2007 MITSUBISHI LANCER EVOLUTION engine oil

ENGINE AND EMISSION CONTROL -Emission Control System17-5
SERVICE SPECIFICATIONS
ItemsStandard value
Purge control solenoid valve coil resistance (at 20_C)Ω30 - 34
EGR control solenoid valve coil resistance (at 20_C)Ω29 - 35
VACUUM HOSE
VACUUM HOSE PIPING DIAGRAM
Fuel
pressure
control
solenoid
valve
Oxygen
sensor
(front)
Check
valve
Fuel
pressure
regulator
PCV valve To
fuel tank
Oxygen sensor (rear) From
fuel pump
Air
inletEGR control
solenoid valve
Purge
control
solenoid
valveCanisterFrom
fuel tank
EGR
valve Injector
Three - way
catalytic converter A
P
E

MANUAL TRANSMISSION -General/General Information/
Service Specification/Lubricants22A-3
GENERAL
OUTLINE OF CHANGE
With the addition of the EVOLUTION-VII, the W5M51 transmission service adjustment procedure has
been set as follows.
GENERAL INFORMATION
ItemsSpecifications
GradeRS, RS IIRS, RS II (With super cross gear)
Transmission modelW5M51
Engine model4G63-DOHC-T/C
Type5-speed, floor-shift
Gear ratio1st2.7852.785
2nd1.9501.950
3rd1.4071.444
4th1.0311.096
5th0.7200.825
Reverse3.4163.416
Final reduction ratio
(Differential gear ratio)4.5294.529
Front limited-slip differential
(Helical-gear type)Not providedProvided
TransferReduction ratio3.3073.307
Limited-slipdifferentialVCU or hydraulic multi plate
clutch (ACD)VCU or hydraulic multi plate
clutch (ACD)
SERVICE SPECIFICATION
ItemStandard value
Hydraulic unit generation oil pressureMPa1.0 - 1.6
LUBRICANTS
ItemSpecified lubricantQuantity L
Transmission oilGear oil SAE 75W-90 or 75W-85W conforming to API GL-42.8
Transfer
oilVehicles without ACD or ve-
hicles without ACD and AYCMITSUBISHI Genuine Gear Oil Part No.8149630 EX,
CASTROL HYPOY LS (GL-5, SAE 90), SHELL-LSD
(GL 5SAE80W90)orequivalent
0.55
Vehicles with ACD or vehicles
with ACD and AYC(GL-5, SAE 80W - 90) or equivalent0.6
FluidPiping between ACD and
hydraulic unitDIA QUEEN ATF SP III0.9
Pipes between ACD and hy-
draulic unit and between AYC
and hydraulic unit1.0

MANUAL TRANSMISSION - Special Tools22A-4
SPECIAL TOOLS
ToolNumberNameUse
MB991502MUT-IISub as-
semblyDiagnosis code checking
MB991529Diagnosis code
checking harness
MB991348Test harness setGsensor check
MD998330
(including
MD998331)Oil pressure gauge
(3.0 MPa)Hydraulic pressure measurement
MB991705Adapter
MB990635,
MB991113 or
MB991406
Steering linkage
pullerTie rod end and lower disconnection
GENERAL
SERVICE
TOOL
MZ203827Engine lifterSupporting the engine assembly during
removal and installation of the transmission
MB991453Engine hangerat-
tachment set
MB991721Slide hammerOutput shaft removal

MANUAL TRANSMISSION - Troubleshooting 22A-34
Inspection procedure 4
More than two ACD mode indicator lamps remain lit even
after the engine starts
Probable cause
The output circuit of the ACD mode indicator lamp may be faulty.DHarness or connector fault
D4WD-ECU fault
DACD mode indicator lamp assembly fault
NOTE
This phenomenon occurs only when communication with the MUT-IIis possible (4WD-ECU power supply
fault) and at the same time, no diagnostic code (no trouble code) is output.
NO
Replace the 4WD-ECU.
Do all the ACD mode indicator lamps go off when 4WD-ECU
connector C-43 is disconnected?
YES
Replace the ACD mode indicator lamp assembly.OK
NG
Check the trouble symptoms.
Check the following connectors:
C-43, C-128, C-01
C-43, C-01
NG→Repair
OK
Check the harness between the ACD mode indicator lamp
assembly and 4WD-ECU.
DCheck for ground and short circuit of output line.
NG→Repair
Inspection procedure 5
ACD does not operate (No diagnosis code)
Probable cause
Insufficient operating oil, oil leakage, faulty operations of the oil pressure unit, and
faulty operations of the ACD transfer may be suspected.DLeakage of transfer oil
DInsufficient transfer oil
DLeakage of oil pressure line
DInsufficient fluid
DHydraulic unit fault
DACD transfer fault
NOTE:
1. This malfunction is restricted to only when no diagnostic code (no trouble code) is output.
2. *: Refer to GROUP 22B.
OK
NG OKNG OKNG
NG
NO
NG
OK
Replenish transfer oil.
Replace the oil pressure unit.
Have foreign particles mixed into the oil pressure line?
YES→Repair
Check the hydraulic pressure (P.22A-43).Perform bleeding (P.22A-42).
Check the fluid (P.22A-41).Check for leakage of the oil pressure line.
NG→Repair
Check the transfer oil (P.22A-40).Check for leakage of the transfer oil.
NG→Repair
Check the trouble symptoms.
Replace the ACD transfer.*OK
Replenish the fluid.
OK
NG
Check the operations of the ACD (P.22A-42).Check the trouble symptoms.

MANUAL TRANSMISSION - Troubleshooting 22A-36
Item
no.Normal conditions Check condition Check item
19Pressure sensor power
supplyIgnition switch: ONApprox.5 V
20Valve power supplyIgnition switch: ONSystem voltage
21Steering wheel sensor
voltage Ignition switch: ONSteering wheel: Turn1 - 2 V and 2.5 - 4.5 V
are displayed alter-
nately.
22Steering wheel sensor
voltage Ignition switch: ONSteering wheel: Turn1 - 2 V and 2.5 - 4.5 V
are displayed alter-
nately.
23Steering wheel sensor
ltSTN
Ignition switch: ONSteering wheel: Neutral1-2Vg
voltage
g
Steering wheel: Turn2.5 - 4.5 V
51Idle switchIgnition switch: ONAccelerator pedal: Full
closedON
Accelerator pedal: PressOFF
52Steering wheel sensor
STN
Ignition switch: ONsteering wheel: NeutralONg

g
Steering wheel: Turn from
the neutral positionOFF
53Steering wheel sensor
Ignition switch: ONSteering wheel: Turn slowlyON and OFF are dis-
played alternaltely.
54Steering wheel sensor
Ignition switch: ONSteering wheel: Turn slowlyON and OFF are dis-
played alternately
55Steering wheel sensor
learning Perform actual drivingSteering wheel sensor neu-
tral position learning exe-
cutedON
Steering wheel sensor neu-
tral position learning unex-
ecutedOFF
56Stop lamp switchIgnition switch: ONBrake pedal: DepressONppg
Engine: StoppedBrake pedal: ReleaseOFF
57Motor monitorElectric pump motor is currently operatingON
Electric pump motor is currently not operatingOFF
58Oil pressure stateElectric pump motor is currently operatingLOWp
Electric pump motor is currently not operatingHIGH
59Directional valve
Ri ht
AYC clutch right side is currently operatingON
AYC clutch right side is currently not operatingOFF
60Directional valve
Lft
AYC clutch left side is currently operatingON
AYC clutch left side is currently not operatingOFF
61ABS monitorABS is currently operatingON
ABS is currently not operatingOFF
62Parking brake switchIgnition switch: ONParking brake lever: PullONgg
Engine:StoppedParking brake lever: Re-
leaseOFF
63ACD mode switchIgnition switch: ONACD mode switch: PressONg
Engine:StoppedACD mode switch: ReleaseOFF

MANUAL TRANSMISSION - On-vehicle Service22A-42
BLEEDING VEHICLES WITH ACD AND AYC>
1. Lift up the vehicle.
2. Set the MUT-IIto the 16-pin diagnosis connector.
Caution
Turn the ignition switch to the “LOCK”(OFF) position
before connecting or disconnecting the MUT-II.
3. Turn the ignition switch to the “ON” position.
4. Set the steering wheel in the straight-ahead position.
5. Perform the MUT-IIactuator test (Item No.02), and forcibly
drive the hydraulic unit.
NOTE
(1) The actuator test (Item No.01: Bleeding Mode) will
be performed for 5 minutes, after which it will be
cleared automatically. Drive can also be cleared during
forced driving using the clear key of the MUT-II.
(2) If the hydraulic unit function has been stopped by
fail-safe, the hydraulic unit cannot be forcibly driven.
6. Remove the cap of the bleeder screw on the transfer,
and connect the vinyl hose.
7
.Slowly turn the steering wheel to the left or right from
the neutral state. Loosen the bleeder screw, and check
that air is discharged together with the fluid.
8
.After the air is discharged, tighten the bleeder screw,
and return the steering wheel to the neutral state.
Caution
During bleeding, replenish the fluid so that some
always remains in the oil reservoir.
9. Repeat steps 6 and 7 several 2 to 3 times, and after
checking that no more air mixes in, tighten the bleeder
screw at the specified torque.
Tightening torque: 5±1 N·m
10. After bleeding, check the fluid level. (Refer to P. 22A-41.)
Caution
If bleeding is not performed completely, noise may
be produced from the hydraulic unit, or the durability
of the pump, etc. may drop.
11. On vehicles with AYC, perform bleeding when the
hydraulic unit is removed. (Refer to GROUP 27B -
On-vehicle Service.)
ACD OPERATION CHECK ACD OR VEHICLES WITH ACD AND AYC>
1. Lift up the vehicle.
2
.Set the MUT-IIto the 16-pin diagnosis connector.
Caution
Turn the ignition switch to the “LOCK”(OFF) position
before connecting or disconnecting the MUT-II.
3. Start the engine.
Bleeder screw
Front exhaust pipe

MANUAL TRANSMISSION - On-vehicle Service22A-43
4. Set the gear to the 2nd gear or above, operate the MUT-II,
and check from the service data (Item No.09) that the
wheel speed is within 10 km/h to 20 km/h.
NOTE
(1) Set the steering wheel to the neutral position
(2) The ACD may continue operating (operation sounds
can be heard) when the steering wheel is steered,
this is not a system fault. In this case, set the steering
wheel to the neutral position, and perform the following
operations to stop the ACD.
DRelease the clutch.
DSet the gear to “N”.
DStop the engine
5. Perform the MUT-IIactuator test (Item No.05), and forcibly
drive the transfer.
NOTE
(1) The actuator test (Item No. 05: ACD Operation Check
Mode) is performed for 1 minute, after which it will
be cleared automatically. Drive can also be cleared
during forced driving using the clear key of the MUT-II.
(2) If the hydraulic unit function has been stopped by
fail-safe, the transfer cannot be forcibly driven.
6. Check that the front and rear wheel speeds satisfy the
following in the MUT-IIactuator test (Item No.05).

The front wheel will be faster than the back wheels by
more than 2 km/h.
NOTE
If the above are not satisfied, check the oil pressure as
the system may be faulty.
HYDRAULIC PRESSURE CHECK WITH ACD OR VEHICLES WITH ACD AND AYC>
1. Lift up the vehicle.
2. Set the MUT-IIto the 16-pin diagnosis connector.
Caution
Turn the ignition switch to the “LOCK”(OFF) position
before connecting or disconnecting the MUT-II.
3. Disconnect the hydraulic unit and transfer connector
assembly, and connect the special tool to the hydraulic
unit.
4. Turn the ignition switch to “ON”.
5. Perform the MUT-IIactuator test (Item No.05), and forcibly
drive the hydraulic unit.
NOTE
(1) The actuator test (Item No. 05 ACD Operation Check
Mode) is performed for 1 minute, after which it will
be cleared automatically. Drive can also be cleared
during forced driving using the clear key of the MUT-II.
MD998330
MB991705

MANUAL TRANSMISSION - Transfer Assembly22A-49
TRANSFER ASSEMBLY
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
DUnder Cover Removal and Installation (Refer to GROUP 51 - Front Bumper.)
DSide Under Cover Removal and Installation
DTransmission Oil Draining and Supplying (Refer to P.22A-40.)
DTransfer Oil Draining and Supplying (Refer to P.22A-40.)
DEngine Coolant Draining and Supplying (Refer to GROUP 14 - On-vehicle Service.)
DCrossmember Bar Removal and Installation (Refer to GROUP 32 - Engine Roll Stopper, Centermember.)
DFront Exhaust Pipe Removal and Installation (Refer to GROUP 15 - Exhaust Pipe and Main Muffler.)
DBattery and Battery Tray Removal and Installation
DAir Cleaner, Air Intake Hose Removal and Installation (Refer to GROUP 15 - Air Cleaner.)
DSecondary Air Hose Removal and Installation (Refer to GROUP 15 - Secondary Air Control System.)
DStrut Tower Bar Removal and Installation (Refer to GROUP 42.)
DAir Hose E, Air By-pass Hose and Air By-pass Valve, Air Pipe C, Air Hose D, Air Pipe B, Air Hose A Removal and
Installation (Refer to GROUP 15 - Intercooler.)
DRadiator Removal and Installation (Refer to GROUP 14.)
DBleeding and Hydraulic Pressure Check (Refer to P.22A-42, 43)
12 3
4
5 6 7
8
25±5 N·m
108±10 N·m
39±5 N·m
39±5 N·m
245±29 N·m
Removal steps
1. Stabilizer bar connection
2. Stabilizer link
3. Wheel speed sensor cable clamp
and brake hose clampAA"4. Tie rod end connection
5. Lower arm ball joint connection
AB"6. Drive shaft connection
AB"7. Drive shaft connection
AC"8. Output shaft