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Workshop Manual
WORKSHOP
MANUAL
FOREWORD
This Workshop Manual contains procedures for
service mechanics, including removal, disassembly,
inspection,
adjustment,
installation.
Use
the
combination with this manual as required.
TECHNICAL INFORMATION MANUAL
All
information,
illustrations
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-VII is sold exclusively through
RALLIART Inc. Since the EVOLUTION-VII is a
rally-based model, it will not be warranted and will
not be homologated for general production.
Therefore,
any
service
EVOLUTION-VII should be inquired to RALLIART
Inc. as usual.
Mitsubishi Motors Corporation
E
reassembly
and
following
manuals
N0104CT9A
and
product
matters
on
the
May 2001
General . . . . . . . . . . . . . . . . . . . . . . . .
Engine . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Lubrication . . . . . . . . . . . . .
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Cooling . . . . . . . . . . . . . . . . .
Intake and Exhaust
Engine Electrical . . . . . . . . . . . . . . .
Engine and Emission Control . . . .
Clutch . . . . . . . . . . . . . . . . . . . . . . . . .
Manual Transmission . . . . . . . . . . .
Propeller Shaft . . . . . . . . . . . . . . . . .
Front Axle . . . . . . . . . . . . . . . . . . . . . .
Rear Axle . . . . . . . . . . . . . . . . . . . . . .
in
Wheel and Tyre . . . . . . . . . . . . . . . . .
Power Plant Mount . . . . . . . . . . . . . .
Front Suspension . . . . . . . . . . . . . . .
Rear Suspension . . . . . . . . . . . . . . .
Service Brakes . . . . . . . . . . . . . . . . .
Parking Brakes . . . . . . . . . . . . . . . . .
Steering . . . . . . . . . . . . . . . . . . . . . . . .
Body . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exterior . . . . . . . . . . . . . . . . . . . . . . . .
Interior and Supplemental
Restraint System (SRS) . . . . . . . .
Chassis Electrical . . . . . . . . . . . . . .
Heater, Air Conditioner and
Ventilation . . . . . . . . . . . . . . . . . . . . .
Electrical Wiring . . . . . . . . . . . . . . . .
Body Repair . . . . . . . . . . . . . . . . . . . .
00
11
12
13
14
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15
16
17
21
22
25
26
27
31
32
33
34
35
36
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42
51
52
54
55
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Table of Contents
Related Manuals for Mitsubishi LANCER EVOLUTION-VII
Summary of Contents for Mitsubishi LANCER EVOLUTION-VII
- Page 1 Electrical Wiring ....Body Repair ....Mitsubishi Motors Corporation May 2001...
- Page 2 (3) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized MITSUBISHI dealer. (4) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B - Supplemental Restraint System (SRS), before beginning any service or maintenance of any SRS component or any SRS-related component.
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Page 3: Table Of Contents
00-1 GENERAL CONTENTS HOW TO USE THIS MANUAL ....Models ........Model Code . -
Page 4: How To Use This Manual
00-2 GENERAL - How to Use This Manual HOW TO USE THIS MANUAL SCOPE OF MAINTENANCE, REPAIR DEFINITION OF TERMS AND SERVICING EXPLANATIONS STANDARD VALUE This manual provides explanations, etc. concerning Indicates the value used as the standard for judging procedures for the inspection, maintenance, repair the quality of a part or assembly on inspection and servicing of the subject model. -
Page 5: Model Indications
00-3 GENERAL - How to Use This Manual MODEL INDICATIONS The following abbreviations are used in this manual for classification of model types. MPI: Indicates the multipoint injection, or engine equipped with the multipoint injection. DOHC: Indicates an engine with the double overhead camshaft, or a model equipped with such an engine. -
Page 6: Explanation Of Manual Contents
00-4 GENERAL - How to Use This Manual 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. 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-... - Page 7 00-5 GENERAL - How to Use This Manual Indicates the Indicates the Indicates the Indicates the page number. group title. section title. group num- ber. denotes non-re- usable part. Denotes tightening torque. For bolts and nuts which do not have a tightening torque listed, refer to the “Standard Parts- tightening-torque Table”.
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Page 8: How To Use
00-6 GENERAL - How to Use Troubleshooting/Inspection Service Points HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS Troubleshooting of electronic control systems for which the MUT-II can be used follows the basic outline described below. Furthermore, even in systems for which the MUT-II cannot be used, part of these systems still follow this outline. -
Page 9: Diagnosis Function
00-7 GENERAL - How to Use Troubleshooting/Inspection Service Points 4. INSPECTION CHART FOR DIAGNOSIS CODES 5. INSPECTION PROCEDURE FOR DIAGNOSIS CODES Indicates the inspection procedures corresponding to each diagnosis code. (Refer to P.00-10 for how to use the inspection procedures.) 6. - Page 10 00-8 GENERAL - How to Use Troubleshooting/Inspection Service Points WHEN USING THE WARNING LAMP MB991529 1. Use the special tool to earth No.1 terminal (diagnosis control terminal) of the diagnosis connector. 2. Turn the ignition switch to “ON” position. 3. Read out a diagnosis code by observing how the warning lamp flashes.
- Page 11 00-9 GENERAL - How to Use Troubleshooting/Inspection Service Points INPUT SIGNAL CHECK <SWS> MUT- Ⅱ WHEN USING THE MUT-II 1. Connect the MUT-II to the diagnosis connector and erase the diagnosis code. Caution Turn the ignition switch to “LOCK”(OFF) position before connecting or disconnecting the MUT-II.
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Page 12: How To Use The Inspection Procedures
00-10 GENERAL - How to Use Troubleshooting/Inspection Service Points 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. -
Page 13: Connector Measurement Service Points
00-11 GENERAL - How to Use Troubleshooting/Inspection Service Points CONNECTOR MEASUREMENT SERVICE POINTS Turn the ignition switch to OFF when connecting disconnecting the connectors, and turn the ignition switch to ON when measuring if there are no instructions to be contrary. IF INSPECTING WITH THE CONNECTOR CONNECTED Harness connector (WITH CIRCUIT IN A CONDITION OF CONTINUITY) -
Page 14: Connector Inspection
00-12 GENERAL - How to Use Troubleshooting/Inspection Service Points CONNECTOR INSPECTION Connector disconnected or improperly connected VISUAL INSPECTION Connector is disconnected or improperly connected Connector pins are pulled out Due to harness tension at terminal section Low contact pressure between male and female terminals Low connection pressure due to rusted terminals or foreign matter lodged in terminals Defective connector contact... -
Page 15: Inspection Service Points For A Blown Fuse
00-13 GENERAL - How to Use Troubleshooting/Inspection Service Points INSPECTION SERVICE POINTS FOR A BLOWN FUSE Remove the blown fuse and measure the resistance between the load side of the blown fuse and the earth. Set the switches of all circuits which are connected to this fuse to a condition Battery of continuity. -
Page 16: Vehicle Identification
00-14 GENERAL - Vehicle Identification VEHICLE IDENTIFICATION VEHICLE INFORMATION CODE PLATE LOCATION Vehicle information code plate is riveted on the toeboard inside the engine compartment. CODE PLATE DESCRIPTION The plate shows model code, engine model, transmission model, and body colour code. Item Contents Contents... -
Page 17: Model Code
00-15 GENERAL - Vehicle Identification MODEL CODE Items Contents CT 9 A S N D F Development MITSUBISHI LANCER EVOLUTION-VII Engine type 1,997 mL petrol engine 2 3 4 5 6 7 8 9 Sort Passenger car Body style 4-door sedan... -
Page 18: Chassis Number
Distribution channel Japan channel Destination For Europe and General Export Body style 4-door sedan Transmission type 5-speed manual transmission Development order MITSUBISHI LANCER EVOLUTION-VII Engine 4G63: 1,997 mL petrol engine Sort Passenger car Model year 2002 Plant MIZUSHIMA-1 Serial number ENGINE MODEL NUMBER 1. -
Page 19: Major Specifications
00-17 GENERAL - Major Specifications MAJOR SPECIFICATIONS Items CT9A SNDFZL/R SNGFZL/R Vehicle Front track 1 1,500, 1,515 dimensions Overall width 2 1,770 Front overhang 3 895 Wheel base 4 2,625 Rear overhang 5 935 Overall length 6 4,455 Ground clearance 7 140 (unladen) Overall height (unladen) -
Page 20: Precautions Before Service
00-18 GENERAL - Precautions Before Service PRECAUTIONS BEFORE SERVICE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 1. Items to follow when servicing SRS (1) Be sure to read GROUP 52B - Supplemental Restraint System (SRS). For safe operations, please follow the directions and heed all warnings. (2) Wait at least 60 seconds after disconnecting the battery cable before doing any further work. - Page 21 00-19 GENERAL - GENERAL - Precautions Before Service Precautions Before Service 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.
- Page 22 00-20 GENERAL - GENERAL - Precautions Before Service Precautions Before Service MUT-II MUT-II sub-assembly Refer to the “MUT-II REFERENCE MANUAL” or “MUT-II OPERATING INSTRUCTIONS” for instructions on handling the MUT-II. ROM pack Connect the MUT-II to the diagnosis connector as shown MUT- Ⅱ...
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Page 23: Supplemental Restraint System
00-21 GENERAL - Supplemental Restraint System (SRS) SUPPLEMENTAL RESTRAINT SYSTEM (SRS) To improve safety, the SRS and seat belts with instrument panel indicates the operational status pre-tensioner. These systems enhance collision of the SRS. The clock spring is installed in the safety by restraining the front passengers in case steering column. -
Page 24: Srs Service Precautions
00-22 GENERAL - Supplemental Restraint System (SRS) SRS SERVICE PRECAUTIONS 1. In order to avoid injury to yourself or others NOTE from accidental deployment of the air bag and If any of these components are diagnosed as accidental operation of the seat belt with faulty, they should only be replaced, in pre-tensioner during servicing,... - Page 25 00-23 GENERAL - Supplemental Restraint System (SRS) SRS-ECU Destination of harness Corrective action Terminal No. Instrument panel wiring harness → Earth Repair or replace each wiring harness harness Instrument panel wiring harness → Combination meter (SRS warning lamp) 9, 10 Instrument panel wiring harness →...
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Page 26: Support Locations For Lifting And Jacking
00-24 GENERAL - Support Locations for Lifting and Jacking SUPPORT LOCATIONS FOR LIFTING AND JACKING Caution Do not support the vehicles at locations other than specified supporting points. Doing so will cause damage, etc. SUPPORT POSITIONS FOR A GARAGE JACK AND AXLE STANDS GARAGE JACK Caution Never support any point other than the specified ones, or deformation will result. -
Page 27: Double-Post Lift
00-25 GENERAL - Support Locations for Lifting and Jacking SUPPORT POSITIONS FOR AXLE STANDS AND A SINGLE-POST LIFT OR DOUBLE-POST LIFT Caution 1. If rubber attachments with grooves that are too thick are used at the front support positions, the front fender may become bent, so be sure to use rubber attachments with groove thicknesses of 18 mm or less. -
Page 28: Support Positions And Support Method For An H-Bar Lift
00-26 GENERAL - Support Locations for Lifting and Jacking PLATE TYPE LIFT To avoid damaging the side sill garnish, put a wooden block between the side sill and a lift. NOTE The wooden block should be 100 mm wide and 50 mm high. SUPPORT POSITIONS AND SUPPORT METHOD H-bar lift FOR AN H-BAR LIFT... - Page 29 00-27 GENERAL - Support Locations for Lifting and Jacking PREPARATION OF “ATTACHMENTS” Block (A) 1. Prepare the blocks (wooden) and nails as shown in the figure. 1,800 Item Dimensions mm Quantity Block (A) 90 × 95 × 1,800 Block (B) 60 ×...