brake fluid MITSUBISHI LANCER EVOLUTION 2007 Service Repair Manual

WIRING HARNESS CONFIGURATION DIAGRAMS
Connector
symbol
-01
thru
-37
B
B-37
B-34
B-23
B-01B-27B-26
Earth cable
B-21B-22
Connector colour code
B:Black
Y:Yellow
L:Blue
G:Green
R:Red
BR:Brown
V:Violet
O:Orange
GR:Gray
None: Milk white
B-10
ENGINE AND TRANSMISSION
L.H. drive vehicles
B-01 (5-GR) Windshield wiper motor
B-02 (4-B) Throttle position sensor
B-03 (3-B) Vehicle speed sensor
B-04 (2-GR) Brake fluid level switch
B-05X (1) Engine speed detection connector
B-06X (5) No connection
B-07X (4) No connectionB-08X (4) No connection
B-09X (4) No connection
B-10X (4) No connection
B-11X (4) Engine control relay
B-12X (4) A/C compressor relay
B-14 (10-B) Control wiring harness and battery wiring
harness combination

WIRING HARNESS CONFIGURATION DIAGRAMS
Connector
symbol
-01
thru
-37
B
Earth cable
B-27B-26B-04
B-22B-21
B-37
B-34
B-23
Connector colour code
B:Black
Y:Yellow
L:Blue
G:Green
R:Red
BR:Brown
V:Violet
O:Orange
GR:Gray
None: Milk white
B-14
ENGINE AND TRANSMISSION
R.H. drive vehicles
B-01 (5-GR) Windshield wiper motor
B-02 (4-B) Throttle position sensor
B-03 (3-B) Vehicle speed sensor
B-04 (2-GR) Brake fluid level switch
B-05X (1) Engine speed detection connector
B-06X (5) No connection
B-07X (4) No connectionB-08X (4) No connection
B-09X (4) Ignition coil relay
B-10X (4) No connection
B-11X (4) Engine control relay
B-12X (4) A/C compressor relay
B-14 (10-B) Control wiring harness and battery wiring
harness combination

CIRCUIT DIAGRAMSB-155
FUEL WARNING LAMP (See P.B-156.)
OIL PRESSURE WARNING LAMP (See P.B-157.)
BRAKE WARNING LAMP (See P.B-157.)
OPERATION

DWhen the ignition switch is at the “ON” position,
the fuel gauge unit resistance is small when
the fuel level is high, and the fuel gauge unit
resistance is large when the fuel level is low.
When this resistance rises above a specified
value, the fuel warning lamp illuminates to notify
the driver that the fuel level is low.

DWhen the lubrication system fails after engine
starting, resulting in the oil pressure failing to
build up, the oil pressure switch turns on
causing the oil pressure warning lamp to
illuminate.

DWhen the brake fluid level goes down below
a predetermined level with the ignition switch
in the “ON” position, the brake fluid level switch
is activated or the parking brake switch is turned
on, causing the brake warning lamp to
illuminate.TROUBLESHOOTING HINTS
1. No warning lamps illuminate.
DCheck multi-purpose fuse No.(2).
2. Some warning lamps do not illuminate.
DCheck lamp valve.
DCheck the switches and the gauge unit.

INDEX - In order of connector No.C-2
Wiring diagram
page Circuit diagram page Parts name Connector
No.
AA-45Condenser fan motorB-177,183B-7,9
A-46Condenser fan motorB-177,183B-7,9
A-47A/C compressorB-178,184B-7,9
A-48Power steering oil pressure switchB-90,98B-7,9
BB-01Windshield wiper motorB-186,190B-10,14
B-02Throttle position sensorB-89,97,215,223,231,241B-10,14
B-03Vehicle speed sensorB-92,100,150,154,197B-10,14
B-04Brake fluid level switchB-157B-10,14
B-05XEngine speed detection connectorB-73,82,83,90,98B-10,14
B-06XNo connectionB-73B-10,14
B-07XNo connectionB-73B-10,14
B-08XNo connectionB-73B-10,14
B-09XIgnition coil relay or no
connection B-73,83B-10,14
B-10XNo connectionB-73B-10,14
B-11XEngine control relayB-73,86,94,252,254B-10,14
B-12XA/C compressor relayB-73,178,184B-10,14
B-14Control wiring harness and battery
wiring harness combinationB-79,84,91,99,157B-10,14
B-18StarterB-79B-11,15
B-19StarterB-79B-11,15
B-20Oil pressure switchB-157B-11,15
B-21AlternatorB-84B-11,15
B-22AlternatorB-84B-11,15
B-23Purge control solenoid valveB-91,99B-11,15
B-24Injector 4B-89,97B-11,15
B-25Injector 3B-89,97B-11,15
B-26Injector 2B-89,97B-11,15
B-27Injector 1B-89,97B-11,15
B-31Air flow sensorB-90,98B-11,15
B-34Oxygen sensorB-88,96B-11,15
B-36Waste gate solenoid valveB-91,99B-11,15
B-37Fuel pressure solenoid valveB-90,98B-11,15

INDEX - In order of parts nameC-11
INDEX
In order of parts name
Parts nameConnector
No.Circuit diagram pageWiring diagram
page
4WD-ECU C-43B-201,209,212,213,214,215,216,218,
219,220,221,222,223,224,226,227,
228,230,231,232,234,236,237,238,
240,241,242,244, 246,247B-19,25
4WD-ECU C-44B-201,209,212,213,216,217,219,220,
221,224,225,227,228,229,232,234,
235,237,238,239,242,244,245,247B-19,25
AA/C compressorA-47B-178,184B-7,9
A/C compressor relayB-12XB-73,178,184B-10,14
A/C-ECU or heater control unitC-32B-175,181,185B-19,25
ABS-ECUB-123B-198,200,201,202,203,204,205,206,
208,209,210,211,229,232,233,239,
242,243B-13,17
ACD mode changeover switchC-142B-214,222,230,240B-21,27
Air bag module (squib) C-207B-248,250B-22,28
Air bag module (squib) side>C-109B-249,251B-20,26
Air flow sensorB-31B-90,98B-11,15
AlternatorB-21B-84B-11,15
AlternatorB-22B-84B-11,15
Ashtray illumination lampD-20B-195B-31,33
BBack-up lamp switchB-108B-142,143B-12,16
Blower motorC-14B-174,180B-18,24
Blower relayC-215B-54,55,174,180B-23,29
Blower switchC-131B-174,180B-21,27
Brake fluid level switchB-04B-157B-10,14
CCamshaft position sensorB-116B-88,96B-12,16
Cigarette lighterD-18B-195B-31,33
Cigarette lighterD-19B-195B-31,33
Cigarette lighter illumination lampD-21B-195B-31,33
ClockC-04B-194B-18,24
Clock spring C-204B-248,250B-22,28
Clock spring C-205B-146B-22,28

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.

CLUTCH -General Information/Service Specifications/Lubricants/On-vehicle Service21A-3
GENERAL INFORMATION
The clutch is a dry single-disc, diaphragm type;
hydraulic pressure is used for the clutch control.
SERVICE SPECIFICATIONS
ItemsStandard value
Clutch pedal height mm202.1 - 206.1
173.5 - 177.5
Clutch pedal clevis pin play mm1-3
Clutch pedal free play mm4-13
Distance between the clutch pedal and the toeboard
when the clutch is disengaged mm114.3 or more
100 or more
LUBRICANTS
ItemsSpecified lubricantsQuantity
Clutch fluidBrake fluid DOT3 or DOT4As required
Push rod assemblyRubber grease
Boot
Release cylinder push rodMITSUBISHI genuine grease Part No.
0101011
ON-VEHICLE SERVICE
CLUTCH PEDAL INSPECTION AND
ADJUSTMENT
1. Turn up the carpet, etc. under the clutch pedal.
2. Measure the clutch pedal height and the clutch pedal
clevis pin play.
Standard value (A):
202.1 - 206.1 mm
173.5 - 177.5 mm
Standard value (B): 1 - 3 mm
Clutch pedal height

A
A
Clutch pedal
stopper
Clutch pedal clevis pin play
B

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

CLUTCH -Clutch Control21A-9
DISASSEMBLY AND REASSEMBLY
CLUTCH MASTER CYLINDER
Caution
Do not disassemble piston assembly.
1
4 5
27
223
4
Grease: Rubber grease
Clutch fluid:
Brake fluid DOT3 or DOT4
Piston repair kit
13±2 N·m
12
3
6
8

4 5
8
Disassembly steps
1. Piston stopper ring
2. Piston assembly
"AA3. Push rod assembly
4. Boot5. Spring pin
6. Reservoir tank
7. Seal
8. Master cylinder body
INSTALLATION SERVICE POINT
"AAPUSH ROD ASSEMBLY INSTALLATION
Set the length of the push rod assembly to the shown
dimension to make the adjustment of clutch pedal easier.
104.3±0.5 mm

CLUTCH OVERHAUL -General Description/Specifications/Service Specifications/
Tightening Torque/Lubricants21B-2
GENERAL DESCRIPTION
The pull-type clutch has been adopted to improve the cut-off at high rotations and reduce the clutch
pedal pressing force.
SPECIFICATIONS
Clutch discTypeDry single-disc type
Facing dimension mm240×160
Clutch coverTypeDiaphragm spring, pull-type
Set load N9,320
Clutch control methodHydraulic method
SERVICE SPECIFICATIONS
ItemsLimit value mm
Clutch disc facing rivet sink0.3
Clearance between release cylinder inner diameter and
piston outer diameter0.15
TIGHTENING TORQUE
ItemsTorque N•m
Clutch tube flare nut15±2
Clutch fluid line bracket mounting bolt18±3
Clutch release cylinder air breather11±1
Clutch release cylinder mounting bolt18±3
Clutch release fork shaft mounting bolt9.8±2
Clutch release cylinder union bolt22±2
LUBRICANTS
ItemsSpecified lubricants
Release fork and release cylinder push rod contact sectionMITSUBISHI genuine grease Part No.0101011
orequivalent
Release fork and release fork shaft sliding section
or equivalent
Release fork and release bearing contact section
Piston and piston cup circumferenceMITSUBISHI genuine brake fluid
“
DIA QUEENBRAKEFLUIDSUPER4”
Release cylinder inner circumference
“DIA-QUEENBRAKEFLUIDSUPER4”
or equivalent