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Lancer Evolution-VII
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
Table of Contents
106
Electrical Wiring
3
Wiring and Piping Diagram
6
New Colour Numbers
10
Location of Synthetic-Resin Parts
13
Upper Body
20
Headlamp Support
21
Fender Shield
24
Front Pillar
25
Center Pillar
26
Center Pillar
31
Quarter, Outer
35
Rear End Panel
36
Rear Floor
38
Quarter, Inner
40
Front Door Outer Panel
41
Rear Door Outer Panel
56
Rear Body
106
Table of Contents
111
Engine Compartment
115
Engine and Transmission
123
Dash Panel
143
Luggage Compartment
151
Solenoid Valve
153
Fusible Link and Fuse
154
Earth Cable
173
Centralized Junction
179
Power Distribution System
184
Starting System
187
Ignition System
187
L.H. Drive Vehicles
188
R.H. Drive Vehicles
189
Charging System
193
ENGINE CONTROL SYSTEM L.H. Drive Vehicles
199
R.H. Drive Vehicles
207
Cooling System
209
HEADLAMP L.H. Drive Vehicles
211
R.H. Drive Vehicles
217
TAIL LAMP, POSITION LAMP, LICENCE PLATE LAMP and LIGHTING MONITOR BUZZER L.H. Drive Vehicles
223
L.H. Drive Vehicles
225
ROOM LAMP and LUGGAGE COMPARTMENT LAMP L.H. Drive Vehicles
226
R.H. Drive Vehicles
231
REAR FOG LAMP L.H. Drive Vehicles
232
R.H. Drive Vehicles
235
Headlamp Leveling System
235
L.H. Drive Vehicles
237
R.H. Drive Vehicles
241
TURN-SIGNAL LAMP and HAZARD WARNING LAMP L.H. Drive Vehicles
243
R.H. Drive Vehicles
247
Back-Up Lamp
247
L.H. Drive Vehicles
248
R.H. Drive Vehicles
249
Stop Lamp
249
L.H. Drive Vehicles
250
R.H. Drive Vehicles
251
Horn
255
METER and GAUGE L.H. Drive Vehicles
257
R.H. Drive Vehicles
261
Fuel Warning Lamp
262
Brake Warning Lamp
262
Oil Pressure Warning Lamp
265
POWER WINDOWS L.H. Drive Vehicles
269
R.H. Drive Vehicles
275
Central Door Locking System
275
L.H. Drive Vehicles
277
R.H. Drive Vehicles
281
HEATER and MANUAL AIR CONDITIONER L.H. Drive Vehicles
285
R.H. Drive Vehicles
290
Defogger
293
WINDSHIELD WIPER and WASHER L.H. Drive Vehicles
294
R.H. Drive Vehicles
297
Remote Controlled Mirror
297
L.H. Drive Vehicles
298
R.H. Drive Vehicles
299
Clock
300
Cigarette Lighter and Ashtray Illumination Lamp
301
Audio System
303
L.H. Drive Vehicles
310
R.H. Drive Vehicles
317
Acd
317
Vehicles Without AYC <L.H. Drive Vehicles
325
Vehicles Without AYC <R.H. Drive Vehicles
335
ACD and AYC L.H. Drive Vehicles
343
R.H. Drive Vehicles
353
Supplemental Restraint System (Srs) and Seat Belt Pretensioner
353
L.H. Drive Vehicles
355
R.H. Drive Vehicles
357
Immobilizer System
357
L.H. Drive Vehicles
359
R.H. Drive Vehicles
361
Intercooler Water Splay
363
Spare Connector
372
Wire Colour Codes
378
Ventilation
379
Special Tools
380
Troubleshooting
391
Performance Test
392
Compressor Drive Belt Adjustment
392
Dual Pressure Switch Check
396
Discharging System
398
Refrigerant Leak Repair
399
A/C Compressor Relay Continuity Check
400
Condenser Fan Relay (Hi) Check
402
Removal and Installation
399
Blower Relay Continuity Check
405
Heater Unit and Blower Assembly
411
Evaporator and Air Thermo Sensor
419
Refrigerant Lines
425
Chassis Electrical
427
Battery
427
Service Specification
427
On-Vehicle Service
427
Fluid Level and Specific Gravity Check
427
Charging
428
Battery Testing Procedure
429
Ignition Switch and Immobilizer System
429
Special Tools
429
Troubleshooting
430
Chassis Electrical
430
Ignition Key
433
Immobilizer-Ecu Check
434
Ignition Switch
437
Combination Meter
437
Service Specifications
437
Sealant
438
Special Tools
438
Troubleshooting
442
On-Vehicle Service
442
Speedometer Check
443
Tachometer Check
443
Fuel Gauge Unit Check
444
Engine Coolant Temperature Gauge Unit Check
445
Combination Meter
447
Headlamp Assembly
447
Service Specifications
447
Troubleshooting
447
On-Vehicle Service
447
Headlamp Aiming
451
Headlamp Intensity Measurement
451
Headlamp Bulb (Low Beam)Replacement
452
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
453
Headlamp Assembly
454
Room Lamp
454
Troubleshooting
454
Side Turn-Signal Lamp
454
Special Tool
455
Rear Combination Lamp
455
Special Tool
455
Troubleshooting
457
High-Mounted Stop Lamp
457
On-Vehicle Service
457
High-Mounted Stop Lamp Bulb Replacement
458
On-Vehicle Service
458
License Plate Lamp Replacement
459
Hazard Warning Lamp Switch
459
Special Tool
460
Hazard Warning Lamp Switch
460
Cigarette Lighter
460
Horn
461
Column Switch
461
Special Tool
463
Clock
463
Special Tool
464
Pole Antenna
465
Defogger
465
Troubleshooting
466
On-Vehicle Service
466
Printed Heater Check
466
Defogger Relay Continuity Check
466
Defogger Switch
465
Roof Antenna
468
Smart Wiring System (Sws)
469
Special Tools
469
Troubleshooting
469
Before Commencing Troubleshooting
469
Standard Flow of Diagnostic Troubleshooting
469
SWS Troubleshooting
469
Diagnostic Functions
470
Diagnosis Code Chart
471
Diagnosis Code Inspection Procedures
474
54B-7 Sws - Troubleshooting Trouble Symptom Chart
474
Trouble Symptom Chart
477
Inspection Procedures for Trouble Symptoms
477
No Communication with Mut-II
477
Lights Left On Reminder Warning Function Not Working Normally
478
Central Door Locking System Not Working at All
478
Some Doors Not Locking or Unlocking
479
Main Switch
484
The Windshield Wipers Do Not Work at All
486
The Windshield Washer Does Not Work at All
487
The Tail Lamps Do Not Work
488
The Headlamps (High-Beam) Do Not Light
490
Rear Fog Lamp Is Not Properly Illuminated
491
The Hazard Warning Lamps Do Not Light Up
492
The Room Lamps Do Not Come On or Off Normally
501
Check at ECU Terminals
507
Interior
508
Instrument Panel
508
Special Tool
515
Front Floor Console
517
Rear Floor Console
520
Trims
522
Headlining
524
Seat
524
Front Seat
527
Rear Seat
530
Seat Belt
530
Front Seat Belt
531
Rear Seat Belt
532
Supplemental Restraint System (Srs)
533
General Information
534
Srs Service Precautions
536
Special Tools
537
Test Equipment
537
Troubleshooting
553
Possible Cause
573
Srs Maintenance
576
Post-Collision Diagnosis
580
Individual Component Service
580
Warning/Caution Labels
581
Srs Air Bag Control Unit (Srs-Ecu)
583
Air Bag Modules and Clock Spring
594
Seat Belt Pre-Tensioner
595
Air Bag Module and Seat Belt Pre-Tensioner Disposal Procedures
595
Pre-Tensioner Disposal
595
Pre-Tensioner Disposal Procedures
608
Exterior
609
Front Bumper
609
Adhesive
610
Front Bumper
613
Rear Bumper
615
Side Air Dam, Molding and Garnish
615
Special Tool
615
Adhesive
616
Side Air Dam Molding Garnish
619
Rear Spoiler
619
Adhesive
620
Windshield Wiper and Washer
620
Service Specifications
620
Troubleshooting
620
On-Vehicle Service
627
Marks
630
Outside Mirror
630
Special Tool
634
Table of Contents
635
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
636
Hood
637
Fender
637
Special Tool
638
Fender
640
Fuel Filler Door
641
Strut Tower Bar and Rear End Cross Bar
642
Window Glass
642
Adhesive
642
Special Tools
642
Window Repair
644
Windshield
649
Rear Window Glass
652
Doors
652
Service Specifications
652
Adhesives
652
Special Tools
653
Troubleshooting
653
On-Vehicle Service
653
Door Adjustment
654
Door Window Glass Adjustment
655
Window Malfunction
655
Power Window Safety Mechanism Check
655
Power Window Timer Function Check
656
Door Outside Handle Looseness Check
656
Circuit Breaker Check
656
Power Window Check
657
Door Inside Handle Looseness Check and Adjustment
658
Door Assembly
660
Door Trim and Waterproof Film
665
Door Glass and Regulator
668
Door Handle and Latch
671
Window Glass Runchannel and Door Opening Weatherstrip
674
Trunk Lid
678
Steering
679
General Information
681
Lubricants
681
Sealant
681
Service Specifications
681
Special Tools
684
On-Vehicle Service
684
Steering Wheel Free Play Check
684
Steering Angle Check
684
Tie Rod End Ball Joint Turning Torque Check
685
Stationary Steering Effort Check
685
Checking Steering Wheel Return to Centre
685
Drive Belt Tension Check
686
Power Steering Fluid Level Check
686
Power Steering Fluid Replacement
686
Power Steering System Bleeding
687
Oil Pump Pressure Test
688
Power Steering Oil Pressure Switch Check
688
Ball Joint Dust Cover Check
689
Steering Wheel
691
Steering Shaft
693
Power Steering Gear Box and Linkage
706
Power Steering Oil Pump
707
Power Steering Oil Hoses
712
Parking Brakes
713
General Information
713
Lubricants
713
Service Specifications
714
On-Vehicle Service
714
Parking Brake Lever Stroke Check and Adjustment
714
Parking Brake Switch Check
715
Lining Running-In
716
Parking Brake Lever
716
Parking Brakes
717
Parking Brake Cable
718
Parking Brake Drum
720
Service Brakes
721
Basic Brake System
722
General Information
724
Service Specifications
725
Lubricants
725
Sealant
725
Special Tools
726
On-Vehicle Service
726
Brake Pedal Check and Adjustment
727
Brake Booster Operating Test
728
Check Valve Operation Check
728
Proportioning Valve Function Test
728
Vehicles Without ABS
729
Bleeding
730
Brake Fluid Level Sensor Check
730
Disc Brake Pad Check and Replacement
732
Disc Brake Rotor Check
733
Brake Disc Thickness Check
733
Brake Disc Run-Out Check and Correction
735
Brake Pedal
737
Proportioning Valve, Master
738
Master Cylinder
739
Disc Brake
748
Braking System
784
Front Suspension
785
General Information
786
Service Specifications
786
Special Tools
786
Front Suspension
787
On-Vehicle Service
787
Wheel Alignment Check and Adjustment
788
Ball Joint Dust Cover Check
789
Strut Assembly
792
Lower Arm Assembly
795
Stabilizer Bar
798
Crossmember Bar
800
Power Plant Mount
801
General Information
802
Special Tool
803
Engine Mounting
804
Transmission Mounting
805
Engine Roll Stopper, Centermember
807
Crossmember
812
Wheel and Tyre
813
General Information
817
On-Vehicle Service
817
Tyre Inflation Pressure Check
817
Tyre Wear Check
817
Wheel Runout Check
817
Wheel and Tyre
818
Rear Axle
819
General Information
820
Lubricants
820
Service Specifications
821
Sealants
821
Special Tools
825
Rear Axle Troubleshooting
833
On-Vehicle Service
833
Rear Axle Total Backlash Check
833
Gear Oil Level Check
834
Gear Oil Change
836
Fluid Level Check
836
Bleeding
837
AYC Operation Check
838
Oil Pressure Check
839
Wheel Bearing Axial Play Check
839
Wheel Bearing Rotary-Sliding Resistance Check
840
Hub Bolt Replacement
840
Differential Carrier Oil Seal Replacement
841
Action When Battery Runs Out
842
Rear Hub Assembly
845
Knuckle
846
Drive Shaft
847
Differential Carrier
848
Vehicles with Mechanical Lsd
855
26. Differential Carrier
872
Vehicles with Ayc
879
Hydraulic Unit
880
Front Axle
881
General Information
882
Lubricants
882
Service Specifications
882
Special Tools
882
Front Axle
884
On-Vehicle Service
884
Wheel Bearing Axial Play Check
884
Hub Bolt Replacement
886
Hub and Knuckle Assembly
889
Drive Shaft
899
Propeller Shaft
909
Manual Transmission
910
General
910
General Information
910
Lubricants
910
Manual Transmission
910
Service Specification
911
Special Tools
912
Troubleshooting <Acd
947
On-Vehicle Service
947
Transmission Oil Check
947
Transmission Oil Replacement
947
Transfer Oil Check
947
Transfer Oil Replacement
948
Fluid Check <Vehicles with ACD or Vehicles with ACD and AYC
949
Bleeding <Vehicles with ACD or Vehicles with ACD and AYC
949
ACD Operation Check <Vehicles with ACD or Vehicles with ACD and AYC
950
Hydraulic Pressure Check <Vehicles with ACD or Vehicles with ACD and AYC
951
Wheel Speed Sensor Output Voltage
953
Transmission Control
956
Transfer Assembly
959
Transmission Assembly
962
4Wd-Ecu <Vehicles with Acd or Vehicles with Acd and Ayc
962
Ayc
966
Manual Transmission Overhaul
967
General Description
971
Service Specifications
971
Specifications
972
Sealants
973
Lubricants
974
Plates for Adjustment
974
Snap Rings, Spacers and Thrust
976
Tightening Torque
977
Special Tools
980
Transmission
987
Input Shaft
994
Output Shaft
1002
Reverse Idler Gear
1003
Speedometer Gear
1004
Select Lever
1005
Control Housing
1008
Clutch Housing
1011
Transmission Case
1013
Center Differential
1016
Transfer
1019
Clutch
1020
General Information
1020
Lubricants
1020
On-Vehicle Service
1020
Clutch Pedal Inspection and Adjustment
1021
Bleeding
1022
Clutch Pedal
1024
Clutch Pedal Position Switch Adjustment
1020
Service Specifications
1024
Clutch Control
1024
Clutch Master Cylinder
1028
Clutch Overhaul
1029
General Description
1029
Tightening Torque
1030
Clutch
1033
Clutch Release Cylinder
1036
Engine and Emission Control
1037
Engine Control System
1037
General Information
1037
Service Specifications
1037
On-Vehicle Service
1037
Accelerator Cable Check and Adjustment
1038
Accelerator Cable and Pedal
1039
Emission Control System
1039
General Information
1039
Emission Control Device Reference Table
1040
Service Specifications
1040
Vacuum Hose
1040
Vacuum Hose Piping Diagram
1041
Vacuum Circuit Diagram
1042
Vacuum Hose Check
1042
Vacuum Hose Installation
1043
Crankcase Emission Control System
1043
General Information
1043
System Diagram
1044
Component Location
1044
Positive Crankcase Ventilation System Check
1044
PCV Valve Check
1045
Evaporative Emission Control System
1045
General Information
1045
System Diagram
1045
Component Location
1046
Purge Control System Check
1046
Purge Port Vacuum Check
1047
Purge Control Solenoid Valve Check
1047
Check Valve Check
1048
Exhaust Gas Recirculation (Egr) System
1048
General Information
1048
Operation
1048
System Diagram
1049
Component Location
1049
Exhaust Gas Recirculation (EGR) Control System Check
1050
EGR Valve Check
1050
EGR Port Vacuum Check
1051
EGR Control Solenoid Valve Check
1052
Egr Valve
1054
Catalytic Converter
1056
Engine Electrical
1057
Charging System
1057
General Information
1058
Service Specifications
1058
Special Tool
1059
Alternator Output Line Voltage Drop Test
1059
Engine Electrical
1060
Output Current Test
1062
Regulated Voltage Test
1063
Waveform Check Using an Analyzer
1059
On-Vehicle Service
1065
Alternator
1072
Starting System
1072
General Information
1073
Starter
1081
Ignition System
1081
General Information
1082
Service Specifications
1082
Special Tool
1083
Ignition Coil (With Built-In Power Transistor) Check
1083
Resistive Cord Check
1084
Spark Plug Check, Cleaning and Replacement
1084
Camshaft Position Sensor Check
1084
Crank Angle Sensor Check
1084
Detonation Sensor Check
1085
Waveform Check Using an Analyzer
1089
Ignition Coil
1090
Camshaft Position Sensor
1090
Crank Angle Sensor
1092
Detonation Sensor
1094
Intake and Exhaust
1095
General Information
1096
On-Vehicle Service
1096
Turbocharger Supercharging Pressure Check
1097
Supercharging Pressure Control System Check
1097
Waste Gate Actuator Check
1098
Waste Gate Solenoid Valve Check
1098
Air Bypass Valve Check
1099
Intake Manifold Pressure Check
1099
Secondary Air Control System Check
1099
Secondary Air Control Solenoid Valve Check
1100
Secondary Air Valve Check
1100
Vacuum Tank Check
1096
Special Tool
1101
Air Cleaner
1102
Intercooler
1102
Intake and Exhaust
1103
Intercooler Water Spray
1104
Intercooler Water Spray
1107
Secondary Air Supply System
1109
Intake Manifold
1112
Exhaust Manifold
1115
Turbocharger
1119
Exhaust Pipe and Main Muffler
1120
Engine Cooling
1120
Lubricants
1121
General Information
1121
Service Specifications
1121
Lubricant
1121
Sealant
1122
Special Tools
1122
Troubleshooting
1123
Engine Cooling
1125
On-Vehicle Service
1125
Engine Coolant Leak Checking
1125
Radiator Cap Opening Pressure Check
1125
Engine Coolant Replacement
1126
Concentration Measurement
1127
Radiator Fan Relay Continuity Check
1127
Radiator Fan Controller Check
1129
Radiator Fan Motor Check
1130
Thermostat
1132
Water Pump
1133
Water Hose and Water Pipe
1134
Radiator
1139
Multipoint Fuel Injection (Mpi)
1140
General Information
1141
General Specifications
1143
Sealant
1143
Service Specifications
1144
Special Tools
1146
Troubleshooting
1189
Inspection Chart for Trouble Symptoms
1195
Starting Disabled (Starter Does Not Rotate)
1203
Engine Stalls When Starting Travel. (Pass Out)
1204
Engine Stalls During Deceleration
1207
Shock During Acceleration
1208
Shock During Deceleration
1210
Deviation of Ignition Interval
1211
Run On (Dieseling)
1214
Battery Dies
1217
Abnormal Radiator Fan Motor Rotation
1218
A/C Ineffective
1222
Fuel Pump System
1224
Radiator Fan Control Relay System
1226
Condenser Fan Relay System
1229
A/C Switch System
1230
A/C Compressor Relay System
1232
A/C Load Signal System
1233
Secondary Air Control Solenoid Valve System
1234
Intercooler Water Spray Circuit System
1236
Intercooler Water Spray Lamp System
1262
On-Vehicle Service
1262
(How to Reduce the Fuel Pressure)
1262
Fuel Pump Operation Check
1263
Throttle Body (Throttle Valve Area) Cleaning
1263
Throttle Position Sensor Adjustment
1264
Basic Idle Speed Adjustment
1265
Fuel Pressure Test
1268
Component Location
1269
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
1270
Engine Coolant Temperature Sensor Check
1271
Throttle Position Sensor Check
1271
Oxygen Sensor Check
1273
Injector Check
1275
Resistor (For Injector) Check
1275
Idle Speed Control Servo (Stepper Motor) Check
1277
Purge Control Solenoid Valve Check
1277
EGR Control Solenoid Valve Check
1277
Fuel Pressure Control Solenoid Valve Check
1278
Injector
1280
Throttle Body
1283
Engine Control Resistor, Relay
1284
Engine-Ecu
1286
Fuel Supply
1288
Fuel Tank
1294
Engine Lubrication
1295
General Information
1296
Lubricants
1296
Sealant
1296
Service Specifications
1296
Special Tool
1296
Engine Lubrication
1297
On-Vehicle Service
1297
Engine Oil Check
1297
Engine Oil Replacement
1298
Oil Filter Replacement
1298
Oil Pressure Check
1300
Engine Oil Cooler
1303
Engine
1304
General Information
1305
Sealants
1305
Service Specifications
1306
Special Tools
1308
On-Vehicle Service
1308
Drive Belt Tension Check
1308
Auto-Tensioner Check
1310
Ignition Timing Check
1310
Idle Speed Check
1311
Idle Mixture Check
1312
Compression Pressure Check
1313
Manifold Vacuum Check
1313
Lash Adjuster Check
1316
Crankshaft Pulley
1317
Camshaft and Camshaft Oil Seal
1324
Oil Pan
1327
Crankshaft Oil Seal
1329
Cylinder Head Gasket
1335
Timing Belt and Timing Belt B
1344
Engine Assembly
1350
Engine Overhaul
1351
General Description
1352
Specifications
1352
Service Specifications
1354
Machining Standards
1354
Tightening Torque
1357
Sealants
1357
Form-In-Place Gasket
1358
Special Tools
1361
Alternator and Ignition System
1362
Timing Belt
1375
Fuel System
1377
Secondary Air System and Intake Manifold
1379
Exhaust Manifold
1381
Water Pump and Water Hose
1383
Rocker Arms and Camshaft
1389
Cylinder Head and Valve
1396
Oil Pump and Oil Pan
1405
Piston and Connecting Rod
1413
Crankshaft and Cylinder Block
1420
General
1421
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
1422
Model Indications
1423
Explanation of Manual Contents
1425
Points
1425
Troubleshooting Contents
1425
Diagnosis Function
1429
How to Use the Inspection Procedures
1430
Connector Measurement Service Points
1431
Connector Inspection
1432
Inspection Service Points for a Blown Fuse
1432
Points to Note for Intermittent Malfunctions
1433
Vehicle Identification
1433
Vehicle Information Code Plate
1433
Models
1434
Model Code
1435
Chassis Number
1435
Engine Model Number
1436
Major Specifications
1437
Precautions before Service
1440
Supplemental Restraint System (Srs)
1441
Srs Service Precautions
1443
Support Locations for Lifting and Jacking
1443
Support Positions for a Garage Jack and Axle Stands
1444
Double-Post Lift
1445
H-Bar Lift
1447
Standard Part/Tightening-Torque Table
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