oil MITSUBISHI LANCER EVOLUTION IV 1998 Workshop Manual

REAR AXLE – Torque Transfer Differential <Vehicles with AYC>27-45
DISASSEMBLY SERVICE POINT
ASELF-LOCKING NUT REMOVAL
ASSEMBLY SERVICE POINTS
AOIL SEAL INSTALLATION
(1) Using the special tool, pressfit the oil seal as far as it
will go.
(2) Apply the specified grease to the oil seal lip.
Specified grease: Vaseline
BOIL SEAL INSTALLATION
(1) Using the special tool, pressfit the oil seal as far as it
will go.
(2) Apply the multi-purpose grease to the oil seal lip.
MB990850
MD998812MD998829
MD998813
MB990938
MB991115

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 – LSD Case Assembly <Vehicles without AYC>27-48
BSCREW TIGHTENING
(1) Align the alignment mark on differential case A with that
on differential case B.
(2) Tighten the screws connecting differential case A and
B a uniform amount little by little in the diagonal order.
NOTE
If tightening the screws does not bring the two cases
properly together, spring plates are not probably
assembled properly. Reassemble from the start.
CLSD DIFFERENTIAL TORQUE CHECK
(1) Using the special tool, check for differential torque.
Standard value:
When new clutch plate is
installed Nm {kgf
m}When existing clutch plate is
reused Nm {kgf
m}
5 – 19 {0.5 – 1.9}2 – 19 {0.2 – 1.9}
NOTE
Before measuring the differential torque, first turn the
gears so they snug each other, then take measurements
during rotation.
(2) If the measurement falls outside the specified range,
disassemble the differential case assembly and repair
or replace defective parts.
INSPECTION
1. DIFFERENTIAL CASE INTERNAL PARTS
CONTACT/SLIDING SURFACE CHECK
(1) Clean the disassembled parts with cleaning oil and dry
them with compressed air.
(2) Check each plate, disc, and pressure ring for the following:
A. Friction and sliding surfaces of friction discs, friction
plates, and spring plates.
Replace a defective part with heat discoloration and
excessive wear with a new one, as it degrades locking
performance.
NOTE
If the inner periphery of the friction face shows traces
of harsh contact, it is because of the spring tension
of each plate, disc and other part. Do not confuse
this with abnormal wear.
B. Inner periphery and outer periphery protrusions of
friction discs, friction plates, and spring plates.
Replace a cracked or damaged part with a new one.
C. Friction and sliding surfaces between pressure rings
and friction discs.
MB990989MB990990
Friction disc
Friction plateSpring plate
Pressure ring

REAR AXLE – LSD Case Assembly <Vehicles without AYC>27-49
Grind a dented or scratched part with oil stone and
then lap and correct with a compound on a surface
plate.
NOTE
If the inner periphery of the friction face shows traces
of harsh contact, it is because of the spring tension
of each plate, disc and other part. Do not confuse
this with abnormal wear.
(3) Check the following parts for contact and sliding surfaces
(D to M) and correct burrs and dents with oil stone.
D: Sliding surfaces of side gear and case
E: Contacting surfaces of differential case and spring
plate
F: Contacting surfaces of pressure ring and differential
case inner face
G: Sliding surfaces of pressure ring hole and side gear
H: Protrusions on outer periphery of pressure ring
I: Pressure ring inner surface and differential pinion
gear spherical surface
J: Pressure ring V-groove and pinion shaft V
K: Sliding surfaces of pinion shaft and differential pinion
gear hole
L: Side gear grooves on outer periphery
M: Slits in inner periphery of differential
2. FRICTION PLATE AND FRICTION DISC
DISTORTION CHECK
Apply a dial indicator to the friction plate or disc on a surface
plate and, turning the friction plate or disc, measure the
distortion (flatness).
Limit: 0.08 mm (total runout)
3. FRICTION PLATE, FRICTION DISC, AND SPRING
PLATE WEAR CHECK
(1) For the purpose of determining wear, measure thickness
(A, B) of the friction surface and protrusion at several
places and find the difference between the two.
Limit: 0.1 mm
(2) If the wear exceeds the limit, replace the part with a
new one.

REAR AXLE – Hydraulic Unit <Vehicles with AYC>27-50
HYDRAULIC UNIT <VEHICLES WITH AYC>
REMOVAL AND INSTALLATION
Pre-removal Operation
(1) Trunk Side Trim Removal
(2) Hydraulic Piping Fluid DrainingPost-installation Operation
(1) Hydraulic Piping Fluid Filling and Bleeding
(Refer to P.27-29.)
(2) Trunk Side Trim Installation
1 23 45
6
7 8 9
10 11 12
1314
Unit: Nm {kgf
m}
12 {1.2}
4
12 {1.2}
18 {1.8}
12 {1.2}
12 {1.2} 18 {1.8}
34 {3.5}
34 {3.5}
Removal steps
1. Dust guard
2. Suction hose and return hose con-
nection
3. Hydraulic unit hose assembly con-
nection
4. Hydraulic unit and bracket assem-
bly mounting bolt
C5. Hydraulic unit and bracket assem-
bly
6. Hydraulic unit
7. Hydraulic unit bracket
8. AYC harness9. Hydraulic unit bracket
10. Hydraulic unit hose assembly
B11. Return hose
B12. Suction hose
A13. Grommet
14. Oil reservoir
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.

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

REAR SUSPENSION – Rear Suspension Assembly34-5
REMOVAL SERVICE POINTS
ABRAKE CALIPER ASSEMBLY REMOVAL
Remove the brake caliper assembly and secure it with a
wire.
BPROPELLER SHAFT DISCONNECTION
(1) Make an alignment mark on the differential carrier
companion flange and propeller shaft flange yoke.
(2) Remove the mounting bolts and nuts of the differential
carrier and propeller shaft.
CCROSSMEMBER MOUNTING BOLT REMOVAL
Support the differential case with a garage jack or transmission
jack and then remove the crossmember mounting bolt.
INSTALLATION SERVICE POINTS
ACROSSMEMBER MOUNTING BOLT
INSTALLATION
Tighten the mounting bolts in the numerical order shown.
NOTE
To ensure both good installation accuracy and ease of
installation, the crossmember mounting holes have different
diameters between front and rear. This is the reason for
specifying the tightening sequence of the mounting bolts.
BPROPELLER SHAFT CONNECTION
Align the alignment mark on the differential carrier with that
of the propeller shaft at installation.
Caution
Oil or grease on the threads of the mounting bolt or nut
can allow the bolt or nut to come loose. Be sure to
degrease the threads before installation.
Bolt size (thread dia. × length mm)
1 to 3: Flange bolt (with washer) 12 × 70
4: Flange bolt (with washer) 12 × 152
5: Bolt (with spring washer + washer) 12 × 105 Front of vehicle
13
3
44
2
55

ABS – Troubleshooting35B-7
Code No.33: Stop lamp switch system (open circuit or
stop lamp stays ON)Probable cause
This code is output, if the stop lamp switch is continuously on for 15 minutes or
more.
Malfunction of stop lamp switch

Malfunction of wiring harness or connector

Malfunction of ABS-ECU
OK
Check the trouble symptom.NGCheck the harness wire, and repair
if necessary.

Between dedicated fuse No. 11
and ABS-ECU
OK
Check the trouble symptom.NGReplace the ABS-ECU.
OK
Check the trouble symptom.NGCheck the harness wire, and repair
if necessary.

Between stop lamp switch and
ABS-ECU
OK
Check the following connectors:
B-15, B-21, B-25, B-32, B-65NG
Repair
OK
Check the following connector:
B-25NG
Repair
YES
Measure at the ABS-ECU connector
B-25.

Disconnect the connector, and
measure at the harness side
connector.

Stop lamp switch: ON

Voltage between 34 and body
ground
OK:Battery voltageNG
Check the following connectors:
B-25, B-32, B-65NG
Repair
OK
Stop lamp switch checkNG
Repair
Does the stop lamp turn on and off
normally?NOStop lamp switch installation checkNG
Repair
Code No. 41, 42, 43, 44: Solenoid valve systemProbable cause
ABS-ECU monitors the solenoid valve energization circuit at all times. This code is
output when no current flows through the solenoid even when ABS-ECU energizes
it or when current continues flowing through the solenoid even when ABS-ECU
deenergizes it, which is considered to be attributable to an open- or short-circuited
solenoid coil or open- or short-circuited harness.
Defective hydraulic unit

Defective harness or connector

Defective ABS-ECU
OK
Replace the ABS-ECU.
OK
Check the trouble symptom.NGCheck the harness between hydraulic
unit (solenoid valve) and ABS-ECU.NG
Repair
OK
Check the trouble symptom.NGCheck and repair the harness between
hydraulic unit and valve relay.
OK
Check the following connectors:
A-21, B-24, B-25NG
Repair
OK
Measure at A-22 hydraulic unit connec-
tor and A-76 valve relay connector.

Disconnect the connector and
measure at the harness side.

Continuity across the following
terminals
Hydraulic Valve relay
unit side side
11–3
OK:Battery voltageNGCheck the following connectors:
A-22, A-76NG
Repair
Check the solenoid valve.NGReplace the hydraulic unit.

37A-1
STEERING
CONTENTS
SERVICE SPECIFICATIONS 2. . . . . . . . . . . . . .
SPECIAL TOOLS 2. . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE 2. . . . . . . . . . . . . . . . . .
1. Steering Angle Check 2. . . . . . . . . . . . . . . . .
2. Oil Pump Belt Tension Check and
Adjustment 2. . . . . . . . . . . . . . . . . . . . . . . . . . .
STEERING WHEEL
<EVOLUTION-IV RS> 3. . . . . . . . . . . . . . . . . . . .
POWER STEERING GEAR & LINKAGE 3. . .
POWER STEERING OIL PUMP 7. . . . . . . . . . .
POWER STEERING FLUID COOLER 9. . . . .

STEERING – Service Specifications / Special Tools / On-vehicle Service37A-2
SERVICE SPECIFICATIONS
ItemsStandard value
Steering angleEVOLUTION-IVInner wheel33
30’ ± 2

Outer wheel28
20’
EVOLUTION-VInner wheel33
10’ ± 2

Outer wheel28
10’
Steering gearPinion total turning torque
Nm {kgfcm}
Total turning torque0.9 – 1.7 {9 – 17}
Nm {kgf
cm}Torque fluctuations0.4 {4} or less
SPECIAL TOOLS
ToolNumberNameUse
MB991197Installer barPressfitting of gear housing oil seal
MB991199Oil seal installer
MB991214Oil seal protectorInstallation of rack assembly
ON-VEHICLE SERVICE
1. STEERING ANGLE CHECK
Locate front wheels on turning radius gauge and measure
steering angle.
Standard value:
Inner wheel
33
30’ ± 2
<EVOLUTION-IV>
33
10’ ± 2
<EVOLUTION-V>
Outer wheel
28
20’ <EVOLUTION-IV>
28
10’ <EVOLUTION-V>
When the angle is not within the standard value, the toe
is probably incorrect. Adjust toe (Refer to GROUP 33A –
On-vehicle Service) and recheck steering angle.
2. OIL PUMP BELT TENSION CHECK AND
ADJUSTMENT
Refer to GROUP 11 – Engine Adjustments.