clutch MITSUBISHI LANCER EVOLUTION IV 1998 Workshop Manual

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General . . . . . . . . . . . . . . . . . . . . . . . .
Engine . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Lubrication . . . . . . . . . . . . .
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Cooling . . . . . . . . . . . . . . . . .
Intake and Exhaust . . . . . . . . . . . .
Engine Electrical . . . . . . . . . . . . . . .
Engine and Emission Control . . . .
Clutch . . . . . . . . . . . . . . . . . . . . . . . . .
Manual Transmission . . . . . . . . . . .
Front Axle . . . . . . . . . . . . . . . . . . . . . .
Rear Axle . . . . . . . . . . . . . . . . . . . . . .
Power Plant Mount . . . . . . . . . . . . . .
Front Suspension . . . . . . . . . . . . . . .
Rear Suspension . . . . . . . . . . . . . . .
Service Brakes . . . . . . . . . . . . . . . . .
Parking Brakes . . . . . . . . . . . . . . . . .
Steering . . . . . . . . . . . . . . . . . . . . . . . .
Body . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exterior . . . . . . . . . . . . . . . . . . . . . . . .
Chassis Electrical . . . . . . . . . . . . . .
Electrical Wiring . . . . . . . . . . . . . . . .
WORKSHOP MANUAL
FOREWORD
This Workshop Manual contains procedures for
service mechanics, including removal, disassembly,
inspection, adjustment, reassembly and
installation. Figures taken from registration
documents are given in metric units only. All other
figures are given in SI units with metric units in
brackets. Use the following manuals in combination
with this manual as required.
TECHNICAL INFORMATION MANUAL
N9806CNCP9
All information, illustrations and product
descriptions contained in this manual are current
as at the time of publication. We, however, reserve
the right to make changes at any time without prior
notice or obligation.
July 1998
EVOLUTION-IV
EVOLUTION-V

ENGINE – Crankshaft Oil Seal11-15
CRANKSHAFT OIL SEAL
REMOVAL AND INSTALLATION
4
3 2
1
5127 – 137
{13.0 – 14.0}
3
Unit: Nm {kgf
m} Engine oil
5
Crankshaft front oil seal removal
steps
Timing belt and timing belt B
(Refer to P.11-21.)
Crank angle sensor
(Refer to GROUP 16.)
1. Crankshaft sprocket B
2. Key
C3. Crankshaft front oil sealCrankshaft rear oil seal removal
steps
Transmission assembly
Clutch cover and disc
AB4. Flywheel
A5. Crankshaft rear oil seal

MPI – Troubleshooting13-20
Item
No.Normal condition Inspection contents Inspection
item
41Injector
drive time*2Engine: CrankingWhen engine coolant temper-
ature is 0C (injection is
carried out for all cylinders
simultaneously)27 – 41 ms
When engine coolant temper-
ature is 20C14 – 22 ms
When engine coolant temper-
ature is 80C3.9 – 5.9 ms
Injector
drive time*3Engine coolant temperature:
8095C
Engine is idling1.2 – 2.4 ms
drive time*380 – 95C
Lamps, electric cooling fan and
all accessories: OFF
2,500 r/min1.0 – 2.2 ms
all accessories: OFF
Transmission: NeutralWhen engine is suddenly
racedIncreases
44Ignition
advanceEngine: After having been
warmed up
Timing lamp is set (The timing
Engine is idling3 – 13BTDC
Timing lamp is set. (The timing
lamp is set in order to check
actual ignition timing.)2,500 r/min24 – 44BTDC
45ISC
(stepper)
motor
Engine coolant temperature:
80 – 90C
Lamps electric coolingfan and
A/C switch: OFF2 – 25 steps
motor
position *4Lamps, electric cooling fan and
all accessories: OFF
Transmission: Neutral
Idle position switch: ON
Engine: Idling
A/C switch: OFF → ONIncreases by 10 – 70
steps
Engine: Idling
(When A/C switch is ON, A/C
compressor should be operat-
ing.)A/C switch: OFFIncreases by 5 – 50
steps
49A/C relayEngine: After having been warmed
up/Engine is idlingA/C switch: OFFOFF (Compressor
clutch is not operating)
A/C switch: ONON (Compressor
clutch is operating)
NOTE
*1: The idle position switch normally turns off when the voltage of the throttle position sensor is 50 – 100 mV
higher than the voltage at the idle position. If the idle position switch turns back on after the throttle valve
is opened, the idle position switch and the throttle position sensor need to be adjusted.
*2: The injector drive time represents the time when the cranking speed is at 250 r/min or below when the power
supply voltage is 11 V.
*3: In a new vehicle [driven approximately 500 km or less], the injector drive time is sometimes 10% longer than
the standard time.
*4: In a new vehicle [driven approximately 500 km or less], the step of the stepper motor is sometimes 30 steps
greater than the standard value.

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 – Transmission Assembly22A-7
TRANSMISSION ASSEMBLY
REMOVAL AND INSTALLATION
Pre-removal Operation
(1) Transmission Oil Draining (Refer to P.22A-3.)
(2) Transfer Oil Draining (Refer to P.22A-3.)
(3) Under Cover Removal
(4) Front Exhaust Pipe Removal (Refer to GROUP 15.)
(5) Battery and Battery Tray Removal
(6) Air Cleaner Assembly RemovalPost-installation Operation
(1) Air Cleaner Assembly Installation
(2) Battery and Battery Tray Installation
(3) Front Exhaust Pipe Installation
(Refer to GROUP 15.)
(4) Under Cover Installation
(5) Transfer Oil Supplying (Refer to P.22A-3.)
(6) Transmission Oil Supplying (Refer to P.22A-3.)
(7) Shift Lever Operation Check
(8) Speedometer Operation Check
1
2
34 5
6
7
8 8
Unit: Nm {kgfm}
49 {5.0} 98 {10.0}*
88 {9.0}19 {1.9}
48 {4.9}19 {1.9}
Removal steps
1. Shift cable and select cable con-
nection
2. Backup lamp switch connector
3. Vehicle speed sensor connector
A4. Starter motor
5. Clutch release cylinder connection
6. Transmission assembly upper part
coupling bolts7. Transmission mount bracket
8. Transmission mount stopper

Engine assembly supporting
Caution
Mounting locations marked by * should be
provisionally tightened, and then fully tightened
when the body is supporting the full weight of the
engine.