Drain MITSUBISHI LANCER EVOLUTION 2007 Service Service Manual

REAR AXLE -Differential Carrier <Vehicles with AYC>27B-55
DIFFERENTIAL CARRIER <VEHICLES WITH AYC>
REMOVAL AND INSTALLATION
Pre-removal Operation
DHydraulic Piping Fluid Draining
DDifferential Gear Oil Draining (Refer to P. 27B-17.)
DLower Arm Assembly Removal (Refer to GROUP
34.)
DRear Stabilizer Removal (Refer to GROUP 34.)
DDrive Shaft Removal (Refer to P. 27B-29.)Post-installation Operation
DDrive Shaft Installation (Refer to P. 27B-29.)
DRear Stabilizer Installation (Refer to GROUP 34.)
DLower Arm Assembly Installation (Refer to GROUP
34.)
DDifferential Gear Oil Filling (Refer to P. 27B-17.)
DHydraulic Piping Fluid Filling and Bleeding (Refer
to P.27B-17 and P.27B-19.)
1
2
88¶10 Nm
7 6
5
48
9
10 3
11
44¶10 Nm
120¶10 Nm34¶5Nm*
1
32¶2Nm
12¶2Nm 26¶4Nm*
2
88¶10 Nm
88¶10 Nm 88¶10 Nm 88¶10 NmNOTE:
*1:Thread is not lubricated
*2:Thread is lubricated
Removal steps
1. Hydraulic unit hose assembly con-
nection
AA"2. Propeller shaft connection (Refer to
GROUP 25.)
3. Differential support member mount-
ing nuts
4. Rear crossmember and differential
carrier assembly
(Refer to P. 27B-35.)5. Differential support member
"AA6. Upper stopper
"AA7. Lower stopper
8. Differential support arm
9. Differential mount bracket
10. Differential mount bracket
11. Differential carrier assembly

REAR AXLE -Differential Carrier <Vehicles with AYC>27B-58
TORQUE TRANSFER DIFFERENTIAL <VEHICLES WITH AYC>
DISASSEMBLY AND REASSEMBLY
Caution
1. The differential carrier assembly is non-maintainable.
2. No foreign matter should be allowed inside and at the joints of the differential carrier assembly.
14
2
6
4
35
7
1
9
10
8
3
4
11
13
12
186¶29 Nm
32¶2Nm 49¶10 Nm
5¶1Nm
9¶1Nm 49¶10 Nm
Disassembly steps
1. Drain plug
2. Packing
3. Filler plug
4. Gasket
5. Vent plug
6. Bleeder screw
7. CoverAA"8. Self-locking nut
9. Washer
10. Companion flange
11. Oil seal
"BA12. Oil seal
"AA13. Oil seal
14. Differential carrier assembly

REAR AXLE- Hydraulic Unit <Vehicles with ACD+AYC>27B-61
HYDRAULIC UNIT <VEHICLES WITH ACD+AYC>
REMOVAL AND INSTALLATION
Caution
(1) When connecting the return hose and suction hose, do not apply lubricant.
(2) No foreign matter should be allowed in the hydraulic piping and joints.
Pre-removal Operation
DTrunk Side Trim Removal (Refer to GROUP 52A.)
DHydraulic Piping Fluid DrainingPost-installation Operation
DHydraulic Piping Fluid Filling and Bleeding
(Refer to P.27B-17 and P.27B-19.)
DTrunk Side Trim Installation (Refer to GROUP 52A.)
12
7 6 4
8 9
10
311
34¶5Nm*1
24¶4Nm
12¶2Nm
26¶4Nm*
2
5
12¶2Nm
12¶2Nm
18¶2Nm 34¶5Nm*1
26¶4Nm*2
18¶2Nm12¶2Nm 34¶5Nm*
1
26¶4Nm*2
12¶2Nm
NOTE:
*1:Thread is not lubricated
*2:Thread is lubricated
Removal steps
1. Dust guard
2. Reservoir hose assembly and hy-
draulic unit connection
3. Hydraulic unit hose assembly and
hydraulic unit connection
4. Transfer connector assembly and
hydraulic unit connection
5. Hydraulic unit bracket assembly
mounting bolt
"BA6. Hydraulic unit assembly7. Hydraulic unit bracket
DStabilizer bar to differential support
arm connection (Refer to GROUP 34.)
DDifferential support arm (Refer to P.
27B-55.)
AA"8. Hydraulic unit hose assembly <ve-
hicles with ACD+AYC>
9. Transfer connector assembly
"AA10. Reservoir hose assembly
11. Oil reserve

POWER PLANT MOUNT - Crossmember32-8
CROSSMEMBER
REMOVAL AND INSTALLATION
Caution
1. Before removing the steering wheel and air bag module assembly, always refer to GROUP
52B - Service Precautions, Air bag Module and Clock Spring. Also, set the front wheels so
that they are facing straight forward, and remove the ignition key. If you fail to do this, the
SRS clock spring will be damaged, causing the SRS air bag to be inoperative and serious
injury.
2. *
1: Indicates parts which should be initially tightened, and then fully tightened after placing
the vehicle horizontally and loading the full weight of the engine on the vehicle body.
3. *
2: Indicates parts which should be temporarily tightened, and then fully tightened with the
vehicle on the ground in the unladen condition.
Caution
If the vehicle is equipped the Brembo disc brake, during maintenance, take care not to contact
the parts or tools to the caliper because the paint of caliper will be scratched.
Pre-removal Operations
DUnder Cover Removal
(Refer to GROUP 51 - Front Bumper.)
DCentermember, Crossmember Bar Removal
(Refer to P.32-6.)
DFront Exhaust Pipe Removal
(Refer to GROUP 15.)
DSteering Wheel Air Bag Module Assembly Removal
(Refer to GROUP 37A.)
DPower Steering Fluid Draining
(Refer to GROUP 37A - On-vehicle Service.)Post-installation Operations
DCentermember, Crossmember Bar Installation
(Refer to P.32-6.)
DFront Exhaust Pipe Installation
(Refer to GROUP 15.)
DSteering Wheel Air Bag Module Assembly
Installation (Refer to GROUP 37A.)
DPower Steering Fluid Supplying
(Refer to GROUP 37A - On-vehicle Service.)
DPower Steering Fluid Line Bleeding
(Refer to GROUP 37A - On-vehicle Service.)
DPress the dust cover with a finger to check whether
the dust cover is cracked or damaged.
DChecking Steering Wheel Position with Wheels
Straight Ahead
DFront Wheel Alignment Check and Adjustment
(Refer to GROUP 37A - On-vehicle Service.)
DUnder Cover Installation
(Refer to GROUP 51 - Front Bumper.)

BASIC BRAKE SYSTEM -Brake Pedal/Proportioning Valve,
Master Cylinder and Brake Booster35A-17
INSPECTION
STOP LAMP SWITCH CHECK
1. Connect an ohmmeter between the stop lamp switch
connector terminals.
2. There should be no continuity between the terminals when
the plunger is pushed in as shown. There should be
continuity when it is released.
PROPORTIONING VALVE, MASTER CYLINDER AND BRAKE
BOOSTER
REMOVAL AND INSTALLATION
Pre-removal Operation
DAir Intake Hose and Air Cleaner Removal
<L.H. drive vehicles>
DStrut Tower Bar Removal (Refer to GROUP 42.)
DBrake Fluid DrainingPost-installation Operation
DBrake Fluid Supplying and Air Bleeding
(Refer to P.35A-10.)
DBrake Pedal Adjustment (Refer to P.35A-7.)
DAir Intake Hose and Air Cleaner Installation
<L.H. drive vehicles>
DStrut Tower Bar Installation (Refer to GROUP 42.)
510
11 3
12 4
14
15±2N·m 15±2N·m
22±3N·m
10±2N·m
13 2
8
14±3N·m
519
<R.H. drive vehicles>
9<L.H. drive vehicles>
15±2N·m
5
Proportioning valves
<Vehicles without ABS>
67
30±5N·m
9
15
16±1N·m <L.H. drive vehicles>
<R.H. drive vehicles>
9
15
16±1N·m
Vacuum hose, fitting
Specified Sealant: 3M ATD
Part No.8661, 8663 or
equivalent
15
Fitting
4mm
No continuityContinuity

BASIC BRAKE SYSTEM -Disc Brake35A-20
DISC BRAKE
REMOVAL AND INSTALLATION
Caution
If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to contact
the parts or tools to the caliper because the paint of caliper will be scratched. And if there is
brake fluid on the caliper, wipe out quickly.
Pre-removal Operation
Brake Fluid DrainingPost-installation Operation
Brake Fluid Supplying and Air Bleeding
(Refer to P.35A-10.)
34
21
100±10 N·m <Except for Brembo disc brake>
108±10 N·m <Brembo disc brake>
30±5 N·m
3 2 1
54±5 N·m
15±2 N·m
<Front>
<Rear>
4
Removal steps
1. Brake hose connection
2. Gasket
"AA3. Disc brake assembly
4. Brake disc

ABS <4WD> -Hydraulic Unit and ABS-ECU35B-30
HYDRAULIC UNIT AND ABS-ECU
REMOVAL AND INSTALLATION
<L.H. drive vehicles>
Pre-removal Operation
DStrut Tower Bar Removal (Refer to GROUP 42.)
DBrake Fluid DrainingPost-installation Operation
DBrake Fluid Supplying and Brake Line Bleeding
(Refer to GROUP 35A - On-vehicle Service.)
DHydraulic Unit Check (Refer to P.35B-28.)
DStrut Tower Bar Installation (Refer to GROUP 42.)
23
42
2
2
15±2 N·m
25±6 N·m
1
25±6 N·m
Removal steps
AA"1. Harness connector
"AA2. Brake pipe connectionAB"3. Hydraulic unit and ABS-ECU
4. Hydraulic unit bracket assembly

ABS <4WD> -Hydraulic Unit and ABS-ECU35B-31
<R.H. drive vehicles>
Pre-removal Operation
DStrut Tower Bar Removal (Refer to GROUP 42.)
DBrake Fluid Draining
DAir Intake Hose and Air Cleaner RemovalPost-installation Operation
DBrake Fluid Supplying and Brake Line Bleeding
(Refer to GROUP 35A - On-vehicle Service.)
DHydraulic Unit Check (Refer to P.35B-28.)
DAir Intake Hose and Air Cleaner Installation
DStrut Tower Bar Installation (Refer to GROUP 42.)
213
4 2
2
2
15±2 N·m
25±6 N·m
25±6 N·m
Removal steps
AA"1. Harness connector
"AA2. Brake pipe connectionAB"3. Hydraulic unit and ABS-ECU
4. Hydraulic unit bracket assembly

STEERING -On-vehicle Service37A-9
POWER STEERING FLUID LEVEL CHECK
1. Park the vehicle on a flat, level surface, start the engine,
and then turn the steering wheel several times to raise
the temperature of the fluid to approximately 50 - 60_C.
2. With the engine running, turn the wheel all the way to
the left and right several times.
3. Check the fluid in the oil reservoir for foaming or milkiness.
Check the difference of the fluid level when the engine
is stopped, and while it is running. If the change of the
fluid level is 5 mm or more, air bleeding should be done.
POWER STEERING FLUID REPLACEMENT
1. Raise the front wheels on a jack, and then support them
with rigid racks.
2. Disconnect the return hose connection.
3. Connect a vinyl hose to the return hose, and drain the
oil into a container.
4. Disconnect the ignition coil connectors. (Refer to
GROUP16 - Ignition System.)
5. While operating the starting motor intermittently, turn the
steering wheel all the way to the left and right several
times to drain all of the fluid.
6. Connect the return hoses securely, and then secure it
with the clip.
7. Fill the oil reservoir with specified fluid up to the lower
position of the filter, and then bleed air.
Specified fluid:
Automatic transmission fluid DEXRONII
Caution
Do not use ATF-SPIIM and ATF-SPIII.
POWER STEERING SYSTEM BLEEDING
1. Jack up the vehicle and support the front wheels with
rigid racks.
2. Disconnect the ignition coil connectors. (Refer to
GROUP16 - Ignition System.)
3. Cranking the engine with the starter several times
intermittently (during 15 to 20 seconds), turn the steering
wheel left and right fully five or six times.
Caution
(1) During the bleeding, refill the fluid so that the
level never falls below the lower position of the
filter.
(2) Be sure to bleed air only while cranking. If the
bleeding is done with the engine running, the air
will be broken up and absorbed into the fluid.
4. Connect the ignition coil connectors and idle the engine.
5. Turn the steering wheel left and right fully until no bubbles
comes out in the oil reservoir.
6. See that the fluid is not milky and that the fluid level
is up to the specified position on the level gauge.
7. See that the fluid level changes little when the steering
wheel is turned left and right.
8. Check difference in fluid levels between the engine
stopped and running.
Fluid level change: Within 5 mm
While engine
runningWhile engine
stopped
Return hose
Vinyl hose

STEERING - Power Steering Gear Box and Linkage37A-16
POWER STEERING GEAR BOX AND LINKAGE
REMOVAL AND INSTALLATION
Caution: SRS
Before removing steering gear box, refer to GROUP 52B. Also, put the front wheels in straight-ahead
position. Failure to do so may damage the SRS clock spring and render the SRS air bag inoperative,
which results serious driver injury.
Caution
If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to contact
the parts or tools to the caliper because the paint of caliper will be scratched. And if there is
brake fluid on the caliper, wipe out quickly.
Pre-removal Operation
DClock Spring Removal (Refer to GROUP 52B.)
DPower Steering Fluid Draining (Refer to P.37A-9.)Post-installation Operation
DClock Spring Installation (Refer to GROUP 52B.)
DPower Steering Fluid Supplying and bleeding
(Refer to P.37A-9.)
DChecking Steering Wheel Position with Wheels
Straight Ahead
<L.H. drive vehicles>
17
6
3 4
57±7 N·m5
8
70±10 N·m
2
15±3 N·m
9
10
12±2 N·m 12±2 N·m
70±10 N·m
Removal steps
1. Crossmember
(Refer to GROUP 32.)
DRear roll stopper(Refer to GROUP 32.)
2. Joint cover grommet
3. Return hose
4. Return tube5. O ring
6. Return tube
7. Eye bolt
8. Pressure hose assembly
9. Clamp
10. Steering gear and linkage