service MITSUBISHI LANCER EVOLUTION IV 1998 Owners Manual

REAR AXLE – LSD Case Assembly <Vehicles without AYC>27-47
ASSEMBLY SERVICE POINTS
AINSTALLATION TO DIFFERENTIAL CASE B
Before starting the assembly procedure, perform the following
steps to adjust dimensional differences (clutch plate friction
force) in the axial direction of the components inside the
differential case and axial clearance of the differential side
gear.
(1) Place friction discs (two each) and friction plates (three
each) one on top of another as illustrated and, using
a micrometer, measure the thickness of each of the right
and left assemblies. Select different discs and plates so
that the difference between the right and left assemblies
falls within the specified range.
Standard value: 0 – 0.05 mm
NOTE
If a new part is used, note that the friction disc comes
in two thicknesses: 1.6 mm and 1.7 mm.
(2) Measure the thickness of each of the right and left spring
plates.
(3) Assemble the pressure ring internal parts (pinion shaft
and pressure ring), friction plates, and friction discs and,
using a micrometer, measure the overall width.
NOTE
When taking measurements, press the assembly from
both sides so that the pinion shaft makes a positive contact
with the groove in the pressure ring.
(4) Find value (A) which is the thickness measured in step
(3) added to the thickness of two spring plates.
(5) Find dimension (B) between the spring plate faying
surfaces when differential case A and B are assembled
together.
B = C + D – E
(6) If the clearance between the spring plate and differential
case (B – A) is outside the specified range, change the
friction discs and make adjustments.
Standard value: 0.06 – 0.25 mm
(7) Coat each part with the specified gear oil and mount
it in the specified direction and order into differential case
B.
Gear oil: DIA QUEEN LSD GEAR OIL
NOTE
Apply a careful coat of gear oil to the contacting and
sliding surfaces.
Groove
Differential
case ADifferential case B
Spring plate
Friction disc
Friction plate

REAR AXLE – Hydraulic Unit <Vehicles with AYC>27-51
INSTALLATION SERVICE POINTS
AGROMMET INSTALLATION
On the vehicle mounted with a sun roof, mount the drain
pipe to the grommet as illustrated.
BSUCTION HOSE / RETURN HOSE INSTALLATION
Fit the suction hose and return hose to the nipple of hydraulic
unit as illustrated.
CHYDRAULIC UNIT AND BRACKET ASSEMBLY
INSTALLATION
Hook the hydraulic unit bracket hook to the rear floor side
member and install the hydraulic unit and bracket assembly
mounting bolt.Grommet
Drain pipe
25 ± 5 mm
Nipple
Suction hose and
return hose15 mm
Hook
Rear floor side member

REAR AXLE – Sensor Relay <Vehicles with AYC>27-52
SENSOR RELAY <VEHICLES WITH AYC>
REMOVAL AND INSTALLATION
12
3
4
Steer sensor removal steps
Steering wheel and column cover
(Refer to GROUP 37 – Steering Wheel
and Shaft.)
A1. Steer sensorAcceleration sensor and AYC relay
removal
2. Longitudinal acceleration sensor
3. Lateral acceleration sensor
4. AYC relay
NOTE
For the wheel speed sensor, refer to GROUP 35B.
REMOVAL SERVICE POINT
ASTEER SENSOR REMOVAL
Remove the steer sensor from the column switch.
Caution
(1) A photocoupler is used as the steer sensor. Use care
not to allow dust or grease to be on the sensor.
(2) Do not bend or dirty with grease the slit plate on
the column switch side.Slit plate
Steer sensor

POWER PLANT MOUNT – Roll Stopper and Centermember32-2
ROLL STOPPER AND CENTERMEMBER
REMOVAL AND INSTALLATION
Caution
When tightening the portion marked with *, first
temporarily tighten it, then torque to specification
with the engine weight applied to the body.
1
2 34
5
Unit: Nm {kgf
m}
52 {5.3}*
22
34 {3.5}34 {3.5}
93 {9.5}
69 {7.0} 93 {9.5}
2
Removal steps
1. Front crossmember bar <vehicles
with 17’ wheels>
2. Bolt

B3. Front roll stopper bracket assembly

A4. Rear roll stopper bracket assembly
5. CentermemberNOTE
The conventional service procedures apply for the
installation service points.

33A-1
FRONT
SUSPENSION
CONTENTS
SERVICE SPECIFICATIONS 2. . . . . . . . . . . . . .
SPECIAL TOOLS 2. . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE 3. . . . . . . . . . . . . . . . . .
Wheel Alignment Check and Adjustment
<EVOLUTION-V> 3. . . . . . . . . . . . . . . . . . . . . . . . .
STRUT ASSEMBLY 4. . . . . . . . . . . . . . . . . . . . . .
LOWER ARM <EVOLUTION-IV> 5. . . . . . . . . .
LOWER ARM <EVOLUTION-V> 7. . . . . . . . . . .
STABILIZER BAR 9. . . . . . . . . . . . . . . . . . . . . . . .

FRONT SUSPENSION – Service Specifications / Special Tools33A-2
SERVICE SPECIFICATIONS
<EVOLUTION-IV>
ItemsStandard value
Toe-in mm–3
3
Camber–1
00’ ± 30’
(difference between right and left wheel: less than 30’)
Caster3
50’ ± 30’
(difference between right and left wheel: less than 30’)
Kingpin inclination13
25’
Lower arm ball joint rotation starting torque Nm {kgfcm}2.0 – 8.8 {20 – 90}
<EVOLUTION-V>
Same as EVOLUTION-IV except for following.
ItemsStandard value
Camber (selectable from 2 options)–1
00’ ± 30’ or –2
00’ ± 30’
(difference between right and left wheel: less than 30’)
Caster3
54’ ± 30’
(difference between right and left wheel: less than 30’)
Kingpin inclination14
18’
SPECIAL TOOLS
ToolNumberNameUse
A
BA: MB991237
B: MB991238A: Spring
compressor
body
B: Arm setCoil spring compression
MB991006Preload socketLower arm ball joint rotation starting torque
measurement

FRONT SUSPENSION – On-vehicle Service33A-3
ON-VEHICLE SERVICE
WHEEL ALIGNMENT CHECK AND
ADJUSTMENT <EVOLUTION-V>
Use the conventional procedures to measure wheel alignment.
1. CAMBER
Standard value:
–1
00’ ± 30’ (difference between right and left
wheel: less than 30’) or
–2
00’ ± 30’ (difference between right and left
wheel: less than 30’)
Select the camber angle as follows.
If the arrow on the bolt that couples the strut assembly
to knuckle faces inboard → –1
00’ ± 30’.
If the arrow on the bolt that couples the strut assembly
to knuckle faces outboard → –2
00’ ± 30’.
2. CASTER
Standard value: 3
54’ ± 30’ (difference between right
and left wheel: less than 30’)
NOTE
The suspension system is designed so as to retain the
preset caster value, requiring no adjustment for caster.
<Camber: –1
00’> <Camber: –2
00’>
Bolt coupling strut
assembly to
knuckle

FRONT SUSPENSION – Strut Assembly33A-4
STRUT ASSEMBLY
REMOVAL AND INSTALLATION
Post-installation Operation
Front Wheel Alignment Adjustment
(Refer to P.33A-3.)
12 3
4
5
6 7
Unit: Nm {kgfm}
44 {4.5}
108 – 127
{11.0 – 13.0}
Removal steps
1. Brake hose clamp
2. Front speed sensor bracket
<Vehicles with ABS>
3. Flange nut4. Strut tower bar
5. Plain washer
A6. Bolts
7. Strut assembly
REMOVAL SERVICE POINT
ABOLTS REMOVAL
(1) Suspend the lower arm from the vehicle with wire.
(2) Remove the strut and knuckle connection.

FRONT SUSPENSION – Lower Arm <EVOLUTION-IV>33A-5
LOWER ARM <EVOLUTION-IV>
REMOVAL AND INSTALLATION
Post-installation Operation
(1) Push the Dust Cover of the Lower Arm and Stabilizer
Link Ball Joint with a Finger to Check for Possible
Cracks or Damage.
(2) Wheel Alignment Check and Adjustment
12
3
45
6
Unit: Nm {kgfm}
39 {4.0}113 {11.5}
Molybdenum disulfide-base chassis
grease:
SHOWA SHELL SEKIYU SUNLITE
MB2, NISSEKI CLAKNOCK FL, or
equivalent
137 {14.0}
88 {9.0} 106 {10.8}*
6
Removal steps
1. Stabilizer link mounting nut
A2. Lower arm to knuckle coupling bolt
3. Bolt
4. Stabilizer bracket
A5. Bushing assembly
6. Lower arm assemblyCaution
The part marked with * should be first temporarily
tightened, then torqued to specification with the
vehicle on the ground in unloaded condition.
NOTE
Follow the conventional procedures for removal service
points.

FRONT SUSPENSION – Lower Arm <EVOLUTION-IV>33A-6
INSTALLATION SERVICE POINT
ABUSHING ASSEMBLY INSTALLATION
Install the bushing assembly to the lower arm assembly with
a relative angle as shown and tighten the self-locking nut
to the specified torque.
Tightening torque: 137 Nm {14.0 kgfm}
INSPECTION
BALL JOINT ROTATION STARTING TORQUE
Use the conventional procedures except the special tool used
and the standard value as given below.
Standard value: 2.0 – 8.8 Nm {20 – 90 kgfcm}
LOWER ARM BALL JOINT DUST COVER
REPLACEMENT
Replace the dust cover by using the conventional procedure
only if it has been inadvertently damaged during servicing.
After the dust cover has been replaced with a new one, push
it with a finger to check for possible cracks or damage.
Bushing assembly
Lower arm assembly
MB991006