22 - EvoScan
Contents
1. MANUAL TRANSMISSION GENERAL LUBRICANTS 22 1 SECTION 22 MANUAL TRANSMISSION General On vehicle Servicing 1 Replacing transmission oil lt 6M T gt LUDIICANKS ce ceeeseeeenenseeeeeseeeeeseeeeenseeeeeneneesseneeeaseeenenseenense Special TOMS c ccceccesecsscesccereoceseneereceesenseneesdecesneesccess TrOUDIESHOOTING ceccsseecesseeeesseeeeenseeeenseeeeaseeeenseeeennseeenes CONTENTS 2 Select cable inside cabin adjustment lt 6M T gt 9 Transmission CONtrOl sssssssssssssescsscsseeeeeeeeeeeneeseens 10 Transfer ASSY lt 6M Ts ccccscssssssssssssscsssssseeeeesseeeeeenenees 12 Transmission ASSY lt 6M T gt ssssscessssssesseeeeeeeeeees 14 Sensors Switches Relays lt vehicles fitted with ACD ACD AYC gt ccssseeees 18 Precautions Regarding Servicing of Vehicles Fitted with SRS Airbags 1 Before removing or fitting any SRS Airbag related components it is essential that you refer to the 00 5 Lancer Sedia Service Manual No 1036K00 Chapter 52B Servicing Precautions 2 Make certain that when removing or fitting any component in a system marked with an in the above list of section titles you do not knock any SRS Airbag related components General The following servicing information has been changed with the introduction of the new Lancer Evolution VIII Servicing details otherwise remain unchanged and are the same as2. OK OK battery voltage Check harness between 4WD ECU and ABS ECU e Check output wire to see if it is broken has a short yoK or is damaged Check connector C 37 NG gt repair OK B 109 ABS ECU connector measurement yOK e Measure ECU terminal voltage MUT II III service data e Voltage across 3 body earth e No 61 ABS monitor e Do ABS actuator test No 05 ABS signal OK OFF OK 1V or less for a period of 10 seconds during the NG gt replace 4WD ECU test and battery voltage after that OK gt intermittent fault NG gt replace hydraulic unit and ABS ECU ref Chapter 00 Countermeasures for Intermittent Malfunctions 2 lt Vehicles fitted with ACD gt NG C 37 4WD ECU connector measurement Undo connector then take measurement on harness side e Resistance across 50 body earth sx Check connectors C 37 C 107 e Check to see if earth wire is broken or damaged NG gt repair OK Check harness between 4WD ECU and body earth Check earth wire to see if it is broken or damaged NG gt repair OK 2 or less OK Check connectors C 37 C 107 NG gt repair OK Replace 4WD ECU MANUAL TRANSMISSION TROUBLESHOOTING 22 7 Code No 82 Electric Pump Relay System Probable causes Code No 82 is output when the pressure sensor does not Insufficient fluid reach the specified value even if the 4WD ECU has out
3. for the Lancer Evolution VII Lubrication Item Name Capacity dm Transmission oil lt 6M T gt Mitsubishi Genuine DIA QUEEN Super Multi gear oil 75W 85W 2 2 22 2 MANUAL TRANSMISSION SPECIAL TOOLS Special Tools Tools Number Name Use MB991502 MUT II Sub ASSY Diagnosis code checking MB991955 MUT III Sub ASSY A MB991824 A V C I Vehicle B MB991827 Communication Interface C MB991910 B USB cable D MB991911 C MUT III main harness A E MB991825 vehicles with CAN F MB991826 communication MB991826 MB991955 D MUT III main harness B vehicles without CAN communications Adapter for measurements Trigger harness mm MANUAL TRANSMISSION SPECIAL TOOLS TROUBLESHOOTING 22 3 Tools Number Name Use Recommended tools Engine lifter To hold the engine ASSY Anzen Jidosha Co Ltd when removing or fitting the MZ203831 transmission Or Note Banzai Co Ltd 1 The engine lifter balancer MZ203830 MB991454 is one part of the engine lifter ASSY MB991928 Engine lifter MB991453 2 Only use a chain with the A MB991929 A Joint 50 x 2 engine lifter balancer B MB991930 B Joint 90 x 2 MB991454 C MB991931 C Joint 140 x 2 D MB991932 D Feet stand x 4 E MB991933 E Feet short x 2 F MB991934 F Chain amp hook ASSY B991928 MB991453 Engine lifter attachment set 8991453 MB991454 Engine lifte
4. II service data 2 e No 62 Parking brake switch 1 Pull parking brake lever OK ON 2 Release parking brake lever OK OFF NG gt replace 4WD ECU OK gt intermittent malfunction ref Chapter 00 Countermeasures for Intermittent Malfunctions 2 Check brake warning light bulb 3 OK NG gt replace lg Replace combi meter Replace hydraulic unit and ABS ECU 22 6 MANUAL TRANSMISSION TROUBLESHOOTING Code No 65 ABS Monitoring System Probable causes When ABS operating for 1 minute or more continuously is detected code No 65 is output lt Vehicles fitted with ACD AYC gt Harness connector malfunction e ABS ECU malfunction lt vehicles fitted with ACD AYC gt e 4WD ECU malfunction 1 NG MUT II IIl service data 2 gt Check connectors C 37 C 20 B 109 e No 61 ABS monitor NG gt repair 1 ABS ECU connector disconnect OK ON OK 2 ABS ECU connector connect Check harness between 4WD ECU and ABS ECU OK OFF e Check output wire to see if it broken or damaged OK gt intermittent malfunction NG gt repair ref Chapter 00 Countermeasures for Intermittent Malfunctions 2 J2 NG NG C 37 4WD ECU connector measurement si Check connectors C 37 C 20 B 109 e Undo connector then take measurement on harness NG gt repair side e Voltage across 48 body earth
5. bin 5 Clip inside cabin 11 Gear stick ASSY 6 Snap pin 12 Distance piece gt A 7 Shift cable connection transmission side 13 Bush A gt gt A 8 Select cable connection transmission side 4B gt A 9Q Clip transmission side 10 Shift cable amp select cable ASSY MANUAL TRANSMISSION TRANSMISSION CONTROL 22 11 Removal A gt Removal of select cable connection transmission side Set the select cable clip in the position indicated in the diagram then undo the select cable connection 4B Clip removal transmission side Select cable Use a screwdriver or similar device to undo the claws of the clip then and shift remove the clip and each of the cables from the bracket AY2380AU Fitting gt A4 Fitting of select cable connection transmission side shift cable connection transmission side clip transmission side 1 Set the gear stick on the transmission side to neutral position 2 Fit the shift cable end transmission side and the select cable transmission side facing the snap pin 3 After fitting the new clip to the transmission cable bracket fit the shift cable and select cable to the cable bracket NOTE The clip can be fitted either way round CAUTION When fitting the clip select cable and shift cable make sure you UL Cable bracket hear them snap tight so that they are securely connected Select cable and shift cable 4 Check that the gear stick inside cabin moves sm
6. d Check connector C 37 NG lt gt Repair fox MUT II III Service Data 2 e No 21 Steering sensor voltage lt ST 1 gt e No 22 Steering sensor voltage lt ST 2 gt e No 23 Steering sensor voltage lt ST N gt OK ref P 22 32 ref Service Data List 2 NG gt replace 4WD ECU OK lt gt Intermittent malfunction ref Chapter 00 Countermeasures for Intermittent Malfunctions 2 Check connectors C 228 C 119 C 209 C 210 NG lt gt Repair Jot Check harness between steering sensor and ignition switch e Power supply cable broken earthed or is damaged NG lt gt Repair Check connectors C 228 C 107 NG lt gt Repair Jor NG lt gt Repair Jok j Replace steering sensor Check harness between steering sensor and body earth Check earth wire to see if it is broken or damaged NG lt gt Repair MANUAL TRANSMISSION TROUBLESHOOTING 22 5 Code No 63 Parking brake switch system Probable causes At vehicle speeds of 15km h and over code No 63 is output if the parking brake stays ON for 15 minutes or more e Parking brake switch malfunction e Harness connector malfunction e ABS ECU malfunction vehicles fitted with ACD AYC 4WD ECU malfunction MUT II III service data 2 e No 62 Parking brake switch 1 Pull parking brake lever OK ON 2 Release parking brake lever OK OFF OK gt in
7. e about 90 and separate the release bearing and wedge collar NOTE The release fork will be forced to move fully in direction B by the return spring as soon as it is separated from the collar CAUTION If it is hard to turn the screwdriver the release bearing cannot be separated remove the screwdriver then repeat the above procedure after pushing the release fork in direction A 2 or three times Forcibly trying to separate the release bearing could damage or break it MANUAL TRANSMISSION TRANSMISSION ASSY lt 6M T gt 22 17 Engine side Fitting gt A4 Fitting transmission mount stopper Transmission mount bracket Fit so that the arrow on the transmission mount stopper is vertical relative to the vehicle body Trans mission mount stopper AWO0199AU 22 18 MANUAL TRANSMISSION SENSOR SWITCH RELAY lt ACD ACD AYC gt Sensor Switch Relay lt ACD ACD AYC gt Removal and fitting AC211853AB Z P R Electric pump relay Check Electric pump relay continuity check 1 Remove electric pump relay connector AC211871AB Check item Tester connection terminal No Battery connection terminal No Normal condition No continuity Connect battery terminal to 2 and battery terminal to 1 2 or less 2 If there is a malfunction replace electric pump relay
8. er ASSY with the transmission jack then remove the transfer fixing bolt and transfer ASSY 22 14 MANUAL TRANSMISSION TRANSFER ASSY lt 6M T gt Transmission ASSY lt 6M T gt CAUTION 1 Before removing steering wheel and airbag module ASSY be sure to read Chapter 52 B Precautions for Servicing Airbag Module and Clock Spring 2 When Brembo brake calipers are used there is concern over paint peeling off so when doing servicing work make sure they are not scratched by other components and tools 3 Indicates parts which should be initially tightened and then fully tightened when the engine weight is supported by the vehicle body Removal and fitting Pre removal and Post fitting operations e Removal and fitting of transfer ASSY ref P 22 18 e Removal and fitting of battery and battery tray e Removal and fitting of strut and tower bar e Temporary fitting of strut ASSY fixing bolt lt only before e Removal and fitting of air pipe hose air hose E air pipe C air hose D ref Chapter 15 Intercooler e Removal and fitting of air cleaner ASSY e Removal and fitting of air intake hose removal gt e Removal and fitting of air duct e Removal and fitting of canister e Removal and fitting of starter ASSY ref Chapter 16 Starter 18 3 Nm 1 3 AC211629AB Removal procedure 1 Main harness clamp connection AD 6 Select cable connection 2 Reversing light switch connector connection 7 Contro
9. g the special engine lifter tool MZ203831 or MZ203830 1 2 Fit the special engine lifter to the strut mounting nuts and radiator support upper insulator mounting bolts shown in the diagram in the engine bay Fit the special engine lifter MB991527 and engine lifter balancer MB991454 chains supporting the engine and transmission ASSY lt When using the special engine lifter MB991928 gt 1 Assemble the special engine lifter tool MB991928 Fit the following parts to the lower lifter e slide bracket HI foot standard MB991932 e joint 90 MB991930 Fit the special engine lifter MB991928 to the strut mounting nuts and radiator support upper insulator mounting bolts shown in the diagram in the engine bay Fit the special engine lifter MB991527 and engine lifter balancer MB991454 chains NOTE Adjust the balance by sliding the special engine lifter MB991928 slide bracket Hl Support the engine and transmission ASSY 4 D Separate clutch release bearing 1 2 Remove the clutch housing service hole cover Whilst lightly pushing the release fork by hand in direction A insert a flat tip screwdriver between the release bearing and wedge collar CAUTION 1 Do not insert the flat tip screwdriver before pressing the release fork in direction A 2 Do not insert the flat tip screwdriver between the wedge collar and wave spring by mistake Twist the screwdriver gently turning the handl
10. gear NOTE Repeat steps 3and10 if the gear stick does not go into a gear or if it catches and does not move smoothly Fit the front floor console ref 01 1 Lancer Evolution VII Service Manual No 1036K02 Chapter 52A 22 10 MANUAL TRANSMISSION TRANSMISSION CONTROL lt 6M T gt Transmission Control lt 6M T gt Removal and Fitting CAUTION 1 On the gear stick ASSY do not disassemble anything other than the distance piece and bush Non supplied parts 2 Never use mineral oil on the moving parts of the gear stick ASSY This is because if mineral oil is used it could cause plastic parts to break Pre removal and post fitting operations Caution SRS Removal and fitting of air cleaner ASSY Do not subject the SRS ECU to any shocks when Removal and fitting of air by pass hose air hose E air removing or fitting shift and select cable ASSY or gear pipe C air hose D ref Chapter 15 Intercooler stick ASSY Removal and fitting of battery battery tray AC211367AB Shift cable amp select cable ASSY removal Gear stick ASSY fitting procedure procedure 1 Gear stick knob 1 Gear stick knob e Front floor console e Front floor console 2 Front floor console bracket 2 Front floor console bracket gt B4 3 Select cable connection inside cabin gt B4 3 Select cable connection inside cabin 4 Shift cable connection inside cabin 4 Shift cable connection inside cabin 5 Clip inside ca
11. itting of cover ref Chapter 51 Front Removal and fitting of drive shaft output shaft Bumper Draining and filling of transmission oil e Removal and fitting of side cover ref Chapter 51 e Draining and filling of transfer oil Front Bumper e Bleeding and hydraulic pressure check lt ACD gt lt only Removal and fitting of steering shaft cover after fitting gt e Removal and fitting of steering gear and joint e Bleeding lt AYC gt lt only after fitting gt connection e Power steering fluid filling and bleeding lt only after e Removal and fitting of cross member bar fitting gt e Removal and fitting of front exhaust pipe e Wheel alignment check adjustment lt only after fitting gt Ka Sf We N 167 9 Nm AC211381AB MANUAL TRANSMISSION TRANSFER ASSY lt 6M T gt 22 13 Removal procedure 1 Centre member A gt 3 Cross member ASSY e Power steering return hose and steering 4 Transfer pressure hose ASSY gear connection 5 Gasket e Power steering pressure hose and steering lt B gt 6 Transfer ASSY gear connection 7 O ring 2 Rear roll stopper connecting bolt Removal Transmission jack o ss J ot By Cross member ASSY Qh a AK of 4 A Removal of cross member ASSY Support the cross member ASSY with the transmission jack then remove the cross member fixing bolt and cross member ASSY 4 B Removal of transfer ASSY Support the transf
12. l cable ASSY amp bracket transmission 3 Vehicle speed sensor connector connection side 4 Snap pin 8 Clutch release cylinder amp clutch oil pipe 5 Shift cable connection MANUAL TRANSMISSION TRANSMISSION ASSY lt 6M T gt 22 15 26 5 Nm 9 0 1 0 N m AC211628AB 9 Transmission ASSY upper part coupling C gt e Engine ASSY support bolts e For lifting the engine 10 Harness clamp 14 Bell housing cover lt B gt 11 Transmission mount ASSY D gt Clutch release bearing connection gt A4 12 Transmission mount stopper 15 Transmission lower coupling bolts 13 Transmission mount bracket 16 Transmission ASSY Removal 4 A gt Removal of select cable connection transmission side removal Set the select cable clip in the positions indicated 1 2 in the diagram then undo the select cable connection 4 B Transmission mount ASSY removal Support the engine and transmission ASSY with a garage jack then remove the transmission mount ASSY 22 16 MANUAL TRANSMISSION TRANSMISSION ASSY MZ203827 x MZ203826 gr AAN Dna AC211734 4 Joint 90 MB991932 Ji a Eve 2 Foot standard MB991932 AC209516AB A ae a 1S 2 canal i Y Bootes A 2 a Z MB991527 TA MB991930 MB991454 E Se MB991932 oS AC211735AB Refer CAUTI Wedge collar AC211679AB lt 6M T gt 4 C Engine ASSY Support lt When usin
13. lic unit MUT II IIl Actuator test e No 04 Electric pump drive OK electric pump operating sound audible NG gt replace 4WD ECU OK gt Intermittent fault ref Chapter 00 Countermeasures for Intermittent Malfunctions 2 22 8 MANUAL TRANSMISSION TROUBLESHOOTING 5 Inspection Chart for Trouble Symptoms Fault symptom Checking Procedure No Page No communication possible between MUT II III and any other system 1 22 8 6 Trouble Symptom Checking Procedures Checking Procedure 1 No communication possible between MUT II III and any other system Possible causes It is possible that there is a malfunction in the diagnosis connector e Diagnosis connector malfunction power supply circuit the earth circuit or the MUT II III e Harness connector malfunction e MUT II III malfunction NG C 122 Diagnosis connector measurement gt Check connectors C 122 C 212 C 211 C 32 e Voltage across 16 earth NG gt repair OK Battery voltage OK OK Confirm trouble symptoms NG Check harness between fusible link No 1 and diagnosis connector e Check to see if power supply cable is broken or damaged NG gt repair y NG C 122 Diagnosis connector measurement gt Check connector C 122 e Resistance across 4 5 body earth OK 2 or less OK OK Confirm trouble symptoms Replace MUT II III y NG Check harnes
14. oothly into all of the gears AC209411 AB 5 6 gear gt B4 Fitting of select cable connection inside cabin direction i 1 Move the gear stick towards 5th and 6th gears until it touches the stopper then check the cable connection is secure and the assembly is running smoothly run in 2 Remove hand from the gear stick then fit the select cable inside cabin to the select lever in the neutral position to which it returns naturally 3 Check that the shift cable inside cabin and select cable inside cabin are securely connected then move the gear stick into each of the gear positions 4 lf the gear stick does not go into all of the gear positions adjust the select cable ref P 22 9 22 12 MANUAL TRANSMISSION TRANSFER ASSY lt 6M T gt Transfer ASSY lt 6M T gt CAUTION 1 Before removing steering wheel and airbag module ASSY without fail read Chapter 52 B Precautions for Servicing and Airbag Module and Clock Spring 2 When Brembo brake calipers are used there is concern over paint peeling off so when doing servicing work make sure they are not scratched by other components and tools 3 Indicates parts which should be initially tightened and then fully tightened when the engine weight is supported by the vehicle body Removal and fitting Pre removal and Post fitting operations Removal and fitting of steering wheel Removal and fitting of front propeller shaft e Removal and f
15. put e Pressure sensor malfunction the electric pump motor drive command e Hydraulic pressure unit malfunction e Harness connector malfunction 4WD ECU malfunction e Electric pump relay malfunction NO Does the reservoir tank contain the correct quantity of Is there a fluid leak fluid YES gt add fluid YES NO Repair leaks y YES MUT II III Diagnosis code H Check code Nos 45 46 47 pressure sensor system e Have diagnosis code Nos 45 46 47 been output ref P 22 16 17 NO YES MUT II III Diagnosis code __ Check code No 81 electric pump relay system e Has diagnosis code No 81 been output ref P 22 26 2 NO MUT II III Actuator test e No 04 Electric pump drive OK electric pump operating sound audible OK gt Intermittent fault ref Chapter 00 Countermeasures for Intermittent Malfunctions 2 NG OK B 127 Electric pump relay connector measurement L gt Check connectors B 127 C 43 F 21 e Undo connector and take measurement on harness NG gt repair side e Voltage across 4 earth OK SN Baller VO lays Check harness between electric pump relay and body NG earth e Check earth wire to see if it is broken or damaged Check connector B 127 NG gt repair NG gt repair OK OK Check the harness between the fusible link No 7 and Electric pump relay e Check power supply cable to see if it is broken is earthing or is damaged NG gt repair Replace hydrau
16. r balancer i B991454 MB991527 Engine lifter l B991527 Troubleshooting 1 Diagnosis Code List Diagnosis code Diagnosis item Reference No page 31 Steering sensor lt ST 1 ST 2 ST N gt system Broken wire or short 22 4 63 Parking brake switch system Short or forgotten to return 22 5 65 ABS monitor system vehicles fitted with ACD AYC Broken wire or ABS fault 22 6 82 Electromotive pump relay system Electromotive pump fault or 22 7 pressure sensor abnormality 22 4 2 Checking Procedure for each Diagnosis Code Note 1 Refer to 00 5 Lancer Sedia Service Manual No 103K00 2 Refer to 01 1 Lancer Evolution VII Service Manual No 1036K02 MANUAL TRANSMISSION TROUBLESHOOTING Code No 31 Steering sensor lt ST 1 ST 2 ST 3 gt Possible causes broken or has a short circuit No 31 will be output When a steering sensor output wire ST 1 ST 2 or ST N is Steering sensor malfunction Harness connector malfunction 4WD ECU malfunction YES MUT II III Diagnosis codes 2 e Has ABS diagnosis code No 81 82 83 been output __ NO C 228 Steering sensor connector measurement e Undo connector take measurement on harness side e Ignition switch ON e Voltage across 2 earth OK Battery voltage NG __ Check connectors C 228 C 119 C 209 C 210 Jok Check harness between ignition switch and steering sensor MUT II III Se
17. rvice Data e No 21 Steering sensor voltage Tox e Check to see if power supply wire is broken or damaged lt ST 1 gt e No 22 Steering sensor voltage lt ST 2 gt Check connector 228 NG repair NG gt repair e No 23 Steering sensor voltage lt ST N gt OK ref P 22 32 ref Service ie Replace steering sensor Data List 2 OK gt Intermittent malfunction ref Chapter 00 Countermeasures for Intermittent Malfunctions 2 NG OK C 37 4WD ECU Connector measurement e ECU terminal voltage measurement e Ignition switch ON 1 Voltage across 33 earth Steering sensor lt ST 1 gt 2 Voltage across 34 earth Steering sensor lt ST 2 gt 3 Voltage across 44 earth Steering sensor lt ST N gt OK When the steering wheel is turned there is a voltage change about 1 5V lt gt 3 5V NG Changes 1V or less lt gt 4 5V or more NG either stays at OV or does not change and remains at 4 5V or more C 228 Steering sensor connector measurement Undo connector take measurement on harness side e Ignition switch ON 1 Voltage across 2 earth OK Battery voltage 2 Resistance between 3 body OK 2 or less 2 NG y OK Check connectors C 228 C 37 NG gt Repair y OK Check harness between 4WD ECU and steering sensor e Check output cable to see if it is broken has a short circuit or is damage
18. s between body earth and diagnosis connector Check earth wire to see if it is broken or damaged NG gt repair MANUAL TRANSMISSION ON VEHICLE SERVICING 22 9 Roe ee 5 6 gear side fy Ct Middle 4 een aus Fastening clip be AC211248AB On vehicle Servicing De 1 Changing transmission oil lt 6 M T gt i Servicing information other than that noted below remains the same Transmission oil Specified transmission oil Mitsubishi DIA QUEEN SUPER MULTIGRADE OIL lt 75W 85W gt Quantity 2 2 dm Select cable inside cabin adjustment lt 6M T gt Put gear stick in the neutral position Remove front floor console ref 01 1 Lancer Evolution VII Service Manual No 1036K02 Chapter 52A Disconnect the select cable from the select lever Move the gear stick towards the 5th and 6th gears so that it touches the stopper then check the cable connection is secure and the assembly is running smoothly run in Remove hand from gear stick and allow it to return naturally to the neutral position Move the select cable lock clip in the direction of the arrow in the diagram pulling the fastening clip Without moving the gear stick from the neutral position connect the select cable to the select lever Adjust the select cable Press the select cable fastening clip in and move the lock clip back Check by shifting the gear stick into each
19. termittent malfunction ref Chapter 00 Countermeasures for Intermittent Malfunctions 2 ny YES When the parking brake is released does the parking brake warning light go off OK c Check connectors C 37 D 25 NG gt repair NO D 25 Parking brake switch connector measurement Undo connector then take measurement on harness side e Ignition switch ON e Voltage across 1 earth OK Battery voltage Check harness between D 25 and 4WD ECU e Check to see if the output wire is broken or damaged NG gt repair fok NG Check connectors D 25 C 37 C 20 B 109 vehicles fitted with lt ACD AYC gt D 25 C 37 vehicles fitted with lt ACD gt ir OK Check connector D 25 NG gt repair OK Check and adjust parking brake lever stroke ref Chapter 36 On vehicle servicing NG lt gt Adjust OK Check parking brake switch ref Chapter 36 On vehicle Servicing 1 NG replace NG gt repair 1 Check harness between parking brake switch and 4WD ECU e Check output wire for earthing or damage 2 Check harness between parking brake switch and combi meter e Check power supply cable for earthing or damage 3 Check harness between parking brake switch and ABS ECU lt vehicles fitted with ACD AYC gt e Check output wire for earthing or damage NG gt repair MUT II I
Download Pdf Manuals
Related Search