air bleeding MITSUBISHI LANCER EVOLUTION 2007 Service Repair Manual

ENGINE -On-vehicle Service11A-13
(2) If there is a problem with the lash adjusters, the noise
will almost never disappear, even if the engine has
been run at idle to let it warm up.
The only case where the noise might disappear is
if the oil in the engine has not been looked after
properly and oil sludge has caused the lash adjusters
to stick.
1. Start the engine.
2. Check that the noise occurs immediately after the engine
is started, and that the noise changes in accordance
with changes in the engine speed.
If the noise does not occur immediately after the engine
is started, or if it does not change in accordance with
the engine speed, the problem is not being caused by
the lash adjusters, so check for some other cause of
the problem. Moreover, if the noise does not change in
accordance with the engine speed, the cause of the
problem is probably not with the engine. (In these cases,
the lash adjusters are normal.)
3. While the engine is idling, check that the noise level does
not change when the engine load is varied.
If the noise level changes, the cause of the noise is
probably parts striking because of worn crankshaft
bearings or connecting rod bearings. (In such cases, the
lash adjusters are normal.)
4. After the engine has warmed up, run it at idle and check
if any noise can be heard.
If the noise has become smaller or disappeared, oil sludge
could make the lash adjusters stick. Clean the lash
adjusters. (Refer to the Engine Workshop Manual.) If not
improved, go to step 5.
5. Bleed air from the lash adjusters.
6. If the noise has not disappeared even after the air
bleeding, clean the lash adjusters.
(Refer to GROUP 11B - Rocker Arms and Camshaft.)

NOTE
(1) If the vehicle is parked on a slope for a long period
of time, the amount of oil inside the lash adjuster
will decrease, and air may get into the high pressure
chamber when starting the engine.
(2) After parking the vehicle for long periods, the oil drains
out of the oil passage, and it takes time for the oil
to be supplied to the lash adjuster, so air can get
into the high pressure chamber.
(3) If either of the above situations occur, the abnormal
noise can be eliminated by bleeding the air from inside
the lash adjusters.

ENGINE -On-vehicle Service11A-14
1. Check the engine oil and replenish or replace the oil
if necessary.
NOTE
(1) If there is a only small amount of oil, air will be drawn
in through the oil screen and will get into the oil
passage.
(2) If the amount of oil is greater than normal, then the
oil will being mixed by the crankshaft and a large
amount of air may get mixed into the oil.
(3) If the oil is degenerated, air and oil will not separate
easily in oil, and the amount of air mixed into the
oil will increase.
(4) If the air which has been mixed in with the oil due
to any of the above reasons gets into the high pressure
chamber of the lash adjuster, the air inside the high
pressure chamber will be compressed when the valve
is open and the lash adjuster will over-compress,
resulting in abnormal noise when the valve closes.
This is the same effect as if the valve clearance is
adjusted to be too large by mistake. If the air inside
the lash adjusters is then released, the operation
of the lash adjusters will return to normal.
2. Run the engine at idle for 1 - 3 minutes to let it warm
up.
3. With no load on the engine, repeat the drive pattern shown
in the illustration at left and check if the abnormal noise
disappears. (The noise should normally disappear after
10 - 30 repetitions, but if there is no change in the noise
level after 30 repetitions or more, the problem is probably
not due to air inside the lash adjusters.)
4. After the noise has disappeared, repeat the drive pattern
shown in the illustration at left a further 5 times.
5. Run the engine at idle for 1 - 3 minutes and check that
the noise has disappeared.
Good
High-pressure chamber
Gradually open the
throttle valve.
Drive pattern for air bleeding
Close the throttle
valve.
Approx.
3,000 r/min
15
seconds15
seconds
Idle speed
Once

ENGINE OVERHAUL -Special Tools11B-10
Tool UseName Number
MD998442Air bleed wireBleeding of lash adjuster
MB991654Cylinder head bolt
wrenchLoosening/tightening of cylinder head bolt
MD998772Valve spring
compressorCompression of valve spring
MD998735Valve spring
compressorCompression of valve spring
MD998737Valve stem seal
installerInstallation of valve stem seal
MD998727Oil pan removerRemoval of oil pan
MD998162Plug wrenchRemoval and installation of front case plug cap
(Use together with MD998783.)
MD998783Plug wrench
retainerRemoval and installation of front case plug cap
(Use together with MD998162.)
MD998371Silent shaft bearing
pullerRemoval of counter balance shaft front bearing

CLUTCH -On-Vehicle Service21A-4
3. If the height of the clutch pedal is outside the standard
value, loosen the setting nut to adjust the pedal height
to the standard value.
Caution
Do not push in the master cylinder push rod at this
time, otherwise the clutch will not operate properly.
4. After completing the adjustments, confirm that the clutch
pedal free play (measured at the face of the pedal pad)
and the distance between the clutch pedal (the face of
the pedal pad) and the clutch pedal stopper or toeboard
when the clutch is disengaged are within the standard
value ranges.
Standard value (C): 4 - 13 mm
Standard value (D):
114.3 mm or more
100 mm or more
5. If the clutch pedal free play and the distance between
the clutch pedal and the clutch pedal stopper or toeboard
when the clutch is disengaged do not agree with the
standard values, it is probably the result of either air in
the hydraulic system or a faulty master cylinder, clutch
cylinder or clutch. Bleed the air, or disassemble and inspect
the master cylinder, clutch cylinder or clutch.
6. Turn back the carpet, etc.
BLEEDING
Specified fluid: Brake fluid DOT 3 or DOT 4
Caution
Use the specified brake fluid. Avoid using a mixture
of the specified fluid and other fluid.
CLUTCH PEDAL POSITION SWITCH
ADJUSTMENT
1. Adjust the clutch pedal. (Refer to P. 21A-3).
2. Disconnect the connector from clutch pedal position
switch.
3. Loosen the clutch pedal position switch by rotating approx.
quarter turn to counterclockwise.
4. Fix the clutch pedal in full stroke.
Clutch pedal Setting nut
13±2 N·m
Clutch pedal clevis pin play
C


Clutch
pedal
stopper
D D

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 - 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-37
ACTUATOR TEST JUDGEMENT VALUE
Item
no.Check itemTest descriptionNormal state
01Bleeding Input current to the Proportional valve
according to the steering angle, and operate
the Proportional valve for five minutes.Make sure no air leaks from the bleeder
screw on the transfer.
02Bleeding Input current to the Proportional valve
according to the steering angle, and operate
the directional valve for five minutes.Make sure no air leaks from the bleeder
screw on the torque transfer differential.
03Check the oil vol-
umeOperate the directional valve to the left and
right for 20 seconds.Check that the oil volume of the reservoir
tank is appropriate.
04Electric pump
driveOperate the electric pump for 5 seconds.Operation sounds of the electric pump
can be heard.
05Check the opera-
tions of the ACDOperate the Proportional valve and
supply the maximum oil pressure to the multi
plate clutch.9Generate the tight corner braking
phenomenon.
06Check clutch op-
erations Operate the direction valve and supply the
maximum oil pressure to the left clutch.When the wheels are lifted, speed
difference will occur between the rear
left and right wheels.
07Check clutch op-
erations Operate the direction valve and supply the
maximum oil pressure to the right clutch.When the wheels are lifted, speed
difference will occur between the rear
left and right wheels.
08Control OFFTurn OFF the electric pump relay, and turn
OFF the control of the ACD and AYC.In actual driving, there is difference
between control ON and OFF.
(1) The actuator test can be executed only when all the following conditions are satisfied.
DAll wheel speed sensor inputs below 20 km/h
DNo system malfunction detected
DSteering angle is within±30 degrees from the neutral position
(2) When the actuator test corresponds to one of the following conditions, forced driving will be cleared.
DWhen any one of the wheel speed sensor input is detected to be above 20 km/h (excluding
Item No.08 “Control OFF”.)
DWhen system malfunction is detected (excluding diagnostic code No.82, 84, and 85)
DWhen the forced drive time is exceeded
DWhen the MUT-IIis removed
DWhen the Clear key of the MUT-IIis operated

MANUAL TRANSMISSION - On-vehicle Service22A-42
BLEEDING VEHICLES WITH ACD AND AYC>
1. Lift up the vehicle.
2. Set the MUT-IIto the 16-pin diagnosis connector.
Caution
Turn the ignition switch to the “LOCK”(OFF) position
before connecting or disconnecting the MUT-II.
3. Turn the ignition switch to the “ON” position.
4. Set the steering wheel in the straight-ahead position.
5. Perform the MUT-IIactuator test (Item No.02), and forcibly
drive the hydraulic unit.
NOTE
(1) The actuator test (Item No.01: Bleeding Mode) will
be performed for 5 minutes, after which it will be
cleared automatically. Drive can also be cleared during
forced driving using the clear key of the MUT-II.
(2) If the hydraulic unit function has been stopped by
fail-safe, the hydraulic unit cannot be forcibly driven.
6. Remove the cap of the bleeder screw on the transfer,
and connect the vinyl hose.
7
.Slowly turn the steering wheel to the left or right from
the neutral state. Loosen the bleeder screw, and check
that air is discharged together with the fluid.
8
.After the air is discharged, tighten the bleeder screw,
and return the steering wheel to the neutral state.
Caution
During bleeding, replenish the fluid so that some
always remains in the oil reservoir.
9. Repeat steps 6 and 7 several 2 to 3 times, and after
checking that no more air mixes in, tighten the bleeder
screw at the specified torque.
Tightening torque: 5±1 N·m
10. After bleeding, check the fluid level. (Refer to P. 22A-41.)
Caution
If bleeding is not performed completely, noise may
be produced from the hydraulic unit, or the durability
of the pump, etc. may drop.
11. On vehicles with AYC, perform bleeding when the
hydraulic unit is removed. (Refer to GROUP 27B -
On-vehicle Service.)
ACD OPERATION CHECK ACD OR VEHICLES WITH ACD AND AYC>
1. Lift up the vehicle.
2
.Set the MUT-IIto the 16-pin diagnosis connector.
Caution
Turn the ignition switch to the “LOCK”(OFF) position
before connecting or disconnecting the MUT-II.
3. Start the engine.
Bleeder screw
Front exhaust pipe

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 OVERHAUL -Clutch Housing22B-44
AB"OUTER RACE REMOVAL
Using the special tool, remove the outer race from the clutch
housing.
REASSEMBLY SERVICE POINTS
"AACOVER A/COVER B INSTALLATION
Install each cover onto the clutch housing in the direction
shown in the illustration.
"BABUSH INSTALLATION
Press the bush into the clutch housing to the position shown
in the illustration. Make sure that the split face of the bush
does not cover the air bleeding groove on the housing.
"CAOUTER RACE INSTALLATION
Using the special tool, install the outer race onto the clutch
housing.
MD999566
Cover A
Cover B
Air bleeding groove
Bush
Bush
1mm
MB990938
MB990935