2007 MITSUBISHI LANCER EVOLUTION Service Repair Manual

GENERAL -Vehicle Identification00-15
MODEL CODE
No.ItemsContents
1DevelopmentCT: MITSUBISHI LANCER
EVOLUTION-VII
2Engine type9: 1,997 mL petrol engine
3SortA: Passenger car
4Body styleS: 4-door sedan
5Transmission typeN: 5-speed manual
transmission
6Trim levelD: RS
G: RS-IIor GSR
7Specification engine
featureF: MPI-DOHC-intercooler
turbo
8Special featureZ: 4WD
9Steering wheel locationL: Left hand
R: Right hand
123456789 CT 9 A S N D F L
Z

GENERAL -Vehicle IdentificationGENERAL -Vehicle Identification00-16
CHASSIS NUMBER
The chassis number is stamped on the toeboard inside the
engine compartment.
1
234
5
67
8911
10
No.ItemsContents
1Fixed figureJAsia
2Distribution channelMJapan channel
3DestinationYFor Europe and General Export
4Body styleS4-door sedan
5Transmission typeN5-speed manual transmission
6Development orderCTMITSUBISHI LANCER EVOLUTION-VII
7Engine94G63: 1,997 mL petrol engine
8SortAPassenger car
9Model year22002
10PlantUMIZUSHIMA-1
11Serial number--
ENGINE MODEL NUMBER
1. The engine model number is stamped on the cylinder
block as shown below.
Engine modelEngine displacement mL
4G631,997
2. The engine serial number is stamped near the engine
model number.
Engine serial numberAA0201 to YY9999

GENERAL -Major Specifications00-17
MAJOR SPECIFICATIONS
1
234
5
6 78
9
ItemsCT9A
SNDFZL/RSNGFZL/R
Vehicle
di i
Front track11,500, 1,515*1
dimensions
mmOverall width21,770mm
Front overhang3895
Wheel base42,625
Rear overhang5935
Overall length64,455
Ground clearance
(unladen)7140
Overall height (unladen)81,450
Rear track91,500, 1,515*1
Vehicle
ihtk
Kerb weight1,3201,380
weight kgMax. gross vehicle weight1,6551,695
Max. axle weight
rating-front950970
Max. axle weight
rating-rear705725
Seating capacity5
EngineModel No.4G63g
Total displacement mL1,997
Transmis-
i
Model No.W5M51
sionType5-speed manual
Fuel systemFuel supply systemMPI
NOTE
*1: Vehicles with 17 inch wheels.

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)00-21
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
To improve safety, the SRS and seat belts with
pre-tensioner. These systems enhance collision
safety by restraining the front passengers in case
of an accident. The SRS works with the
pre-tensioner simultaneously when a collision is
detected.
The SRS consists of two air bag modules, SRS
air bag control unit (SRS-ECU), SRS warning lamp
and clock spring. The air bags are located in the
center of the steering wheel, above the glove box.
Each air bag has a folded air bag and an inflator
unit. The SRS-ECU under the floor console monitors
the system and has a safing G-sensor and an
analog G-sensor. The warning lamp on theinstrument panel indicates the operational status
of the SRS. The clock spring is installed in the
steering column. The seat belt pre-tensioner is built
into the front seat belt retractor. Only authorized
service personnel should do work on or around
the SRS components and seat belt with
pre-tensioner. Those service personnel should read
this manual carefully before starting any such work.
Extreme care must be used when servicing the
SRS to avoid injury to the service personnel (by
inadvertent deployment of the air bags or
inadvertent operation of the seat belt with
pre-tensioner) or the driver (by rendering the SRS
or the seat belt with pre-tensioner inoperative).
Diagnosis
connectorFront passenger’s
air bag module
Clock spring Driver’s air bag
module
SRS-ECU
SRS warning lamp
Driver’s air bag
Front
passenger’s
air bag
Seat belt with
pre-tensioner

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