1998 MITSUBISHI LANCER EVOLUTION IV Workshop Manual

Pub. No. S9806CNCP9
WORKSHOP MANUAL
EVOLUTION-IV
EVOLUTION-V
Pub. No. S9806CNCP9
Pub. No. S9806CNCP9
Jul. ’98 Printed in Japan
WORKSHOP MANUAL
EVOLUTION-IV
EVOLUTION-V

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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

HOW TO READ THE WIRING DIAGRAMS A. . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL WIRING (EVOLUTION-IV) B. . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL WIRING (EVOLUTION-V) C. . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL
WIRING
CONTENTS

NOTES

MODELS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
00-1
GENERAL
CONTENTS

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

11-1
ENGINE
CONTENTS
SERVICE SPECIFICATIONS 2. . . . . . . . . . . . . .
SEALANTS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 2 . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE ADJUSTMENTS 4 . . . . . . . . . . . . . . . . .
1. Drive Belt Tension Check 4 . . . . . . . . . . . . . . .
2. Auto Tensioner Check 5 . . . . . . . . . . . . . . . . . . .
3. Lash Adjuster Check 5 . . . . . . . . . . . . . . . . . . . .
4. Lash Adjuster Replacement 7 . . . . . . . . . . . . . .
5. Ignition Timing Check 7 . . . . . . . . . . . . . . . . . . .
6. Idle Speed Check and Idle Mixture Check 7
7. Compression Pressure Check 7 . . . . . . . . . . . .
8. Manifold Vacuum Check 8 . . . . . . . . . . . . . . . . .
CRANKSHAFT PULLEY 9. . . . . . . . . . . . . . . . . .
CAMSHAFT AND CAMSHAFT
OIL SEAL 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OIL PAN 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRANKSHAFT OIL SEAL 15 . . . . . . . . . . . . . .
CYLINDER HEAD GASKET 17 . . . . . . . . . . . .
TIMING BE LT . . . . . . . . . . . . . . 21 . . . .
ENGINE ASSEMB LY 32
. . . . . . . . . . . . . . . . . . .

ENGINE – Service Specifications / Sealants / Special Tools11-2
SERVICE SPECIFICATIONS
ItemsStandard valueLimit
Basic ignition timing5
BTDC ± 3
–
Ignition timing (at idle)Approx. 5
BTDC–
Idle speed rpm850 ± 50–
CO contents %0.6 or less–
HC contents ppm300 or less–
Compression pressure kg/cm2 – rpm11.5 – 250Min. 9.7 – 250
Compression pressure difference of all cylinders kg/cm2–Max. 1.0
Intake manifold vacuum kPa {mmHg}–Min. 55 {410}
Cylinder head bolt shank length mm–99.4
SEALANTS
ItemsSpecified sealants
Rocker coverSemi-drying sealant: THREEBOND 1207D [MZ 100168] (containing 150 g)
Oil panSemi-drying sealant: THREEBOND 1207F [MZ 100191] (containing 150 g)
NOTE:
Given in [ ] are MITSUBISHI GENUINE PART numbers.
SPECIAL TOOLS
ToolNumberNameUse
MD998782Valve lifter setReplacing the lash adjuster
MB990767End yoke holderHolding the crankshaft pulley
Holding the camshaft sprocket