00
11
12
13
14
15
16
17
21
22
25
26
27
31
32
33
34
35
36
37
42
51
52
54
55
General........................
Engine .........................
Engine Lubrication .............
Fuel ...........................
Engine Cooling .................
Intake and Exhaust ............
Engine Electrical ...............
Engine and Emission Control ....
Clutch .........................
Manual Transmission ...........
Propeller Shaft .................
Front Axle ......................
Rear Axle ......................
Wheel and Tyre .................
Power Plant Mount ..............
Front Suspension ...............
Rear Suspension ...............
Service Brakes .................
Parking Brakes .................
Steering ........................
Body ...........................
Exterior ........................
Chassis Electrical ..............
Electrical Wiring ................
Body Repair ....................
WORKSHOP
MANUAL
FOREWORD
This Workshop Manual contains procedures for
service mechanics, including removal, disassembly,
inspection, adjustment, reassembly and
installation. Use the following manuals in
combination with this manual as required.
TECHNICAL INFORMATION MANUAL N0104CT9A
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.
The EVOLUTION-VII is sold exclusively through
RALLIART Inc. Since the EVOLUTION-VII is a
rally-based model, it will not be warranted and will
not be homologated for general production.
Therefore, any service matters on the
EVOLUTION-VII should be inquired to RALLIART
Inc. as usual.
EMitsubishi Motors Corporation May 2001
Interior and Supplemental
Restraint System (SRS) ........
Heater, Air Conditioner and
Ventilation .....................
BODY CONSTRUCTION -Body ComponentsA-3
1. Headlamp support panel
2. Hood lock stay
3. Front end crossmember
4. Front end upper bar
5. Headlamp support panel side
6. Front fender shield
7. Front upper frame inner
8. Upper frame bulkhead front
9. Upper frame bulkhead
10. Upper frame bulkhead rear
11. Front sidemember inner
12. Engine mount bracket
13. Front sidemember rear
14. Front sidemember outer
15. Spring house panel
16. Dash panel
17. Dash panel silencer
18. Dash panel reinforcement
19. Upper frame to front pillar brace
20. Upper frame extension outer
21. Upper frame extension inner
22. Cowl top lower panel
23. Cowl top inner panel
24. Cowl top upper panel
25. Front deck crossmember
26. Hood inner panel
27. Hood outer panel
28. Front roof rail
29. Front roof bow
30. Roof panel
31. Rear roof bow
32. Rear roof rail
33. Seat back plate
34. Rear seat back panel
35. Rear shelf panel
36. Rear seat back brace
37. Trunk lid outer panel
38. Trunk lid inner panel
39. Trunk lid hinge
40. Quarter inner extension rear
41. Quarter corner panel42. Rear combination lamp housing
43. Side roof rail inner
44. Front pillar inner upper
45. Front pillar inner lower
46. Center pillar inner
47. Side outer panel
48. Rear wheel house inner panel
49. Quarter inner panel
50. Rear floor side brace
51. Quarter outer extension lower
52. Fuel filler door
53. Rear license plate bracket
54. Rear end panel outer
55. Rear end panel inner
56. Rear door outer panel
57. Rear door side door beam
58. Rear door inner panel
59. Front door outer panel
60. Front door side door beam
61. Front door inner panel
62. Fender panel
63. Front floor crossmember rear
64. Front floor crossmember front
65. Front floor side sill inner
66. Front floor sidemember
67. Backbone reinforcement
68. Installment panel center bracket reinforcement
69. Front floor pan
70. Front floor extension panel rear
71. Rear floor extension
72. Rear floor pan
73. Seat back plate extension
74. Jack bracket
75. Spare tire bracket
76. Towing hook reinforcement
77. Rear floor sidemember extension
78. Crossmember center support
79. Rear floor crossmember
80. Rear floor sidemember
81. Rear seat back reinforcement
BODY CONSTRUCTION -Body Construction CharacteristicsA-13
SIDE BODY
Side Structure
1 2710
4 5
68 911
1213
1415
320 17
18
19 16
2425
26 22
23 21
27
28
3231
30 33 3438
37 41
40
39
36
3529 424344
45
3646
4748
1. Front pillar reinforcement lower extension
2. Front pillar inner lower extension
3. Front pillar reinforcement lower
4. Front door hinge reinforcement lower
5. Front door check reinforcement
6. Side sill to floor plate
7. Front pillar inner lower
8. Front door hinge reinforcement upper
9. Deck crossmember bracket front
10. Deck crossmember bracket
11. Front pillar inner upper
12. Front pillar inner upper reinforcement (LHD,
Left side)
13. Side roof rail inner
14. Rear seat back brace
15. Rear shelf upper brace
16. Rear shelf lower brace (Europe and General
Export spec. models)
17. Rear pillar inner
18. Quarter inner panel
19. Oil tank bracket (Vehicles with ACD, Left side)
20. Rear pillar reinforcement
21. Rear floor side brace
22. Rear floor brace reinforcement (Vehicles with
ACD, Left side)
23. Fuel filler neck bracket (Left side)24. Quarter inner extension rear
25. Quarter corner panel
26. Rear combination lamp housing
27. Rear bumper bracket
28. Quarter outer extension lower
29. Striker reinforcement
30. Side outer panel
31. Side sill outer reinforcement rear
32. Side sill outer reinforcement center
33. Side sill outer reinforcement front
34. Side sill reinforcement support
35. Side sill (A) bulkhead (LHD, Left side)
36. Side sill bulkhead
37. Center pillar reinforcement
38. Rear door hinge reinforcement lower
39. Rear door hinge reinforcement upper
40. Center pillar inner
41. Front pillar reinforcement upper
42. Center pillar seatbelt reinforcement
43. Rear seatbelt wheel house reinforcement
44. Spring house brace
45. Rear wheel house inner panel
46. Spring house panel
47. Spring house bracket
48. Side sill end plate
BODY CONSTRUCTION -Body Construction CharacteristicsA-18
Rear Floor
1 23
4
5
6
7
8
9
10
11
12
13
14
15 16
17 18
1. Rear floor pan
2. Seat back plate extension
3. Jack bracket
4. Spare tire bracket
5. Rear seat back reinforcement
6. Towing hook reinforcement
7. Crossmember center support
8. Rear floor crossmember
9. Rear floor seatbelt reinforcement
10. Differential/fuel support bracket rear (Vehicles
with mechanical LSD)11. Rear floor sidemember
12. Fuel tank rear bracket (Vehicles with AYC)
13. Differential/fuel support bracket front (Vehicles
with mechanical LSD)
14. Rear seat crossmember
15. Seat crossmember reinforcement
16. Fuel tank front reinforcement
17. Front floor sidemember extension
18. Rear floor extension
WELDED PANEL REPLACEMENT -Quarter, OuterC-16
2. After attaching the quarter outer, seal the holes and
flanges with bolts and plate tape, and fill foam material from
hole shown in the illustration.
Foam materialTypeBrand Used
Foam acoustic
materialTwo-part expanded
wretane3M ULTRAPRO
Panel foam - Yellow
3. After two hours after filling the foam material, remove
the bolts and plate tape, and solder the sealed holes
until a clip, etc. can be inserted completely.
Reference
Parts replacement is advised. depending on the damaged
range.
: Cuttable range
Caution
Avoid the fuel filler bracket (left side).
HOW TO READ THE WIRING DIAGRAMS -Abbreviation SymbolsA-10
ABBREVIATION SYMBOLS
The abbreviation symbols used in wiring diagrams are defined below.
1. Abbreviation symbols used for system name
Abbreviation
symbolsMeaningAbbreviation
symbolsMeaning
A/CAir conditionerEGRExhaust gas recirculation
ABSAnti-skid braking systemETACSElectronic time alarm control system
ACDActive center differentialSRSSupplemental restraint system
AY CActive yaw control
2. Abbreviation symbols used for combination meters
Abbreviation
symbolsMeaningAbbreviation
symbolsMeaning
ABSAnti-skid braking system warning lampSNOWActive center differential mode indicator
lamp
BEAMHigh beam indicator lampSPEEDSpeedmeter
BRAKEBrake warning lampSRSSupplemental restraint system warning
lamp
CHECK
ENGINECheck engine warning lampTARMACActive center differential mode indicator
lamp
CHGCharging warning lampT/GAEngine coolant temperature gauge
DOORDoor-ajar warning lampTACHOTachometer
F/GAFuel gaugeTAILTail, position and licence plate indicator
lamp
FRONT FOGFront fog indicator lamp
lamp
FUELLow fuel warning lampTRIPTripmeter
GRAVELActive center differential mode indicator
lampTURN (LH)Turn signal indicator lamp (LH)
ODOOdometerTURN (RH)Trun signal indicator lamp (RH)
OILOil pressure warning lampWATER
SPRAY
Intercooler water spray indicator lamp
REAR FOGRear fog indicator lamp
SPRAY
3. Abbreviation symbols used for switched and relay
Name of switches and
relaysAbbreviation
symbolsOperation
Blower switchLOBlower operates at low speed
MLBlower operates at medium low speed
MHBlower operates at medium high speed
HIBlower operates at high speed
B-2
S
PWGEE
IGNITION SYSTEM
L.H. drive vehicles 82.......................
R.H. drive vehicles 83.......................
CHARGING SYSTEM 84...................
ENGINE CONTROL SYSTEM
L.H. drive vehicles 86.......................
R.H. drive vehicles 94.......................
COOLING SYSTEM 102...................
HEADLAMP
L.H. drive vehicles 103......................
R.H. drive vehicles 106......................
TAIL LAMP, POSITION LAMP, LICENCE
PLATE LAMP AND LIGHTING MONITOR
BUZZER
L.H. drive vehicles 110......................
R.H. drive vehicles 114......................
ROOM LAMP AND LUGGAGE
COMPARTMENT LAMP
L.H. drive vehicles 118......................
R.H. drive vehicles 121......................
REAR FOG LAMP
L.H. drive vehicles 124......................
R.H. drive vehicles 127......................
HEADLAMP LEVELING SYSTEM
L.H. drive vehicles 130......................
R.H. drive vehicles 132......................
TURN-SIGNAL LAMP AND HAZARD
WARNING LAMP
L.H. drive vehicles 134......................
R.H. drive vehicles 138......................
BACK-UP LAMP
L.H. drive vehicles 142......................
R.H. drive vehicles 143......................
STOP LAMP
L.H. drive vehicles 144......................
R.H. drive vehicles 145......................
HORN 146................................
METER AND GAUGE
L.H. drive vehicles 148......................
R.H. drive vehicles 152......................
FUEL WARNING LAMP 156...............
OIL PRESSURE WARNING LAMP 157.....
BRAKE WARNING LAMP 157.............
POWER WINDOWS
L.H. drive vehicles 158......................
R.H. drive vehicles 164......................
CENTRAL DOOR LOCKING SYSTEM
L.H. drive vehicles 170......................
R.H. drive vehicles 172......................
HEATER AND MANUAL AIR CONDITIONER
L.H. drive vehicles 174......................
R.H. drive vehicles 180......................
DEFOGGER 185..........................
WINDSHIELD WIPER AND WASHER
L.H. drive vehicles 186......................
R.H. drive vehicles 189......................
REMOTE CONTROLLED MIRROR
L.H. drive vehicles 192......................
R.H. drive vehicles 193......................
CLOCK 194..............................
CIGARETTE LIGHTER AND ASHTRAY
ILLUMINATION LAMP 195.................
AUDIO SYSTEM 196......................
WIRING HARNESS CONFIGURATION DIAGRAMSB-4
WIRING HARNESS CONFIGURATION DIAGRAMS
OVERALL WIRING DIAGRAM
L.H. drive vehicles
Front wiring
harness (RH)
Control wiring
harnessInstrument panel
wiring harnessRoof wiring
harnessFloor wiring
harness (RH)
Battery wiring
harnessFront wiring
harness (LH)Front door
wiring harness*Floor wiring
harness (LH)Fuel wiring
harness
Rear door
wiring harness*
NOTE
(1) This illustration shows only major wiring harness.
(2) *: also equipped at the right side.