MITSUBISHI LANCER EVOLUTION 2007 Service Repair Manual

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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 ......................
Wheel and Tyre .................
Power Plant Mount ..............
Front Suspension ...............
Rear Suspension ...............
Service Brakes .................
Parking Brakes .................
Steering ........................
Body ...........................
Exterior ........................
Chassis Electrical ..............
Electrical Wiring ................
Body Repair ....................
WORKSHOP
MANUAL
FOREWORD
This Workshop Manual contains procedures for
service mechanics, including removal, disassembly,
inspection, adjustment, reassembly and
installation. Use the following manuals in
combination with this manual as required.
TECHNICAL INFORMATION MANUAL N0104CT9A
All information, illustrations and product
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 matters on the
EVOLUTION-VII should be inquired to RALLIART
Inc. as usual.
EMitsubishi Motors Corporation May 2001
Interior and Supplemental
Restraint System (SRS) ........
Heater, Air Conditioner and
Ventilation .....................

WARNING REGARDING SERVICING OF SUPPLEMENTAL
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 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.
NOTE
Section titles with asterisks (*) in the table of contents in each group indicate operations requiring warnings.

A-1
BODY
CONSTRUCTION
CONTENTS
BODY COMPONENTS 2...................
BODY MAIN CROSS-SECTIONAL VIEWS 4.
MAINTENANCE, SERVICEABILITY 6........
BODY CONSTRUCTION
CHARACTERISTICS 8.....................
FRONT BODY 8...........................
SIDE BODY 13.............................
REAR BODY 15............................
ROOF 16...................................UNDER BODY 17...........................
DOOR 20..................................
SILENCER APPLICATION LOCATIONS 21..
LOCATIONS USING URETHANE FOAM
AND FOAM
MATERIAL 22.............................
STIFFENER AND DUMP SHEET
APPLICATION
LOCATIONS 24............................

BODY CONSTRUCTION -Body ComponentsA-2
BODY COMPONENTS
1 2 3 45 6789
10
11 1 213 14 15 1617
18
1921
20 22 232425 262728
29 303132
333536
37
38
39
4041
42
43
44
4546
47484950
5152
53
54
55
56 58
57
59
60 61
6263
64
65
66 7071727374
6869
: High-tensile steel panels : Anticorrosion steel plates
67
75 34
76
77
78 79
80 81

BODY CONSTRUCTION -Body ComponentsA-3
1. Headlamp support panel
2. Hood lock stay
3. Front end crossmember
4. Front end upper bar
5. Headlamp support panel side
6. Front fender shield
7. Front upper frame inner
8. Upper frame bulkhead front
9. Upper frame bulkhead
10. Upper frame bulkhead rear
11. Front sidemember inner
12. Engine mount bracket
13. Front sidemember rear
14. Front sidemember outer
15. Spring house panel
16. Dash panel
17. Dash panel silencer
18. Dash panel reinforcement
19. Upper frame to front pillar brace
20. Upper frame extension outer
21. Upper frame extension inner
22. Cowl top lower panel
23. Cowl top inner panel
24. Cowl top upper panel
25. Front deck crossmember
26. Hood inner panel
27. Hood outer panel
28. Front roof rail
29. Front roof bow
30. Roof panel
31. Rear roof bow
32. Rear roof rail
33. Seat back plate
34. Rear seat back panel
35. Rear shelf panel
36. Rear seat back brace
37. Trunk lid outer panel
38. Trunk lid inner panel
39. Trunk lid hinge
40. Quarter inner extension rear
41. Quarter corner panel42. Rear combination lamp housing
43. Side roof rail inner
44. Front pillar inner upper
45. Front pillar inner lower
46. Center pillar inner
47. Side outer panel
48. Rear wheel house inner panel
49. Quarter inner panel
50. Rear floor side brace
51. Quarter outer extension lower
52. Fuel filler door
53. Rear license plate bracket
54. Rear end panel outer
55. Rear end panel inner
56. Rear door outer panel
57. Rear door side door beam
58. Rear door inner panel
59. Front door outer panel
60. Front door side door beam
61. Front door inner panel
62. Fender panel
63. Front floor crossmember rear
64. Front floor crossmember front
65. Front floor side sill inner
66. Front floor sidemember
67. Backbone reinforcement
68. Installment panel center bracket reinforcement
69. Front floor pan
70. Front floor extension panel rear
71. Rear floor extension
72. Rear floor pan
73. Seat back plate extension
74. Jack bracket
75. Spare tire bracket
76. Towing hook reinforcement
77. Rear floor sidemember extension
78. Crossmember center support
79. Rear floor crossmember
80. Rear floor sidemember
81. Rear seat back reinforcement

BODY CONSTRUCTION -Body Main Cross-sectional Views
ARoof panel
Map lamp
bracket
Front roof railB
Side
outer
panel
Front pillar
reinforcement upper
Side roof
rail inner Roof panel
CCowl top
upper
panel
Cowl top
inner panel Cowl top
lower panel
Front end crossmember
reinforcement
Front
end
cross-
member
inner
Front end
crossmember
outer
D
EFront pillar reinforcement
lower
Front pillar
inner lower
Side outer panel
F
Side outer
panel Front floor
side sill inner
Side sill
reinforcement
supportSide sill
outer
reinforce-
ment cen-
ter
A-4
BODY MAIN CROSS-SECTIONAL VIEWS
C
AB
D
EF

BODY CONSTRUCTION -Body Main Cross-sectional Views
GFront pillar
inner upperFront pillar rein-
forcement upper
Side outer panelH
Rear roof railRoof panel
I
Center pillar
reinforcement
Center pillar
seatbelt
reinforcement Center pillar
inner
Side
outer
panelRear pillar
innerJ
Side outer
panel
K
Rear wheel
house inner
panel Side
outer
panel
Quarter
inner panel
Rear end
panel
outer
L
Rear end
panel inner
A-5
G
H
I
J
K
L

BODY CONSTRUCTION -Maintenance, ServiceabilityA-6
MAINTENANCE, SERVICEABILITY
Fender Shield
Positioning holes, marks, and notches have been provided at the following overlapped areas to improve
operation performance when replacing panels.

BODY CONSTRUCTION -Maintenance, ServiceabilityA-7
Side Structure
Panel positioning notches have been provided at the door opening section to improve operation performance
when replacing panels.
Panel positioning notch
Side Outer Panel
Spare parts are provided in the following cut form with the adoption of the pillar integral type side outer
panel.
Front pillar outerCenter pillar outer
Quarter outer
Side sill outer

BODY CONSTRUCTION -Body Construction CharacteristicsA-8
BODY CONSTRUCTION CHARACTERISTICS
FRONT BODY
Headlamp Support
1. By adopting a steel sheet with variable thickness* for the front end crossmember outer, the steel
sheet thickness on the right side of the vehicle has been increased to improve safety in collision
and body rigidity.
NOTE
*: Steel sheets with different thickness welded to formone steel sheet.
1
2 3
4 10 9
8765
1. Front end upper bar
2. Headlamp support panel
3. Hood lock stay
4. Front end crossmember inner reinforcement
5. A/C condenser bracket6. Radiator bracket
7. Front end crossmember inner
8. Front end crossmember outer
9. Shipping hook
10. Front end crossmember reinforcement