MITSUBISHI LANCER EVOLUTION IV 1998 Workshop Manual

STEERING – Power Steering Gear & Linkage37A-6
JADJUSTMENT OF PINION TOTAL TURNING
TORQUE
(1) With special tool, tighten rack support cover to 15 Nm
{1.5 kgf
m}.
(2) Return rack support cover approx. 30
.
(3) Using the special tools, rotate the pinion shaft at the
rate of one rotation in approximately 4 to 6 seconds to
check that the turning torque and the torque fluctuation
confirm to the standard values.
Standard value:
Pinion total turning torque
0.9 – 1.7 Nm {9 – 17 kgf
cm}
Torque fluctuation 0.4 Nm {4 kgf
cm} or less
(4) If either the turning torque or the torque fluctuation
deviates from the standard value, turn back the rack
support cover within the range of 0 to 30
to adjust it
for the standard value.
Caution
1. When adjusting, set the standard value at its
highest value.
2. Assure no ratcheting or catching when operating
rack towards the axial direction.
3. Be sure to measure the turning torque through
the whole stroke of the rack.
NOTE
If the standard value cannot be obtained by turning back
the rack support cover within the specified angle range,
check rack support cover components and replace as
required.
NTIE ROD END / LOCK NUT INSTALLATION
Turn down the tie rod until the dimension shown in the
illustration is reached; then, temporarily tighten the lock nut.
NOTE
The lock nut is to be tightened to the specified torque after
toe-in has been adjusted with the steering gear & linkage
mounted in the vehicle.
MB990607
MB991006
End of groove in
which bellows fitsLock nut
197.2 mm <EVOLUTION-IV>
212.2 mm <EVOLUTION-V>

STEERING – Power Steering Oil Pump37A-7
POWER STEERING OIL PUMP
<EVOLUTION-IV>
REMOVAL AND INSTALLATION
Pre-removal Operation
Power Steering Fluid DrainingPost-installation Operation
(1) Power Steering Fluid Supplying
(2) Drive Belt Tension Adjusting
(Refer to GROUP 11 – On-vehicle Service.)
12 3
4 5
6 7
8 9 10
Unit: Nm {kgf
m}
49 {5.0}
59 – 69
{6.0 – 7.0} 10 – 12
{1.0 – 1.2}39 {4.0}
49 {5.0}
18 {1.8}
12 {1.2}
39 {4.0}
Removal steps
1. Drive belt
2. Pressure switch connector
3. Suction hose
4. Pressure hose
5. O-ring6. Heat protector
7. Bolt
8. Bolt
9. Oil pump assembly
10. Oil pump bracket

STEERING – Power Steering Oil Pump37A-8
<EVOLUTION-V>
REMOVAL AND INSTALLATION
Pre-removal Operation
Power Steering Fluid DrainingPost-installation Operation
(1) Power Steering Fluid Supplying
(2) Drive Belt Tension Adjusting
(3) Power Steering Fluid Line Bleeding
12
34
56
7
8 9 10
Unit: Nm {kgf
m}
22 {2.2}
11
22 {2.2}
52 {5.3}24 {2.4} 12 {1.2}
18 {1.8}
Removal steps
1. Drive belt
2. Suction hose
3. Pully
4. Pressure hose
5. O-ring
6. Heat protector A7. Heat protector B
8. Pressure switch connector
9. Bolt
10. Bolt
11. Oil pump assembly

STEERING – Power Steering Fluid Cooler37A-9
POWER STEERING FLUID COOLER
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
(1) Power Steering Fluid Draining and Refilling
(2) Front Bumper Removal and Installation
(Refer to GROUP 51.)
1
2
Unit: Nm {kgf
m}
12 {1.2}
13 {1.3}
Removal steps
1. Cooler hose
2. Power steering fluid cooler

42-1
BODY
CONTENTS
HOOD 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FENDER 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRUNK LID <EVOLUTION-V> 4. . . . . . . . . . . .
BODY CONSTRUCTION
(Difference between
EVOLUTION-IV and V) 5. . . . . . . . . . . . . . . . . . . TYPE A (PROJECTED DIMENSIONS) 7. . . . .
TYPE B (ACTUAL-MEASUREMENT
DIMENSIONS) 11. . . . . . . . . . . . . . . . . . . . . . . . . .

BODY – Hood42-2
HOOD
REMOVAL AND INSTALLATION
Adjustment of hood step and hood
striker linkageAdjustment of clearance and height
around hood
12
3 4
5
678 9
10
11
12 1314
15
Unit: Nm {kgf
m}9 {0.9}
12
156 1
1. Hood latch
2. Hood lock release handle
3. Hood weatherstrip
4. Hood weatherstrip
5. Hood insulator
6. Bumper
7. Hood support rod
8. Hood outlet garnish weatherstrip
9. Hood outlet garnish
10. Hood inlet garnish, upper
11. Hood inlet garnish, lowerHood lock release cable removal
steps

Splash shield <Driver’s side>
12. Hood lock release cable
Hood and hood hinge removal
steps
13. Washer hose connection
14. Hood
15. Hood hinge
Caution
For hood hinge and hood mounting, use only
specially surface-treated bolts.

BODY – Fender42-3
FENDER
<EVOLUTION-V>
REMOVAL AND INSTALLATION
Caution
A rust preventive treatment has been applied to the
washers marked with * to prevent contact corrosion
between aluminum and metal of different kind. Be
sure to these special washers.Pre-removal and Post-installation Operation
(1) Front Bumper Removal and Installation
(Refer to GROUP 51.)
(2) Front Turn Signal Lamp Removal and Installation
(3) Side Air Dam Removal and Installation
(Refer to GROUP 51 – Aero Parts.)
Butyl rubber tape:
PAND-690E or equivalent
12
3
1
Removal steps
1. Splash shield
AA2. Side turn signal lamp
3. Overfender

BODY – Fender / Trunk Lid <EVOLUTION-V>42-4
REMOVAL SERVICE POINT
ASIDE TURN SIGNAL LAMP REMOVAL
Using a flat-tip screwdriver or similar tool, release the lock
from the fender panel and remove the side turn signal lamp.
INSTALLATION SERVICE POINT
ASIDE TURN SIGNAL LAMP INSTALLATION
Fit the hook into the fender panel to secure the side turn
signal lamp into position.
TRUNK LID <EVOLUTION-V>
The conventional procedures shall be used except for
followings.
INSTALLATION SERVICE POINT
TRUNK LID TORSION BAR INSTALLATION
(1) Torsion bars are color-coded, as indicated at their center.
Torsion bar <LH> ID colorTorsion bar <RH> ID color
White greenOrange
(2) Fit the end of the torsion bar into the mounting hole.
(3) As you did during removal, mount the special tool to
the torsion bar and twist the torsion bar to hook it onto
the link; then, hook it onto the holder.
Caution
Make sure that the special tool is positively mounted
to the torsion bar. If the torsion bar comes off the
special tool, it can damage the body and other parts.
Fender panel
Lock
Hook
Fender panel
Front of vehicle

BODY – Body Construction (Difference between EVOLUTION-IV and V)42-5
BODY CONSTRUCTION
(Difference between EVOLUTION-IV and V)
EVOLUTION-V has a different rear suspension configuration from that of EVOLUTION-IV because of
adoption of reinforced suspension elements and wide tread tyres. For this reason, the configuration and
the dimensions of the following body sections are also different.
SIDE BODY
Side Structure
(1) The quarter panel has a cut-out provided at the inner section.
(2) The quarter inner extension front and the quarter inner extension rear is provided in the quarter
panel inner cut-out section.
Cut-out
Quarter panel inner
<EVOLUTION-V> <EVOLUTION-IV>
<EVOLUTION-V>
Quarter inner
extension front
Quarter inner
extension rear

BODY – Body Construction (Difference between EVOLUTION-IV and V)42-6
UNDER BODY
Rear Floor
The upper link bracket, rear floor sidemember reinforcement and toe control link bracket have been changed
in configuration.
<EVOLUTION-V> <EVOLUTION-IV><EVOLUTION-V>
<EVOLUTION-IV>
Upper link bracket
Rear floor
sidemember
reinforcement
Upper link bracket
Rear floor
sidemember
reinforcement
Toe control link bracket