Mitsubishi Lancer Evolution VII Workshop Manual

Engine . . . . . . . . . . . . . . . . . . . . . . . . . Engine Lubrication . . . . . . . . . . . . . Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Cooling . . . . . . . . . . . . . . . . . Intake and Exhaust . . . . . . . . . . . . Engine Electrical . . . . . . . . . . . . . . . Engine and Emission Control . . . . Clutch . . . . . . . . . . . . . . . . . . . . . . . . . Manual Transmission . . . . . . . . . . . Propeller Shaft . . . . . . . . . . . . . . . . . Front Axle . . . . . . . . . . . . . . . . ...

RESTRAINT SYSTEM (SRS) EQUIPPED VEHICLE WARNING! (1) Improper service or maintenance of any component of the SRS, or any SRS-related component, can lead to personal injury or death to service personnel (from inadvertent firing of the air bag) or to the driver and passenger (from rendering the SRS inoperative). (2) The SRS components should not be subjected to temperature of 93_C or more. So, remove the SRS-ECU, driver’s and front passenger’s air bag modules and clock spring before drying or baking the vehicle after painting. (3) Service or maintenance of any SRS component or SRS-related component must be ...

2 . . . . . . . . . . . . . . Scope of Maintenance, Repair and Servicing Explanations 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Indication of Destination 2 . . . . . . . . . . . . . . . . . . . . . . Definition of Terms 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . Indication of Tightening Torque 2 . . . . . . . . . . . . . . . . Model Indications 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Explanation of Manual Contents 4 . . . . . . . . . . . . . . . HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

00-2 HOW TO USE THIS MANUAL SCOPE OF MAINTENANCE, REPAIR AND SERVICING EXPLANATIONS This manual provides explanations, etc. concerning procedures for the inspection, maintenance, repair and servicing of the subject model. Note, however, that for engine and transmission-related component parts, this manual covers only on-vehicle inspections, adjustments, and the removal and installation procedures for major components. For detailed information concerning the inspection, checking, adjustment, disassembly and reassembly of the engine, transmission and major components after they have been removed from the vehicle, please r ...

00-3 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. M/T: Indicates the manual transmission, or models equipped with the manual transmission. A/C: Indicates the air conditioner. ...

00-4 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. Indicates (by symbols) where lubrica- tion is necessary. Maintenance and Servicing Procedures The numbers provided within the diagram indi- cate the sequence for maintenance and servic- ing procedures. D Removal steps: The part designation number corresponds to the number in the illustration to indicate removal steps. D Disassembly steps: The part designation number corresponds to the number in the illustration to indicate disassem ...

00-5 Denotes tightening torque. For bolts and nuts which do not have a tightening torque listed, refer to the “Standard Parts- tightening-torque Table”. indicates that there is a continuity between the termi- nals. indicates terminals to which battery voltage is applied. Indicates the section title. Indicates the group num- ber. Indicates the page number. Indicates the group title. denotes non-re- usable part. Repair kit or set parts are shown. (Only very frequently used parts are shown.) Operating procedures, cau- tions, etc. on removal, installa- tion, disassembly and reas- sembly are described. The title of the p ...

00-6 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. TROUBLESHOOTING CONTENTS 1. STANDARD FLOW OF DIAGNOSIS TROUBLESHOOTING The troubleshooting sections follow the basic diagnosis flow which is given below. If the diagnosis flow is different from that given below, or if additional explanation is required, the details of such differences or additions wil ...

00-7 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. INSPECTION CHART FOR TROUBLE SYMPTOMS If there are trouble symptoms even though the results of inspection using the MUT-II show that all diagnosis codes are normal, inspection procedures for each trouble symptom will be found by means of this chart. 7. INSPECTION PROCEDURE FOR TROUBLE SYMPTOM Indicates the inspection procedures corresponding to each trouble symptoms c ...

00-8 WHEN USING THE WARNING LAMP 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. Applicable systems System name Warning lamp name ACD, AYC ACD mode indicator lamp ABS ABS warning lamp Indication of diagnosis code by warning lamp When the diagnosis code No.24 is output When no diagnosis code is output* On Off 1.5 secs. 0.5 sec. 0.5 sec. Pause time 3 secs. Tens signal Place division 2 secs. Units signal On Off 0.25 se ...

00-9 INPUT SIGNAL CHECK 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. 2. If the MUT-II buzzer sounds once when each switch is operated (ON/OFF), the input signal for that switch circuit system is normal. WHEN USING A VOLTMETER 1. Use the special tool to connect the ETACS terminal (terminal 9) and the earth terminals (terminals 4 and 5) of the diagnosis connector to the voltage meter. 2. If the needle of the voltage meter fli ...

00-10 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. D Indicator does not turn on or off even if control mode switch is pressed. D Indicator switch should not be illuminated is illuminated. Probable cause OK OK OK Measure at switch connector A-44 D Disconnect the connector, and measure at the ha ...

00-11 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 (WITH CIRCUIT IN A CONDITION OF CONTINUITY) Waterproof Connectors Be sure to use the special tool (harness connector). Never insert a test bar from the harness side, because to do so will reduce the waterproof performance and result in corrosion. Ordinary (non-waterproof) Connectors Check by inserting the test bar from the harness side. ...

00-12 CONNECTOR INSPECTION VISUAL INSPECTION D Connector is disconnected or improperly connected D Connector pins are pulled out D Due to harness tension at terminal section D Low contact pressure between male and female terminals D Low connection pressure due to rusted terminals or foreign matter lodged in terminals CONNECTOR PIN INSPECTION If the connector pin stopper is damaged, the terminal connections (male and female pins) will not be perfect even if the connector body is connected, and the pins may pull out of the reverse side of the connector. Therefore, gently pull the harnesses on ...

00-13 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 of continuity. If the resistance is almost 0 Ω at this time, there is a short somewhere between these switches and the load. If the resistance is not 0 Ω, there is no short at the present time, but a momentary short has probably caused the fuse to blow. The main causes of a short circuit are the following. D Harness being clamped by the vehicle body D Damag ...

00-14 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. No. Item Contents Contents 1 MODEL CT9A SNDFZL CT9A: Vehicle model SNDFZL SNDFZL: Model series 2 ENGINE 4G63-DOHC Engine model 3 EXT A37B Exterior code 4 TRANS AXLE W5M51 W5M51: Transmission code 5 COLOR INT OPT A37 14H A37: Body colour code INT OPT 14H R11 14H: Interior code R11: Equipment code For monotone colour vehicles, the body colour code shall be indic ...

00-15 MODEL CODE No. Items Contents 1 Development CT: MITSUBISHI LANCER EVOLUTION-VII 2 Engine type 9: 1,997 mL petrol engine 3 Sort A: Passenger car 4 Body style S: 4-door sedan 5 Transmission type N: 5-speed manual transmission 6 Trim level D: RS G: RS-II or GSR 7 Specification engine feature F: MPI-DOHC-intercooler turbo 8 Special feature Z: 4WD 9 Steering wheel location L: Left hand R: Right hand 1 2 3 4 5 6 7 8 9 CT 9 A S N D F L Z ...

GENERAL - Vehicle Identification 00-16 CHASSIS NUMBER The chassis number is stamped on the toeboard inside the engine compartment. 1 2 3 4 5 6 7 8 9 11 10 No. Items Contents 1 Fixed figure J Asia 2 Distribution channel M Japan channel 3 Destination Y For Europe and General Export 4 Body style S 4-door sedan 5 Transmission type N 5-speed manual transmission 6 Development order CT MITSUBISHI LANCER EVOLUTION-VII 7 Engine 9 4G63: 1,997 mL petrol engine 8 Sort A Passenger car 9 Model year 2 2002 10 Plant U MIZUSHIMA-1 11 Serial number - - ENGINE MODEL NUMBER 1. The engine model number is stamped on the cylinder block as sho ...

00-17 MAJOR SPECIFICATIONS 1 2 3 4 5 6 7 8 9 Items CT9A SNDFZL/R SNGFZL/R Vehicle di i Front track 1 1,500, 1,515 *1 dimensions mm Overall width 2 1,770 mm Front overhang 3 895 Wheel base 4 2,625 Rear overhang 5 935 Overall length 6 4,455 Ground clearance (unladen) 7 140 Overall height (unladen) 8 1,450 Rear track 9 1,500, 1,515 *1 Vehicle i ht k Kerb weight 1,320 1,380 weight kg Max. gross vehicle weight 1,655 1,695 Max. axle weight rating-front 950 970 Max. axle weight rating-rear 705 725 Seating capacity 5 Engine Model No. 4G63 g Total displacement mL 1,997 Transmis- i Model No. W5M51 sion Type 5-speed manual Fuel syst ...

00-18 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. The SRS system is designed to retain enough voltage to deploy the air bag even after the battery has been disconnected. Serious injury may result from unintended air bag deployment if work is done on the SRS system immediately after the battery cable is disconnected. (3) Warn ...