MITSUBISHI LANCER EVOLUTION IV 1998 Workshop Manual

ENGINE EMISSION CONTROL – Emission Control System 17-3
VACUUM HOSE PIPING CIRCUIT DIAGRAM
Fuel pressure
control valve
Surge tank
Secondary air
control solenoid
valveBlue White
Canister
Check
valve
Throttle body
Fuel
pressure
regulatorWastegate
solenoid
valve
Secondary
air valve
Bypass
valve
Front of vehicle
Wastegate
actuator Vacuum hose color
B: Black
L: Blue
R: Red
W: White
Y: Yellow
CANISTER
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation

Air Cleaner Removal and Installation
2
1
3
4
Removal steps
1. Vapor hose
2. Purge hose
3. Canister
4. Canister bracket

ENGINE EMISSION CONTROL – Emission Control System 17-4
CATALYTIC CONVERTER
REMOVAL AND INSTALLATION
Unit: Nm {kgf
m}
3
2
154
49 {5.0}
5 {0.5}19 {1.9}
49 {5.0}
49 {5.0}
34 {3.5}13 {1.3}
Removal steps
1. Spring
2. Heat protector
3. Front exhaust pipe4. High temperature sensor

5. Catalytic converter

21-1
CLUTCH
CONTENTS
SERVICE SPECIFICATIONS 2. . . . . . . . . . . . . .
LUBRICANTS 2. . . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE 2. . . . . . . . . . . . . . . . . .
1. Clutch Pedal Inspection and Adjustment 2. .
2. Bleeding 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH PEDAL 4. . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH CONTROL 5. . . . . . . . . . . . . . . . . . . . .
Clutch Master Cylinder 6. . . . . . . . . . . . . . . . . . . . .

CLUTCH –
Service Specifications /
Lubricants / On-vehicle Service21-2
SERVICE SPECIFICATIONS
ItemsStandard value
Clutch pedal height mm162.5 – 165.5
Clutch pedal clevis pin play mm1 – 3
Clutch pedal free play mm6 – 13
Distance between the clutch pedal and the toeboard when the clutch is disengaged mm70 or more
LUBRICANTS
ItemsSpecified lubricantsQuantity
Clutch fluidMITSUBISHI genuine brake fluid “DIA-QUEEN
BRAKE FLUID SUPER 4”As required
Push rod assemblyRubber grease
Boot
Release cylinder push rodMOLYKOT BR-2 PUS
ON-VEHICLE SERVICE
1. CLUTCH PEDAL INSPECTION AND
ADJUSTMENT
(1) Turn up the carpet, etc. under the clutch pedal.
(2) Measure the clutch pedal height.
Standard value (A): 162.5 – 165.5 mm
(3) If the height of the clutch pedal is outside the standard
value, loosen the lock nut and adjust the pedal height
to the standard value using the adjusting bolt.
Clutch pedal height
A
Setting nutAdjusting bolt
Locking
nut
13 {1.3}
6 {0.6}

CLUTCH – On-vehicle Service21-3
(4) Measure the clutch pedal play.
Standard value (B): 1 – 3 mm
(5) If the clutch pedal play is not within the standard value,
loosen the setting nut and move the push rod to adjust.
Caution
Do not push in the master cylinder push rod at this
time.
(6) 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 toeboard when the clutch is
disengaged are within the standard value ranges.
Standard value (C): 6 – 13 mm
Standard value (D): 70 mm or more
(7) If the clutch pedal free play and the distance between
the clutch pedal and the 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 or clutch. Bleed the air, or
disassemble and inspect the master cylinder, release
cylinder or clutch.
(8) Turn back the carpet, etc.
2. BLEEDING
Specified fluid:
MITSUBISHI genuine brake fluid “DIA-QUEEN BRAKE
FLUID SUPER 4”
Caution
Use the specified brake fluid. Avoid using a mixture of
the specified fluid and other fluid.
Clutch pedal clevis pin play
B
Clutch pedal free
playDistance between the
clutch pedal and the
toeboard when the
clutch is disengaged
CD

CLUTCH – Clutch Pedal21-4
CLUTCH PEDAL
REMOVAL AND INSTALLATION
Post-installation Operation

Clutch Pedal Adjustment (Refer to P.21-2.)
(Spring installation position)
13
5
Unit: Nm {kgf
m}
13 {1.3}
1134
11
122
7
6
89 106
3 5
24 {2.4} 13 {1.3}
12 {1.2}
Removal steps
1. Clutch master cylinder installation
nut
2. Master cylinder member bracket
installation bolt
3. Clevis pin
4. Bolt
5. Return spring
6. Bushing7. Pipe
8. Clutch pedal
9. Pedal pad
10. Stopper
11. Adjusting bolt
12. Locking nut
13. Pedal and master cylinder support
member

CLUTCH – Clutch Control21-5
CLUTCH CONTROL
REMOVAL AND INSTALLATION
Pre-removal Operation

Clutch Fluid DrainingPost-installation Operation
(1) Clutch Fluid Supplying
(2) Clutch Line Bleeding (Refer to P.21-3.)
(3) Clutch Pedal Adjustment (Refer to P.21-2.)
Specified grease:
MOLYKOT BR-2 PLUS
5
Unit: Nm {kgf
m}
13 {1.3}
66
46
7
8 231
5 {0.5} 15 {1.5}19 {1.9} Release
cylinder
push rodRelease
fork
Clutch master cylinder removal
steps
1. Clevis pin
2. Clutch pipe connection
3. Clutch master cylinder
Clutch release cylinder removal
steps
4. Clutch pipe connection
5. Clutch release cylinderClutch line removal steps
6. Clutch pipe
7. Hose clip
8. Clutch hose

CLUTCH – Clutch Control21-6
CLUTCH MASTER CYLINDER
DISASSEMBLY AND REASSEMBLY
6 7
4
1
3
Piston repair kitClutch fluid:
DIA-QUEEN BRAKE
FLUID SUPER 4
Grease: Rubber grease
5
2
21422 8
3
Unit: Nm {kgf
m}
13 {1.3}
Disassembly steps
1. Piston stopper ring
2. Piston assembly
3. Push rod assembly
4. Boot
5. Reservoir cap
6. Spring pin
7. Reservoir tank
8. Clutch master cylinder bodyCaution
Do not disassemble piston assembly.

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

22-2
NOTES