lock MITSUBISHI LANCER EVOLUTION IV 1998 User Guide

ENGINE – Engine Assembly11-3 5
E ENGINE ASSEMBLY REMOVAL
After checking that all cables, hoses and harness connectors,
etc., are disconnected from the engine, lift the chain block
slowly to remove the engine assembly upward from the engine
compartment.
INSTALLATION SERVICE POINTS
 A ENGINE ASSEMBLY INSTALLATION
Install the engine assembly, checking that the cables, hoses,
and harness connectors are not clamped.
 B ENGINE MOUNT BRACKET INSTALLATION
(1) Place a garage jack against the engine oil pan with a piece of wood in between, and install the engine mount
bracket while adjusting the position of the engine.
(2) Support the engine with the garage jack.
(3) Remove the chain block and support the engine assembly
with the special tools.
 C HIGH-PRESSURE FUEL HOSE INSTALLATION
(1) Apply a small amount of new engine oil to the O-ring, then fit the O-ring in the delivery pipe.
Caution
Do not let any engine oil get into the delivery pipe.
(2) Check that the high pressure hose turns smoothly. If the hose does not turn smoothly, the O-ring is probably
being clamped. Disconnect the high-pressure fuel hose
and check the O-ring for damage. After this, re-install
the hose to the delivery pipe and check that the hose
turns smoothly.
(3) Tighten the mounting bolt to the specification.
MZ203826 or MZ203827
MB991453

ENGINE COOLING – Service Specifications / Lubricant / On-vehicle Service14-2
SERVICE SPECIFICATIONS
ItemsStandard value
Thermostat valve opening temperature
CWhen open76.5 ± 1.5
When fully open90
Thermostat lift mm8.5 or more
LUBRICANT
ItemsBrandQuantity dm3 {
}
Coolant capacity (in condenser tank)MITSUBISHI GENUINE DIA QUEEN SUPER
LONG LIFE COOLANT6 {6}
ON-VEHICLE SERVICE
COOLANT REPLACEMENT
CYLINDER BLOCK DRAIN PLUG
Unit: Nm {kgfm}
Drying sealant: HELMESEAL H-1M
44 {4.5}
RADIATOR CAP VALVE OPENING PRESSURE
CHECK
On EVOLUTION-V, the radiator cap valve opening pressure
must be as shown below.
Standard value: 93 – 123 kPa {0.95 – 1.25 kgf/cm
2}
Limit: 83 kPa {0.85 kgf/cm
2}

INTAKE AND EXHAUST – On-vehicle Service15-3
(3) If the boost pressure is lower than the standard value,
check for following which are probably the cause:
Wastegate actuator inoperative
Boost pressure leak
Turbocharger defective
(4) If the boost pressure is higher than the standard value,
boost pressure control is probably faulty. Make the
following checks:
Wastegate actuator inoperative
Wastegate valve inoperative
Wastegate actuator rubber hose disconnected or
cracked
2. BOOST PRESSURE CONTROL SYSTEM
CHECK
(1) Disconnect the hose (black) from the wastegate solenoid
valve and connect a three-way joint between the hose
and solenoid valve.
(2) Connect a hand vacuum pump to the three-way joint.
(3) Disconnect the hose (black) from the intake pipe nipple
connected to the turbocharger compressor housing and
fit a blank plug to this nipple.
(4) Disconnect the negative cable from the battery, keep it
disconnected for 10 sec. or more, and then reconnect
it back again.
(5) Block and unblock the end of the vacuum hose (black)
with a finger to apply vacuum and check for the vacuum
condition.
Engine conditionHose (black) endNormally
Stationary
(ignition switch: ON)
UnblockedVacuum leaks.
(ignition switch: ON)
BlockedVacuum retained.
Idling after warmupVacuum leaks.
NOTE
If the vacuum condition is faulty, the wastegate actuator,
wastegate solenoid valve, or hose is probably defective.
Wastegate
solenoid valve

INTAKE AND EXHAUST – Exhaust Pipe and Muffler15-14
EXHAUST PIPE AND MUFFLER
REMOVAL AND INSTALLATION
Unit: Nm {kgf
m}
15
44 {4.5}
49 {5.0}
34 {3.5}
5 {0.5}13 {1.3}
14
16
7 5 13
172 1
3
46 18
8
9 12
10 11
34 {3.5}
19 {1.9}49 {5.0}
Hanger mounting bolt tightening
torque
13 {1.3}
3, 9, 18
93 3 9
Main muffler removal steps
1. Bolt
2. Main muffler
3. Hanger
Center exhaust pipe removal steps
1. Bolt
4. Spring
5. Heat protector
6. Self-locking nut
7. Hanger bracket
8. Center exhaust pipe
9. Hanger
10. Protector11. High-temperature sensor
12. Bolt
13. Catalytic converter
14. Front floor heat protector panel
Front exhaust pipe removal steps
4. Spring
5. Heat protector
12. Bolt
15. Self-locking nut
16. Front exhaust pipe
17. Front exhaust pipe bracket
18. Hanger

CLUTCH –
Service Specifications /
Lubricants / On-vehicle Service21-2
SERVICE SPECIFICATIONS
ItemsStandard value
Clutch pedal height mm162.5 – 165.5
Clutch pedal clevis pin play mm1 – 3
Clutch pedal free play mm6 – 13
Distance between the clutch pedal and the toeboard when the clutch is disengaged mm70 or more
LUBRICANTS
ItemsSpecified lubricantsQuantity
Clutch fluidMITSUBISHI genuine brake fluid “DIA-QUEEN
BRAKE FLUID SUPER 4”As required
Push rod assemblyRubber grease
Boot
Release cylinder push rodMOLYKOT BR-2 PUS
ON-VEHICLE SERVICE
1. CLUTCH PEDAL INSPECTION AND
ADJUSTMENT
(1) Turn up the carpet, etc. under the clutch pedal.
(2) Measure the clutch pedal height.
Standard value (A): 162.5 – 165.5 mm
(3) If the height of the clutch pedal is outside the standard
value, loosen the lock nut and adjust the pedal height
to the standard value using the adjusting bolt.
Clutch pedal height
A
Setting nutAdjusting bolt
Locking
nut
13 {1.3}
6 {0.6}

CLUTCH – Clutch Pedal21-4
CLUTCH PEDAL
REMOVAL AND INSTALLATION
Post-installation Operation

Clutch Pedal Adjustment (Refer to P.21-2.)
(Spring installation position)
13
5
Unit: Nm {kgf
m}
13 {1.3}
1134
11
122
7
6
89 106
3 5
24 {2.4} 13 {1.3}
12 {1.2}
Removal steps
1. Clutch master cylinder installation
nut
2. Master cylinder member bracket
installation bolt
3. Clevis pin
4. Bolt
5. Return spring
6. Bushing7. Pipe
8. Clutch pedal
9. Pedal pad
10. Stopper
11. Adjusting bolt
12. Locking nut
13. Pedal and master cylinder support
member

MANUAL TRANSMISSION – Transmission Control22A-6
SHIFT LEVER ASSEMBLY
DISASSEMBLY AND REASSEMBLY
1
23
4
57
8
9
10 39
6
Unit: Nm {kgfm}
14 {1.4}
10 {1.0}
Disassembly steps
1. Bolt
2. Select lever
3. Bushing
4. Return spring
5. Collar6. Bolt
7. Cap
8. Shift lever
9. Shift lever bushing
10. Base block

MANUAL TRANSMISSION OVERHAUL – Sealants and Adhesives22B-5
SEALANTS AND ADHESIVES
TRANSMISSION
ItemsSpecified sealants and adhesives
Clutch housing-transmission case mating surfaceTHREEBOND 1216
Control housing-transmission case mating surface
Under cover-transmission case mating surface
Air breatherTHREEBOND 1501
Center differential drive gear boltTHREEBOND 1303 or LOKTITE 648
TRANSFER
ItemsSpecified sealants and adhesives
Air breatherTHREEBOND 1501
FORM-IN-PLACE GASKET
The transmission has several areas where the form-in-place gasket (FIPG) is in use. To ensure that
the gasket fully serves its purpose, it is necessary to observe some precautions when applying the gasket.
Bead size, continuity and location are of paramount importance. Too thin a bead could cause leaks.
Too thick a bead, on the other hand, could be squeezed out of location, causing blocking or narrowing
of the fluid feed line. To eliminate the possibility of leaks from a joint, therefore, it is absolutely necessary
to apply the gasket evenly without a break, while observing the correct bead size.
DISASSEMBLY
The parts assembled with the FIPG can be easily disassembled without use of a special method. In
some cases, however, the sealant between the joined surfaces may have to be broken by lightly striking
with a mallet or similar tool. A flat and thin gasket scraper may be lightly hammered in between the
joined surfaces. In this case, however, care must be taken to prevent damage to the joined surfaces.
SURFACE PREPARATION
Thoroughly remove all substances deposited on the gasket application surfaces, using a gasket scraper
or wire brush. Check to ensure that the surfaces to which the FIPG is to be applied is flat. Make sure
that there are no oils, greases and foreign substances deposited on the application surfaces. Do not
forget to remove the old sealant remaining in the bolt holes.
FORM-IN-PLACE GASKET APPLICATION
Applied FIPG bead should be of the specified size and without breaks. Also be sure to encircle the
bolt hole circumference with a completely continuous bead. The FIPG can be wiped away unless it is
hardened. While the FIPG is still moist (in less than 10 minutes), mount the parts in position. When
the parts are mounted, make sure that the gasket is applied to the required area only. In addition, do
not apply any oil or water to the sealing locations or start the engine until a sufficient amount of time
(about one hour) has passed after installation is completed.
The FIPG application procedure may vary on different areas. Observe the procedure described in the
text when applying the FIPG.

Snap Rings, Spacers and Thrust Plates
for Adjustment / Torque Specifications MANUAL TRANSMISSION
OVERHAUL –22B-9
Part namePart No. Identification symbol Thickness mm
Spacer
(For adj stment of center differential case
1.19LMD710456
(For adjustment of center differential case
preload)1.22GMD700271p
1.25MMD710457
1.28NMD710458
1.31EMD706574
Spacer
(For adj stment of center differential case pinion
0.6–MD748362
(For adjustment of center differential case pinion
backlash)0.7–MD748363
0.8–MD748364
0.9–MD748365
1.0–MD748366
1.1–MD748367
TORQUE SPECIFICATIONS
TRANSMISSION
ItemsNm {kgf
m}
Under cover mounting bolt6.9 {0.7}
Interlock plate bolt30 {3.1}
Clutch housing-transmission case mounting bolt44 {4.5}
Clutch release bearing retainer mounting bolt9.8 {1.0}
Control housing mounting bolt18 {1.9}
Shift cable bracket mounting bolt18 {1.9}
Speedometer gear mounting bolt3.9 {0.4}
Stopper bracket mounting bolt18 {1.9}
Select lever mounting bolt18 {1.9}
Select lever mounting nut11 {1.2}
Center differential drive gear mounting bolt132 {13.5}
Back-up lamp switch32 {3.3}
Poppet spring plug32 {3.3}
Reverse idler gear shaft mounting bolt48 {4.9}
Roll stopper bracket mounting bolt69 {7.0}

MANUAL TRANSMISSION OVERHAUL – Transmission22B-14
Apply gear oil to all
moving parts before
installation.
12
13 14
15
1617 18
1920
21
22 23
24
25 26
27
Unit: Nm {kgf
m}
18 {1.9}
30 {3.1}
48 {4.9}
3.9 {0.7} 44 {4.5}
Disassembly steps
12. Interlock plate bolt
13. Gasket

G14. Control housing
15. Neutral return spring

F16. Under cover
17. Reverse idler gear shaft bolt
18. Gasket
19. Reverse idler gear
E20. Transmission case
21. Outer race
22. Outer race

D23. Spacer

D24. Spacer

D25. Spacer
26. Oil guide
27. Oil guide