transmission 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

GENERAL – Models00-2
MODELS

Model
codeClass
codeModel
yearGradeEngine modelTransmission
modelFuel supply
system
E-CN9ASNDF’97RS4G63 (2,000-DOHC –
16 valves-intercooler
W5M51
(4WD-5M/T)
Electronically
controlledfuel
SRGF’97GSR
16 valves-intercooler
turbo)
(4WD-5M/T)controlled fuel
injection (MPI)

Model
codeClass
codeModel
yearGradeEngine modelTransmission
modelFuel supply
system
GF-CP9ASNDF’98EVOLUTION-V RS4G63 (2,000-DOHC –
16 valves intercooler
W5M51
(4WD 5M/T)
MPI
SNGF’98EVOLUTION-V
GSR
16 valves-intercooler
turbo)(4WD-5M/T)
Applicable serial numbers
E-CN9A: CN9A – 0000001

GF-CP9A: CP9A – 0000001

ENGINE – Special Tools / Engine Adjustments11-4
Tool UseName Number
MB991654Cylinder head bolt
wrenchRemoving and reinstalling the cylinder head
bolt
MD998767Tensioner pulley
socket wrenchTiming belt tension adjustment
Recommended
tool MZ203826
by Anzen
Jidosha or
MZ203827 by
BanzaiEngine lifterSupporting the engine assembly during
removal and installation of the transmission
MD991453Engine hanger
assembly
ENGINE ADJUSTMENTS
1. DRIVE BELT TENSION CHECK
NOTE
Use of the auto tensioner eliminates the need for belt tension
adjustment. Check that the indicator mark on the auto
tensioner is in the range of A shown.
If it is outside the specified range (i.e., in range of B shown),
replace the drive belt.
(For the removal and installation of the drive belt, refer to
P.11-9.)
Auto tensioner
Indicator mark
AB

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

ENGINE – Engine Assembly11- 33
25
27 2819
20 21
22 23
24
26
Unit: Nm {kgf
m}
98 {10.0}*
29
57 {5.8}
22
12 {1.2} 39 {4.0}
9 {0.9}
19. Solenoid valve connector
20. Vacuum tank/solenoid valve/vacuum hose assembly
21. Oil pressure switch connector
22. Alternator connector  Drive belt tension inspection
(Refer to P.11-4.)
 A 23. Drive belt
 B 24. A/C compressor
 C 25. Power steering oil pump
 Transmission assembly 26. A/C relay box
27. A/C receiver bracket mounting bolt
28. Oil pressure hose mounting bolt
 C B 29. Engine mount bracket
 E A 30. Engine assembly
Caution
Mounting locations marked by * should be
provisionally tightened, and then fully tightened after
placing the vehicle horizontally and loading the full
weight of the engine on the vehicle body.

ENGINE – Engine Assembly 11- 34
REMOVAL SERVICE POINTS
 A DRIVE BELT REMOVAL
(1) Align the hole in the auto tensioner bracket with that in the arm and insert a screwdriver into the holes.
(2) Remove the drive belt.
 B POWER STEERING OIL PUMP REMOVAL
Remove the power steering oil pump from the bracket with
the hose attached.
NOTE
Place the removed power steering oil pump in a place where
it will not be a hindrance when removing and installing the
engine assembly, and tie it with a cord.
 C A/C COMPRESSOR REMOVAL
Disconnect the A/C compressor connector and remove the
compressor from the compressor bracket with the hose still
attached.
NOTE
Place the removed A/C compressor where it will not be a
hindrance when removing and installing the engine assembly,
and tie it with a cord.
 D ENGINE MOUNT BRACKET REMOVAL
(1) Support the engine with a garage jack.
(2) Remove the special tools which was attached when the transmission assembly was removed.
(3) Hold the engine assembly with a chain block or similar tool.
(4) Place a garage jack against the engine oil pan with a piece of wood in between, jack up the engine so that
the weight of the engine is no longer being applied to
the engine mount bracket, and then remove the engine
mount bracket.
Phillips
screwdriver
Hole in arm
Auto tensioner
Hole in bracket
MZ203826 or MZ203827
MB991453

MPI – Troubleshooting13-18
5. SERVICE DATA LIST

Item
No.Inspection
itemInspection contentsNormal condition
11Oxygen
sensorEngine: After having been warmed
up
Air/fuel mixture is made leaner when
When at 4,000 r/min, engine is
suddenly decelerated200 mV or less
Air/fuel mixture is made leaner when
decelerating, and is made richer
when racing.
When engine is suddenly
raced600 – 1,000 mV
Engine: After having been warmed
up
The ox
ygen sensor signal is used to
Engine is idling400 mV or less
(Chan
ges)The oxygen sensor signal is used to
check the air/fuel mixture ratio, and
control condition is also checked by
the ECU.2,500 r/min
(Changes)
600 – 1,000 mV
12Air flow
sensor*
Engine coolant temperature:
8095C
Engine is idling17 – 43 Hz
sensor*80 – 95C
Lamps, electric cooling fan and
all accessories: OFF
2,500 r/min46 – 86 Hz
all accessories: OFF
Transmission: NeutralEngine is racedFrequency increases
in response to racing
13Intake air
temperature
sensor
Ignition switch: ON or with engine
runningWhen intake air temperature
is –20C–20C
sensorWhen intake air temperature
is 0C0C
When intake air temperature
is 20C20C
When intake air temperature
is 40C40C
When intake air temperature
is 80C80C
14Throttle
position
Ignition switch: ONSet to idle position300 – 1,000 mV
position
sensor
Gradually openIncreases in proportion
to throttle opening
angle
Open fully4,500 – 5,500 mV
16Power
supply
voltageIgnition switch: ONSystem voltage
18Cranking
signal Ignition switch: ONEngine: StoppedOFF
g
(ignition
switch-ST)Engine: CrankingON
NOTE
*: When the car is new (distance it travelled is less than 500 km), output frequency of the air flow sensor may
become about 10% higher.

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.

MPI – Troubleshooting13-21

Descriptions other than those given below are the same as for the EVOLUTION-IV.
Item
No.Inspection
itemInspection contentsNormal condition
12Air flow
sensor*1Engine coolant temperature:
80–95C
Engine is idling12 – 38 Hz
sensor*180 – 95C
Lamps, electric cooling fan and
all accessories: OFF
2,500 r/min36 – 76 Hz
all accessories: OFF
Transmission: NeutralEngine is racedFrequency increases
in response to racing
41Injector
drive time*2Engine: Cranking*2When engine coolant temper-
ature is 0C27 – 40 ms
When engine coolant temper-
ature is 20C14.5 – 21.7 ms
When engine coolant temper-
ature is 80C3.8 – 5.6 ms
Injector
drive time*3Engine coolant temperature:
8095C
Engine is idling0.9 – 2.1 ms
drive time *380 – 95C
Lamps, electric cooling fan and
all accessories: OFF
2,500 r/min0.7 – 1.9 ms
all accessories: OFF
Transmission: NeutralWhen engine is suddenly
racedIncreases
44Ignition
advance
Engine: After having been
warmed up
Engine is idling0 – 13BTDC
advancewarmed up
Timing lamp is set.2,500 r/min24 – 44BTDC
NOTE
*1: In a new vehicle (driven approximately 500 km or less), the air flow sensor output frequency is sometimes
10 % higher than the standard frequency.
*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.

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