................................412 SEALANT..............................................................................................................413 SPECIAL TOOLS........................................................................................................413 TROUBLESHOOTING......................................................................................................414 ON-VEHICLE SERVICE...................................................................................................417 COMBINATION METERS...................................................................................................420 HEADLAMP.................................................................................................................422 SERVICE SPECIFICATIONS...............................................................................................422 SPECIAL TOOLS........................................................................................................422 TROUBLESHOOTING......................................................................................................423 ON-VEHICLE SERVICE...................................................................................................424 HEADLAMP AND FRONT TURN-SIGNAL LAMP..................................................................................426 FRONT FOG LAMP...........................................................................................................429 SERVICE SPECIFICATIONS...............................................................................................429 ON-VEHICLE SERVICE...................................................................................................429 FOG LAMP.............................................................................................................431 REAR COMBINATION LAMP....................................................................................................432 TROUBLESHOOTING......................................................................................................432 REAR COMBINATION LAMP................................................................................................432 SIDE TURN-SIGNAL LAMP....................................................................................................433 SPECIAL TOOL.........................................................................................................433 SIDE TURN-SIGNAL LAMP................................................................................................433 HAZARD WARNING LAMP SWITCH, CLOCK........................................................................................434 SPECIAL TOOL.........................................................................................................434 HAZARD WARNING LAMP SWITCH...........................................................................................434 RADIO AND TAPE PLAYER....................................................................................................435 TROUBLESHOOTING......................................................................................................435 RADIO AND TAPE PLAYER................................................................................................437 SPEAKER..................................................................................................................437 ANTENNA..................................................................................................................438 POLE ANTENNA.........................................................................................................438 REAR WINDOW ANTENNA AND GLASS DIVERSITY ANTENNA......................................................................439 REAR WINDOW DEFOGGER.....................................................................................................440 TROUBLESHOOTING <VEHICLES WITH AUTOMATIC A/C>............................................................................440 ON-VEHICLE SERVICE.......................................................................................................440 REAR WINDOW DEFOGGER SWITCH <VEHICLES WITH AUTOMATIC A/C>................................................................441 HEATER, AIR CONDITIONER AND VENTILATION......................................................................................442 HEATER AND MANUAL AIR CONDITIONER........................................................................................444 GENERAL..............................................................................................................444 OUTLINE OF CHANGE................................................................................................444 SERVICE SPECIFICATIONS...............................................................................................444 LUBRICANTS...........................................................................................................444 SPECIAL TOOLS........................................................................................................444 TROUBLESHOOTING......................................................................................................445 ON-VEHICLE SERVICE...................................................................................................447 REFRIGERANT CHARGING.............................................................................................447 REFRIGERANT CHARGING AMOUNT CHECK................................................................................450 REPLENISHING SYSTEM..............................................................................................451 DISCHARGING SYSTEM...............................................................................................452 PERFORMANCE TEST.................................................................................................452 DUAL PRESSURE SWITCH SIMPLE CHECK................................................................................454 POWER RELAY CHECK................................................................................................454 IDLE-UP OPERATION CHECK..........................................................................................455 HEATER CONTROL ASSEMBLY AND A/C SWITCH...............................................................................456 HEATER UNIT AND BLOWER UNIT <VEHICLES WITHOUT AIR CONDITIONER>.......................................................459 HEATER UNIT, COOLING AND BLOWER UNIT <VEHICLES WITH AIR CONDITIONER>................................................460 BLOWER MOTOR ASSEMBLY, RESISTOR AND EVAPORATOR.......................................................................461 COMPRESSOR AND TENSION PULLEY........................................................................................464 CONDENSER AND CONDENSER FAN..........................................................................................469 REFRIGERANT LINE.....................................................................................................471 DUCTS................................................................................................................472 FULL-AUTOMATIC AIR CONDITIONER...........................................................................................474 GENERAL..............................................................................................................474 OUTLINE OF CHANGE................................................................................................474 SERVICE SPECIFICATIONS...............................................................................................474 LUBRICANTS...........................................................................................................474 SPECIAL TOOLS........................................................................................................474 TROUBLESHOOTING......................................................................................................475 ON-VEHICLE SERVICE...................................................................................................497 REFRIGERANT CHARGING, LEVEL CHECK, ADDITION AND REMOVAL, PERFORMANCE TEST, DUAL PRESSURE SWITCH SIMPLE CHECK ....497 POWER RELAY CHECK................................................................................................498 IDLE-UP OPERATION CHECK..........................................................................................498 DAMPER CONTROL MOTOR ASSEMBLY AND POWER TRANSISTOR...................................................................499 PHOTO SENSOR.........................................................................................................502 OUTSIDE AIR TEMPERATURE SENSOR.......................................................................................503 HEATER WATER TEMPERATURE SENSOR......................................................................................504 OTHER MAINTENANCE SERVICE POINTS.....................................................................................505 ELECTRICAL WIRING <EVOLUTION-VI>.............................................................................................506 HOW TO READ THE WIRING DIAGRAMS..........................................................................................507 HOW TO READ CIRCUIT DIAGRAMS.........................................................................................508 ELECTRICAL WIRING (L.H. DRIVE VEHICLES)......................................................................................509 WIRING HARNESS CONFIGURATION DIAGRAMS....................................................................................511 OVERALL WIRING DIAGRAM...............................................................................................511 ENGINE COMPARTMENT...................................................................................................512 DASH PANEL...........................................................................................................516 INSTRUMENT PANEL.....................................................................................................519 FLOOR AND ROOF.......................................................................................................520 DOOR.................................................................................................................521 LUGGAGE COMPARTMENT..................................................................................................522 SINGLE PART INSTALLATION POSITION........................................................................................524 RELAY................................................................................................................524 ECU..................................................................................................................525 SENSOR...............................................................................................................527 SOLENOID AND SOLENOID VALVE..........................................................................................528 INSPECTION CONNECTOR.................................................................................................529 FUSSIBLE LINK AND FUSE...............................................................................................530 EARTH CABLE..........................................................................................................531 EARTH................................................................................................................532 CIRCUIT DIAGRAM..........................................................................................................534 JUNCTION BLOCK (J/B).................................................................................................534 JOINT CONNECTOR (J/C)................................................................................................536 CENTRALIZED JUNCTION.................................................................................................538 POWER DISTRIBUTION SYSTEM............................................................................................544 STARTING SYSTEM......................................................................................................549 IGNITION SYSTEM......................................................................................................550 CHARGING SYSTEM......................................................................................................551 MPI SYSTEM...........................................................................................................552 COOLING SYSTEM.......................................................................................................558 HEADLAMP.............................................................................................................560 TAIL LAMP, POSITION LAMP AND LICENCE PLATE LAMP......................................................................562 REAR FOG LAMP AND FRONT FOG LAMP SPARE CIRCUIT.......................................................................564 ROOM LAMP AND LUGGAGE COMPARTMENT LAMP...............................................................................568 HEADLAMP LEVELING SYSTEM.............................................................................................569 TURN-SIGNAL LAMP AND HAZARD WARNING LAMP.............................................................................570 STOP LAMP............................................................................................................574 BACK-UP LAMP.........................................................................................................575 HORN.................................................................................................................576 Vehicles without SRS.............................................................................................576 Vehicles with SRS................................................................................................577 METER AND GAUGE......................................................................................................578 FUEL WARNING LAMP AND BRAKE WARNING LAMP.............................................................................582 OIL PRESSURE WARNING LAMP AND SEAT BELT WARNING LAMP.................................................................583 CENTRAL DOOR LOCKING SYSTEM..........................................................................................584 POWER WINDOWS........................................................................................................586 HEATER AND AIR CONDITIONER...........................................................................................590 WINDSHIELD WIPER AND WASHER..........................................................................................595 DEFOGGER.............................................................................................................596 REMOTE CONTROLLED MIRROR.............................................................................................597 RADIO SPARE CIRCUIT..................................................................................................598 CLOCK................................................................................................................600 CIGARETTE LIGHTER....................................................................................................601 SUPPLEMENTAL RESTRAINT SYSTEM (SRS)..................................................................................602 LIGHTING MONITOR BUZZER AND KEY REMINDER BUZZER......................................................................604 IMMOBILIZER SYSTEM...................................................................................................606 INTERCOOLER AND RADIATOR WATER SPRAY SYSTEM..........................................................................608 ELECTRICAL WIRING (R.H. DRIVE VEHICLES)......................................................................................609 GENERAL..................................................................................................................611 WIRING HARNESS CONFIGURATION DIAGRAMS....................................................................................612 ENGINE COMPARTMENT...................................................................................................612 DASH PANEL...........................................................................................................616 FLOOR AND ROOF.......................................................................................................620 LUGGAGE COMPARTMENT..................................................................................................622 SINGLE PART INSTALLATION POSITION........................................................................................624 RELAY................................................................................................................624 ECU..................................................................................................................625 SENSOR...............................................................................................................625 SOLENOID AND SOLENOID VALVE..........................................................................................627 INSPECTION CONNECTOR.................................................................................................628 FUSIBLE LINK AND FUSE................................................................................................628 EARTH CABLE..........................................................................................................629 EARTH................................................................................................................629 CIRCUIT DIAGRAM..........................................................................................................631 CENTRALIZED JUNCTION.................................................................................................631 POWER DISTRIBUTION SYSTEM............................................................................................632 STARTING SYSTEM......................................................................................................637 IGNITION SYSTEM......................................................................................................638 CHARGING SYSTEM......................................................................................................639 MPI SYSTEM...........................................................................................................640 COOLING SYSTEM.......................................................................................................646 HEADLAMP.............................................................................................................648 TAIL LAMP, POSITION LAMP, LICENCE PLATE LAMP AND LIGHTING MONITOR BUZZER.............................................650 ROOM LAMP AND LUGGAGE COMPARTMENT LAMP...............................................................................653 IGNITION KEY CYLINDER ILLUMINATION LAMP..............................................................................654 TURN-SIGNAL LAMP AND HAZARD WARNING LAMP.............................................................................656 STOP LAMP............................................................................................................659 BACK-UP LAMP.........................................................................................................660 METER AND GAUGE......................................................................................................662 FUEL WARNING LAMP AND BRAKE WARNING LAMP.............................................................................664 OIL PRESSURE WARNING LAMP AND SEAT BELT WARNING LAMP.................................................................665 CENTRAL DOOR LOCKING SYSTEM.........................................................................................666 WITHOUT KEYLESS ENTRY SYSTEM.....................................................................................666 WITH KEYLESS ENTRY SYSTEM........................................................................................668 HEATER AND AIR CONDITIONER...........................................................................................672 FULL-AUTO AIR CONDITIONER............................................................................................678 WINDSHIELD WIPER AND WASHER..........................................................................................686 WITH INTERMITTENT WIPER..........................................................................................686 REAR WIPER AND WASHER................................................................................................687 DEFOGGER AND DOOR MIRROR HEATER......................................................................................688 WITHOUT FULL-AUTO AIR CONDITIONER................................................................................688 WITH FULL-AUTO AIR CONDITIONER...................................................................................690 RADIO................................................................................................................692 RADIO SPARE CIRCUIT..............................................................................................692 4 SPEAKER, 6 SPEAKER.............................................................................................694 KEY REMINDER BUZEER..................................................................................................697 ANTI-SKID BRAKING SYSTEM (ABS).......................................................................................698 SUPPLEMENTAL RESTRAINT SYSTEM (SRS)..................................................................................704 ACTIVE YAW CONTROL SYSTEM (AYC)......................................................................................706 INTERCOOLER AND RADIATOR WATER SPRAY SYSTEM..........................................................................712
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