2007 MITSUBISHI LANCER EVOLUTION stop start

ENGINE COOLING -On-vehicle ServiceENGINE COOLING -On-vehicle Service14-7
3. Remove the cylinder block drain plug from the cylinder
block to drain the engine coolant.
4. Remove the reserve tank to drain the engine coolant.
5. When the engine coolant has drained, pour in water from
the radiator cap to clean the engine coolant line.
6. Coat the thread of the cylinder block drain plug with the
specified sealant and tighten to the specified torque.
Specified sealant:
3M Nut Locking Part No. 4171 or equivalent
7. Securely tighten the radiator drain plug.
8. Install the under cover.
(Refer to GROUP 51 - Front Bumper.)
9. Install the reserve tank.
10. Slowly pour the engine coolant into the mouth of the
radiator until the radiator is full, and pour also into the
reserve tank up to the FULL line.
Recommended anti-freeze:
MITUBISHI GENUINE COOLANT or equivalent
Quantity: 6.0 L
Caution
Do not use alcohol or methanol anti-freeze or any
engine coolants mixed with alcohol or methanol
anti-freeze. The use of an improper anti-freeze can
cause the corrosion of the aluminium components.
11. Install the radiator cap securely.
12. Start the engine and warm the engine until the thermostat
opens. (Touch the radiator hose with your hand to check
that warm water is flowing.)
13. After the thermostat opens, race the engine several times,
and then stop the engine.
14. Cool down the engine, and then pour engine coolant into
the reserve tank until the level reaches the FULL line. If
the level is low, repeat the operation from step 11.
CONCENTRATION MEASUREMENT
Measure the temperature and specific gravity of the engine
coolant to check the antifreeze concentration.
Standard value: 30 - 60 % (allowable concentration range)
RECOMMENDED ANTI-FREEZE
AntifreezeAllowable concentration
MITSUBISHI GENUINE COOLANT
or equivalent30 - 60 %
Caution
If the concentration of the anti-freeze is below 30 %, the
anti-corrosion property will be adversely affected. In
addition, if the concentration is above 60 %, both the
anti-freezing and engine cooling properties will decrease,
affecting the engine adversely. For these reasons, be
sure to maintain the concentration level within the
specified range.
44±5N·m
Water inlet
pipe

INTAKE AND EXHAUST -Exhaust Manifold15-19
EXHAUST MANIFOLD
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
DUnder Cover Removal and Installation
(Refer to GROUP 51 - Front bumper.)
DRadiator Removal and Installation
(Refer to GROUP 14.)
DAir Intake Hose Removal and Installation
(Refer to P.15-8.)DAir Pipe A, Air Pipe C, Air Hose D, Air Pipe B Removal
and Installation (Refer to P.15-9.)
DCrossmember Bar Removal and Installation (Refer
to GROUP 32 - Engine Roll Stopper, Centermember.)
DFront Exhaust Pipe Removal and Installation
(Refer to P.15-26.)
13 12
3
6 5
8
9
11 192122
14¶1 N·m
4
7
11
12 15
16
17
18
20
1010
14
14±1 N·m
14±1 N·m
29±3 N·m
59±5 N·m
49±5 N·m
44±5 N·m
59±5 N·m
35±6 N·m
44±5 N·m
14±1 N·m9.0±1.0 N·m30±3 N·m
30±3 N·m10±1 N·m
42±7 N·m
10±1 N·m
10±1 N·m
17±2 N·m
31±2 N·m
49±5 N·m
42±7 N·m
19±1 N·m
Removal steps
1. Exhaust manifold heat protector
2. Air pipe assembly
AA"3. Oxygen sensor
4. Turbocharger heat protector
5. Turbocharger water feed pipe
assembly connection
6. Turbocharger water return hose
connection
AB"7. Oil feed pipe
8. Starter Motor
9. Oil return pipe
"CA10. Oil return pipe gasket
11. Vacuum hose connection12. Air outlet fitting
"BA13. Air outlet fitting gasket
14. Exhaust fitting bracket
"AA15. Turbocharger assembly
16. Turbocharger
17. Exhaust fitting gasket
18. Exhaust fitting
19. Turbocharger gasket
20. Turbocharger water return pipe
assembly connection
21. Exhaust manifold
22. Exhaust manifold gasket

ENGINE ELECTRICAL -Starting System16-18
STARTER
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
DUnder Cover Removal and Installation (Refer to GROUP51 - Front Bumper.)
DCrossmember Bar Removal and Installation (Refer to GROUP 32 - Engine Roll Stopper, Centermember.)
DFront Exhaust Pipe Assembly Removal and Installation (Refer to GROUP 15.)
30±3 N·m
1 2
30±3 N·m 13±2 N·m
Removal steps
1. Starter connector
2. Starter
INSPECTION
PINION GAP ADJUSTMENT
1. Disconnect field coil wire from M-terminal of magnetic
switch.
2. Connect a 12 V battery between S-terminal and
M-terminal.
3. Set switch to “ON” position, and pinion will move out.
Caution
This test must be performed quickly (in less than
10 seconds) to prevent coil from burning.
4. Check pinion to stopper clearance (pinion gap) with a
thickness gauge.
Standard value: 0.5 - 2.0 mmS
Switch
Battery
Field coil wire M
B
Stopper
Pinion gap
Pinion

ENGINE ELECTRICAL -Starting System16-19
5. If pinion gap is out of specification, adjust by adding or
removing gaskets between magnetic switch and front
bracket.
MAGNETIC SWITCH PULL-IN TEST
1. Disconnect field coil wire from M-terminal of magnetic
switch.
2. Connect a 12 V battery between S-terminal and
M-terminal.
Caution
This test must be performed quickly (in less than
10 seconds) to prevent coil from burning.
3. If pinion moves out, then pull-in coil is good. If it doesn’t,
replace magnetic switch.
MAGNETIC SWITCH HOLD-IN TEST
1. Disconnect field coil wire from M-terminal of magnetic
switch.
2. Connect a 12 V battery between S-terminal and body.
Caution
This test must be performed quickly (in less than 10
seconds) to prevent coil from burning.
3. Manually pull out the pinion as far as the pinion stopper
position.
4. If pinion remains out, everything is in order. If pinion moves
in, hold-in circuit is open. Replace magnetic switch.
FREE RUNNING TEST
1. Place starter motor in a vise equipped with soft jaws
and connect a fully-charged 12 V battery to starter motor
as follows:
2. Connect a test ammeter (100-ampere scale) and carbon
pile rheostat in series with battery positive post and starter
motor terminal.
3. Connect a voltmeter (15 V scale) across starter motor.
4. Rotate carbon pile to full-resistance position.
5. Connect battery cable from battery negative post to starter
motor body.
6. Adjust the rheostat until the battery voltage shown by
the voltmeter is 11 V Reduction.
7. Confirm that the maximum amperage is within the
specifications and that the starter motor turns smoothly
and freely.
Current:
max. 90 A
Field coil wire S
M
Battery
B
Field coil wire S
Battery
M S
B
Starter
motorAmmeter
Battery
Voltmeter
Carbon-pile rheostat
A
V

ENGINE ELECTRICAL -Starting System16-21
DISASSEMBLY AND REASSEMBLY
1 1713
1512
4 3
211
6 1614
1098
7 5
182021
19
22
Disassembly steps
1. Cover
2. Screw
AA"3. Magnetic switch
4. Screw
5. Through
6. Rear bracket
7. Brush holder
8. Rear bearing
AB"9. Armature
10. Yoke assembly
AB"11. Ball12. Packing A
13. Packing B
14. Plate
15. Planetary gear
16. Lever
AC""AA17. Snap ring
AC""AA18. Stop ring
19. Overrunning clutch
20. Internal gear
21. Planetary gear holder
22. Front bracket

ENGINE ELECTRICAL -Starting System16-22
DISASSEMBLY SERVICE POINTS
AA"MAGNETIC SWITCH REMOVAL
Disconnect field coil wire from “M” terminal of magnetic switch.
AB"ARMATURE/BALL REMOVAL
Caution
When removing the armature, take care not to lose the
ball (which is used as a bearing) in the armature end.
AC"SNAP RING/STOP RING REMOVAL
1. Press stop ring off snap ring with a suitable socket.
2. Remove snap ring with snap ring pliers and then remove
stop ring and overrunning clutch.
STARTER MOTOR PARTS CLEANING
1. Do not immerse parts in cleaning solvent. Immersing the
yoke and field coil assembly and/or armature will damage
insulation. Wipe motor assembly with a cloth only.
2. Do not immerse drive unit in cleaning solvent. Overrunning
clutch is pre-lubricated at the factory and solvent will wash
lubrication from clutch
3. The drive unit may be cleaned with a brush moistened
with cleaning solvent and wiped dry with a cloth.
“B” terminal“S” terminal
“M” terminalField coil
wire
Socket
Overrunning
clutch Stop ring
Pinion gear
Snap ring pliers
Overrunning
clutch Pinion gear Snap ring

ENGINE ELECTRICAL -Starting System16-23
REASSEMBLY SERVICE POINT
"AASTOP RING/SNAP RING INSTALLATION
Using a suitable pulling tool, pull overrunning clutch stop ring
over snap ring.
INSPECTION
COMMUTATOR CHECK
1. Place the armature in a pair of “V” blocks and check
the runout with a dial indicator.
Standard value: 0.05 mm
Limit: 0.1 mm
2. Measure the commutator outer diameter.
Standard value: 29.4 mm
Limit: 28.8 mm
3. Check the undercut depth between segments.
Standard value: 0.5 mm
Limit: 0.2 mm
BRUSH HOLDER CHECK
Confirm that the spring is activated when the brush is pressed
into the brush holder by hand.
Replace the brush holder if the spring is not activated.
Stop ringOverrunning
clutchStop ring
Snap ring
Undercut
Segment
Mica

MANUAL TRANSMISSION - Troubleshooting 22A-31
INSPECTION CHART FOR TROUBLE SYMPTOMS
Trouble symptomInspection
procedure No.Reference
page
No communication possible between MUT-IIand all systems.122A-31
No communication possible between MUT-IIand 4WD-ECU.222A-32
ACD mode indicator lamp does not light up when the ignition switch is set to ”ON“
(engine is stopped).322A-33
More than two ACD mode indicator lamps remain lit even after the engine is started422A-34
The ACD does not operate (no diagnostic code).522A-34
The AYC does not operate (no diagnostic code).6Refer to
GROUPThe rear tire sounds when turning at low speed corners (vehicle slows down)7GROUP
27B.
Noise is produced from the torque transfer differential during turning.8
27B.
INSPECTION PROCEDURES FOR TROUBLE SYMPTOMS
Inspection procedure 1
No communication possible between MUT-IIand all
systems.
Probable cause
The diagnosis connector power supply circuit, earth circuit, or MUT-IImay be
faulty.DDiagnostic connector fault
DHarness or connector fault
DMUT-IIfault
OK
NG
NG
Check the harness between the fusible link No.1 and
diagnosis connector.
DCheck for open circuit or damage of the power line.
NG→Repair
OK
Check the trouble symptoms.
Measure at diagnosis connector C-22.
DVoltage between terminal 16 and body earth
OK:System voltageNGCheck the following connectors:
C-22, C-213, C-211, C-132
C-22, C-213, C-211, C-35, C-132
NG→Repair
Check the harness between the body earth and diagnosis
connector.
DCheck for open circuit and damage of the earth line.
NG→Repair
OK
Replace the MUT-II.
Measure at diagnosis connector C-22.
DResistance between terminals 4 and 5 and body earth.
OK:2Ωor less