Mitsubishi Electric Lancer Evolution-VII Manuals

Manuals and User Guides for Mitsubishi Electric Lancer Evolution-VII. We have 1 Mitsubishi Electric Lancer Evolution-VII manual available for free PDF download: Workshop Manual

Mitsubishi Electric Lancer Evolution-VII Workshop Manual (1449 pages)

Brand: Mitsubishi Electric | Category: Automobile | Size: 62.13 MB

Wiring and Piping Diagram
3
New Colour Numbers
6
Location of Synthetic-Resin Parts
10
Upper Body
13
Headlamp Support
20
Fender Shield
21
Front Pillar
24
Center Pillar
25
Center Pillar
26
Quarter, Outer
31
Rear End Panel
35
Rear Floor
36
Quarter, Inner
38
Front Door Outer Panel
40
Rear Door Outer Panel
41
Rear Body
56
Table of Contents
106
Engine Compartment
111
Engine and Transmission
115
Dash Panel
123
Luggage Compartment
143
Solenoid Valve
151
Fusible Link and Fuse
153
Earth Cable
154
Centralized Junction
173
Power Distribution System
179
Starting System
184
Ignition System
187
L.H. Drive Vehicles
187
R.H. Drive Vehicles
188
Charging System
189
ENGINE CONTROL SYSTEM L.H. Drive Vehicles
193
R.H. Drive Vehicles
199
Cooling System
207
HEADLAMP L.H. Drive Vehicles
209
R.H. Drive Vehicles
211
TAIL LAMP, POSITION LAMP, LICENCE PLATE LAMP and LIGHTING MONITOR BUZZER L.H. Drive Vehicles
217
L.H. Drive Vehicles
223
ROOM LAMP and LUGGAGE COMPARTMENT LAMP L.H. Drive Vehicles
225
R.H. Drive Vehicles
226
REAR FOG LAMP L.H. Drive Vehicles
231
R.H. Drive Vehicles
232
Headlamp Leveling System
235
L.H. Drive Vehicles
235
R.H. Drive Vehicles
237
TURN-SIGNAL LAMP and HAZARD WARNING LAMP L.H. Drive Vehicles
241
R.H. Drive Vehicles
243
Back-Up Lamp
247
L.H. Drive Vehicles
247
R.H. Drive Vehicles
248
Stop Lamp
249
L.H. Drive Vehicles
249
R.H. Drive Vehicles
250
Horn
251
METER and GAUGE L.H. Drive Vehicles
255
R.H. Drive Vehicles
257
Fuel Warning Lamp
261
Oil Pressure Warning Lamp
262
Brake Warning Lamp
262
POWER WINDOWS L.H. Drive Vehicles
265
R.H. Drive Vehicles
269
Central Door Locking System
275
L.H. Drive Vehicles
275
R.H. Drive Vehicles
277
HEATER and MANUAL AIR CONDITIONER L.H. Drive Vehicles
281
R.H. Drive Vehicles
285
Defogger
290
WINDSHIELD WIPER and WASHER L.H. Drive Vehicles
293
R.H. Drive Vehicles
294
Remote Controlled Mirror
297
L.H. Drive Vehicles
297
R.H. Drive Vehicles
298
Clock
299
Cigarette Lighter and Ashtray Illumination Lamp
300
Audio System
301
L.H. Drive Vehicles
303
R.H. Drive Vehicles
310
Acd
317
Vehicles Without AYC <L.H. Drive Vehicles
317
Vehicles Without AYC <R.H. Drive Vehicles
325
ACD and AYC L.H. Drive Vehicles
335
R.H. Drive Vehicles
343
Supplemental Restraint System (Srs) and Seat Belt Pretensioner
353
L.H. Drive Vehicles
353
R.H. Drive Vehicles
355
Immobilizer System
357
L.H. Drive Vehicles
357
R.H. Drive Vehicles
359
Intercooler Water Splay
361
Spare Connector
363
Wire Colour Codes
372
Special Tools
379
Troubleshooting
380
Performance Test
391
Compressor Drive Belt Adjustment
392
Dual Pressure Switch Check
392
Discharging System
396
Refrigerant Leak Repair
398
Blower Relay Continuity Check
399
A/C Compressor Relay Continuity Check
399
Condenser Fan Relay (Hi) Check
400
Removal and Installation
402
Heater Unit and Blower Assembly
405
Evaporator and Air Thermo Sensor
411
Refrigerant Lines
419
Battery
427
Service Specification
427
On-Vehicle Service
427
Fluid Level and Specific Gravity Check
427
Charging
427
Battery Testing Procedure
428
Ignition Switch and Immobilizer System
429
Special Tools
429
Troubleshooting
429
Chassis Electrical
430
Ignition Key
430
Immobilizer-Ecu Check
433
Ignition Switch
434
Combination Meter
437
Service Specifications
437
Sealant
437
Special Tools
438
Troubleshooting
438
On-Vehicle Service
442
Speedometer Check
442
Tachometer Check
443
Fuel Gauge Unit Check
443
Engine Coolant Temperature Gauge Unit Check
444
Combination Meter
445
Headlamp Assembly
447
Service Specifications
447
Troubleshooting
447
On-Vehicle Service
447
Headlamp Aiming
447
Headlamp Intensity Measurement
451
Headlamp Bulb (Low Beam)Replacement
451
Headlamp Bulb (High Beam)Replacement
452
Position Lamp Bulb Replacement
452
Front Turn Signal Lamp Bulb Replacement
452
Headlamp Auto Cut Adjustment Procedure
452
Headlamp Auto Cut Function Check
452
Headlamp Assembly
453
Side Turn-Signal Lamp
454
Special Tool
454
Room Lamp
454
Troubleshooting
454
Rear Combination Lamp
455
Special Tool
455
Troubleshooting
455
High-Mounted Stop Lamp
457
On-Vehicle Service
457
High-Mounted Stop Lamp Bulb Replacement
457
On-Vehicle Service
458
License Plate Lamp Replacement
458
Hazard Warning Lamp Switch
459
Special Tool
459
Hazard Warning Lamp Switch
460
Horn
460
Cigarette Lighter
460
Column Switch
461
Special Tool
461
Clock
463
Special Tool
463
Pole Antenna
464
Roof Antenna
465
Defogger
465
Troubleshooting
465
On-Vehicle Service
466
Printed Heater Check
466
Defogger Relay Continuity Check
466
Defogger Switch
466
Special Tools
469
Troubleshooting
469
Before Commencing Troubleshooting
469
Standard Flow of Diagnostic Troubleshooting
469
SWS Troubleshooting
469
Diagnostic Functions
469
Diagnosis Code Chart
470
Diagnosis Code Inspection Procedures
471
Trouble Symptom Chart
474
Inspection Procedures for Trouble Symptoms
477
No Communication with Mut-II
477
Lights Left on Reminder Warning Function Not Working Normally
477
Central Door Locking System Not Working at All
478
Some Doors Not Locking or Unlocking
478
Main Switch
479
The Windshield Wipers Do Not Work at All
484
The Windshield Washer Does Not Work at All
486
The Tail Lamps Do Not Work
487
The Headlamps (High-Beam) Do Not Light
488
Rear Fog Lamp Is Not Properly Illuminated
490
The Hazard Warning Lamps Do Not Light up
491
The Room Lamps Do Not Come on or off Normally
492
Check at ECU Terminals
501
Special Tool
508
Instrument Panel
508
Front Floor Console
515
Rear Floor Console
517
Trims
520
Headlining
522
Seat
524
Front Seat
524
Rear Seat
527
Seat Belt
530
Front Seat Belt
530
Rear Seat Belt
531
General Information
533
Srs Service Precautions
534
Special Tools
536
Test Equipment
537
Troubleshooting
537
Possible Cause
553
Srs Maintenance
573
Post-Collision Diagnosis
576
Individual Component Service
580
Warning/Caution Labels
580
Srs Air Bag Control Unit (Srs-Ecu)
581
Air Bag Modules and Clock Spring
583
Seat Belt Pre-Tensioner
594
Air Bag Module and Seat Belt Pre-Tensioner Disposal Procedures
595
Pre-Tensioner Disposal
595
Pre-Tensioner Disposal Procedures
595
Front Bumper
609
Adhesive
609
Front Bumper
610
Rear Bumper
613
Side Air Dam, Molding and Garnish
615
Special Tool
615
Adhesive
615
Side Air Dam Molding Garnish
616
Rear Spoiler
619
Adhesive
619
Windshield Wiper and Washer
620
Service Specifications
620
Troubleshooting
620
On-Vehicle Service
620
Marks
627
Outside Mirror
630
Special Tool
630
Hood
635
On-Vehicle Service
635
Adjustment of Clearance Around Hood
635
Adjustment of Alignment of Hood Stepped Portion and Hood Striker
635
Adjustment of Hood Height
635
Hood
636
Fender
637
Special Tool
637
Fender
638
Fuel Filler Door
640
Strut Tower Bar and Rear End Cross Bar
641
Window Glass
642
Adhesive
642
Special Tools
642
Window Repair
642
Windshield
644
Rear Window Glass
649
Doors
652
Service Specifications
652
Adhesives
652
Special Tools
652
Troubleshooting
653
On-Vehicle Service
653
Door Adjustment
653
Door Window Glass Adjustment
654
Window Malfunction
655
Power Window Safety Mechanism Check
655
Power Window Timer Function Check
655
Door Outside Handle Looseness Check
656
Circuit Breaker Check
656
Power Window Check
656
Door Inside Handle Looseness Check and Adjustment
657
Door Assembly
658
Door Trim and Waterproof Film
660
Door Glass and Regulator
665
Door Handle and Latch
668
Window Glass Runchannel and Door Opening Weatherstrip
671
Trunk Lid
674
General Information
679
Service Specifications
681
Lubricants
681
Sealant
681
Special Tools
681
On-Vehicle Service
684
Steering Wheel Free Play Check
684
Steering Angle Check
684
Tie Rod End Ball Joint Turning Torque Check
684
Stationary Steering Effort Check
685
Checking Steering Wheel Return to Centre
685
Drive Belt Tension Check
685
Power Steering Fluid Level Check
686
Power Steering Fluid Replacement
686
Power Steering System Bleeding
686
Oil Pump Pressure Test
687
Power Steering Oil Pressure Switch Check
688
Ball Joint Dust Cover Check
688
Steering Wheel
689
Steering Shaft
691
Power Steering Gear Box and Linkage
693
Power Steering Oil Pump
706
Power Steering Oil Hoses
707
General Information
713
Service Specifications
713
Lubricants
713
On-Vehicle Service
714
Parking Brake Lever Stroke Check and Adjustment
714
Parking Brake Switch Check
714
Lining Running-In
715
Parking Brake Lever
716
Parking Brakes
716
Parking Brake Cable
717
Parking Brake Drum
718
Service Brakes
720
General Information
722
Service Specifications
724
Lubricants
725
Sealant
725
Special Tools
725
On-Vehicle Service
726
Brake Pedal Check and Adjustment
726
Brake Booster Operating Test
727
Check Valve Operation Check
728
Proportioning Valve Function Test
728
Vehicles Without ABS
728
Bleeding
729
Brake Fluid Level Sensor Check
730
Disc Brake Pad Check and Replacement
730
Disc Brake Rotor Check
732
Brake Disc Thickness Check
733
Brake Disc Run-Out Check and Correction
733
Brake Pedal
735
Proportioning Valve, Master
737
Master Cylinder
738
Disc Brake
739
Braking System
748
General Information
785
Service Specifications
786
Special Tools
786
Front Suspension
786
On-Vehicle Service
787
Wheel Alignment Check and Adjustment
787
Ball Joint Dust Cover Check
788
Strut Assembly
789
Lower Arm Assembly
792
Stabilizer Bar
795
Crossmember Bar
798
General Information
801
Special Tool
802
Engine Mounting
803
Transmission Mounting
804
Engine Roll Stopper, Centermember
805
Crossmember
807
General Information
813
On-Vehicle Service
817
Tyre Inflation Pressure Check
817
Tyre Wear Check
817
Wheel Runout Check
817
Wheel and Tyre
817
General Information
819
Service Specifications
820
Lubricants
820
Sealants
821
Special Tools
821
Rear Axle Troubleshooting
825
On-Vehicle Service
833
Rear Axle Total Backlash Check
833
Gear Oil Level Check
833
Gear Oil Change
834
Fluid Level Check
836
Bleeding
836
AYC Operation Check
837
Oil Pressure Check
838
Wheel Bearing Axial Play Check
839
Wheel Bearing Rotary-Sliding Resistance Check
839
Hub Bolt Replacement
840
Differential Carrier Oil Seal Replacement
840
Action When Battery Runs out
841
Rear Hub Assembly
842
Knuckle
845
Drive Shaft
846
Differential Carrier
847
Vehicles with Mechanical Lsd
848
26. Differential Carrier
855
Vehicles with Ayc
872
Hydraulic Unit
879
General Information
881
Service Specifications
882
Lubricants
882
Special Tools
882
Front Axle
882
On-Vehicle Service
884
Wheel Bearing Axial Play Check
884
Hub Bolt Replacement
884
Hub and Knuckle Assembly
886
Drive Shaft
889
Propeller Shaft
899
General
910
General Information
910
Service Specification
910
Lubricants
910
Manual Transmission
910
Special Tools
911
Troubleshooting <Acd
912
On-Vehicle Service
947
Transmission Oil Check
947
Transmission Oil Replacement
947
Transfer Oil Check
947
Transfer Oil Replacement
947
Fluid Check <Vehicles with ACD or Vehicles with ACD and AYC
948
Bleeding <Vehicles with ACD or Vehicles with ACD and AYC
949
ACD Operation Check <Vehicles with ACD or Vehicles with ACD and AYC
949
Hydraulic Pressure Check <Vehicles with ACD or Vehicles with ACD and AYC
950
Wheel Speed Sensor Output Voltage
951
Transmission Control
953
Transfer Assembly
956
Transmission Assembly
959
4Wd-Ecu <Vehicles with Acd or Vehicles with Acd and Ayc
962
Ayc
962
General Description
967
Specifications
971
Service Specifications
971
Sealants
972
Lubricants
973
Snap Rings, Spacers and Thrust
974
Plates for Adjustment
974
Tightening Torque
976
Special Tools
977
Transmission
980
Input Shaft
987
Output Shaft
994
Reverse Idler Gear
1002
Speedometer Gear
1003
Select Lever
1004
Control Housing
1005
Clutch Housing
1008
Transmission Case
1011
Center Differential
1013
Transfer
1016
General Information
1020
Service Specifications
1020
Lubricants
1020
On-Vehicle Service
1020
Clutch Pedal Inspection and Adjustment
1020
Bleeding
1021
Clutch Pedal
1022
Clutch Pedal Position Switch Adjustment
1024
Clutch Control
1024
Clutch Master Cylinder
1024
General Description
1029
Tightening Torque
1029
Clutch
1030
Clutch Release Cylinder
1033
Engine Control System
1037
General Information
1037
Service Specifications
1037
On-Vehicle Service
1037
Accelerator Cable Check and Adjustment
1037
Accelerator Cable and Pedal
1038
Emission Control System
1039
General Information
1039
Emission Control Device Reference Table
1039
Service Specifications
1040
Vacuum Hose
1040
Vacuum Hose Piping Diagram
1040
Vacuum Circuit Diagram
1041
Vacuum Hose Check
1042
Vacuum Hose Installation
1042
Crankcase Emission Control System
1043
General Information
1043
System Diagram
1043
Component Location
1044
Positive Crankcase Ventilation System Check
1044
PCV Valve Check
1044
Evaporative Emission Control System
1045
General Information
1045
System Diagram
1045
Component Location
1045
Purge Control System Check
1046
Purge Port Vacuum Check
1046
Purge Control Solenoid Valve Check
1047
Check Valve Check
1047
Exhaust Gas Recirculation (Egr) System
1048
General Information
1048
Operation
1048
System Diagram
1048
Component Location
1049
Exhaust Gas Recirculation (EGR) Control System Check
1049
EGR Valve Check
1050
EGR Port Vacuum Check
1050
EGR Control Solenoid Valve Check
1051
Egr Valve
1052
Catalytic Converter
1054
General Information
1057
Charging System
1057
Service Specifications
1058
Special Tool
1058
On-Vehicle Service
1059
Engine Electrical
1059
Alternator Output Line Voltage Drop Test
1059
Output Current Test
1060
Regulated Voltage Test
1062
Waveform Check Using an Analyzer
1063
Alternator
1065
Starting System
1072
General Information
1072
Starter
1073
Ignition System
1081
General Information
1081
Service Specifications
1082
Special Tool
1082
Ignition Coil (with Built-In Power Transistor) Check
1083
Resistive Cord Check
1083
Spark Plug Check, Cleaning and Replacement
1084
Camshaft Position Sensor Check
1084
Crank Angle Sensor Check
1084
Detonation Sensor Check
1084
Waveform Check Using an Analyzer
1085
Ignition Coil
1089
Camshaft Position Sensor
1090
Crank Angle Sensor
1090
Detonation Sensor
1092
General Information
1095
Special Tool
1096
On-Vehicle Service
1096
Turbocharger Supercharging Pressure Check
1096
Supercharging Pressure Control System Check
1097
Waste Gate Actuator Check
1097
Waste Gate Solenoid Valve Check
1098
Air Bypass Valve Check
1098
Intake Manifold Pressure Check
1099
Secondary Air Control System Check
1099
Secondary Air Control Solenoid Valve Check
1099
Secondary Air Valve Check
1100
Vacuum Tank Check
1100
Air Cleaner
1101
Intercooler
1102
Intake and Exhaust
1102
Intercooler Water Spray
1103
Intercooler Water Spray
1104
Secondary Air Supply System
1107
Intake Manifold
1109
Exhaust Manifold
1112
Turbocharger
1115
Exhaust Pipe and Main Muffler
1119
Lubricants
1120
General Information
1121
Service Specifications
1121
Lubricant
1121
Sealant
1121
Special Tools
1122
Troubleshooting
1122
Engine Cooling
1123
On-Vehicle Service
1125
Engine Coolant Leak Checking
1125
Radiator Cap Opening Pressure Check
1125
Engine Coolant Replacement
1125
Concentration Measurement
1126
Radiator Fan Relay Continuity Check
1127
Radiator Fan Controller Check
1127
Radiator Fan Motor Check
1129
Thermostat
1130
Water Pump
1132
Water Hose and Water Pipe
1133
Radiator
1134
General Information
1140
General Specifications
1141
Service Specifications
1143
Sealant
1143
Special Tools
1144
Troubleshooting
1146
Starting Disabled (Starter Does Not Rotate)
1195
Engine Stalls When Starting Travel. (Pass Out)
1203
Engine Stalls During Deceleration
1204
Shock During Acceleration
1207
Shock During Deceleration
1208
Deviation of Ignition Interval
1210
Run on (Dieseling)
1211
Battery Dies
1214
Abnormal Radiator Fan Motor Rotation
1217
A/C Ineffective
1218
Fuel Pump System
1222
Radiator Fan Control Relay System
1224
Condenser Fan Relay System
1226
A/C Switch System
1229
A/C Compressor Relay System
1230
A/C Load Signal System
1232
Secondary Air Control Solenoid Valve System
1233
Intercooler Water Spray Circuit System
1234
Intercooler Water Spray Lamp System
1236
On-Vehicle Service
1262
(How to Reduce the Fuel Pressure)
1262
Fuel Pump Operation Check
1262
Throttle Body (Throttle Valve Area) Cleaning
1263
Throttle Position Sensor Adjustment
1263
Basic Idle Speed Adjustment
1264
Fuel Pressure Test
1265
Component Location
1268
Engine Control Relay Continuity Check
1269
Fuel Pump Relay 1, 2 Continuity Check
1269
Fuel Pump Relay 3 Continuity Check
1269
Fuel Pump Resistor Check
1269
Intake Air Temperature Sensor Check
1269
Engine Coolant Temperature Sensor Check
1270
Throttle Position Sensor Check
1271
Oxygen Sensor Check
1271
Injector Check
1273
Resistor (for Injector) Check
1275
Idle Speed Control Servo (Stepper Motor) Check
1275
Purge Control Solenoid Valve Check
1277
EGR Control Solenoid Valve Check
1277
Fuel Pressure Control Solenoid Valve Check
1277
Injector
1278
Throttle Body
1280
Engine Control Resistor, Relay
1283
Engine-Ecu
1284
Fuel Supply
1286
Fuel Tank
1288
General Information
1295
Service Specifications
1296
Sealant
1296
Lubricants
1296
Special Tool
1296
Engine Lubrication
1296
On-Vehicle Service
1297
Engine Oil Check
1297
Engine Oil Replacement
1297
Oil Filter Replacement
1298
Oil Pressure Check
1298
Engine Oil Cooler
1300
General Information
1304
Service Specifications
1305
Sealants
1305
Special Tools
1306
On-Vehicle Service
1308
Drive Belt Tension Check
1308
Auto-Tensioner Check
1308
Ignition Timing Check
1310
Idle Speed Check
1310
Idle Mixture Check
1311
Compression Pressure Check
1312
Manifold Vacuum Check
1313
Lash Adjuster Check
1313
Crankshaft Pulley
1316
Camshaft and Camshaft Oil Seal
1317
Oil Pan
1324
Crankshaft Oil Seal
1327
Cylinder Head Gasket
1329
Timing Belt and Timing Belt B
1335
Engine Assembly
1344
General Description
1351
Specifications
1352
Service Specifications
1352
Machining Standards
1354
Tightening Torque
1354
Sealants
1357
Form-In-Place Gasket
1357
Special Tools
1358
Alternator and Ignition System
1361
Timing Belt
1362
Fuel System
1375
Secondary Air System and Intake Manifold
1377
Exhaust Manifold
1379
Water Pump and Water Hose
1381
Rocker Arms and Camshaft
1383
Cylinder Head and Valve
1389
Oil Pump and Oil Pan
1396
Piston and Connecting Rod
1405
Crankshaft and Cylinder Block
1413
How to Use this Manual
1421
Scope of Maintenance, Repair and Servicing Explanations
1421
Indication of Destination
1421
Definition of Terms
1421
Indication of Tightening Torque
1421
Model Indications
1422
Explanation of Manual Contents
1423
Points
1425
Troubleshooting Contents
1425
Diagnosis Function
1425
How to Use the Inspection Procedures
1429
Connector Measurement Service Points
1430
Connector Inspection
1431
Inspection Service Points for a Blown Fuse
1432
Points to Note for Intermittent Malfunctions
1432
Vehicle Identification
1433
Vehicle Information Code Plate
1433
Models
1433
Model Code
1434
Chassis Number
1435
Engine Model Number
1435
Major Specifications
1436
Precautions before Service
1437
Supplemental Restraint System (Srs)
1440
Srs Service Precautions
1441
Support Locations for Lifting and Jacking
1443
Support Positions for a Garage Jack and Axle Stands
1443
Double-Post Lift
1444
H-Bar Lift
1445
Standard Part/Tightening-Torque Table
1447

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Mitsubishi Electric Lancer Evolution-VII Manuals

Manuals and User Guides for Mitsubishi Electric Lancer Evolution-VII. We have 1 Mitsubishi Electric Lancer Evolution-VII manual available for free PDF download: Workshop Manual

Mitsubishi Electric Lancer Evolution-VII Workshop Manual (1449 pages)

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