2007 MITSUBISHI LANCER EVOLUTION to pair

GENERAL -How to Use This Manual00-5
Denotes tightening torque.
For bolts and nuts which do not
have a tightening torque listed,
refer to the “Standard Parts-
tightening-torque Table”.
indicates that there is
a continuity between the termi-
nals.
indicates terminals to
which battery voltage is applied.
Indicates the
section title.Indicates the
group num-
ber.Indicates the
page number.Indicates the
group title.
denotes non-re-
usable part.
Repair kit or set parts
are shown. (Only very
frequently used parts
are shown.)
Operating procedures, cau-
tions, etc. on removal, installa-
tion, disassembly and reas-
sembly are described.
The title of the page (following
the page on which the diagram
of component parts is pres-
ented) indicating the locations of
lubrication and sealing proce-
dures.

GENERAL -How to Use Troubleshooting/Inspection Service Points00-10
HOW TO USE THE INSPECTION PROCEDURES
The causes of a high frequency of problems occurring in electronic circuitry are generally the connectors,
components, the ECU and the harnesses between connectors, in that order. These inspection procedures
follow this order, and they first try to discover a problem with a connector or a defective component.
DIndicator does not turn on or off even if control
mode switch is pressed.
DIndicator switch should not be illuminated is
illuminated.Probable cause
OK
OK
OK
Measure at switch connector A-44
DDisconnect the connector, and measure at the harness
side.
DVoltage between terminal 6 - earth and terminal 8 -
earth
OK:Approx. 5V
OK
NG
Check the following connector.A-44
Repair
OK
Check trouble symptom.
Replace the ECS-ECU.
In the above cases, the ECS switch circuit is defective or the indicator
circuit is defective.
CHECKING PROCEDURE 4
2. Indicates inspection carried out using the
MUT-II.
Indicates the operation and inspection proce-
dures.
Indicates the OK judgement conditions.
3. Detailed inspection procedures (methods)
such as component inspection and circuit
inspection are listed on a separate page, and
are given here for reference.
5. Inspect the contact condition at each connector terminal.
(Refer to Connector Inspection Service Points.)
The connector position can be located in the wiring diagram in the
electrical wiring manual by means of this symbol.
Caution
After carrying out connector inspection, always be sure to
reconnect the connector as it was before.
6. Confirm that there are trouble symptoms. If trouble symptoms have
disappeared, the connector may have been inserted incorrectly and the
trouble symptom may have disappeared during inspection.
If it seems that trouble symptoms still remain, proceed to the next page of
instructions.
7. If trouble symptoms still remain up to this stage, there is a possibility that there is an
open or short circuit in the harness between the connectors, so check the harness.
Alternatively, the cause may be a defective ECU, so try replacing the ECU and check
if the trouble symptom disappears.
NGECU switch component inspection (Refer to P.33-44.)
NG
1. Comments on the diagnosis code or trouble
symptom above.
MUT-IIData list
17 Control mode selection switch
OK:Voltage changes between approx. 0V→approx.
2.5V→approx. 5V when the switch is operated.
4. Indicates voltage and resistance to be measured at a particular
connector.
(Refer to Connector Measurement Service Points.)
The connector position can be located in the wiring diagram in the
electrical wiring manual by means of this symbol.
Indicates operation and inspection procedures, inspection terminals
and inspection conditions.
Indicates the OK judgement conditions.
HARNESS INSPECTION
Check for an open or short circuit in the harness between the terminals which were defective according
to the connector measurements. Carry out this inspection while referring to the electrical wiring manual.
Here, “Check harness between power supply and terminal xx” also includes checking for blown fuses.
For inspection service points when there is a blown fuse, refer to “Inspection Service Points for a Blown
Fuse.”
MEASURES TO TAKE AFTER REPLACING THE ECU
If the trouble symptoms have not disappeared even after replacing the ECU, repeat the inspection procedure
from the beginning.

GENERAL -Precautions Before Service00-18
PRECAUTIONS BEFORE SERVICE
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
1. Items to follow when servicing SRS
(1) Be sure to read GROUP 52B - Supplemental Restraint System (SRS).
For safe operations, please follow the directions and heed all warnings.
(2) Wait at least 60 seconds after disconnecting the battery cable before doing any further work.
The SRS system is designed to retain enough voltage to deploy the air bag even after the battery
has been disconnected. Serious injury may result from unintended air bag deployment if work
is done on the SRS system immediately after the battery cable is disconnected.
(3) Warning labels must be heeded when servicing or handling SRS components. Warning labels
are located in the following locations.
DSun visor
DGlove box
DSRS-ECU
DSteering wheel
DSteering Joint Cover
DAir bag module (driver’s side and front passenger’s side)
DClock spring
DSeat belt with pre-tensioner
(4) Always use the designated special tools and test equipment.
(5) Store components removed from the SRS in a clean and dry place.
The air bag module should be stored on a flat surface and placed so that the pad surface is
facing upward.
Do not place anything on top of it.
(6) Never attempt to disassemble or repair the SRS components (SRS-ECU, air bag module, clock
spring and seat belt with pre-tensioner).
(7) Whenever you finish servicing the SRS, check the SRS warning lamp operation to make sure
that the system functions properly.
(8) Be sure to deploy the air bag before disposing of the air bag module or disposing of a vehicle
equipped with an air bag. (Refer to GROUP 52B - Air Bag Module Disposal Procedures.)
2. Observe the following when carrying out operations on places where SRS components are installed,
including operations not directly related to the SRS air bag.
(1) When removing or installing parts do not allow any impact or shock to the SRS components.
(2) SRS components should not be subjected to heat, so remove the SRS components before drying
or baking the vehicle after painting.
DSRS-ECU, air bag module, clock spring: 93_C or more
DSeat belt with pre-tensioner: 90_C or more
After re-installing them, check the SRS warning lamp operation to make sure that the system
functions properly.

GENERAL -Precautions Before ServiceGENERAL -Precautions Before Service00-19
SERVICING THE ELECTRICAL SYSTEM
Before replacing a component related to the electrical system
and before undertaking any repair procedures involving the
electrical system, be sure to first disconnect the negative
( - ) cable from the battery in order to avoid damage caused
by short-circuiting.
Caution
Before connecting or disconnecting the negative ( - ) cable,
be sure to turn off the ignition switch and the lighting
switch.
(If this is not done, there is the possibility of
semiconductor parts being damaged.)
APPLICATION OF ANTI-CORROSION AGENTS
AND UNDERCOATS
If oil or grease gets onto the oxygen sensor, it will cause
a drop in the performance of the sensor.
Cover the oxygen sensor with a protective cover when applying
anti-corrosion agents and undercoats.
PRE-INSPECTION CONDITION
“Pre-inspection condition” refers to the condition that the
vehicle must be in before proper engine inspection can be
carried out. If you see the words “Set the vehicle to the
pre-inspection condition”. in this manual, it means to set the
vehicle to the following condition.
DEngine coolant temperature: 80 to 90_C
DLamps, electric cooling fan and all accessories: OFF
DM/T: Neutral
DA/T: P range
VEHICLE WASHING
If high-pressure car-washing equipment or steam car-washing
equipment is used to wash the vehicle, be sure to note the
following information in order to avoid damage to plastic
components, etc.
DSpray nozzle distance: Approx. 40 cm or more
DSpray pressure: 3,900 kPa or less
DSpray temperature: 82_C or less
DTime of concentrated spray to one point: within 30 sec.
Approx.
40 cm

GENERAL -Precautions Before ServiceGENERAL -Precautions Before Service00-20
MUT-II
Refer to the “MUT-IIREFERENCE MANUAL” or “MUT-II
OPERATING INSTRUCTIONS” for instructions on handling
the MUT-II.
Connect the MUT-IIto the diagnosis connector as shown
in the illustration.
Caution
Turn the ignition switch to the LOCK (OFF) position before
connecting or disconnecting the MUT-II.
IN ORDER TO PREVENT VEHICLES FROM FIRE
“Improper installation of electrical or fuel related parts could cause a fire. In order to retain the high
quality and safety of the vehicle, it is important that any accessories that may be fitted or modifications/repairs
that may be carried out which involve the electrical or fuel systems, MUST be carried out in accordance
with MMC’s information/Instructions”.
ENGINE OILS
Health Warning
Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin,
leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful
contaminants which may cause skin cancer. Adequate means of skin protection and washing facilities
must be provided.
Recommended Precautions
The most effective precaution is to adapt working practices which prevent, as far as practicable, the
risk of skin contact with mineral oils, for example by using enclosed systems for handling used engine
oil and by degreasing components, where practicable, before handling them.
Other precautions:
DAvoid prolonged and repeated contact with oils, particularly used engine oils.
DWear protective clothing, including impervious gloves where practicable.
DAvoid contaminating clothes, particularly underpants, with oil.
DDo not put oily rags in pockets, the use of overalls without pockets will avoid this.
DDo not wear heavily soiled clothing and oil-impregnated foot-wear. Overalls must be cleaned regularly
and kept separately from personal clothing.
DWhere there is a risk of eye contact, eye protection should be worn, for example, chemical goggles
or face shields; in addition an eye wash facility should be provided.
DObtain First Aid treatment immediately for open cuts and wounds.
DWash regularly with soap and water to ensure all oil is removed, especially before meals (skin cleansers
and nail brushes will help). After cleaning, the application of preparations containing lanolin to replace
the natural skin oils is advised.
DDo not use petrol, kerosine, diesel fuel, gas oil, thinners or solvents for cleaning skin.
DUse barrier creams, applying them before each work period, to help the removal of oil from the skin
after work.
DIf skin disorders develop, obtain medical advice without delay.
MUT-II
sub-assembly
ROM pack
MUT-˜

GENERAL -Supplemental Restraint System (SRS)00-22
SRS SERVICE PRECAUTIONS
1. In order to avoid injury to yourself or others
from accidental deployment of the air bag and
accidental operation of the seat belt with
pre-tensioner during servicing, read and
carefully follow all the precautions and
procedures described in this manual.
2. Do not use any electrical test equipment on
or near SRS components, except those
specified on P.52B-6.
3. Never Attempt to Repair the Following
Components:
DSRS air bag control unit (SRS-ECU)
DClock spring
DDriver’s and front passenger’s air bag
modules
DSeat belt with pre-tensionerNOTE
If any of these components are diagnosed as
faulty, they should only be replaced, in
accordance with the INDIVIDUAL COM-
PONENTS SERVICE procedures in this
manual. (Refer to P.52B-49.)
4. After disconnecting the negative (–) battery cable,
wait 60 seconds at least before any service and
insulate the disconnected cable with tape. The SRS
retain enough voltage to deploy the air bags for a
short time even after the disconnection of the battery.
So, serious injury may result by accidental air bag
deployment if a work is done on the SRS just after
the disconnection of the battery.
5. Do not attempt to repair the wiring harness connectors
of the SRS. If the connector(s) are diagnosed as defective,
replace the wiring harness(es). If the harness(es) are
diagnosed as faulty, replace or repair the wiring
harness(es) according to the table that follows.
Insulating tape
Battery
SRS-ECU connector

GENERAL -Supplemental Restraint System (SRS)00-23
SRS-ECU
Terminal No.Destination of harnessCorrective action
7Instrument panel wiring harness→EarthRepair or replace each wiring
harness
8Instrument panel wiring harness→Combination meter
(SRS warning lamp)
harness
9, 10Instrument panel wiring harness→Front passenger’s air bag
module
11 , 1 2Instrument panel wiring harness→Clock spring→Driver’s air bag
module)Repair or replace the dash wiring
harness. Replace clock spring.
13Instrument panel wiring harness→Junction block (fuse No.3)Repair or replace each wiring
harness
16Instrument panel wiring harness→Junction block (fuse No.2)
harness.
20Instrument panel wiring harness→Diagnosis connector
29, 30Floor wiring harnessàDriver’s seat belt pre-tensioner
27, 28Floor wiring harnessàFront passenger’s seat belt pre-tensioner
6. Inspection of the SRS-ECU harness connector should be carried out by the following procedure.
Insert the special tool (probe, MB991222, in the harness set) into the connector from harness side
(rear side), and connect the tester to this probe. If any tool than specified is used, damage to the
harness and other components will result. Furthermore, measurement should not be carried out by
touching the probe directly against the terminals from the front of the connector. The terminals are
plated to increase their conductivity, so that if they are touched directly by the probe, the plating
may break, which will cause drops in reliability.
MB991222 SRS-ECU harness connector
SRS-ECU harness connector (rear view)
7. SRS components and seat belt with pre-tensioner should not be subjected to hart, so remove the
SRS-ECU, driver’s and front passenger’s air bag modules, clock spring, and seat belt with pre-tensioner
before drying or baking the vehicle after painting.
DSRS - ECU, air bag module, clock spring : 93Æ
or more
DSeat belt with pre-tensioner : 90Æ
or more
8. Whenever you finish servicing the SRS, check warning lamp operation to make sure that the system
functions properly. (Refer to P.52B-6.)
9. Make certain that the ignition switch is LOCK (OFF) position when the MUT-IIis connected or
disconnected.
10. If you have any questions about the SRS, please contact your local distributor.
NOTE
SERIOUS INJURY CAN RESULT FROM UNINTENDED AIR BAG DEPLOYMENT, SO USE ONLY
THE PROCEDURES AND EQUIPMENT SPECIFIED IN THIS MANUAL.

ENGINE OVERHAUL -Crankshaft and Cylinder Block11B-68
INSPECTION
1. CRANKSHAFT OIL CLEARANCE (PLASTIC GAUGE
METHOD)
The oil clearance can be measured easily by using the
“plastic gauge”.
Use the following steps to use the “plastic gauge”.
(1) Wipe off all oil from the crankshaft’s outer diameter
and bearing’s inner diameter.
(2) Assemble the crankshaft.
(3) Set a plastic gauge as long as the bearing width
on the journal shaft so that straightly aligned with
the shaft centre.
(4) Carefully install the beam bearing cap, and tighten
the bolt at the specified torque 25±2N•m+90_
to 100_.
(5) Remove the bolt, and carefully remove the beam
bearing cap.
(6) Measure the width of the crushed plastic gauge (at
the section crushed the most) with the scale printed
on the plastic gauge bag.
Standard value: 0.03 - 0.04 mm
Limit value: 0.1 mm
2. CYLINDER BLOCK
(1) Visually check for the presence of scratches, rusting,
or corrosion, and using flaw detection agent, etc.,
check for cracks. If any faults are found, repair or
replace the part.
(2) Using a straight edge and thickness gauge, measure
the flatness of the cylinder block’s upper surface.
Make sure that no gasket pieces, etc., are adhered
to the upper surface of the cylinder block when
measuring.
Standard value: 0.05 mm
Limit value: 0.1 mm
(3) Check for the presence of scratches or seizure on
the cylinder wall. If any faults are found, repair (over
size) or replace the part.
(4) Using a cylinder gauge, measure the inner diameter
and cylindricity of the cylinder. If greatly worn, repair
the cylinder to the over size, and replace the piston
ring.
Standard value: 85.0 mm
Cylindricity: 0.01 mm
Plastic gauge
12 mm