oil MITSUBISHI LANCER EVOLUTION 2007 Service Repair Manual

ENGINE ELECTRICAL -Ignition System16-35
CAMSHAFT POSITION SENSOR
REMOVAL AND INSTALLATION
1 2
3
8.8±1.0 N·m
Removal steps
1. Camshaft position sensor connector
2. Camshaft position sensor
3. O-ring
CRANK ANGLE SENSOR
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
DCenter Cover Removal and Installation (Refer to GROUP 11A - Camshaft and Camshaft Oil Seal.)
DTiming Belt Removal and Installation (Refer to GROUP 11A.)
DReserve Tank Removal and Installation (Refer to GROUP 14 - Radiator.)

ENGINE ELECTRICAL -Ignition System16-36
12
3
8.8±1.0 N·m
4 5
6 7
8.8±1.0 N·m49±9 N·m
49±9 N·m40±5 N·m 12±2 N·m
22±4 N·m
22±4 N·m
12±2 N·m
22±4 N·m
Removal steps
1. Power steering oil pressure switch
connector
2. Heat protector
AA"3. Power steering oil pump, bracket and
oil reservoir assembly4. Power steering oil pump bracket
5. Crank angle sensor connector
6. Crank angle sensor
7. Connector bracket
REMOVAL SERVICE POINT
AA"POWER STEERING OIL PUMP, BRACKET AND
OIL RESERVOIR ASSEMBLY REMOVAL
Remove the power steering oil pump, bracket and oil reservoir
assembly with the hose attached from the bracket.
NOTE
Tie the removed oil pump with a rope and set aside where
they cannot hinder the removal of the power steering oil pump
bracket.

ENGINE AND EMISSION CONTROL -Emission Control System17-5
SERVICE SPECIFICATIONS
ItemsStandard value
Purge control solenoid valve coil resistance (at 20_C)Ω30 - 34
EGR control solenoid valve coil resistance (at 20_C)Ω29 - 35
VACUUM HOSE
VACUUM HOSE PIPING DIAGRAM
Fuel
pressure
control
solenoid
valve
Oxygen
sensor
(front)
Check
valve
Fuel
pressure
regulator
PCV valve To
fuel tank
Oxygen sensor (rear) From
fuel pump
Air
inletEGR control
solenoid valve
Purge
control
solenoid
valveCanisterFrom
fuel tank
EGR
valve Injector
Three - way
catalytic converter A
P
E

CLUTCH OVERHAUL -Clutch21B-5
INSPECTION
CLUTCH COVER
(1) Check the pressure plate surface for wear, cracks or
discoloration.
(2) Check the strap plate rivet for looseness. If loose, replace
the clutch cover.
CLUTCH DISC
Caution
Do not wash the clutch disc with cleaning oil.
(1) Check the facing for decomposition caused by rivet
looseness, single-side contact or seizure, and check for
the presence of grease. If any fault is found, replace
the clutch disc.
(2) Measure the rivet sinking level, and replace the clutch
disc if the limit is exceeded.
Limit value: 0.3 mm
(3) Check the torsion spring for play and breakage. If faulty,
replace the clutch disc.
(4) Set the clutch disc onto the input shaft, and check the
sliding state and for play in the rotation direction. If the
sliding state is poor, wash the disc, reassemble and then
check the state again. If there is extreme play, replace
the clutch disc or input shaft or both parts.
CLUTCH RELEASE BEARING
Caution
Grease is filled in the release bearing, so do not wash with
washing oil.
(1) Check the bearing for seizure, damage, abnormal noise
or improper rotation.
(2) Check that the pull ring of the release bearing is not
worn.
(3) If the surface where the bearing contacts the release
fork is abnormally worn, replace the bearing.
RELEASE FORK AND RELEASE FORK SHAFT
(1) If the surface where the release fork contacts the bearing
is abnormally worn, replace the release fork.
(2) Check the release fork shaft for bending and wear. If
any abnormality is found, replace the release fork shaft.

22A-2
MANUAL
TRANSMISSION
CONTENTS
GENERAL 3.................................
Outline of Changes 3...........................
GENERAL INFORMATION 3..................
SERVICE SPECIFICATION 3..................
LUBRICANTS 3..............................
SPECIAL TOOLS 4...........................
TROUBLESHOOTING 5...............
ON-VEHICLE SERVICE 40....................
Transmission Oil Check 40......................
Transmission Oil Replacement 40................
Transfer Oil Check 40..........................
Transfer Oil Replacement 40....................
Fluid Check ACD and AYC> 41.............................
Bleeding ACD and AYC> 42.............................ACD Operation Check vehicles with ACD and AYC> 42................
Hydraulic Pressure Check vehicles with ACD and AYC> 43................
Wheel Speed Sensor Output Voltage
Measurement ACD and AYC> 44.............................
TRANSMISSION CONTROL* 46...............
TRANSFER ASSEMBLY 49...................
TRANSMISSION ASSEMBLY 52...............
4WD-ECU VEHICLES WITH ACD AND AYC> 55.........
SENSOR, SWITCH AND RELAY WITH ACD OR VEHICLES WITH ACD AND
AYC> 56.....................................
HYDRAULIC UNIT Refer to GROUP27B.......
WARNING REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM (SRS) EQUIPPED VEHICLES
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 driver and passenger (from rendering
the SRS inoperative).
(2) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized
MITSUBISHI dealer.
(3) 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 component of the SRS or any SRS-related
component.
NOTE
The SRS includes the following components: SRS-ECU, SRS warning lamp, air bag module, clock spring, and interconnecting
wiring. Other SRS-related components (that may have to be removed/installed in connection with SRS service or maintenance) are
indicated in the table of contents by an asterisk (*).

MANUAL TRANSMISSION -General/General Information/
Service Specification/Lubricants22A-3
GENERAL
OUTLINE OF CHANGE
With the addition of the EVOLUTION-VII, the W5M51 transmission service adjustment procedure has
been set as follows.
GENERAL INFORMATION
ItemsSpecifications
GradeRS, RS IIRS, RS II (With super cross gear)
Transmission modelW5M51
Engine model4G63-DOHC-T/C
Type5-speed, floor-shift
Gear ratio1st2.7852.785
2nd1.9501.950
3rd1.4071.444
4th1.0311.096
5th0.7200.825
Reverse3.4163.416
Final reduction ratio
(Differential gear ratio)4.5294.529
Front limited-slip differential
(Helical-gear type)Not providedProvided
TransferReduction ratio3.3073.307
Limited-slipdifferentialVCU or hydraulic multi plate
clutch (ACD)VCU or hydraulic multi plate
clutch (ACD)
SERVICE SPECIFICATION
ItemStandard value
Hydraulic unit generation oil pressureMPa1.0 - 1.6
LUBRICANTS
ItemSpecified lubricantQuantity L
Transmission oilGear oil SAE 75W-90 or 75W-85W conforming to API GL-42.8
Transfer
oilVehicles without ACD or ve-
hicles without ACD and AYCMITSUBISHI Genuine Gear Oil Part No.8149630 EX,
CASTROL HYPOY LS (GL-5, SAE 90), SHELL-LSD
(GL 5SAE80W90)orequivalent
0.55
Vehicles with ACD or vehicles
with ACD and AYC(GL-5, SAE 80W - 90) or equivalent0.6
FluidPiping between ACD and
hydraulic unitDIA QUEEN ATF SP III0.9
Pipes between ACD and hy-
draulic unit and between AYC
and hydraulic unit1.0

MANUAL TRANSMISSION - Special Tools22A-4
SPECIAL TOOLS
ToolNumberNameUse
MB991502MUT-IISub as-
semblyDiagnosis code checking
MB991529Diagnosis code
checking harness
MB991348Test harness setGsensor check
MD998330
(including
MD998331)Oil pressure gauge
(3.0 MPa)Hydraulic pressure measurement
MB991705Adapter
MB990635,
MB991113 or
MB991406
Steering linkage
pullerTie rod end and lower disconnection
GENERAL
SERVICE
TOOL
MZ203827Engine lifterSupporting the engine assembly during
removal and installation of the transmission
MB991453Engine hangerat-
tachment set
MB991721Slide hammerOutput shaft removal

MANUAL TRANSMISSION - Troubleshooting MANUAL TRANSMISSION - Troubleshooting 22A-29
Code No.74 Proportional valve systemProbable cause
Code No.74 is output when open circuit or short circuit of the control circuit of
the proportional valve has occurred.DProportional valve fault
DHarness or connector fault
D4WD-ECU fault
OK
OK
OK
Replace the hydraulic unit.NG
NG
MUT-IIData List
DNo.11 Proportional valve current
OK:Refer to P.22A-35 (Data List Reference Table).
OK→Intermittent malfunction (Refer to GROUP 00 - Points to
Note for Intermittent Malfunctions)
MUT-IIData List
DNo.11 proportional valve current
OK:Refer to P.22A-35 (Data List Reference Table).
NG→Replace the 4WD-ECU.
OK→Intermittent malfunction (Refer to GROUP 00 - Points to
Note for Intermittent Malfunctions)
OK
Measure at proportional valve connector F-27.
DDisconnect the connector, and measure at the proportional
valve.
DResistance between terminals 2 and 3.
OK:Below 4.7Ω
Measure at proportional valve connector F-27.
DDisconnect the connector and measure at the harness
side.
DResistance between terminal 2 and body earth.
OK:2Ωor less
Check the harness between the proportional valve and
body earth.
DCheck for open circuit and damage of the earth line.
NG→Repair
Check the following connectors:F-27, F-24
NG→Repair
OK
Check the following connectors:
F-27, F-24, C-134, C-130, C-44
F-27, F-24, C-134, C-44
NG→Repair
OK
Check the harness between the 4WD-ECU and proportional
valve .
DCheck for open circuit, ground, and damage of the output
line.
NG→Repair
Code No.81 Electric pump relay systemProbable cause
Output when the coil circuit of the electric pump relay has open circuited or
short circuited.DElectric pump relay fault
DHarness or connector fault
D4WD-ECU fault
OK
OK
NG
Replace the electric pump relay.NG
NG
MUT-IIActuator Test
DNo.12 Electric pump drive
OK:The operating sound of the electric pump can be
heard.
OK→Intermittent malfunction (Refer to GROUP 00 - Points to
Note for Intermittent Malfunctions)
OK
Check the harness between the electric pump relay and body
earth.
DCheck for open circuit and damage of the earth line.
NG→Repair
Check the following connector:B-139
NG→Repair
OK
Check the following connectors:
B-139, C-44
B-139, C-147, C-44
NG→Repair
Check the electric pump relay. (Refer to P.22A-57.)
Measure at electric pump relay connector B-139.
DDisconnect the connector and measure at the harness
side.
DResistance between terminal 1 and body earth
OK:2Ωor less
MUT-IIActuator Test
DNo.12 Electric pump drive
OK:Operating sounds of the electric pump can be heard.
NG→Replace the 4WD-ECU.
OK→Intermittent malfunction (Refer to GROUP 00 - Points to
Note for Intermittent Malfunctions)
OK
Check the harness between the 4WD-ECU and electric pump
relay.
DCheck for open circuit, short circuit, and damage of the
power line.
NG→Repair

MANUAL TRANSMISSION - Troubleshooting 22A-34
Inspection procedure 4
More than two ACD mode indicator lamps remain lit even
after the engine starts
Probable cause
The output circuit of the ACD mode indicator lamp may be faulty.DHarness or connector fault
D4WD-ECU fault
DACD mode indicator lamp assembly fault
NOTE
This phenomenon occurs only when communication with the MUT-IIis possible (4WD-ECU power supply
fault) and at the same time, no diagnostic code (no trouble code) is output.
NO
Replace the 4WD-ECU.
Do all the ACD mode indicator lamps go off when 4WD-ECU
connector C-43 is disconnected?
YES
Replace the ACD mode indicator lamp assembly.OK
NG
Check the trouble symptoms.
Check the following connectors:
C-43, C-128, C-01
C-43, C-01
NG→Repair
OK
Check the harness between the ACD mode indicator lamp
assembly and 4WD-ECU.
DCheck for ground and short circuit of output line.
NG→Repair
Inspection procedure 5
ACD does not operate (No diagnosis code)
Probable cause
Insufficient operating oil, oil leakage, faulty operations of the oil pressure unit, and
faulty operations of the ACD transfer may be suspected.DLeakage of transfer oil
DInsufficient transfer oil
DLeakage of oil pressure line
DInsufficient fluid
DHydraulic unit fault
DACD transfer fault
NOTE:
1. This malfunction is restricted to only when no diagnostic code (no trouble code) is output.
2. *: Refer to GROUP 22B.
OK
NG OKNG OKNG
NG
NO
NG
OK
Replenish transfer oil.
Replace the oil pressure unit.
Have foreign particles mixed into the oil pressure line?
YES→Repair
Check the hydraulic pressure (P.22A-43).Perform bleeding (P.22A-42).
Check the fluid (P.22A-41).Check for leakage of the oil pressure line.
NG→Repair
Check the transfer oil (P.22A-40).Check for leakage of the transfer oil.
NG→Repair
Check the trouble symptoms.
Replace the ACD transfer.*OK
Replenish the fluid.
OK
NG
Check the operations of the ACD (P.22A-42).Check the trouble symptoms.

MANUAL TRANSMISSION - Troubleshooting 22A-36
Item
no.Normal conditions Check condition Check item
19Pressure sensor power
supplyIgnition switch: ONApprox.5 V
20Valve power supplyIgnition switch: ONSystem voltage
21Steering wheel sensor
voltage Ignition switch: ONSteering wheel: Turn1 - 2 V and 2.5 - 4.5 V
are displayed alter-
nately.
22Steering wheel sensor
voltage Ignition switch: ONSteering wheel: Turn1 - 2 V and 2.5 - 4.5 V
are displayed alter-
nately.
23Steering wheel sensor
ltSTN
Ignition switch: ONSteering wheel: Neutral1-2Vg
voltage
g
Steering wheel: Turn2.5 - 4.5 V
51Idle switchIgnition switch: ONAccelerator pedal: Full
closedON
Accelerator pedal: PressOFF
52Steering wheel sensor
STN
Ignition switch: ONsteering wheel: NeutralONg

g
Steering wheel: Turn from
the neutral positionOFF
53Steering wheel sensor
Ignition switch: ONSteering wheel: Turn slowlyON and OFF are dis-
played alternaltely.
54Steering wheel sensor
Ignition switch: ONSteering wheel: Turn slowlyON and OFF are dis-
played alternately
55Steering wheel sensor
learning Perform actual drivingSteering wheel sensor neu-
tral position learning exe-
cutedON
Steering wheel sensor neu-
tral position learning unex-
ecutedOFF
56Stop lamp switchIgnition switch: ONBrake pedal: DepressONppg
Engine: StoppedBrake pedal: ReleaseOFF
57Motor monitorElectric pump motor is currently operatingON
Electric pump motor is currently not operatingOFF
58Oil pressure stateElectric pump motor is currently operatingLOWp
Electric pump motor is currently not operatingHIGH
59Directional valve
Ri ht
AYC clutch right side is currently operatingON
AYC clutch right side is currently not operatingOFF
60Directional valve
Lft
AYC clutch left side is currently operatingON
AYC clutch left side is currently not operatingOFF
61ABS monitorABS is currently operatingON
ABS is currently not operatingOFF
62Parking brake switchIgnition switch: ONParking brake lever: PullONgg
Engine:StoppedParking brake lever: Re-
leaseOFF
63ACD mode switchIgnition switch: ONACD mode switch: PressONg
Engine:StoppedACD mode switch: ReleaseOFF