tow MITSUBISHI LANCER EVOLUTION 2007 Service User Guide

MPI -Engine Control Resistor, Relay13A-146
ENGINE CONTROL RESISTOR, RELAY
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
DStrut Tower Bar Removal and Installation (Refer to GROUP 42.)
DHarness Connector Connection
213
4
5.0¶1.0 N·m
5.0±1.0N·m5.0±1.0N·m
2.5±0.5N·m
5.0±1.0N·m
AYC relay
4 2
5.0±1.0N·m
5.0±1.0N·mAYC relay5.0±1.0N·m5.0±1.0N·m
2.5±0.5N·m13


Removal steps
DAYC relay
1. Fuel pump relay
2. Injector resistor
3. Bracket
4. Fuel pump resistor

INTAKE AND EXHAUST -Secondary Air Supply System15-14
SECONDARY AIR SUPPLY SYSTEM
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
DAir Duct Removal and Installation (Refer to P.15-8.)
DStrut Tower Bar Removal and Installation (Refer to GROUP 42.)
1
2 34
5
49±5 N·m14±1 N·m 22±4 N·m
14±1 N·m 14±1 N·m 20±2 N·m
6
8 9 10
22±4 N·m24±3 N·m23±4 N·m
11±1 N·m Air pipe C 5.9±1.0 N·m
7
7 11
Removal steps
1. Control harness connector
connection
2. Heat protector
3. Vacuum hose connection
DAir pipe C (Refer to P.15-9.)
4. Vacuum pipe
5. Secondary air hose6. Secondary air pipe assembly
"AA7. Gasket
"BA8. Gasket
9. Secondary air control valve
10. Engine hanger
11. Secondary air control valve bracket

INTAKE AND EXHAUST -Secondary Air Supply System15-15
INSTALLATION SERVICE POINTS
"AAGASKET INSTALLATION
Install the gasket so that its salient can face towards the
direction as shown in the illustration.
"BAGASKET INSTALLATION
Install the gasket so that its protrusion can face towards the
direction as shown in the illustration.
Salient
Secondary air pipe assembly
Protrusion

INTAKE AND EXHAUST -Intake Manifold15-16
INTAKE MANIFOLD
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
DAir Duct Removal and Installation (Refer to P.15-8.)
DStrut Tower Bar Removal and Installation
(Refer to GROUP 42.)
DUnder Cover Removal and Installation
(Refer to GROUP 51 - Front Bumper.)
DEngine Coolant Draining and Supplying
(Refer to GROUP 14 - On-vehicle Service.)
DThrottle Body Removal and Installation (Refer to
GROUP 13A - Throttle Body.)DCrossmember Bar Removal and Installation (Refer
to GROUP 32 - Engine Roll Stopper, Centermember.)
DFront Exhaust Pipe Removal and Installation (Refer
to GROUP 15 - Exhaust Pipe and Main Muffler.)
DSecondary Air Control Valve Bracket Removal and
Installation (Refer to P.15-14.)
DEngine Oil Draining and Supplying
1
2
3 4
5 6 7
8 10
11
1214
13
15
16 17
18
9
11±1 N·m3.0±0.5 N·m
13±1 N·m
(Engine oil)
(Engine oil) 5.0±1.0 N·m
14 8
Removal steps
1. Center cover
2. Oxygen sensor connector
connection
3. Injector connector connection
4. Fuel pressure solenoid valve
connector connection
5. Purge control solenoid valve
connector connection
6. Knock sensor connector connection
7. Vacuum hose connection
8. Vacuum hose
9. Fuel return hose connection"AA10. Fuel high-pressure hose connection
11. O-ring
AA"12. Delivery pipe, Injector and fuel
pressure regulator assembly
13. Insulator
14. Insulator
15. Oil level gauge and guide
16. O-ring
17. Brake booster vacuum hose
connection
18. Purge hose connection

INTAKE AND EXHAUST -Exhaust ManifoldINTAKE AND EXHAUST -Exhaust Manifold15-20
REMOVAL SERVICE POINT
AA"OXYGEN SENSOR REMOVAL
Use special tool to remove the oxygen sensor.
AB"OIL FEED PIPE REMOVAL
Take care not to let foreign objects get into the oil passage
hole of the turbocharger after the oil feed pipe is removed.
INSTALLATION SERVICE POINT
"AATURBOCHARGER INSTALLATION
1. Clean the oil feed pipe, oil return pipe, water pipe fitting,
the inside of eye bolt, and individual pipe for clogs.
2. Clean or blow the air if carbon particles are stuck to the
oil passage of the turbocharger.
Caution
Take care not to let foreign objects get into the
turbocharger.
3. Refill new engine oil at the oil feed pipe fitting hole of
the turbocharger.
"BAAIR OUTLET FITTING GASKET INSTALLATION
Install the gasket so that its protrusion can face towards the
direction as shown in the illustration.
MD998770
Oxygen sensor
View A
View A
TurbochargerProtrusion

INTAKE AND EXHAUST -Exhaust Manifold15-21
"CAOIL RETURN PIPE GASKET INSTALLATION
Install the gasket so that its print part can face towards the
oil pan side.
INSPECTION
Check the following points; replace the part if a problem is
found.
1. EXHAUST MANIFOLD CHECK
(1) Check for damage or cracking of any part.
(2) Using a straight edge and a feeler gauge, check for
distortion of the cylinder head installation surface.
Standard value: 0.15 mm or less
Limit: 0.20 mm
2. TURBOCHARGER ASSEMBLY CHECK
(1) Visually check the turbine wheel and the compressor
wheel for cracking or other damage.
(2) Check whether the turbine wheel and the compressor
wheel can be easily turned by hand.
(3) Check for oil leakage from the turbocharger assembly.
(4) Check whether or not the waste gate valve remains open.
If any problem is found, replace the part after disassembly.
Gasket
Print
Compressor wheel

ENGINE ELECTRICAL -Charging System16-10
EXAMPLES OF ABNORMAL WAVEFORMS
NOTE
1. The size of the waveform patterns differs largely, depending on the adjustment of the variable knob
on the analyzer.
2. Identification of abnormal waveforms is easier when there is a large output current (regulator is not
operating). (Waveforms can be observed when the headlamps are illuminated.)
3. Check the conditions of the charging warning lamp (illuminated/not illuminated). Also, check the charging
system totally.
Abnormal waveformsProblem
causeAbnormal waveformsProblem
cause
Example 1Open diodeExample 4Short in
stator coil
Example 2Short in diodeExample 5Open
supplementa-
ry diode
Example 3Broken wire
in stator coil
At this time, the charging warning lamp
is illuminated.
ALTERNATOR
REMOVAL AND INSTALLATION
Caution
If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to contact
the parts or tools to the caliper because the paint of caliper will be scratched.
Pre-removal and Post-installation Operation
DUnder Cover Removal and Installation (Refer to GROUP 51 - Front Bumper.)
DDrive Belt Tension Check (Refer to GROUP 11A - On-vehicle Service.)
DStrut Tower Bar Removal and Installation (Refer to GROUP 42.)
DCrossmember Bar Removal and Installation (Refer to GROUP 32 - Engine Roll Stopper, Centermember.)
DFront Exhaust Pipe Assembly Removal and Installation (Refer to GROUP 15.)

MANUAL TRANSMISSION - Transmission Control22A-46
TRANSMISSION CONTROL
REMOVAL AND INSTALLATION
Pre-removal Operation
DStrut Tower Bar Removal and Installation (Refer
to GROUP 42.)
DAir Cleaner Removal (Refer to GROUP 15.)
DBattery and Battery Tray Removal
DAir Pipe C, Air By-pass Hose, Air Hose D, Air Hose
E, and Air Hose A Removal (Refer to GROUP 15
- Intercooler.)Caution: SRS
Be careful not to subject the SRS-ECU to any
shocks during removal and installation of the
shift cable and select cable assembly.
12±2 N·m
34
21
5 6
7 8
6 910
12±2 N·m
11
Shift cable and select cable
assembly removal steps
1. Shift knob
DFront floor console
(Refer to GROUP 52A)
2. Snap pin
3. Select cable connection
(Shift lever side)
4. Clip
5. Shift cable connection
(Shift lever side)
6. Snap pin
AA""AA7. Clip
AA""AA8. Select cable connection
(Transmission side)
AA""AA9. Shift cable connection
(Transmission side)
"AA10. Shift cable and Select cable assem-
blyShift lever assembly removal steps
1. Shift knob
DFront floor console
(Refer to GROUP 52A)
2. Snap pin
3. Select cable connection
(Shift lever side)
4. Clip
5. Shift cable connection
(Shift lever side)
11. Shift lever assembly

MANUAL TRANSMISSION - Transfer Assembly22A-49
TRANSFER ASSEMBLY
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
DUnder Cover Removal and Installation (Refer to GROUP 51 - Front Bumper.)
DSide Under Cover Removal and Installation
DTransmission Oil Draining and Supplying (Refer to P.22A-40.)
DTransfer Oil Draining and Supplying (Refer to P.22A-40.)
DEngine Coolant Draining and Supplying (Refer to GROUP 14 - On-vehicle Service.)
DCrossmember Bar Removal and Installation (Refer to GROUP 32 - Engine Roll Stopper, Centermember.)
DFront Exhaust Pipe Removal and Installation (Refer to GROUP 15 - Exhaust Pipe and Main Muffler.)
DBattery and Battery Tray Removal and Installation
DAir Cleaner, Air Intake Hose Removal and Installation (Refer to GROUP 15 - Air Cleaner.)
DSecondary Air Hose Removal and Installation (Refer to GROUP 15 - Secondary Air Control System.)
DStrut Tower Bar Removal and Installation (Refer to GROUP 42.)
DAir Hose E, Air By-pass Hose and Air By-pass Valve, Air Pipe C, Air Hose D, Air Pipe B, Air Hose A Removal and
Installation (Refer to GROUP 15 - Intercooler.)
DRadiator Removal and Installation (Refer to GROUP 14.)
DBleeding and Hydraulic Pressure Check (Refer to P.22A-42, 43)
12 3
4
5 6 7
8
25±5 N·m
108±10 N·m
39±5 N·m
39±5 N·m
245±29 N·m
Removal steps
1. Stabilizer bar connection
2. Stabilizer link
3. Wheel speed sensor cable clamp
and brake hose clampAA"4. Tie rod end connection
5. Lower arm ball joint connection
AB"6. Drive shaft connection
AB"7. Drive shaft connection
AC"8. Output shaft

MANUAL TRANSMISSION - Transfer Assembly22A-51
AB"DRIVE SHAFT /DRIVE SHAFT
DISCONNECTION
1. As shown in the figure, pull out the transfer shaft
from the transmission using the pry bar. As shown in
the illustration, press a hammer, etc. against the driveshaft
, and pull out the driveshaft from the transfer
assembly using the pry shaft.
Caution
As the TJ may damage when the driveshaft is pulled
out from the BJ side, be sure to use the lever.
2. Cover with a cloth to prevent foreign particles from entering
the transfer.
AC"OUTPUT SHAFT REMOVAL
1. Using the special tool (MB991721), remove the output
shaft.
2. Cover with a cloth to prevent foreign particles from entering
the transmission case.
AD"TRANSFER ASSEMBLY REMOVAL
With the engine mount and transmission mount installed,
roll the engine and transmission assembly towards the front
of the vehicle, and remove the transfer assembly from between
the engine block and crossmember.
Transmission
side
Pry bar
Pry barHammer
Protrusion


MB991721
Output shaft
Engine and
transmission
assembly
Transfer assembly
Front of the vehicle