transmission MITSUBISHI LANCER EVOLUTION 2007 Service User Guide

GENERAL -How to Use This Manual00-4
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.
DRemoval steps:
The part designation number corresponds
to the number in the illustration to indicate
removal steps.
DDisassembly steps:
The part designation number corresponds
to the number in the illustration to indicate
disassembly steps.DInstallation steps:
Specified in case installation is impossible
in reverse order of removal steps. Omitted
if installation is possible in reverse order of
removal steps.
DReassembly steps:
Specified in case reassembly is impossible
in reverse order of disassembly steps.
Omitted if reassembly is possible in reverse
order of disassembly steps.
Classifications of Major Maintenance/Service Points
When there are major points relative to maintenance and servicing procedures
(such as essential maintenance and service points, maintenance and service stan-
dard values, information regarding the use of special tools, etc.), these are ar-
ranged together as major maintenance and service points and explained in detail.
AA": Indicates that there are essential points for removal or disassembly.
"AA: Indicates that there are essential points for installation or reassembly.
Symbols for Lubrication, Sealants and Adhesives
Information concerning the locations for lubrica-
tion and for application of sealants and adhe-
sives is provided, by using symbols, in the dia-
gram of component parts or on the page follow-
ing the component parts page, and explained.: Grease
(multipurpose grease unless there is
a brand or type specified)
: Sealant or adhesive
: Brake fluid or automatic transmission fluid
: Engine oil, gear oil or air conditioner
compressor oil
: Adhesive tape or butyl rubber tape
Component Diagram
A diagram of the component parts is
provided near the front of each section
in order to give a reader a better under-
standing of the installed condition of
component parts.

GENERAL -Vehicle Identification00-14
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.ItemContentsContents
1MODELCT9A
SNDFZL
CT9A: Vehicle model
SNDFZL
SNDFZL: Model series
2ENGINE4G63-DOHCEngine model
3EXTA37BExterior code
4TRANS
AXLEW5M51W5M51: Transmission code
5COLOR
INTOPT
A37
14H
A37: Body colour code
INTOPT14H
R1114H: Interior code
R11: Equipment code
For monotone colour vehicles, the body colour code shall
be indicated. For two-tone or three-way two-tone colour
vehicles, each colour code only shall be indicated in series.
MODELS
Model codeClass codeGradeEngine modelTransmission modelFuel supply
system
CT9ASNDFZL/RRS4G63 (1,997 mL-DOHC-
16valves intercoolerturbo)
W5M51 <4WD-5M/T>MPI
SNGFZL/RRS-II
16valves-intercoolerturbo)
1
2
3
4
5

GENERAL -Vehicle Identification00-15
MODEL CODE
No.ItemsContents
1DevelopmentCT: MITSUBISHI LANCER
EVOLUTION-VII
2Engine type9: 1,997 mL petrol engine
3SortA: Passenger car
4Body styleS: 4-door sedan
5Transmission typeN: 5-speed manual
transmission
6Trim levelD: RS
G: RS-IIor GSR
7Specification engine
featureF: MPI-DOHC-intercooler
turbo
8Special featureZ: 4WD
9Steering wheel locationL: Left hand
R: Right hand
123456789 CT 9 A S N D F L
Z

GENERAL -Vehicle IdentificationGENERAL -Vehicle Identification00-16
CHASSIS NUMBER
The chassis number is stamped on the toeboard inside the
engine compartment.
1
234
5
67
8911
10
No.ItemsContents
1Fixed figureJAsia
2Distribution channelMJapan channel
3DestinationYFor Europe and General Export
4Body styleS4-door sedan
5Transmission typeN5-speed manual transmission
6Development orderCTMITSUBISHI LANCER EVOLUTION-VII
7Engine94G63: 1,997 mL petrol engine
8SortAPassenger car
9Model year22002
10PlantUMIZUSHIMA-1
11Serial number--
ENGINE MODEL NUMBER
1. The engine model number is stamped on the cylinder
block as shown below.
Engine modelEngine displacement mL
4G631,997
2. The engine serial number is stamped near the engine
model number.
Engine serial numberAA0201 to YY9999

ENGINE -Special Tools11A-6
Tool UseName Number
MB991367Special spannerFor retaining the crankshaft sprocket
MB991385Pin
MB991704Battery harnessMeasuring the timing belt B tension
(used together with MUT-II)
MD998767Tensioner pulley
socket wrenchFor adjusting timing belt tension
MD998738Adjusting boltFor retaining the tensioner arm and the
auto-tensioner
MB991453Engine hanger
attachment
setSupporting the engine assembly during
removal and installation of the transmission
GENERAL
SERVICE
TOOL
MZ203827Engine lifter

ENGINE -Crankshaft Oil Seal11A-26
CRANKSHAFT OIL SEAL
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.
1 2
34 5
6
Engine oil
(at the lip)
(at the lip)
3
6
132±5 N·m
Crankshaft Front Oil Seal Removal
Steps
DTiming belt and timing belt B
(Refer to P.11A-34.)
"DA1. Crankshaft sprocket B
2. Key
"CA3. Crankshaft front oil sealCrankshaft Rear Oil Seal Removal
Steps
DTransfer assembly
(Refer to GROUP 22A.)
DTransmission assembly
(Refer to GROUP 22A.)
DClutch cover, disc
AA""BA4. Flywheel bolt
5. Flywheel
"AA6. Crankshaft rear oil seal

ENGINE -Engine Assembly11A-45
67±7 N·m*
23 33
24 29
3031
32
2722
98±10 N·m*5.0±1.0 N·m
(Engine oil)
20
21 19
25
42±2 N·m22±4 N·m
40±5 N·m
42±2 N·m
26
26
2834
22±4 N·m12±2 N·m
19. Brake booster vacuum hose
connection
20. Purge hose connection
21. Power steering oil pressure switch
connector
22. Heat protector
AB"23. Power steering oil pump, bracket and
oil reservoir assembly
24. A/C compressor connector

AB"25. A/C compressor
26. Engine oil cooler tube gasket
27. Engine oil cooler feed hose connection28. Engine oil cooler return hose
connection
29. Heater hose connection
30. Fuel return hose connection
"CA31. Fuel high pressure hose connection
"CA32. O-ring
DTransfer assembly
(Refer to Group 22.)
DTransmission assembly
(Refer to Group 22.)
AC""BA33. Engine mounting bracket and stopper
assembly
AD""AA34. Engine assembly

ENGINE -Engine Assembly11A-46
REMOVAL SERVICE POINTS
AA"DRIVE BELT REMOVAL
Due to the adoption of the Serpentine drive system with the
auto-tensioner, the following operation is required:
1. Insert the 12.7sq. spinner handle into the tool hole of
the auto-tensioner and rotate it counterclockwise until
the auto-tensioner reaches to the stopper.
2. Align hole A with hole B for fixing by inserting the L
shaped-hexagon wrench, then remove the drive belt.
Caution
When the drive belt is reused, use a chalk to indicate
an arrow of rotation direction on the back of the belt
so that it can be re-assembled in the same direction
as before.
AB"POWER STEERING OIL PUMP, BRACKET AND
OIL RESERVOIR ASSEMBLY / A/C COMPRESSOR
REMOVAL
Remove the power steering oil pump, bracket, oil reservoir
and A/C compressor with the hose attached from the bracket.
NOTE
Tie the removed oil pump and A/C compressor with a rope
and set aside where they cannot hinder the removal of the
engine assembly.
AC"ENGINE MOUNTING BRACKET AND STOPPER
ASSEMBLY REMOVAL
1. Support the engine with a garage jack.
2. Remove special tool (MZ203827).
(Tool used for removal of transmission assembly)
3. Hold the engine assembly with a chain block.
4. Support the engine oil pan with a garage jack via a block
of wood cut without applying the weight of the engine
and remove the engine mounting bracket and stopper
assembly.
Bore A
L-shaped
hexagon
wrench
Bore B
MZ203827
MB991453
MB991453

ENGINE -Engine Assembly11A-47
AD"ENGINE ASSEMBLY REMOVAL
After checking that all the cables, hoses, and harness
connectors have been disconnected, lift the engine with a
chain block slowly and remove the engine assembly located
at the upper engine room.
INSTALLATION SERVICE POINTS
"AAENGINE ASSEMBLY INSTALLATION
Install the engine assembly while checking that none of cables,
hoses, or harness connectors, etc. has been engaged.
"BAENGINE MOUNTING BRACKET AND STOPPER
ASSEMBLY INSTALLATION
1. Support the engine oil pan with a garage jack via a block
of wood cut adjusting the engine position and install the
engine mounting bracket and stopper assembly. Position
the engine mounting stopper so that a mark indicated
by an arrow can face the direction shown in the illustration.
2. Support engine with garage jack.
3. Remove the chain block and hold the engine assembly
with the special tool.(Tool used for removal of transmission
assembly)
"CAO-RING/FUEL HIGH PRESSURE HOSE
INSTALLATION
1. Apply small quantity of new engine oil on O-ring.
Caution
Do not let engine oil get into the delivery pipe.
2. Install the fuel high pressure pipe to the delivery pipe
rotating in both directions without damaging the O-ring
and check that it rotates smoothly.
3. In case of not rotating smoothly, remove the fuel high
pressure hose and insert it to the delivery pipe again
after checking damage of the O-ring since there is a
possibility of O-ring engagement.
4. Tighten fuel high pressure hose mounting bolt to the
specified torque.
Tightening Torque: 5.0±1.0 N·m
Engine mounting stopper
Engine side

Engine side

MPI -Troubleshooting13A-102
DATA LIST REFERENCE TABLE
NOTE
*1. In a new Vehicle [driven approximately 500 km or less], the air flow sensor output frequency time
is sometimes 10% longer than the standard time.
*2. The injector drive time represents the time when the cranking speed is at 250 r/min or below when
the power supply voltage is 11 V.
*3. In a new vehicle [driven approximately 500 km or less], the injector drive time is sometimes 10%
longer than the standard time.
*4. In a new vehicle [driven approximately 500 km or less], the step of the stepper motor is sometimes
30 steps greater than the standard value.
Item
No.Inspection
itemInspection contentsNormal conditionInspection
procedure
No.Reference
page
11Oxygen
sensor
(front)Engine: After having
warmed up
(Air/fuel mixuture is
made leaner whenWhen at 4,000 r/min,
engine is suddenly de-
celerated200 mV or lessCode No.
P013013A-24
madeleanerwhen
decelerating, and is
made richer when rac-
ing.)When engine is sud-
denly raced600 - 1,000 mV
Engine: After having
warmed up
(The oxygen sensor
(front) signal is used
tochecktheair/fuel
Engine is idling400 mV or less↔
600 - 1,000 mV
(Varies)
to check the air/fuel
mixture ratio, and
control condition is
also checked by the
engine-ECU.)2,500 r/min
12Air flow
sensor*1DEngine coolant
temperature:
Idle operation17 - 43 Hz--
sensor*1temperature:
80 - 95_C
DLightningandall
2,500 r/min40 - 100 Hz
DLightning andall
accessories:
OFF
DTransmission:
NeutralAccelerationAccording to ac-
celeration, fre-
quency is ampli-
fied.
13Intake air
temperature
sensor
Ignition switch: “ON”
or engine runningWhen intake air temper-
ature is - 20_C-20_CCode No.
P011013A-13
sensorWhen intake air tem-
perature is 0_C0_C
When intake air tem-
perature is 20_C20_C
When intake air tem-
perature is 40_C40_C
When intake air tem-
perature is 80_C80_C