transmission MITSUBISHI LANCER EVOLUTION 2007 Service Owner's Manual

MPI -Troubleshooting13A-104
Item
No.Reference
page Inspection
procedure
No. Normal condition Inspection contents Inspection
item
25Barometric
pressure
Ignition switch: ONAltitude: 0 m101 kPaCode No.
P0105
13A-15
pressure
sensor
Altitude: 0 m95 kPa
P0105
Altitude: 0 m88 kPa
Altitude: 0 m81 kPa
27Power
steering
fluidEngine: Idle operationSteering wheel
stationaryOFFCode No.
P055113A-46
fluid
pressure
switchSteering wheel turningON
28A/C switchEngine: Idle operation
(When A/C switch isA/C switch: OFFOFFProcedure
No. 2613A-92
(WhenA/Cswitchis
ON, A/C compressor
should be operating.)A/C switch: ONON
No.26
34Air flow
sensorEngine: After
warm-upIdle operationONCode No.
P010013A-13
sensor
reset
signal
warm up
3,000 r/minOFF
P0100
37Volumetric
efficiency
DEngine coolant
temperature:
Idle operation15 - 35%--
efficiencytemperature:
85 - 95_C
DLightningand
2,500 r/min15 - 35%
DLightning and
accessories:
OFFExcessive
accellerationAccording to ac-
celeration, volu-
metric efficiency
is increased.
41Injectors*1Engine: CrankingWhen engine coolant
temperature is 0_C
(injection is carried out
for all cylinders simulta-
neously)25 - 37 ms--
When engine coolant
temperature is 20_C15 - 22 ms
When engine coolant
temperature is 80_C4.2 - 6.3 ms
Injectors*2DEngine coolant
temperature:
80–95_C
Engine: Idle operation1.5 - 2.7 ms--
80–95_C
DLamps, electric
cooling fan and
allaccessories:
2,500 r/min1.2 - 2.4 ms
allaccessories:
OFF
DTransmission:
Neutral
When engine is sud-
denly racedIncreases

MPI -Troubleshooting13A-105
Item
No.Reference
page Inspection
procedure
No. Normal condition Inspection contents Inspection
item
44Ignition ad-
vanceDEngine: After
having warmed
up
DTiming lamp is
set(Thetiming
Engine: Idle operation0-13_BTDC--
set.(Thetiming
lamp is set in
order to check
actual ignition
timing.)
2,500 r/min20 - 40_BTDC
45Idle speed
control
(stepper)
motor
position*
3
DEngine coolant
temperature:
80 - 90_C
DLamps, electric
cooling fan and
all accessories:
OFF
DTransmission:
A/C switch: OFF2 - 25 STEP--
DTransmission:
Neutral
DEngine: Idle
operation
DWhen A/C switch
is ON, A/C
compressor
should be operat-
ing
A/C switch: OFF→ONIncreases by 10 -
70 steps
49A/C relayEngine: After having
warmed up/Engine is
idlingA/C switch: OFFOFF (Compressor
clutch is not oper-
ating)Procedure
No. 2713A-92
A/C switch: ONON (Compressor
clutch is operat-
ing)
59Oxygen
sensor
(rear)Engine: After having
warmed-upWhen engine is sud-
denly raced0 and 600 - 1,000
mV alternate.Code No.
P013613A-27
81LLearned
valueEngine: After having warmed up, running with no
load at 2,500 r/min. (During air/fuel ratio
feedback control)- 12.5 - 12.5%--
82LFeedbackEngine: After having warmed up, running with no
load at 2,500 r/min. (During air/fuel ratio
feedback control)- 20 - 20%--
87LEngine
load
Engine: After having
warmedup
Idle operation15 - 35%--
loadwarmedup
2,500 r/min15 - 35%--

MPI -Troubleshooting13A-112
Terminal No.Normal condition Check condition (Engine condition) Check item
72Intake air
temperature sensorIgnition switch: “ON”Intake air
temperature: - 20_C3.8 - 4.4 V
Intake air
temperature: 0_C3.2 - 3.8 V
Intake air
temperature: 20_C2.3 - 2.9 V
Intake air
temperature: 40_C1.5 - 2.1 V
Intake air
temperature: 60_C0.8 - 1.4 V
Intake air
temperature: 80_C0.4 - 1.0 V
75Oxygen sensor
(Rear)DTransmission: Second gear
DDriving with the throttle widely open
DEngine: 3,500 r/min or more0.6 - 1.0 V
76Oxygen sensor (front)Engine: Running at 2,500 r/min after warmed
up (Check using a digital type voltmeter)0↔0.8 V
(Changes repeatedly)
80Backup power supplyIgnition switch: “LOCK” (OFF)System voltage
81Sensor impressed
voltageIgnition switch: “ON”4.9 - 5.1 V
82Ignition switch - IGIgnition switch: “ON”System voltage
83Engine coolant
temperature sensorIgnition switch: “ON”Coolant temperature:
-20_C3.9 - 4.5 V
Coolant temperature:
0_C3.2 - 3.8 V
Coolant temperature:
20_C2.3 - 2.9 V
Coolant temperature:
40_C1.3 - 1.9 V
Coolant temperature:
60_C0.7 - 1.3 V
Coolant temperature:
80_C0.3 - 0.9 V
84Throttle position
sensorIgnition switch: “ON”Set throttle valve to
idle position0.535 - 0.735 V
Fully open throttle
valve4.5 - 5.0 V
85Barometric pressure
sensor
Ignition switch: “ON”Altitude: 0 m3.8 - 4.2 V
sensor
Altitude: 600 m3.5 - 3.9 V
Altitude: 1,200 m3.2 - 3.8 V
Altitude: 1,800 m3.0 - 3.4 V

FUEL SUPPLY - Fuel Tank13B-5

303128
25 29
2627
24±4 N·m
Removal steps
25. Filler neck protector
26. Filler neck hose connection
27. Filler neck vapour hose connection
28. Fuel filler cap29. Fuel filler neck assembly
30. Fuel shut-off valve
31. Parking
REMOVAL SERVICE POINT
AA"HARNESS CONNECTOR CONNECTION/FUEL
TANK ASSEMBLY DISCONNECTION
1. Remove the differential support member and tilt the
differential carrier.
(Refer to GROUP 27B.)
2. Hold the fuel tank with a transmission jack and remove
the nut connected to the fuel tank.
3. Tilt the fuel tank to allow access with a hand and disconnect
the harness connector.
4. Remove the fuel tank in the tilting direction to avoid contact
with the differential carrier.Fuel tankFloor
Differntial carrierRemoval
directionTilt

ENGINE ELECTRICAL -Ignition System16-26
IGNITION SYSTEM
GENERAL INFORMATION
This system is equipped with two ignition coils (A
and B) with built-in power transistors for the No.
1 and No. 4 cylinders and the No. 2 and No. 3
cylinders respectively.
Interruption of the primary current flowing in the
primary side of ignition coil A generates a high
voltage in the secondary side of ignition coil A.
The high voltage thus generated is applied to the
spark plugs of No. 1 and No. 4 cylinders to generate
sparks. At the time that the sparks are generated
at both spark plugs, if one cylinder is at the
compression stroke, the other cylinder is at the
exhaust stroke, so that ignition of the compressed
air/fuel mixture occurs only for the cylinder which
is at the compression stroke.
In the same way, when the primary current flowing
in ignition coil B is interrupted, the high voltage
thus generated is applied to the spark plugs of
No. 2 and No. 3 cylinders.
The Engine-ECU turns the two power transistors
inside the ignition coils alternately on and off. Thiscauses the primary currents in the ignition coils
to be alternately interrupted and allowed to flow
to fire the cylinders in the order 1-3-4-2.
The Engine-ECU determines which ignition coil
should be controlled by means of the signals from
the camshaft position sensor which is incorporated
in the camshaft and from the crank angle sensor
which is incorporated in the crankshaft. It also
detects the crankshaft position in order to provide
ignition at the most appropriate timing in response
to the engine operation conditions. It also detects
the crankshaft position in order to provide ignition
at the most appropriate timing in response to the
engine operation conditions.
When the engine is cold or operated at high
altitudes, the ignition timing is slightly advanced
to provide optimum performance.
When the automatic transmission shifts gears, the
ignition timing is also retarded in order to reduce
output torque, thereby alleviating shifting shocks.
SYSTEM DIAGRAM
Barometric pressure sensor
Intake air temperature sensor
Engine coolant temperature sensor
Camshaft position sensor
Crank angle sensor
Ignition switch - ST
Vehicle speed signalEngine-ECU
Ignition coil A
Ignition coil B Ignition switch
Spark plugBattery
To tachometerCylinder No. Air flow sensor
1 4
23
Detonation sensor

MANUAL TRANSMISSION 22A........................................
MANUAL TRANSMISSION OVERHAUL 22B............................
22A-1
MANUAL
TRANSMISSION
CONTENTS

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 22A-5
TROUBLESHOOTING
BASIC TROUBLESHOOTING CONDITIONS
Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points.
NOTE
Before starting the troubleshooting procedure, make sure that the following items have been checked
okay.
DIs the appropriate steering wheel installed at the center of the steering column shaft correctly?
DAre the tire, wheel size, specifications, air pressure, balance, and wear state normal?
DIs the wheel alignment normal?
DHas the engine, suspension, etc. been remodeled in such a way that it will affect the ACD and AYC
systems?
DIAGNOSIS FUNCTION
READING DIAGNOSIS CODE
Read a diagnosis code by the MUT-IIor ACD mode indicator
lamp. (Refer to GROUP 00 - How to Use Troubleshooting/
Inspection Service Points.)
NOTE
Connect the MUT-IIto the diagnosis connector (16-pin).
ERASING DIAGNOSIS CODES
When using the MUT-II
Connect the MUT-IIto the diagnosis connector (16-pin) and
erase the diagnosis code.
Caution
Turn the ignition switch to the “LOCK”(OFF) position
before connecting or disconnecting the MUT-II.
ACDmode indicator lamp