General - Lancer Mitsubishi Lancer Evolution IX

MAINTENANCE, REPAIR AND SERVICING EXPLANATIONS

This information provides explanations, etc. concerning procedures for the inspection, maintenance, repair and servicing of the subject model. Unless otherwise specified, each service procedure covers all models. Procedures covering specific models are identified by the model codes, or similar designation (engine type, transaxle type, etc.). A description of these designations is covered in this article under "VEHICLE IDENTIFICATION."

ON-VEHICLE SERVICE

The "ON-VEHICLE SERVICE" section has procedures for performing inspections and adjustments of particularly important components. These procedures are done with regard to maintenance and servicing, but other inspections (looseness, play, cracking, damage, etc.) must also be performed.

SERVICE PROCEDURES

The service steps are arranged in numerical order. Attention to be paid in performing vehicle service is described in detail in SERVICE POINTS.

STANDARD VALUE

Indicates the value used as the standard for judging whether or not a part or adjustment is correct.

LIMIT

Shows the maximum or minimum value for judging whether or not a part or adjustment is acceptable.

REFERENCE VALUE

Indicates the adjustment value prior to starting the work (presented in order to facilitate assembly and adjustment procedures, and so they can be completed in a shorter time).

DANGER, WARNING, AND CAUTION

DANGER, WARNING, and CAUTION call special attention to a necessary action or to an action that must be avoided. The differences among DANGER, WARNING, and CAUTION are as follows

1. If a DANGER is not followed, the result is severe bodily harm or even death.
2. If a WARNING is not followed, the result could be bodily injury.
3. If a CAUTION is not followed, the result could be damage to the vehicle, vehicle components or service equipment.

TIGHTENING TORQUE INDICATION

The tightening torque indicates a median and its tolerance by a unit of N.m (in-lb) or N.m (ft-lb). For fasteners with no assigned torque value, refer to STANDARD BOLT AND NUT TIGHTENING TORQUE .

SPECIAL TOOL NOTE

Only MMC special tool part numbers are called out in the repair sections of this information. Please refer to the special tool cross-reference chart located at the beginning of each article, for the special tool number that is available in your market.

ABBREVIATIONS

The following abbreviations are used in this information for classification of model types

M/T: Manual transaxle, or models equipped with manual transaxle.

A/T: Automatic transaxle, or models equipped with automatic transaxle.

MFI: Multiport fuel injection, or engines equipped with multiport fuel injection.

A/C: Air conditioning.

2.0L Engine: 2.0 liter < 4G94 > engine, or a model equipped with such an engine.

2.4L Engine: 2.4 liter < 4G69 > engine, or a model equipped with such an engine.

PCM: Powertrain control module

ECM: Engine control module

SWS: Simplified wiring system

Scheme 1

Scheme 2

VERIFY THE COMPLAINT

1. Make sure the customer's complaint and the service writer's work order description are understood before starting work.
2. Make sure the correct operation of the system is understood. Read the description to verify normal system operation.
3. Operate the system to see the symptoms. Look for other symptoms that were not reported by the customer, or on the work order, that may be related to the problem.

DETERMINE POSSIBLE CAUSES

Compare the confirmed symptoms to the diagnostic symptom indexes to find the right diagnosis procedure.

If the confirmed symptoms cannot be found on any symptom index, determine other possible causes.

1. Analyze the system diagrams and list all possible causes for the problem symptoms.
2. Rank all these possible causes in order of probability, based on how much of the system they cover, how likely they are to be the cause, and how easy they will be to check. Be sure to take experience into account. Consider the causes of similar problems seen in the past. The list of causes should be ranked in order from general to specific, from most-likely to least-likely, and from easy-to-check to hard-to-check.

FIND THE PROBLEM

After the symptoms have been confirmed, and probable causes have been identified, the next step is to make step-by-step checks of the suspected system components, junctions, and links in logical order. Use the diagnostic procedures whenever possible. Follow these procedures carefully to avoid missing an important step in the diagnosis sequence. It might be the skipped step that leads to the solution of the problem.

If there aren't any step-by-step procedures to help diagnose the problem, make a series of checks based on the ranked list of probable causes. Troubleshooting checks should be made in the order that the list of causes was ranked

1. general to specific
2. most-likely to least-likely
3. easy-to-check to hard-to-check

REPAIR THE PROBLEM

When the step-by-step troubleshooting checks find a fault, perform the proper repairs. Make sure to fix the root cause of the problem, not just the symptom. Just fixing the symptom, without fixing the root cause, will cause the symptom to eventually return.

VERIFY THE REPAIR

After repairs are made, recheck the operation of the system to confirm that the problem is eliminated. Be sure to check the system thoroughly. Sometimes new problems are revealed after repairs have been made.

TROUBLESHOOTING CONTENTS

Troubleshooting of electronic control systems for which the scan tool can be used follows the basic outline described below. Even in systems for which the scan tool cannot be used, part of these systems still follow this outline.

STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING

Troubleshooting strategy is shown in each group.

SYSTEM OPERATION AND SYMPTOM VERIFICATION TESTS

If verification of the symptom(s) is difficult, procedures for checking operation and verifying symptoms are shown.

DIAGNOSTIC FUNCTION

The following trouble code diagnosis are shown.

1. How to read diagnostic trouble codes
2. How to erase diagnostic trouble codes
3. Input inspection service points

DIAGNOSTIC TROUBLE CODE CHART

If the scan tool displays a diagnostic trouble code, find the applicable inspection procedure according to this chart.

SYMPTOM CHART

If there are symptoms, even though the scan tools show that no DTCs are set, inspection procedures for each symptom will be found by using this chart.

DIAGNOSTIC TROUBLE CODE PROCEDURES

Indicates the inspection procedures corresponding to each diagnostic trouble code (Refer to HOW TO USE THE INSPECTION PROCEDURES ).

SYMPTOM PROCEDURES

Indicates the inspection procedures corresponding to each symptom listed in the Symptom Chart. (Refer to HOW TO USE THE INSPECTION PROCEDURES ).

SERVICE DATA REFERENCE TABLE

Inspection items and normal judgment values have been provided in this chart as reference information.

CHECK AT ECU TERMINALS

Terminal numbers for the ECU connectors, inspection items, and standard values have been provided in this chart as reference information.

TERMINAL VOLTAGE CHECKS

1. Connect a needle-nosed wire probe to a voltmeter probe. CAUTION: Short-circuiting the positive (+) probe between a connector terminal and ground could damage the vehicle wiring, the sensor, the ECU, or all three. Use care to prevent this!
2. Insert the needle-nosed wire probe into each of the ECU connector terminals from the wire side, and measure the voltage while referring to the check chart. NOTE: Measure voltage with the ECU connectors connected. You may find it convenient to pull out the ECU to make it easier to reach the connector terminals. Checks don't have to be carried out in the order given in the chart.
3. If voltage readings differ from normal condition values, check related sensors, actuators, and wiring. Replace or repair as needed.
4. After repair or replacement, recheck with the voltmeter to confirm that the repair has corrected the problem.

TERMINAL RESISTANCE AND CONTINUITY CHECKS

1. Turn the ignition switch to "LOCK" (OFF) position.
2. Disconnect the ECU connector. CAUTION: If resistance and continuity checks are performed on the wrong terminals, damage to the vehicle wiring, sensors, ECU, and/or ohmmeter may occur. Use care to prevent this!
3. Measure the resistance and check for continuity between the terminals of the ECU harness-side connector while referring to the check chart. NOTE: Checks don't have to be carried out in the order given in the chart.
4. If the ohmmeter shows any deviation from the Normal Condition value, check the corresponding sensor, actuator and related electrical wiring, then repair or replace.
5. After repair or replacement, recheck with the ohmmeter to confirm that the repair has corrected the problem.

INSPECTION PROCEDURES USING AN OSCILLOSCOPE

When there are inspection procedures using an oscilloscope, these are listed.

HOW TO USE THE INSPECTION PROCEDURES

The causes of many of the problems occurring in electric circuitry are generally the connectors, components, the ECU, and the harnesses between connectors, in that order. These inspection procedures follow this order. They first try to discover a problem with a connector or a defective component.

Scheme 3

Scheme 4

HARNESS INSPECTION

Check for an open or short circuit in the harness between the terminals which were faulty according to the connector measurements. Carry out this inspection while referring to HARNESS CONNECTOR INSPECTION . Here, "Check harness between power supply and terminal xx" also includes checking for blown fuse. 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.

CONNECTOR MEASUREMENT SERVICE POINTS

Turn the ignition switch to the "LOCK" (OFF) position when connecting and disconnecting the connectors. Turn the ignition switch to "ON" when measuring, unless there are instructions to the contrary.

IF INSPECTING WITH THE CONNECTOR CONNECTED < WATERPROOF CONNECTORS >

Be sure to use special tool. Never insert a test probe from the harness side, as this will reduce the waterproof performance and result in corrosion.

Scheme 5

IF INSPECTING WITH THE CONNECTOR CONNECTED < ORDINARY (NON-WATERPROOF) CONNECTORS >

Required Special Tool

1. MB992006: Extra Fine Probe

Inspect by inserting a test probe from the harness side. If the connector is too small to insert a test probe (e.g. control unit connector), do not insert it forcibly. Use special tool MB992006 (extra fine probe).

Scheme 6

IF INSPECTING WITH THE CONNECTOR DISCONNECTED < WHEN INSPECTING A FEMALE PIN >

Required Special Tool

Scheme 7

Scheme 8

1. MB991219: Inspection Harness (Included in MB991223, Harness Set)
2. The special tool MB991219 for connector pin contact pressure should be used. The test probe should never be forcibly inserted, as it may cause a defective contact.
3. From back side of the connector (SRS-ECU harness side connector)
4. From back side of the connector (SRS-ECU harness side connector)

Since the SRS-ECU harness connector is plated to improve conductivity, observe the warning when checking this connector.

Scheme 9

IF INSPECTING WITH THE CONNECTOR DISCONNECTED < WHEN INSPECTING A MALE PIN >

Touch the pin directly with the test probe.

Scheme 10

CONNECTOR INSPECTION SERVICE POINTS VISUAL INSPECTION

1. Connector is disconnected or improperly connected
2. Connector pins are pulled out
3. Stretched an broken wires at terminal section
4. Low contact pressure between male and female terminals
5. Low connection pressure due to rusted terminals or foreign matter lodged in terminals

Scheme 11

CONNECTOR PIN INSPECTION

If the connector pin stopper is damaged, the terminal connections (male and female pins) will not be perfect even when the connector body is connected, because the pins may pull out of the back side of the connector. Therefore, gently pull the wires one by one to make sure that no pins pull out of the connector.

Scheme 12

CONNECTOR ENGAGEMENT INSPECTION

Required Special Tool

MB991219: Inspection Harness (contained in MB991223 Test Harness)

Use special tool, MB991219 to inspect the engagement of the male pins and female pins. [Pin drawing force: 1 N (0.2 pound) or more]

Scheme 13

HOW TO COPE WITH INTERMITTENT MALFUNCTIONS

Most intermittent malfunctions occur under certain conditions. If those conditions can be identified, the cause will be easier to find.

TO COPE WITH INTERMITTENT MALFUNCTION

1. ASK THE CUSTOMER ABOUT THE MALFUNCTION Ask what it feels like, what it sounds like, etc. Then ask about driving conditions, weather, frequency of occurrence, and so on.
2. DETERMINE THE CONDITIONS FROM THE CUSTOMER'S RESPONSES Typically, almost all intermittent malfunctions occur from conditions like vibration, temperature and/or moisture change, poor connections. From the customer's responses, it should be reasoned which condition is most likely.
3. USE SIMULATION TEST Use the simulation tests below to attempt to duplicate the customer's complaint. Determine the most likely circuit(s) and perform the simulation tests on the connectors and parts of that circuit(s). Be sure to use the inspection procedures provided for diagnostic trouble codes and trouble symptoms. For temperature and/or moisture condition related intermittent malfunctions, try to change the conditions of the suspected circuit components, then use the simulation tests below.
4. VERIFY THE INTERMITTENT MALFUNCTION IS ELIMINATED Repair the malfunctioning part and try to duplicate the condition(s) again to verify the intermittent malfunction has been eliminated.

SIMULATION TESTS

Note. In case of difficulty in finding the cause of the intermittent malfunction, the data recorder function in the scan tool is effective.

For these simulation tests, shake, then gently bend, pull, and twist the wiring of each of these examples to duplicate the intermittent malfunction.

Scheme 14

1. Shake the connector up-and-down, and right-and-left.
2. Shake the wiring harness up-and-down, and right-and-left. Especially, check the splice points of wiring harnesses carefully.
3. Shake the part or sensor.

INSPECTION SERVICE POINTS FOR A BLOWN FUSE

Remove the blown fuse and measure the resistance between the load side of the blown fuse and the ground. Close the switches of all circuits which are connected to this fuse. If the resistance is almost 0 ohm at this time, there is a short somewhere between these switches and the load. If the resistance is not 0 ohm, there is no short at the present time, but a momentary short has probably caused the fuse to blow.

The main causes of a short circuit are the following.

Scheme 15

1. Harness being clamped by the vehicle body
2. Damage to the outer casing of the harness due to wear or heat
3. Water getting into the connector or circuitry
4. Human error (mistakenly shorting a circuit, etc.)

VEHICLE IDENTIFICATION

Note. For Lancer ES fleet vehicles, refer to MODEL YEAR CHANGES (2007 LANCER ES) - SERVICE MANUAL REVISION .

VEHICLES IDENTIFICATION NUMBER LOCATION

The vehicle identification number (VIN) is located on a plate attached to the left top side of the instrument panel.

Scheme 16

VEHICLE IDENTIFICATION CODE CHART PLATE

All vehicle identification numbers contain 17 digits. The vehicle number is a code which tells country, make, vehicle type, etc.

VEHICLE IDENTIFICATION CODE CHART

Scheme 17

VEHICLE IDENTIFICATION NUMBER LIST

Note. For Lancer ES fleet vehicles, refer to MODEL YEAR CHANGES (2007 LANCER ES) - SERVICE MANUAL REVISION .

VEHICLES FOR FEDERAL EMISSION REGULATION

VEHICLES FOR FEDERAL EMISSION REGULATION CHART

VEHICLES FOR CALIFORNIA EMISSION REGULATION

VEHICLES FOR CALIFORNIA EMISSION REGULATION CHART

VEHICLES FOR CANADA

VEHICLES FOR CANADA EMISSION REGULATION CHART

VEHICLES FOR PUERTO RICO

VEHICLES FOR PUERTO RICO EMISSION REGULATION CHART

VEHICLE IDENTIFICATION CODE PLATE

The vehicle information code plate is riveted onto the cowl top outer panel in the engine compartment.

The plate shows model code, engine model, transaxle model and body color code.

VEHICLE IDENTIFICATION CODE CHART

Scheme 18

For monotone color vehicles, the body color code shall be indicated.

VEHICLE SAFETY CERTIFICATION LABEL

The vehicle safety certification label is attached to the face of the left door sill.

This label indicates the month and year of manufacture, Gross Vehicle Weight Rating (GVWR), front and rear Gross Axle Weight Rating (GAWR), and Vehicle Identification Number (VIN).

Scheme 19

ENGINE MODEL STAMPING

The engine model is stamped on the cylinder block.

These engine model numbers are as shown as follows.

ENGINE SPECIFICATION

The engine serial number is stamped near the engine model number.

Scheme 20

THEFT PROTECTION

In order to protect against theft, a Vehicle Identification Number (VIN) is attached as a plate or label to the following major parts of the engine and transaxle, as well as main outer panels: Engine cylinder block, Transaxle housing, Fender, Doors, Trunk lid, Quarter panel, Hood, Bumpers

In addition, a theft-protection label is attached to replacement parts for the body outer panel main components, and the same data is stamped into replacement parts for the engine and the transaxle.

Scheme 21

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

1. Items to review when servicing SRS Be sure to read «SUPPLEMENTAL RESTRAINTS SYSTEM - LANCER»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/airbag/#supplemental-restraint-system-lancer) . For safe operation, please follow the directions and heed all warnings. 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. Warning labels must be heeded when servicing or handling SRS components. Warning labels can be found in the following locations. Sun visor Center pillar SRS-ECU Steering wheel Clock spring Joint cover Air bag module (Driver's or front passenger's) Side-airbag module (Driver's side or front passenger's side) Side impact sensor Seat belt pre-tensioner Always use the designated special tools and test equipment. 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. Never attempt to disassemble or repair the SRS components (SRS-ECU, air bag module, side impact sensor, clock spring and seat belt pre-tensioner). If there is a defect, replace the defective part. Whenever you finish servicing the SRS, check the SRS warning light operation to make sure that the system functions properly. 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 , «AIR BAG MODULE DISPOSAL PROCEDURES»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/airbag/#supplemental-restraint-system-lancer__air-bag-module-and-seat-belt) .)
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. When removing or installing parts, do not allow any impact or shock to occur to the SRS components. If heat damage may occur during paint work, remove the SRS components. After reinstalling them, check the SRS warning light operation to make sure that the system functions properly. SRS-ECU, air bag module, clock spring, side impact sensor: 93° C (200° F) or more Seat belt pre-tensioner: 90° C (194° F) or more

HOW TO PERFORM VEHICLE IDENTIFICATION NUMBER (VIN) WRITING

The Vehicle Identification Number (VIN) is stored in the ECM < M/T > or the PCM < A/T > by the vehicle manufacture. If the VIN to be stored in the ECM < M/T > or the PCM < A/T > is eliminated fraudulently, the Malfunction Indicator Lamp (SERVICE ENGINE SOON or Check Engine Lamp) illuminates and Diagnostic Trouble Code (DTC) No. P0630 (VIN malfunction) is shown. When the ECM < M/T > or the PCM < A/T > is replaced, and entry of the VIN necessary due to DTC No. P0630 (VIN malfunction). Enter the VIN in accordance with the procedure as follows

WRITING PROCEDURE

Required Special Tools

1. MB991958: Scan Tool (MUT-III Sub Assembly) MB991824: V.C.I. MB991827: MUT-III USB Cable MB991911: MUT-III Main Harness B

1. Connect scan tool MB991958 to the data link connector.
2. Turn the ignition switch to the "ON" position.
3. Confirm DTC No. P0630 (EEPROM malfunction) is not shown. NOTE: When DTC No. P0630 (EEPROM malfunction) is shown, the VIN cannot be stored even if entered. Therefore, the troubleshooting is performed when this DTC is shown.
4. Select "Coding" form the menu screen.
5. Select "VIN writing" form the menu screen.
6. Enter the VIN.
7. After entry of the VIN, turn the ignition switch to the "LOCK" (OFF) position. After ten seconds or more passed, turn to the "ON" position again.
8. Confirm DTC No. P0630 (VIN malfunction) is not shown. NOTE: When DTC No. P0630 (VIN malfunction) is shown, enter the VIN again because that would be not appropriate.

INITIALIZATION PROCEDURE FOR LEARNING VALUE IN MFI ENGINE

When the following service is performed, initialize the learning value.

1. At replacing engine assembly*
2. At replacing throttle body and at cleaning
3. At replacing knock sensor

Note. * Initialize A/T-related learning value.

INITIALIZATION PROCEDURE

Required Special Tools

1. MB991958: Scan Tool (MUT-III Sub Assembly) MB991824: V.C.I. MB991827: MUT-III USB Cable MB991911: MUT-III Main Harness B

Scheme 22

1. Connect scan tool MB991958 to the data link connector.
2. Turn the ignition switch to the "ON" position.
3. Select "Check Mode" form the menu screen.
4. Select "ERASE MEMORY" form the menu screen.
5. Initialize the learning value.
6. After initialization of the learning value, learn the idling in MFI engine. (Refer to «LEARNING PROCEDURE FOR IDLING IN MFI ENGINE»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/hoistjack/#general-lancer) ).

PURPOSE

When the ECM < M/T > or the PCM < A/T > is replaced, or when the learning value is initialized, the idling is not stabilized because the learning value in MFI engine is not completed. In this case, carry out the learning method for the idling through the following procedures.

LEARNING PROCEDURE

1. Start the engine and carry out the warm-up for the engine coolant temperature to reach 80°C (176°F) or more.
2. When the engine coolant temperature is 80°C (176°F) or more, the warm-up is not needed if the ignition switch is in "ON" position once.
3. Place the ignition switch in "LOCK" (OFF) position and stop the engine.
4. After 10 seconds or more, start the engine again.
5. For 10 minutes, carry out the idling under the condition shown below and then confirm the engine has the normal idling. Transaxle: "P" range Operation in ignition-related, fan and attachments: Not to be operated Engine coolant temperature: 80°C (176°F) or more NOTE: When the engine stalls during the idling, check the dirtiness (on the throttle valve) of the throttle body and then perform the service from Procedure 1 again.

SERVICING ELECTRICAL SYSTEM

Scheme 23

1. Note the following before proceeding with working on the electrical system. Never perform unauthorized modifications to any electrical device or wiring. Such modifications might lead to a vehicle malfunction, over-capacity or short-circuit that could result in a fire in the vehicle. CAUTION: Before connecting or disconnecting the negative battery cable, be sure to turn the ignition switch to the "LOCK" (OFF) position and turn off the lights. (If this is not done, there is the possibility of semiconductor parts being damaged.) After completion of the work (and the negative battery terminals is connected), warm up the engine and allow it to idle for approximately 10 minutes under the conditions described below in order to stabilize engine control conditions, and then check to be sure that the idle is satisfactory.
2. When servicing the electrical system, disconnect the negative cable terminal from the battery. Engine coolant temperature: 85 - 95°C (185 - 203°F) Lights and all accessories: OFF Transaxle: "N" or "P" position Steering wheel: straight-forward position

VEHICLE WASHING

If high-pressure car-washing equipment or steam car-washing equipment is used to wash the vehicle, be sure to maintain the spray nozzle at a distance of at least approximately 40 cm (16 inches) from any plastic parts and all opening parts (doors, luggage compartment, etc.).

Scheme 24

APPLICATION OF ANTI-CORROSION AGENTS AND UNDERCOATS

Do not to apply oil or grease to the heated oxygen sensor. If applied, the sensor may malfunction. Protect the heated oxygen sensor with a cover before applying anti-corrosion agent, etc.

SCAN TOOL (MUT-III SUB ASSEMBLY)

Note. MUT-III trigger harness is not necessary when pushing V.C.I. ENTER key.

Scheme 25

FRONT TOWING PICKUP

The vehicle may be towed on its rear wheels for extended distances provided the parking brake is released. It is recommended that vehicles be towed using the front pickup whenever possible.

Scheme 26

REAR TOWING PICKUP

Automatic transaxle vehicle may be towed on the front wheels at speeds not to exceed 50 km/h (30 mph) for distances not to exceed 30 km (18 miles).

Scheme 27

TOWING WHEN KEYS ARE NOT AVAILABLE

When a locked vehicle must be towed and keys are not available, the vehicle may be lifted and towed from the front, provided the parking brake is released. If not released, the rear wheels should be placed on a tow dolly.

SAFETY PRECAUTIONS

The following precautions should be taken when towing the vehicle

1. DO NOT LIFT OR TOW THE VEHICLE BY ATTACHING TO OR WRAPPING AROUND THE BUMPER.
2. Any loose, protruding, or damaged parts such as hoods, doors, fenders, trim, etc. should be secured or removed prior to moving the vehicle.
3. Refrain from going under a vehicle when it is lifted by the towing equipment, unless the vehicle is adequately supported by safety stands.
4. Never allow passengers to ride in a towed vehicle.
5. State and local rules and regulations must be followed when towing a vehicle.

LIFTING, JACKING SUPPORT LOCATION

FLOOR JACK

Scheme 28

AXLE STANDS AND A SINGLE-POST LIFT OR DOUBLE-POST LIFT

Scheme 29

PLATE TYPE LIFT

Support the side sill flange with a lift.

Scheme 30

GENERAL SPECIFICATIONS < VEHICLES FOR USA >

GENERAL SPECIFICATIONS - VEHICLES FOR USA

GENERAL SPECIFICATIONS - VEHICLES FOR USA

GENERAL SPECIFICATIONS < VEHICLES FOR CANADA >

GENERAL SPECIFICATIONS - VEHICLES FOR CANADA

GENERAL SPECIFICATIONS - VEHICLES FOR CANADA

GENERAL SPECIFICATIONS < VEHICLES FOR PUERTO RICO >

GENERAL SPECIFICATIONS - VEHICLES FOR PUERTO RICO

TIGHTENING TORQUE

Each torque value in the table is a standard value for tightening under the following conditions.

1. Bolts, nuts and washers are all made of steel and plated with zinc.
2. The threads and bearing surface of bolts and nuts are all in dry condition.

The values in the table are not applicable

1. If toothed washers are inserted.
2. If plastic parts are fastened.
3. If bolts are tightened to plastic or die-cast inserted nuts.
4. If self-tapping screws or self-locking nuts are used

STANDARD BOLT AND NUT TIGHTENING TORQUE

STANDARD BOLT AND NUT TIGHTENING TORQUE

FLANGE BOLT AND NUT TIGHTENING TORQUE

FLANGE BOLT AND NUT TIGHTENING TORQUE

LUBRICATION AND MAINTENANCE

Maintenance and lubrication service recommendations have been compiled to provide maximum protection for the vehicle owner's investment against all reasonable types of driving conditions. Since these conditions vary with the individual vehicle owner's driving habits, the area in which the vehicle is operated and the type of driving to which the vehicle is subjected, it is necessary to prescribe lubrication and maintenance service on a time frequency as well as mileage interval basis.

Oils, lubricants and greases are classified and graded according to standards recommended by the Society of Automotive Engineers (SAE), the American Petroleum Institute (API) and the National Lubricating Grease Institute (NLGI).

MAINTENANCE SCHEDULES

Information for service maintenance is provided in the "SCHEDULED MAINTENANCE TABLE." Three schedules are provided; one for "Required Maintenance." one for "General Maintenance" and one for "Severe Usage Service."

The item numbers in "SCHEDULED MAINTENANCE TABLE" correspond to the section numbers in "MAINTENANCE SERVICE."

SEVERE SERVICE

Vehicles operating under severe service conditions will require more frequent service.

Component service information is included for vehicles operating under one or more of the following conditions

1. Trailer towing or police, taxi or commercial type operation.
2. Operation of Vehicle Short-trip operation at freezing temperature (engine not thoroughly warmed up) More than 50% operation in heavy city traffic during hot weather above 32°C (90°F) Extensive idling Driving in sandy areas Driving in salty areas Driving in dusty conditions Driving off-road

ENGINE OIL

Either of the following engine oils should be used

1. Engine oil displaying ILSAC certification mark.
2. Engine oil conforming to the API classification SL, SL/CF. For further details, refer to LUBRICANTS SELECTION.

LUBRICANTS AND GREASES

Semi-solid lubricants bear the NLGI designation and are further classified as grades 0, 1, 2, 3, etc. Whenever "Chassis Lubricant" is specified, Multipurpose Grease, NLGI grade Number 2, should be used.

FUEL USAGE STATEMENT

This vehicle must use unleaded gasoline only.

This vehicle has a fuel filler tube which is especially designed to accept only the smaller-diameter unleaded gasoline dispensing nozzle.

The 2.0L model is designed to operate on unleaded gasoline having a minimum octane rating of 87 [(MON + RON)/2], or 91 RON.

Note. MON: Motor Octane Number RON: Research Octane Number

GASOLINE CONTAINING ALCOHOL

Some gasoline sold at service stations contain alcohol although they may not be so identified.

Using fuels containing alcohol is not recommended unless the nature of the blend can be determined as being satisfactory.

Gasohol: A mixture of 10% ethanol (grain alcohol) and 90% unleaded gasoline may be used in your vehicle. If driveability problems are experienced as a result of using gasohol, it is recommended that the vehicle be operated on gasoline.

Methanol: Do not use gasoline containing methanol (wood alcohol). Using this type of alcohol can result in vehicle performance deterioration and damage critical parts in the fuel system components. Fuel system damage and performance problems resulting from the use of gasoline containing methanol may not be covered by the new vehicle warranty.

GASOLINE CONTAINING METHYL TERTIARY BUTYL ETHER (MTBE)

Unleaded gasoline containing 15% or less MTBE may be used in your vehicle. (Fuel containing MTBE over 15% in volume may cause reduced engine performance and produce vapor lock or hard starting.

MATERIALS ADDED TO FUEL

Indiscriminate use of fuel system cleaning agents should be avoided. Many of these materials intended for gum and varnish removal may contain highly active solvents or similar ingredients that can be harmful to gasket and diaphragm materials used in fuel system component parts.

RECOMMENDED LUBRICANTS

RECOMMENDED LUBRICANTS

LUBRICANT CAPACITY TABLE

LUBRICANT CAPACITY CHART

Use only engine oils displaying the ILSAC certification mark ("Starburst" symbol) on the container.

Scheme 31

If these oils are not available, an API classification SL or SL/CF can be used.

Scheme 32

OIL VISCOSITY

The SAE grade number indicates the viscosity of the oil. A proper SAE grade number should be selected according to ambient temperature.

Note. SAE 5W-20, SAE 5W-30 and SAE 10W-30 engine oil can be used in outdoor temperatures ranging from -18 to 38 °C (0 to 100 °F). However, for optimum fuel economy and cold starting, select the low SAE viscosity grade oil for the expected temperature range. SAE 5W-20 or SAE 5W-30 engine oil is recommended.

Scheme 33

COOLANT

Relationship between Coolant Concentration and Specific Gravity

COOLANT SPECIFICATION

Example

The safe operating temperature is -15°C (5°F) when the specific gravity is 1.058 at the coolant temperature of 20°C (68°F)

SCHEDULED MAINTENANCE SERVICE FOR EMISSION CONTROL AND PROPER VEHICLE PERFORMANCE

Inspection and service should be performed any time if a malfunction is observed or suspected.

SCHEDULED MAINTENANCE TABLE

GENERAL MAINTENANCE SERVICE FOR PROPER VEHICLE PERFORMANCE

GENERAL MAINTENANCE CHART

SCHEDULED MAINTENANCE UNDER SEVERE USAGE CONDITIONS

Maintenance should be carried out according to the following table

SCHEDULED MAINTENANCE CHART

Severe usage conditions

1. Driving on dusty, rough, muddy or salt-spread roads
2. Towing or police, taxi or commercial operation
3. Extensive idling and/or low speed operation
4. Repeated short-trip operation at freezing temperatures (engine not thoroughly warmed up)
5. Extended use of brakes while driving
6. Driving in sandy areas
7. More than 50% operation in heavy city traffic during hot weather above 90°F (32°C)

1. FUEL SYSTEM (TANK, PIPE LINE AND CONNECTION, AND FUEL TANK FILLER TUBE CAP) (CHECK FOR LEAKS)

Check for damage or leakage in the fuel lines and connections.

2. FUEL HOSES (CHECK CONDITION)

1. Inspect the surface of fuel hoses for heat and mechanical damage. Hard and brittle rubber, cracking, tears, cuts, abrasions and excessive swelling indicate deterioration of the rubber.
2. If the fabric casing of the rubber hose is exposed by cracks and abrasions in the fuel system, the hoses should be replaced.

3. AIR CLEANER ELEMENT (REPLACE)

The air cleaner element will become dirty during use, reducing its effectiveness. Replace it with a new one.

REPLACEMENT OF AIR CLEANER ELEMENT

1. Unclamp the air cleaner cover.
2. Remove the air cleaner element and install a new one.
3. When clamping the air cleaner cover in place, be sure that the cover is completed closed.

Scheme 34

4. EVAPORATIVE EMISSION CONTROL SYSTEM (EXCEPT EVAPORATIVE EMISSION CANISTER) (CHECK FOR CLOGGING)

If the fuel-vapor vent line is clogged or damaged, fuel vapor will escape into the atmosphere causing excessive emissions. Disconnect the line at both ends, and blow it clean with compressed air. Remove the fuel tank filler tube cap from the filler tube and check to see if there is evidence that the seal makes improper contact to the filler tube.

5. SPARK PLUGS (REPLACE)

1. Spark plugs must spark properly to assure proper engine performance and reduce exhaust emission level. Therefore, they should be replaced periodically with new ones. Spark plug type SPARK PLUG TYPE MAKER 2.0L ENGINE 2.4L ENGINE NGK BKR5E-11 LZFR6AI DENSO K16PR-U11 - CHAMPION RC10YC4
2. The new plugs should be checked for the proper gap. Spark plug gap: <2.0L Engine >1.0 - 1.1 mm (0.039 - 0.043 inch) <2.4L Engine >0.7 - 0.8 mm (0.028 - 0.031 inch)
3. Install the spark plugs and tighten to 25 +/- 4 N.m (18 +/- 3 ft-lb)

Scheme 35

6. INTAKE AND EXHAUST VALVE CLEARANCE (4G6-MIVEC ENGINE ONLY) (INSPECT AND ADJUST)

1. Before checks, check that the engine oil, starter and battery are normal. Also, set the vehicle in the following condition: Engine coolant temperature: 80 - 95°C (176 - 203°F) Lights and all accessories: OFF Transaxle: Neutral (P range on vehicles with A/T) NOTE: Vehicles for Canada, the headlight, taillight, etc. remain lit even when the lighting switch is in "OFF" position but this is no problem for checks and adjustment.
2. Remove all of the ignition coils.
3. Remove the rocker cover.
4. Turn the crankshaft clockwise until the notch on the pulley is lined up with "T" mark on the timing indicator.
5. Move the rocker arms on the No.1 and No.4 cylinders up and down by hand to determine which cylinder has its piston at the top dead center on the compression stroke. If both intake and exhaust valve rocker arms have a valve lash, the piston in the cylinder corresponding to these rocker arms is at the top dead center on the compression stroke.
6. Valve clearance inspection and adjustment can be performed on rocker arms indicated by white arrow mark when the No.1 cylinder piston is at the top dead center on the compression stroke, and on rocker arms indicated by black arrow mark when the No.4 cylinder piston is at the top dead center on the compression stroke.
7. Measure the valve clearance. If the valve clearance is not as specified, loosen the rocker arm lock nut and adjust the clearance using a thickness gauge while turning the adjusting screw. Standard value (hot engine): Intake valve: 0.20 mm (0.008 inch) Exhaust valve: 0.30 mm (0.012 inch)
8. While holding the adjusting screw with a screwdriver to prevent it from turning, tighten the lock nut to the specified torque. Tightening torque: 9 +/- 1 N.m (80 +/- 9 in-lb)
9. Turn the crankshaft through 360 degree angle to line up the notch on the crankshaft pulley with the "T" mark on the timing indicator.
10. Repeat steps (7) and (8) on other valves for clearance adjustment.
11. Install the rocker cover.
12. Install the ignition coils.

Scheme 36

7. TIMING BELT (REPLACE)

Replace the belt with a new one according to the maintenance schedule on SCHEDULED MAINTENANCE SERVICE FOR EMISSION CONTROL AND PROPER VEHICLE PERFORMANCE to assure proper engine performance.

<2.0L Engine >

For removal and installation procedures, refer to TIMING BELT - Removal and Installation .

<2.4L Engine >

For removal and installation procedures, refer to REMOVAL AND INSTALLATION .

< WHEN USING SCAN TOOL MB991958 >

Required Special Tools

1. MB991668: Belt Tension Meter Set
2. MB991958: Scan Tool (MUT-III Sub Assembly) MB991824: V.C.I. MB991911: MUT-III Main Harness B

Scheme 37

Scheme 38

1. Connect special tool MB991668 to special tool MB991824.
2. Connect special tool MB991911 to special tool MB991824.
3. Connect special tool MB991911 to the data link connector.
4. Turn the ignition switch to the "ON" position and select "Belt Tension" from the menu special tool MB991824 screen.
5. Hold special tool MB991668 (microphone) near the center of the drive belt between the pulleys (at the place indicated by the arrow), about 10 - 20 mm (0.4 - 0.8 inch) away from the rear surface of the belt and perpendicular to the belt (within an angle of +/- 15 degree angle). CAUTION: The temperature of the surface of the belt should be as close as possible to underhood temperature. Do not let any contaminants such as water or oil get onto the microphone. If strong gusts of wind blow against the microphone or if there are any loud sources of noise nearby, the values measured by the microphone may not correspond to actual values. If the microphone is touching the belt while the measurement is being made, the values measured by the microphone may not correspond to actual values. Do not take the measurement while the vehicle's engine is running.
6. Gently tap the middle of the belt between the pulleys (the place indicated by the arrow) with your finger as shown in the illustration, and check that the vibration frequency of the belt is within the standard value.

Standard value

ITEM DESCRIPTION CHART

< WHEN USING THE TENSION GAUGE >

Use a belt tension gauge to check that the belt tension is within the standard value.

Standard value

ITEM DESCRIPTION CHART

Scheme 39

< BELT DEFLECTION CHECK >

Apply approximately 100 N (22 pound) of force to the middle of the drive belt between the pulleys (at the place indicated by the arrow) and check that the amount of deflection is within the standard value.

Standard value

ITEM DESCRIPTION CHART

Scheme 40

GENERATOR DRIVE BELT TENSION ADJUSTMENT <2.0L Engine >

1. Loosen the nut of the generator pivot bolt.
2. Loosen the lock bolt.
3. Turn the adjusting bolt to adjust the belt vibration frequency, belt tension or deflection to the standard value. CAUTION: Check after turning the crankshaft one or more rotations clockwise. Standard value: ITEM DESCRIPTION CHART ITEM WHEN CHECKED DURING ADJUSTMENT DURING REPLACEMENT Vibration frequency Hz 151 - 195 163 - 185 213 - 246 Tension N (lb) 294 - 490 (66 - 110) 343 - 441 (77 - 99) 588 - 784 (132 - 176) Deflection (Reference value) mm (in) 9.7 - 12.7 (0.38 - 0.50) 10.3 - 11.8 (0.41 - 0.47) 6.7 - 8.5 (0.26 - 0.34)
4. Tighten the lock bolt. Tightening torque: 23 +/- 2 N.m (16 +/- 2 ft-lb)
5. Tighten the nut of the generator pivot bolt. Tightening torque: 44 +/- 10 N.m (33 +/- 7 ft-lb)
6. Tighten the adjusting bolt. Tightening torque: 5.0 +/- 1.0 N.m (44 +/- 8 in-lb)

Scheme 41

POWER STEERING OIL PUMP AND DRIVE BELT TENSION CHECK AND ADJUSTMENT <2.0L Engine >

Check the drive belt tension by the following procedure.

Required Special Tools

1. MB991958: Scan Tool (MUT-III Sub Assembly) MB991824: V.C.I. MB991911: MUT-III Main Harness B
2. MB991668: Belt Tension Meter Set

Gently tap the middle of the belt between the pulleys (the location indicated by the arrow) with your finger as shown in the illustration, and check that the vibration frequency of the belt is within the standard value.

Note. Refer to GENERATOR DRIVE BELT TENSION CHECK <2.0L Engine > for details on the method of measuring the vibration frequency using the scan tool.

Scheme 42

< WHEN USING A TENSION GAUGE >

Use a belt tension gauge to check that the belt tension is within the standard value.

Apply approximately 100 N (22 pound) of force to the middle of the drive belt between the pulleys (at the place indicated by the arrow) and check that the amount of deflection is within the standard value.

Standard value

ITEM DESCRIPTION CHART

If the tension or deflection is outside the standard value, adjust by the following procedure.

1. Loosen the tension pulley fixing nut A behind the tension pulley.
2. Adjust the belt deflection amount using the adjusting bolt B.
3. Tighten the fixing nut A. Tightening torque: 26 +/- 4 N.m (19 +/- 3 ft-lb) CAUTION: Check after turning the crankshaft one or more rotations clockwise.
4. Check the belt deflection amount and tension, and readjust if necessary.

Scheme 43

DRIVE BELT TENSION CHECK <2.4L Engine >

1. Make sure that the indicator mark is within the area marked with A in the illustration.
2. If the mark is out of the area, replace the drive belt. (Refer to , «CRANKSHAFT PULLEY»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/mechanical/#on-vehicle-service-lancer-24l) ). NOTE: The drive belt tension adjustment is not necessary as auto-tensioner is adopted.

Scheme 44

9. EXHAUST SYSTEM (CONNECTION PORTION OF MUFFLER, MUFFLER PIPES AND CONVERTER HEAT SHIELDS) (CHECK AND SERVICE AS REQUIRED)

1. Check for holes and exhaust gas leaks due to damage, corrosion, etc.
2. Check the joints and connections for looseness and exhaust gas leaks.
3. Check the rubber hangers and brackets for damage.

10. ENGINE OIL (CHANGE)

Use the specified oil. (Refer to RECOMMENDED LUBRICANTS AND LUBRICANT CAPACITIES TABLE .)

Scheme 45

Scheme 46

Scheme 47

Scheme 48

1. After warming up the engine, remove the oil filler cap. WARNING: Use care, oil could be hot.
2. Remove the drain plug to allow the engine oil to drain.
3. Replace the drain plug gasket with a new one, and then tighten the drain plug to the specified torque. Tightening torque: 39 +/- 5 N.m (29 +/- 4 ft-lb) NOTE: Install the drain plug gasket so it faces in the direction shown in the illustration.
4. Pour new engine oil in through the oil filler tube. Engine oil capacity: <2.0L Engine > 3.8 dm 3 (4.0 quarts) <2.4L Engine > 4.3 dm 3 (4.5 quarts)
5. Start the engine and run it at idle for a few minutes.
6. Stop the engine and check to ensure that the engine oil level is within the level range indicated on the dip stick.

11. ENGINE OIL FILTER (REPLACE)

The quality of replacement filters varies considerably. Only high quality filters should be used to assure most efficient service. Genuine oil filters require that the filter is capable of withstanding a pressure of 1,765 kPa (256 psi) are high quality filters and are recommended as follows

Mitsubishi Oil Filter Part Number

<2.0L Engine >: MD136466, MD322508, MD325714, MD332687, MD360935 or MD365876

<2.4L Engine >: MD136466, MD322508 or MD356000

Engine Oil Filter Selection

This vehicle is equipped with a full-flow, throw-away oil filter. The same type of filter is recommended as a replacement filter for this vehicle. It is possible, particularly in cold weather, that this vehicle may develop high oil pressure for a short duration. Make sure that any replacement filter used on this vehicle is a high-quality filter. The filter must withstand a pressure of 1,765 kPa (256 psi) [manufacturer's specifications] to avoid filter and ultimately engine damage. The following is a high-quality filter and is strongly recommended for use on this vehicle: Mitsubishi Engine Oil Filter Part number MD136466, MD322508, MD325714, MD332687, MD360935 and MD365876.

Any replacement oil filter should be installed in accordance with the oil filter manufacturer's installation instructions.

Scheme 49

Scheme 50

1. Drain the engine oil by removing the oil drain plug.
2. Use an oil filter wrench to remove the engine oil filter.
3. Clean the contact surface of the filter bracket.
4. Lubricate the O-ring of the new oil filter with a small amount of new engine oil.
5. Screw on the oil filter by hand until it touches the surface of the flange and then tighten it with an oil filter wrench. TIGHTENING TORQUE SPECIFICATION ENGINE NUMBER SPECIAL TOOL TIGHTENING TORQUE 2.0L MD360935 MB991396 or equivalent Approximately one turn [14 +/- 2 N.m (124 +/- 18 in-lb)] MD365876 MB991828 or equivalent Approximately 3/4 turn [16 +/- 4 N.m (12 +/- 3 ft-lb)] MD325714 MD332687 General service tool Approximately 3/4 turn [16 +/- 4 N.m (12 +/- 3 ft-lb)] MD136466 MD322508 General service tool Approximately 3/4 turn [17 +/- 3 N.m (13 +/- 2 ft-lb)] 2.4L MD136466, MD322508 General service tool Approximately 3/4 turn [17 +/- 3 N.m (13 +/- 2 ft-lb)] MD356000 MB991610 or equivalent Approximately 3/4 turn [14 +/- 2 N.m (124 +/- 18 in-lb)]
6. Add new engine oil through the oil filler.

CHECK OIL LEVEL

Inspect each component for evidence of leakage. Check the oil level by removing the filler plug.

1. Remove the filler plug.
2. Check that the oil is not noticeably dirty, and that it has a suitable viscosity.
3. Tighten the filler plug to the specified torque. Tightening torque: 32 +/- 2 N.m (24 +/- 1 ft-lb)

Scheme 51

CHANGE OIL

1. Remove the filler plug.
2. Remove the drain plug and drain the oil.
3. Tighten the drain plug to the specified torque. Tightening torque: 32 +/- 2 N.m (24 +/- 1 ft-lb)
4. Fill with DiaQueen NEW MULTI GEAR OIL API classification GL-3 SAE 75W-80 or Gear oil API classification GL-4, SAE 75W-85W, 75W-90 until the level comes to the lower portion of filler plug hole. Quantity: 2.2 dm 3 (2.3 quarts)
5. Tighten the filler plug to the specified torque. Tightening torque: 32 +/- 2 N.m (24 +/- 1 ft-lb)

Scheme 52

Scheme 53

Scheme 54

1. Drive the vehicle until the A/T fluid temperature rises to the normal temperature [70 - 80°C (158 - 176°F)]. NOTE: The A/T fluid temperature is measured with scan tool MB991958. NOTE: If it takes some amount of time until the A/T fluid reaches its normal operating temperature [70 - 80°C (158 - 176°F)], check the A/T fluid level by referring to the left diagram.
2. Park the vehicle on a level surface.
3. Move the selector lever through all positions to fill the torque converter and the hydraulic circuits with A/T fluid, and then move the selector lever to the "N" position.
4. After wiping off any dirt from around the dipstick, remove the dipstick and check the condition of the A/T fluid. NOTE: If the fluid smells as if it is burnt, it means that the A/T fluid has been contaminated by fine particles from the bushings and friction materials. A transaxle overhaul and cooler line flushing may be necessary.
5. Check that the A/T fluid level is at the "HOT" mark on the dipstick. If the A/T fluid level is lower than this, pour in more MITSUBISHI genuine ATF SP-III or equivalent until the level reaches the "HOT" mark. NOTE: If the A/T fluid level is too low, the oil pump will draw in air along with the A/T fluid, which will cause bubbles to form. If the A/T fluid level is too high, rotating components inside the transaxle will churn the fluid and air into a foamy liquid. Both conditions (level too low or too high) will cause the hydraulic pressure to drop, which will result in late shifting and slipping of the clutches and brakes. In either case, air bubbles can interfere with normal valve, clutch, and brake operation. Also, foaming can cause A/T fluid to escape from the transaxle vent where it may be mistaken for a leak.
6. Securely insert the dipstick. NOTE: The A/T fluid should always be replaced when: When overhauling the transaxle When the oil is noticeably dirty or burnt (vehicle was driven under severe conditions)

CHANGE A/T FLUID

If you have an A/T fluid changer, use this changer to replace the A/T fluid. If you do not have an A/T fluid changer, replace the A/T fluid by the following procedure

Scheme 55

Scheme 56

Scheme 57

Scheme 58

Scheme 59

1. Disconnect the hose shown in the illustration which connects the transaxle and the oil cooler (inside the radiator). Place a container under the hose to collect the A/T fluid. CAUTION: The engine should be stopped within one minute after it is started. If all the A/T fluid has drained out before then, the engine should be stopped at that point.
2. Start the engine and let the A/T fluid drain out. (Running conditions: "N" range with engine idling) Approximately 3.5 dm 3 (3.7 quarts) of A/T fluid should be removed.
3. Remove the drain plug from the bottom of the transaxle case to drain the A/T fluid. Approximately 2.0 dm 3 (2.1 quarts) of A/T fluid should be removed.
4. Install the drain plug with a new gasket, and tighten it to the specified torque. Tightening torque: 32 +/- 2 N.m (24 +/- 1 ft-lb) CAUTION: Stop pouring if the full volume of A/T fluid can not be added.
5. Add new A/T fluid (DIAMOND ATF SP III or equivalent) through the oil filter tube. Approximately 5.5 dm 3 (5.8 quarts) of A/T fluid should be added.
6. Repeat the procedure in Step 2 . (to pump out the rest of the contaminated A/T fluid)
7. Add new A/T fluid (DIAMOND ATF SP III or equivalent) through the oil filter tube. Approximately 3.5 dm 3 (3.7 quarts) of A/T fluid should be added. NOTE: Check for contamination or a burnt odor. If the A/T fluid is still contaminated or burnt, repeat Steps 6 and 7 before proceeding to Step 8.
8. Reconnect the hose which was disconnected in step 1 above, and firmly replace the dipstick.
9. Start the engine and run it at idle for 1 - 2 minutes.
10. Move the selector lever through all positions, and then move it to the "N" position.
11. Check that the A/T fluid level is at the "COLD" mark on the dipstick. If the level is lower than this, pour in more A/T fluid.
12. Drive the vehicle until the A/T fluid temperature rises to the normal temperature [70 - 80°C (158 - 176°F)], and then check the A/T fluid level again. The A/T fluid level must be at the "HOT" mark. NOTE: The A/T fluid temperature is measured with scan tool MB991958. The "COLD" level is for reference only; the "HOT" level should be regarded as the standard level. NOTE: If it takes some amount of time until the A/T fluid reaches its normal operating temperature [70 -80°C (158 - 176°F)], check the A/T fluid level by referring to the left diagram.
13. If the A/T fluid is under the specified level, pour in more A/T fluid. If the A/T fluid is over the specified level, drain the excessive A/T fluid from the drain plug to adjust A/T fluid level to the specified level.
14. Firmly insert the dipstick into the oil filler tube.

14. ENGINE COOLANT (CHANGE)

Check the cooling system parts such as the radiator, heater and oil cooler hoses, thermostat and their connections for leakage and damage.

Scheme 60

Scheme 61

Scheme 62

Scheme 63

Scheme 64

1. Set the temperature control knob to the "HOT" position.
2. Run the engine until the engine coolant warms, and then stop the engine. WARNING: When removing the radiator cap, use care to avoid contact with hot coolant or steam. Place a shop towel over the cap and turn the cap counterclockwise a little to let the pressure escape through the vinyl tube. After relieving the steam pressure, remove the cap by slowly turning it counterclockwise.
3. Drain the water from the radiator, heater core and engine after unplugging the radiator drain plug and removing the radiator cap.
4. Drain the water in the water jacket by unplugging the drain plug of the cylinder block.
5. Remove the radiator condenser tank and drain the coolant.
6. Drain the cooling water then clean the path of the cooling water by injecting water into the radiator from the radiator cap area.
7. Apply the designated sealant to the screw area of the cylinder block drain plug, and then tighten to the standard torque. Specified sealant: 3M™ AAD Part No.8731 or equivalent Tightening torque: <2.0L Engine > 40 +/- 5 N.m (30 +/- 3 ft-lb) <2.4L Engine > 44 +/- 5 N.m (33 +/- 3 ft-lb)
8. Securely tighten the drain plug of the radiator.
9. Assemble the radiator condenser tank. CAUTION: Do not use alcohol or methanol anti-freeze or any engine coolants mixed with alcohol or methanol anti-freeze. The use of an improper anti-freeze can cause corrosion of the aluminum components.
10. By referring to the section on coolant, select an appropriate concentration for safe operating temperature within the range of 30 to 60 %. Use special tool MB991871 to refill the coolant. A convenient mixture is a 50 % water and 50 % antifreeze solution [freezing point: -31°C (-32.8 °F)]. Recommended antifreeze: Long Life Antifreeze Coolant or an equivalent Quantity: <2.0L Engine > 6.0 dm 3 (6.3 quarts) <2.4L Engine > 7.0 dm 3 (7.4 quarts) NOTE: For how to use special tool MB991871, refer to its manufacturer's instructions.
11. Reinstall the radiator cap.
12. Start the engine and let it warm up until the thermostat opens.
13. After repeatedly revving the engine up to 3,000 r/min several times, then stop the engine.
14. Remove the radiator cap after the engine has become cold, and pour in coolant up to the brim. Reinstall the cap. CAUTION: Do not overfill the reserve tank.
15. Add coolant to the reserve tank between the "FULL" and "LOW" mark if necessary.

15. COOLANT HOSES (RADIATOR HOSE, HEATER HOSE) (INSPECT)

Inspect the surface of radiator hoses and heater hoses for heat and mechanical damage. Hard and brittle rubber, cracking, tears, cuts, abrasions and excessive swelling indicate deterioration of the rubber.

16. DISC BRAKE PADS (INSPECT FOR WEAR)

Check for fluid contamination and wear. Replace the complete set of pads if any one pad is defective.

Thickness of lining

Minimum limit: 2.0 mm (0.08 inch)

Scheme 65

17. REAR DRUM BRAKE LININGS AND REAR WHEEL CYLINDERS (INSPECT FOR WEAR AND LEAKS)

1. Remove the brake drum and check the thickness of brake shoe lining for wear. Check the automatic brake adjusting system by hand to see if it operates smoothly. Also see if the gears are in proper mesh with each other. To assure smooth operation, apply a very thin coat of multipurpose grease to the friction surface of the adjuster and link shaft. CAUTION: The shoes for the right and left wheels should be replaced at the same time. Never split or intermix brake shoe sets. All four shoes must be replaced as a complete set.
2. Inspect the wheel cylinder boot for evidence of a brake fluid leak. Visually check the boot for cuts, tears or heat cracks. (A slight amount of fluid on the boot may not be a leak, but may be preservative fluid used at assembly.) Check the brake shoes for wear. Thickness of lining Minimum limit: 1.0 mm (0.04 inch)

Scheme 66

18. BRAKE HOSES (CHECK FOR DETERIORATION OR LEAKS)

Inspection of brake hoses should be included in all brake service operations.

The hoses should be checked for

1. Incorrect length, severe surface cracking, pulling, scuffing or worn spots. (If the fabric casing of the hoses is exposed by cracks or abrasion in the rubber hose cover, the hoses should be replaced. Eventual deterioration of the hose and possible bursting failure may occur.)
2. Incorrect installation, twisting or interference with wheel, tire or chassis.

Scheme 67

19. BALL JOINT AND STEERING LINKAGE SEALS (INSPECT FOR GREASE LEAKS AND DAMAGE)

1. These components, which are permanently lubricated at the factory, do not require periodic lubrication. Damaged seals and boots should be replaced to prevent leakage or grease contamination.
2. Inspect the dust cover and boots for proper sealing, leakage and damage. Replace them if defective.

Scheme 68

Scheme 69

1. These components, which are permanently lubricated at the factory, do not require periodic lubrication. Damaged seals and boots should be replaced to prevent leakage or grease contamination.
2. Inspect the dust cover and boots for proper sealing, leakage and damage. Replace them if defective.

21. SUSPENSION SYSTEM (INSPECT FOR LOOSENESS AND DAMAGE)

Visually inspect the front/rear suspension components for deterioration and damage. Re-tighten the front/rear suspension components retaining bolts to specified torque.

22. TIRES (ROTATE)

Rotate tires regularly to equalize tire wear and help extend tire life. Recommended tire rotation is every 12,000 km (7,500 miles).

Timing for the rotation may vary according to vehicle condition, road surface conditions, and individual driver's habits. When rotating tires, check for uneven wear, damage, and wheel alignment. Abnormal wear is usually caused by incorrect tire pressure, improper wheel alignment, out-of balance wheels, or severe braking.

The first rotation is the most important, to achieve more uniform wear for all tires on the vehicle.

Scheme 70

Scheme 71

1. Remove the glove box. (Refer to - «INSTRUMENT PANEL»(/mitsubishi/lancer-evolution/ix-2005-2007/remont/gauges-instrument-panels/#interior-lancer) )
2. Remove the two screws as shown, and replace the clean air filter.
3. Install the glove box.

MAIN SEALANT AND ADHESIVE TABLE

MAIN SEALANT AND ADHESIVE TABLE

See also:
• HARNESS CONNECTOR INSPECTION
• SUPPLEMENTAL RESTRAINTS SYSTEM - LANCER
• AIR BAG MODULE DISPOSAL PROCEDURES
• TIMING BELT
• REMOVAL AND INSTALLATION
• INSTRUMENT PANEL
• STANDARD BOLT AND NUT TIGHTENING TORQUE
• HOW TO USE THE INSPECTION PROCEDURES
• INSPECTION SERVICE POINTS FOR A BLOWN FUSE
• LEARNING PROCEDURE FOR IDLING IN MFI ENGINE
• SCHEDULED MAINTENANCE SERVICE FOR EMISSION CONTROL AND PROPER VEHICLE PERFORMANCE