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Mitsubishi Lancer Evolution-IV Evolution-V Service Manual – PDF
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Description
Mitsubishi Lancer Evolution-IV Evolution-V Service Manual S9806CNCP9 – PDF DOWNLOAD
FILE DETAILS:
Mitsubishi Lancer Evolution-IV Evolution-V Service Manual S9806CNCP9 – PDF DOWNLOAD
Language : English
Pages : 353
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Mitsubishi Lancer Evolution-IV Evolution-V Service Manual S9806CNCP9 – PDF DOWNLOAD
GENERAL........................................................................... 3 MODELS........................................................................ 4 ENGINE............................................................................ 5 SERVICE SPECIFICATIONS........................................................ 6 SEALANTS...................................................................... 6 SPECIAL TOOLS................................................................. 6 ENGINE ADJUSTMENTS............................................................ 8 DRIVE BERT 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 OIL PAN....................................................................... 17 CRANKSHAFT OIL SEAL........................................................... 19 CYLINDER HEAD GASKET.......................................................... 21 TIMING BELT AND TIMING BELT B................................................. 25 ENGINE ASSEMBLY............................................................... 31 ENGINE LUBRICATION................................................................ 35 LUBRICANTS.................................................................... 36 ENGINE OIL COOLER............................................................. 36 FUEL.............................................................................. 37 MULTIPOINT INJECTION (MPI).................................................... 38 GENERAL INFORMATION....................................................... 38 SERVICE SPECIFICATIONS.................................................... 39 SEALANT................................................................... 39 SPECIAL TOOLS............................................................. 40 TROUBLESHOOTING........................................................... 42 ON-VEHICLE SERVICE........................................................ 66 IDLE POSITION SWITCH AND THROTTLE POSITION SENSOR (TPS) ADJUSTMENT.... 66 FIXED SAS ADJUSTMENT.................................................. 66 BASIC IDLE SPEED ADJUSTMENT........................................... 66 FUEL PRESSURE MEASUREMENT............................................. 66 MPI SYSTEM COMPONENTS LAYOUT.......................................... 67 INTAKE AIR TEMPERATURE SENSOR CHECK................................... 68 ENGINE COOLANT TEMPERATURE SENSOR CHECK............................... 68 OXYGEN SENSOR CHECK................................................... 68 INJECTOR CHECK........................................................ 70 RESISTOR CHECK........................................................ 70 FUEL PUMP RELAY No.2 CHECK............................................ 71 FUEL PUMP RESISTOR CHECK.............................................. 71 INJECTOR.................................................................. 72 THROTTLE BODY............................................................. 73 ENGINE COOLING.................................................................... 74 SERVICE SPECIFICATIONS........................................................ 75 LUBRICANT..................................................................... 75 ON-VEHICLE SERVICE............................................................ 75 COOLANT REPLACEMENT....................................................... 75 THERMOSTAT.................................................................... 76 WATER PUMP.................................................................... 78 WATER HOSE AND WATER PIPE..................................................... 79 RADIATOR...................................................................... 80 INTAKE AND EXHAUST................................................................ 83 SERVICE SPECIFICATIONS........................................................ 84 SPECIAL TOOL.................................................................. 84 ON-VEHICLE SERVICE............................................................ 84 TURBOCHARGER BOOST PRESSURE CHECK......................................... 84 BOOST PRESSURE CONTROL SYSTEM CHECK....................................... 85 WASTEGATE ACTUATOR CHECK.................................................. 86 WASTEGATE SOLENOID VALVE CHECK............................................ 86 AIR BYPASS VALVE CHECK.................................................... 86 SECONDARY AIR CONTROL SYSTEM CHECK........................................ 87 SECONDARY AIR CONTROL SOLENOID VALVE CHECK................................ 87 SECONDARY AIR VALVE CHECK................................................. 88 VACUUM TANK CHECK......................................................... 88 INTERCOOLER................................................................... 89 AIR CONTROL VALVE............................................................. 90 INTAKE MANIFOLD............................................................... 91 EXHAUST MANIFOLD AND TURBOCHARGER............................................. 93 EXHAUST PIPE AND MUFFLER...................................................... 96 ENGINE ELECTRICAL................................................................. 97 CHARGING SYSTEM............................................................... 98 ALTERNATOR................................................................ 98 IGNITION SYSTEM...............................................................100 ON-VEHICLE SERVICE........................................................100 IGNITION COIL WITH BUILT-IN POWER TRANSISTOR CHECK....................100 SPARK PLUG CHECK, CLEANING, AND R REPLACEMENT.........................100 CAMSHAFT POSITION SENSOR AND CRANK ANGLE SENSOR...........................101 ENGINE AND EMISSION CONTROL.......................................................102 ENGINE CONTROL SYSTEM.........................................................103 SERVICE SPECIFICATIONS....................................................103 EMISSION CONTROL SYSTEM.......................................................103 ON-VEHICLE SERVICE........................................................103 SYSTEM CONFIGURATION DIAGRAM..........................................103 VACUUM HOSE PIPING CIRCUIT DIAGRAM....................................104 CANISTER..................................................................104 CATALYTIC CONVERTER.......................................................105 CLUTCH............................................................................106 SERVICE SPECIFICATIONS........................................................107 LUBRICANTS....................................................................107 ON-VEHICLE SERVICE............................................................107 CLUTCH PEDAL INSPECTION AND ADJUSTMENT....................................107 BLEEDING..................................................................108 CLUTCH PEDAL..................................................................109 CLUTCH CONTROL................................................................110 CLUTCH MASTER CYLINDER....................................................111 MANUAL TRANSMISSION...............................................................112 MANUAL TRANSMISSION...........................................................114 LUBRICANTS................................................................115 SPECIAL TOOLS.............................................................115 ON-VEHICLE SERVICE........................................................116 TRANSMISSION OIL CHECK................................................116 TRANSMISSION OIL REPLACEMENT..........................................116 TRANSFER OIL CHECK....................................................116 TRANSFER OIL REPLACEMENT..............................................116 TRANSMISSION CONTROL......................................................117 SHIFT LEVER ASSEMBLY..................................................119 TRANSMISSION ASSEMBLY.....................................................120 TRANSFER ASSEMBLY.........................................................123 MANUAL TRANSMISSION OVERHAUL..................................................124 GENERAL INFORMATION.......................................................125 SPECIFICATIONS............................................................127 SERVICE SPECIFICATIONS....................................................127 SEALANTS AND ADHESIVES....................................................128 LUBRICANTS................................................................129 SNAP RINGS, SPACERS AND THRUST PLATES FOR ADJUSTMENT......................129 TORQUE SPECIFICATIONS.....................................................132 SPECIAL TOOLS.............................................................133 TRANSMISSION..............................................................136 INPUT SHAFT...............................................................143 OUTPUT SHAFT..............................................................150 REVERSE IDLER GEAR........................................................158 SPEEDOMETER GEAR..........................................................159 SELECT LEVER..............................................................160 CONTROL HOUSING...........................................................161 CLUTCH HOUSING............................................................164 TRANSMISSION CASE.........................................................167 CENTER DIFFERENTIAL.......................................................169 TRANSFER..................................................................172 FRONT AXLE........................................................................175 SERVICE SPECIFICATIONS........................................................176 SPECIAL TOOLS.................................................................176 AXLE HUB AND KNUCKLE..........................................................177 REAR AXLE.........................................................................180 SERVICE SPECIFICATIONS........................................................181 LUBRICANT.....................................................................181 SEALANT.......................................................................181 SPECIAL TOOLS.................................................................182 TROUBLESHOOTING <AYC>.........................................................184 ON-VEHICLE SERVICE <VEHICLES WITH AYC>........................................206 REAR AXLE TOTAL BACKLASH CHECK............................................206 GEAR OIL LEVEL CHECK......................................................206 GEAR OIL CHANGE...........................................................207 FLUID LEVEL CHECK.........................................................208 BLEEDING..................................................................208 DIFFERENTIAL CARRIER OIL SEAL REPLACEMENT.................................209 SPEED SENSOR OUTPUT VOLTAGE MEASUREMENT <VEHICLES WITHOUT ABS>............210 ACTION WHEN BATTERY RUNS OUT..............................................211 REAR HUB ASSEMBLY.............................................................212 KNUCKLE.......................................................................214 DRIVE SHAFT...................................................................215 DIFFERENTIAL CARRIER <EVOLUTION-IV, EVOLUTION-V GSR>..........................218 DIFFERENTIAL CARRIER <EVOLUTION-V RS>.........................................220 TORQUE TRANSFER DIFFERENTIAL <VEHICLES WITH AYC>..............................222 LSD CASE ASSEMBLY <VEHICLES WITHOUT AYC>......................................225 HYDRAULIC UNIT <VEHICLES WITH AYC>............................................229 SENSOR RELAY <VEHICLES WITH AYC>..............................................231 AYC-ECU.......................................................................232 POWER PLANT MOUNT.................................................................233 ROLL STOPPER AND CENTERMEMBER.................................................234 FRONT SUSPENSION..................................................................235 SERVICE SPECIFICATIONS........................................................236 SPECIAL TOOLS.................................................................236 ON-VEHICLE SERVICE............................................................237 WHEEL ALIGNMENT CHECK AND ADJUSTMENT <EVOLUTION-V>........................237 STRUT ASSEMBLY................................................................238 LOWER ARM <EVOLUTION-IV>......................................................239 LOWER ARM <EVOLUTION-V>.......................................................241 STABILIZER BAR................................................................243 REAR SUSPENSION...................................................................245 SERVICE SPECIFICATIONS........................................................246 LUBRICANT.....................................................................246 SPECIAL TOOLS.................................................................246 ON-VEHICLE SERVICE............................................................247 REAR WHEEL ALIGNMENT CHECK AND ADJUSTMENT.................................247 BALL JOINT DUST COVER CHECK...............................................247 REAR SUSPENSION ASSEMBLY......................................................248 UPPER ARM ASSEMBLY............................................................250 TRAILING ARM ASSEMBLY.........................................................252 LOWER ARM AND TOE CONTROL ARM ASSEMBLIES......................................254 SHOCK ABSORBER ASSEMBLY.......................................................257 STABILIZER BAR................................................................258 SERVICE BRAKES....................................................................261 BASIC BRAKE SYSTEM............................................................263 SERVICE SPECIFICATIONS....................................................264 LUBRICANTS................................................................264 SEALANT...................................................................265 SPECIAL TOOLS.............................................................265 ON-VEHICLE SERVICE........................................................265 BRAKE BOOSTER OPERATION CHECK.........................................265 PROPORTIONING VALVE FUNCTION TEST.....................................265 BLEEDING <EVOLUTION-V>................................................266 DISC BRAKE PAD CHECK AND REPLACEMENT <EVOLUTION-IV>...................266 DISC BRAKE PAD CHECK AND REPLACEMENT <EVOLUTION-V>....................266 BRAKE DISC THICKNESS CHECK............................................268 BRAKE DRUM I.D. CHECK.................................................268 LINING TO BRAKE DRUM CONTACT CHECK....................................268 FRONT BRAKE...............................................................269 REAR BRAKE................................................................270 ANTI-LOCK BRAKING SYSTEM (ABS)................................................275 TROUBLESHOOTING...........................................................276 INSPECTION CHART FOR DIAGNOSIS CODES..................................276 INSPECTION PROCEDURE FOR DIAGNOSTIC TROUBLE CODES.....................277 INSPECTION CHART FOR TROUBLE SYMPTOMS.................................285 INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS.............................286 CHECK AT ABS-ECU TERMINALS............................................289 ON-VEHICLE SERVICE........................................................291 WHEEL SPEED SENSOR OUTPUT VOLTAGE MEASUREMENT <EVOLUTION-V>...........291 LATERAL ACCELERATION SENSOR...............................................291 WHEEL SPEED SENSOR........................................................292 PARKING BRAKES....................................................................293 SERVICE SPECIFICATIONS........................................................294 LUBRICANTS....................................................................294 SPECIAL TOOLS.................................................................294 ON-VEHICLE SERVICE............................................................295 PARKING BRAKE LEVER STROKE CHECK AND ADJUSTMENT...........................295 LINING RUNNING-IN.........................................................296 PARKING BRAKE CABLE...........................................................297 PARKING BRAKE DRUM............................................................299 STEERING..........................................................................301 SERVICE SPECIFICATIONS........................................................302 SPECIAL TOOLS.................................................................302 ON-VEHICLE SERVICE............................................................302 STEERING ANGLE CHECK......................................................302 OIL PUMP BELT TENSION CHECK AND ADJUSTMENT................................302 STEERING WHEEL <EVOLUTION-IV RS>..............................................303 POWER STEERING GEAR & LINKAGE.................................................303 POWER STEERING OIL PUMP.......................................................307 POWER STEERING FLUID COOLER...................................................309 BODY..............................................................................310 HOOD..........................................................................311 FENDER........................................................................312 TRUNK LID <EVOLUTION-V>.......................................................313 BODY CONSTRUCTION (Difference between EVOLUTION-IV and V).....................314 TYPE A (PROJECTED DIMENSIONS).................................................316 TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)........................................320 EXTERIOR..........................................................................324 SPECIAL TOOLS.................................................................325 FRONT BUMPER <EVOLUTION-IV>...................................................325 FRONT BUMPER <EVOLUTION-V>....................................................327 REAR BUMPER <EVOLUTION-V>.....................................................329 AERO PARTS <EVOLUTION-IV>.....................................................330 AERO PARTS <EVOLUTION-V>......................................................332 REAR FENDER GARNISH <EVOLUTION-V>.............................................334 WATER SPRAY <EVOLUTION-IV>....................................................335 INTERCOOLER & RADIATOR WATER SPRAY SYSTEM <EVOLUTION-V>.......................336 MARK <EVOLUTION-V>............................................................338 CHASSIS ELECTRICAL................................................................340 FRONT FOG LAMP................................................................341
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