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Mitsubishi Lancer Evolution-IV User Manual
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Pub. No. S9806CNCP9
WORKSHOP MANUAL
EVOLUTION-IV
EVOLUTION-V
Pub. No. S9806CNCP9
Pub. No. S9806CNCP9
Jul. ’98 Printed in Japan
WORKSHOP MANUAL
EVOLUTION-IV
EVOLUTION-V
2
Table of Contents
Evolution-IV
2
Table of Contents
2
Engine
5
Service Specifications
6
Sealants
6
Special Tools
6
Engine Adjustments
8
Drive Belt Tension Check
8
Auto Tensioner Check
9
Lash Adjuster Check
9
Lash Adjuster Replacement
11
Ignition Timing Check
11
Idle Speed Check and Idle Mixture Check
11
Compression Pressure Check
11
Manifold Vacuum Check
12
Crankshaft Pulley
13
Camshaft and Camshaft Oil Seal
14
Removal and Installation
14
Oil Pan
17
Crankshaft Oil Seal
20
Cylinder Head Gasket
21
Timing Belt
25
Engine Assembly
36
Engine Lubrication
40
Fuel
42
Multipoint Injection (Mpi)
43
General Information
43
Service Specifications
44
Sealant
44
Special Tools
45
Troubleshooting
47
On-Vehicle Service
71
1 Idle Position Switch and Throttle Position Sensor (TPS) Adjustment
71
2 Fixed SAS Adjustment
71
3 Basic Idle Speed Adjustment
71
4 Fuel Pressure Measurement
71
5 MPI System Components Layout
72
Intake Air Temperature Sensor Check
73
Engine Coolant Temperature Sensor Check
73
8 Oxygen Sensor Check
73
Injector Check
75
10 Resistor Check
75
11 Fuel Pump Relay No.2 Check
76
12 Fuel Pump Resistor Check
76
Injector
77
Throttle Body
78
Engine Cooling
79
Coolant Replacement
80
Lubricant
80
On-Vehicle Service
80
Service Specifications
80
Thermostat
81
Water Pump
83
Water Hose and Water Pipe
84
Radiator
85
Intake and Exhaust
88
Service Specifications
89
Intake and Exhaust
89
Boost Pressure Control System Check
90
Air Bypass Valve Check
91
Wastegate Actuator Check
91
Wastegate Solenoid Valve Check
91
Secondary Air Control Solenoid Valve Check
92
Secondary Air Control System Check
92
Secondary Air Valve Check
93
Vacuum Tank Check
93
On-Vehicle Service
89
Special Tool
89
Intercooler
94
Air Control Valve
95
Intake Manifold
96
Exhaust Manifold and Turbocharger
98
Exhaust Pipe and Muffler
101
Engine Electrical
102
Default Chapter
103
Charging System
103
1 Ignition Coil with Built-In Power Transistor Check
105
2 Spark Plug Check, Cleaning, and Replacement
105
Ignition System
105
On-Vehicle Service
105
Camshaft Position Sensor and Crank Angle Sensor
106
Engine and Emission Control
107
Catalytic Converter
110
Clutch
111
Lubricants
112
On-Vehicle Service
112
Bleeding
113
Service Specifications
112
Clutch Pedal
114
Clutch Control
115
Clutch Master Cylinder
116
Manual Transmission
117
Manual Transmission
118
Special Tools
119
On-Vehicle Service
120
Transmission Oil Check
120
Transmission Oil Replacement
120
Transfer Oil Check
120
Transfer Oil Replacement
120
Transmission Control
121
Shift Lever Assembly
123
Transmission Assembly
124
Transfer Assembly
127
Manual Transmission Overhaul
128
General Information
129
Service Specifications
131
Specifications
131
Sealants and Adhesives
132
Lubricants
133
Snap Rings, Spacers and Thrust Plates for Adjustment
133
Torque Specifications
136
Special Tools
137
Transmission
140
Input Shaft
147
Output Shaft
154
Reverse Idler Gear
162
Speedometer Gear
163
Select Lever
164
Control Housing
165
Clutch Housing
168
Transmission Case
171
Center Differential
173
Transfer
176
Front Axle
179
Rear Axle
184
Lubricant
185
Sealant
185
Service Specifications
185
Special Tools
186
Troubleshooting <Ayc
188
On-Vehicle Service
210
Vehicles with Ayc
210
Rear Axle Total Backlash Check
210
Gear Oil Level Check
210
Gear Oil Change
211
Fluid Level Check
212
Bleeding
212
Differential Carrier Oil Seal Replacement
213
Speed Sensor Output Voltage Measurement <Vehicles Without ABS
214
Action When Battery Runs out
215
Rear Hub Assembly
216
Knuckle
218
Drive Shaft
219
Differential Carrier
222
Differential Carrier <Evolution-IV, Evolution-V Gsr
222
Evolution-V Rs
224
Torque Transfer Differential <Vehicles with Ayc
226
Lsd Case Assembly <Vehicles Without Ayc
229
Hydraulic Unit
233
Vehicles with Ayc
233
Sensor Relay <Vehicles with Ayc
235
Ayc-Ecu
236
Power Plant Mount
237
Front Suspension
239
Service Specifications
240
Special Tools
240
On-Vehicle Service
241
Wheel Alignment Check and Adjustment <EVOLUTION-V
241
Strut Assembly
242
Lower Arm <Evolution-IV
243
Lower Arm <Evolution-V
245
Stabilizer Bar
247
Rear Suspension
249
Default Chapter
250
Lubricant
250
Service Specifications
250
Special Tools
250
1 Rear Wheel Alignment Check and Adjustment
251
2 Ball Joint Dust Cover Check
251
On-Vehicle Service
251
Rear Suspension Assembly
252
Upper Arm Assembly
254
Trailing Arm Assembly
256
Lower Arm and Toe Control Arm Assemblies
258
Shock Absorber Assembly
261
Stabilizer Bar
262
Service Brakes
265
Basic Brake System
266
General
266
General
267
Outline of Change
267
On-Vehicle Service
267
Brake Pedal Check and Adjustment
267
Brake Pedal
269
Master Cylinder and Brake Booster
270
Master Cylinder
272
Disc Brake
274
Anti-Lock Braking System (Abs)
276
Troubleshooting
277
Inspection Chart for Diagnosis Codes
277
Inspection Procedure for Diagnostic Trouble Codes
278
Inspection Chart for Trouble Symptoms
286
Inspection Procedure for Trouble Symptoms
287
Check at ABS-ECU Terminals
290
On-Vehicle Service
292
Wheel Speed Sensor Output Voltage
292
Measurement <EVOLUTION-V
292
Lateral Acceleration Sensor
292
Wheel Speed Sensor
293
Parking Brakes
294
Parking Brake
298
Parking Brake Cable
298
Steering
302
1 Steering Angle Check
303
2 Oil Pump Belt Tension Check and Adjustment
303
On-Vehicle Service
303
Service Specifications
303
Special Tools
303
Evolution-IV Rs
304
Power Steering Gear & Linkage
304
Steering Wheel
304
Power Steering Oil Pump
308
Power Steering Fluid Cooler
310
Body
311
Hood
312
Fender
313
Trunk Lid <Evolution-V
314
BODY CONSTRUCTION (Difference between EVOLUTION-IV and V)
315
Body Dimension
317
Dimensions)
319
Exterior
325
Front Bumper <Evolution-IV
326
Special Tools
326
Front Bumper <Evolution-V
328
Rear Bumper <Evolution-V
330
Aero Parts <Evolution-IV
331
Aero Parts <Evolution-V
333
Rear Fender Garnish <Evolution-V
335
Intercooler & Radiator Water Spray System <Evolution-V
337
Mark <Evolution-V
339
Chassis Electrical
341
General
343
Battery
343
Service Specification
343
On-Vehicle Service
343
Battery Testing Procedure
345
Ignition Switch <Except Evolution-VI with Immobilizer System
346
Special Tool
346
Troubleshooting
346
Ignition Switch
346
Immobilizer System
346
Special Tool
353
Troubleshooting
353
Ignition Switch and Immobilizer System
353
Combination Meters
362
Service Specifications
362
Sealant
363
Special Tools
363
Troubleshooting
364
Inspection Procedure
365
On-Vehicle Service
367
Combination Meters
370
Headlamp
372
Service Specifications
372
Special Tools
372
Troubleshooting
373
Diagnosis Function
373
On-Vehicle Service
374
Headlamp and Front Turn-Signal Lamp
376
Front Fog Lamp
379
Service Specifications
379
On-Vehicle Service
379
Fog Lamp
381
Rear Combination Lamp
382
Troubleshooting
382
Side Turn-Signal Lamp
383
Special Tool
383
Hazard Warning Lamp Switch, Clock
384
Special Tool
384
Hazard Warning Lamp Switch
384
Radio and Tape Player
385
Troubleshooting
385
Radio and Tape Player
387
Speaker
387
Antenna
388
Pole Antenna
388
Rear Window Antenna and Glass Diversity Antenna
389
Rear Window Defogger
390
Troubleshooting <Vehicles with
390
Automatic A/C
390
On-Vehicle Service
390
Rear Window Defogger Switch
391
Vehicles with Automatic A/C
391
4
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Mitsubishi Lancer Evolution-IV Specifications
General
Brand
Mitsubishi
Model
Lancer Evolution-IV
Category
Automobile
Language
English
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