Mitsubishi Lancer Evolution-VII Instruction manual

WORKSHOP MANUAL
TECHNICAL INFORMATION MANUAL Pub. No. S0105CT9A
Pub. No. N0104CT9A
RA-0111
EVOLUTION-VII
表紙111/27/019:07AMページ1

0
1
2
3
4
5
6
7
GROUP INDEX
GENERAL .......................
ENGINE .........................
POWER TRAIN ..................
DRIVE-CONTROL
COMPONENTS ..................
BODY ...........................
EXTERIOR ......................
INTERIOR .......................
EQUIPMENT .....................
TECHNICAL
INFORMATION
MANUAL
FOREWORD
This manual has been prepared as an introduction
to the specifications, features, construction, func-
tions, etc. of the newly developed LANCER EVOLU-
TION-VII. Please read this manual carefully so that
it will be of assistance for your service activities.
Please note that the following service manuals are
also available and should be used in conjunction
with this manual.
WORKSHOP MANUAL S0105CT9A
All information, illustrations and product descrip-
tions contained in this manual are current as of 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 April 2001

NOTES

0-1
GENERAL
CONTENTS
HOW TO USE THIS MANUAL 2..............
Model Indications 2............................
TARGETS OF DEVELOPMENT 2..............
PRODUCTS FEATURES 2....................
TECHNICAL FEATURES 4....................
Exterior 4.....................................
Interior 5......................................
Body Dimensions and Spacious Cabin 6.........
Aerodynamic Performance 6....................
Active Center Differential (ACD), Active Yaw
Control (AYC) 7................................
Engine 8......................................
Transmission 8.................................
All-wheel Independent Suspensions 8............
Safety 10......................................
Equipments 13.................................
Serviceability and Reliability 13..................
VEHICLE IDENTIFICATION 14.................
MAJOR SPECIFICATIONS 15.................

GENERAL - How to Use This Manual/Targets of Development/Product Features
0-2
HOW TO USE THIS MANUAL
MODEL INDICATIONS
The following abbreviations are used in this manual for identification of model types.
MPI: Indicates the multipoint injection, or engine equipped with the multipoint injection.
DOHC: Indicates an engine with the double overhead camshaft, or models equipped with such an engine.
M/T: Indicates the manual transmission, or models equipped with the manual transmission.
A/C: Indicates the air conditioner.
TARGETS OF DEVELOPMENT
A new competitive device in addition to technology established in the previous motor sport events to
improve potential performance as well as outward and inward appearance with a sophisticated view to
represent a high performance sedan of the next generation has been featured to improve the image
of Mitsubishi brand.
Furthermore, enhancement of competitiveness as well as driving performance in various motor sport
events has been sought.
PRODUCT FEATURES
Outward and in-
ward appearance
to represent a
high perfor-
mance sedan of
the next genera-
tion
(1) Exterior with sophisticated and fearless expression
DMulti-lighted headlamp and rear combination lamp exclusively used
for EVOLUTION-VII
DFront bumper with large cooling air inlet
DIncorporate blister fender and overwhelming large- sized tyre
DLarge-sized and light weight rear spoiler with variable elevation angle
that can be adjusted at 4 points
DFront bumper extension and side sill extension
DLarge-sized under cover equipped (for improvement of aerodynamic
and cooling performance in drive system)
(2) Interiors with athletic feeling
DLight weight backet newly designed by RECARO seat (adoption of
silk waving cloth with functionality)
DSteering wheel newly designed by MOMO
DMulti-functional sports meter (with permanent illumination to be visible
in the day light)
The most out-
standing engine
and power per-
formance in the
class
(1) Fine tuned engine that provides improved output at all ranges:Maximum
output 280 PS (206 kW) and maximum torque 39 kgfSm (383 NSm)
Dmprovement of turbo charger
DEnlarged Intercooler and oil cooler
DAutomatic injection control 3-nozzle intercooler spray
(2) Drive system with high reliability to deal with increased engine torque
DReinforcement of transfer, propeller shaft, and drive shaft

GENERAL - Product Features 0-3
Further improve-
ment in handling
performance
made by en-
hancement of the
marginal perfor-
mance
(1) Mitsubishi original revolutionary technology with all wheel control
DNewly developed active center differential system (ACD) (to be
compatible with steering response to cornering and rising traction
performance)
DImprovement of marginal performance in cornering made by integrated
control of ACD{active yawing control (AYC)
(2) Optimally tuned suspension to be adjusted to the new dimensions has
improved cornering performance.
DExtended length of wheel base (+115 mm), enlarged width of treads
(front: +5 mm, rear: +10 mm)
DIncreased suspension stroke in the compression side
(front:+15 mm, rear: +5 mm)
D235/45ZR17 tyres adopting half-radial structure and newly developed
high performance high grip compounds
NOTE
Figures in the parentheses indicate the numbers compared with those
of EVOLUION-VI.
(3) High rigidity body to sustain high marginal performance
(bend rigidity: increased by 50 %, torsion rigidity: equal to that of
EVOLUTION-VII)
DSuspension mounting, fortification of body frame connections, addition
of reinforcements (approximately 20 locations), and addition of welding
spots
DHigh rigidity 3-point mounting strut tower bar
DRear end cross bar<RS>
DAluminum hood and fender attached
Revolutionary
braking system
to correspond
with high margin-
al performance
(1) Sporty type 4ABS (improved braking stability derived from braking control
in both sides at driving in sports mode)
(2) EBD system for EVOLUTION-VII (improvement in deceleration
performance)
(3) Featuring Brenvo made front 17-inch ventilated disc (opposite differential
diameter 4-piston type) and rear 16-inch ventilated disc (opposite
2-piston type)

GENERAL - Technical Features
0-4
TECHNICAL FEATURES
EXTERIOR
DESIGN FEATURES
The 7th generation EVOLUTION has acquired the
image of “high performance sports sedan” equipped
with guaranteed quality and fearless determination
as “high quality driving sedan” in addition to the
rally image of the previous generations.
(1) Aggressive and overwhelming front mask with
multi-lighted headlamps, large-sized inlet
bumper grill, and side outlet
(2) Improved maneuvering capability of the vehicle
at the corners by cutting a large portion of the
front corner
(3) Exclusive blister fender to appeal good road
hanging (traction characteristics) and brisk
driving capability
(4) Front -side sill extension and wing - type rear
spoiler to emphasize the high aerodynamic
performance
(5) Clear type rear combination lamp to appeal
sporty feeling and guaranteed quality
(6) Attaching the newly designed “EVOLUTION
VII” emblem with sharp and sporty image
(4)
(3)
(2)
(3)
(6)
(1)
(4)
(4)
(5)

GENERAL - Technical Features 0-5
INTERIOR
DESIGN FEATURES
High performance interior to provide an impression
of sports minded vehicle as the 7th generation
EVOLUTION
(1) Combination meter exclusively for EVOLU-
TION-VII with a configuration of a circular
tachometer in the center and thick bezels
(partitions between meters) with discreet design
create appeal for fearless determination and
sporty feelings.
(2) The Mitsubishi original design made by MOMO
used for the steering has the same design used
for horn pad as the shift lever to express
integration of the image and high performance
interior.
(3) The Mitsubishi original design made by Recaro
used for the front seat has a sewing line
surrounding circumference of the sides to
emphasize the good holding.
(2)
(1)
(3)
(2)

GENERAL - Technical Features
0-6
BODY DIMENSIONS AND SPACIOUS CABIN
Body Dimensions
The dimensions of the EVOLUTION-VII except for the overall width have been altered in comparison
with those of EVOLUTION-VI.
3
4
7
2
6
1
5
No. Item Dimensions mm No. Item Dimensions mm
1Overall length 4 455 (+105) 6Rear overhang 935 ( - 15)
2Overall width 1 770 (±0) 7Tred
<Vehicles
with
Front 1 515 (+5)
3Overall height 1 450 (+45) <
V
e
hi
c
l
es w
ith
235/45ZR17tyres>Rear 1 515 (+10)
4Wheel base 2 625 (+115) Tred
<Vehicles
with
Front 1 500 (+5)
5Front overhang 895 (+5) <
V
e
hi
c
l
es w
ith
205/65R15tyres>Rear 1 500 (+10)
NOTE
Figures in the parentheses indicate the values in comparison with those of EVOLUTION-VI.
AERODYNAMIC PERFORMANCE
Deterioration of aerodynamic performance accompanied with enlargement of the body size has been
suppressed by attaching a large-sized under cover on the lower part of the engine compartment, optimizing
elevation angle setting of rear spoiler.
(1) Under cover
A large- sized under cover is designed for compatibility of reduction of air resistance and reduction
of lift.
(2) Rear spoiler
Lift control by attaching elevation angle adjustable rear spoiler and optimizing attached position of
the spoiler are designed for reduction of air resistance.
(2)
(1)

GENERAL - Technical Features 0-7
ACTIVE CENTER DIFFERENTIAL (ACD), ACTIVE YAW CONTROL (AYC)
ACD, which is designed for improving drive characteristics by electronically controlling center
differential movement, and AYC, which has been adopted since EVOLUTION-IV are featured by
combing two systems for integrated control so that further improvements in driving performance can
be achieved.
Hydraulic unit
assembly
ACD mode indicator lamp
Steering wheel
sensor
Lateral G sensor
Reserve tank
Wheel speed sensor
Longitudinal
G sensor
ABS-ECU
4WD-ECU
Wheel speed sensor
Throttle position sensor (TPS)
Engine- ECU
Parking brake switch
ACD mode switch
Stop lamp switch
ACD transfer
AYC torque transfer
differential

GENERAL - Technical Features
0-8
ENGINE
The turbo charger specifications have been
optimized by reducing the size of the turbine nozzle
diameter to increase the engine torque at
low-middle speed range as well as high speed
range.
Since adoption of magnesium diecasting rocker
cover and hollow camshaft is intended for light
weight of the upper part of the engine, vibration
of engine-transmission at acceleration can be
reduced to improve the response of the body.
TRANSMISSION
Implementation of fortifying each part to deal with
the increased engine torque and revision of the gear
ratio of the standard transmission are intended for
further improvement in power performance.
ALL-WHEEL INDEPENDENT SUSPENSIONS
While the popular and rally-proven McPherson strut
front and multi-link rear suspension systems have
basically been retained, they were optimized for
the new model.
The improvements to the front include adding a
crossmember brace to the lower arm mount for
more rigidity, flattening the chassis crossmember,
and realigning the roll center to an ideal height.
As a result, the suspension delivers enhanced
handling and straight-line stability, ride comfort,
grounding characteristics, and roll feel, as well as
less vibrations and noise.
The steering gear’s optimal position ensures
predictably linear toe-in changes.
Each arm of the rear multi-links with trailing arms,
as well as its linkage point and length, was
reevaluated to achieve optimal alignment.
Combined with the wider tracks, higher body rigidity,
and improved damping characteristics of the
bushings and bump rubbers, the suspensions
deliver a supple ride with superb handling stability
for relaxing, effortless control.

GENERAL - Technical Features 0-9
Stabilizer bar
Coil spring
Strut assembly
(shock absorber)
Crossmember
Lower arm
Strut insulator
Stabilizer link
Lower arm bushing
(Pillow ball bushing with rubber)
Crossmember bar
<RS (option), RS-II>
Upper arm
Toe control arm
Trailing arm Lower arm
Toe control bar <RS>
Coil spring
Differential support
member
Crossmember
Shock absorber
Differential
support arm
Stabilizer bar

GENERAL - Technical Features
0-10
SAFETY
ACTIVE SAFETY
BRAKING SYSTEM
All models feature fade-resistant 14-inch ventilated
discs up front and rear 8-inch drums for sure, linear
stopping power.
A 4-sensor, 3-channel ABS (Anti-lock Braking
System) with EBD (Electronic Brake-force
Distribution) is available. ABS adjusts the braking
pressure of the front wheels independently and
rear wheels together for controlled emergency
braking.
New for the Lancer, EBD works with the ABS
computer to evenly modulate each channel’s
braking pressure for ideal braking force regardless
of load or surface conditions at all times.
Wheel speed sensor
Diagnosis connector
Stop lamp switch Wheel speed sensor
Hydraulic unit
(integrated in
ABS-ECU)
ABS warning lamp
Steering wheel sensor
Parking brake switch
Longitudinal G sensor
Lateral G sensor

GENERAL - Technical Features 0-11
PASSIVE SAFETY
SRS AIR BAGS
Dual SRS (Supplemental Restraint System) front
airbags deploy only upon detection of frontal impact.
When used in combination with the 3-point ELR
seatbelts, they significantly mitigate head and upper
torso injury to front-seat occupants.
Seat belt with pretensioner featured for the driver’s
and front passenger’s seats is designed for instantly
taking up the slack in the seat belt at the time
of impact to improve restraint effect on a passenger.
It is activated approximately at the same time as
SRS airbag is activated to improve protection effect
on a passenger.
Driver’s side Passenger’s side
SRS warning lamp
Front passenger’s side air bag module
Driver’s side air bag module
Clock spring
Diagnosis connector
SRS - ECU
Seat belt with pretensioner

GENERAL - Technical Features
0-12
BODY CONSTRUCTION
The EVOLUTION-VII safety-enhanced body
structure comprises front and rear crushable zones
that effectively absorb the impact energy of front
and rear collisions.
Adding to all-round occupant protection is a
deformation-resistant, highly rigid cabin structure
that features strategic reinforcements plus large
side-door impact bars.
Enlarged impact bars
Enlarged cross-section of roof bow
Reinforced center pillar
Enlarged cross-section
of side sill
Enlarged cross-section and
minimised vertical offset of
front floor side member
Added dash crossmember
Thicher dash panel lower
Reinforced front pillar
Enlarged cross-section and
extended front side member

GENERAL - Technical FeaturesGENERAL - Technical Features 0-13
SAFETY-ENHANCED FRONT SEATS
The front seats are designed to minimise the risk
of whiplash in a collision from the rear.
The headrestraints have been ideally angled
forward, while the seat frame was moved toward
the rear.
In-house tests show a roughly 40% improvement
in occupant injury figures.
OTHER SAFETY FEATURES
D3-point ELR seatbelts
DFront fog lamps
DChild-protection rear door locks
EQUIPMENTS
IMMOBILIZER SYSTEM
This system lets the engine be started only when
an encrypted code that is recorded in the ignition
key is the same as an encrypted code that is
recorded in the immobilizer-ECU. Immobilizer
system is equipped as an option.
Power
Encrypted code
Transponder
Ignition key
Steering lock key
cylinder and immobilizer-ECU
MUT - II
Engine - ECU
or
Engine A/T-ECU
Start
permission
signal
Registration
of ignition
key
Integrated immobilizer-ECU and antenna
SERVICEABILITY AND RELIABILITY
MAINTENANCE-FREE FEATURES
DAdoption of an auto-tensioner eliminates the
need for timing belt adjustment
DAdoption of auto lash adjusters eliminates the
need for valve clearance adjustment
ENHANCED DIAGNOSIS SYSTEM
Diagnosis functions have been included for the
following systems, so that it is possible to use the
MUT-II to read the diagnosis codes and service
data and to carry out actuator tests. In addition,
it is also possible to read the diagnosis codes by
the flashing of the warning lamp in some systems.
DMPI
DACD
DAYC
D4ABS
DSRS air bag
DSimplified Wiring System (SWS)
IMPROVED SERVICEABILITY AND HANDLING
DA one-touch joint type plastic tube has been
adopted for fuel main lines, which makes
removal and installation easier.
DA small wiper module, which includes wiper
motor and linkage, has been adopted to
facilitate removal and installation.

GENERAL - Vehicle Identification
0-14
VEHICLE IDENTIFICATION
MODELS
Model code Class code Grade Engine model Transmission model Fuel supply
system
CT9A SNDFZL/R RS 4G63 (1,997 mL-DOHC-
16
valves intercooler
turbo)
W5M51 <4WD-5M/T> MPI
SNGFZL/R RS-II
16
va
l
ves-
i
n
t
ercoo
l
er
t
ur
b
o
)
MODEL CODE
No. Items Contents
1Development CT: MITSUBISHI LANCER
EVOLUTION-VII
2Engine type 9: 1,997 mL petrol engine
3 Sort A: Passenger car
4 Body style S: 4-door sedan
5 Transmission type N: 5-speed manual
transmission
6 Trim level D: RS
G: RS-II
7Specification engine
feature
F: MPI-DOHC
8Special feature Z: 4WD
9Steering wheel location L: Left hand
R: Right hand
123456789
CT 9 A S N D F L
Z

GENERAL - Major Specifications 0-15
MAJOR SPECIFICATIONS
1
2345
6
7
8
9
Items CT9A
SNDFZL/R SNGFZL/R
Vehicle
di i
Front track 1 1,500, 1,515 *1
dimensions
mm
Overall width 2 1,770
mm
Front overhang 3 855
Wheel base 4 2,625
Rear overhang 5 975
Overall length 6 4,455
Ground clearance
(unladen)
7 140
Overall height (unladen) 8 1,450
Rear track 9 1,500, 1,515 *1
Vehicle
iht
k
Kerb weight 1,380 1,420
weight kg Max. gross vehicle weight 1,655 1,695
Max. axle weight
rating-front
950 970
Max. axle weight
rating-rear
705 725
Seating capacity 5
Engine Model No. 4G63
g
Total displacement mL 1,997
Transmis-
i
Model No. W5M51
sion Type 5-speed manual
Fuel System Fuel supply system MPI
NOTE
*1: Vehicles with 17 inch wheels.

NOTES

1-1
ENGINE
CONTENTS
GENERAL INFORMATION 2................
Major Specifications 2.......................
BASE ENGINE 3..........................
Piston 3....................................
Piston Ring 3...............................
LUBRICATION SYSTEM 4..................
Engine Oil Cooler 4.........................
COOLING SYSTEM 5......................
Specifications 5.............................
Construction Diagram 5......................
INTAKE AND EXHAUST 6.................
Air Intake System 6.........................
Exhaust System 9...........................
FUEL SYSTEM 11.........................
Specifications 11............................
Construction Diagram 11.....................
Fuel Tank 12...............................
CONTROL SYSTEM 13....................
System Block Diagram 14....................
Control System Diagram 15..................
List of Component Functions 16..............
Fuel Injection Control 19......................
Idle Speed Control 19.......................
Ignition Timing and Distribution Control 20.....
Radiator Fan Motor Control 20...............
Power Supply and A/C Condenser Fan Relay
Control, Oxygen Senser Heater Control, Air Flow
Senser Filter Reset Control, Alternator Control,
Fuel Pressure Control, Supercharging Pressure
Control, Secondary Air Control 20.............
Fuel Pump Relay Control 21..................
EGR Control and Purge Control 22............
Diagnosis System 22.........................
EMISSION CONTROL SYSTEM 23..........
Emission Control System Diagram 23.........
MOUNT 24................................
Construction Diagram 24.....................
ACCELERATOR SYSTEM 26...............
Construction Diagram 26.....................