lock MITSUBISHI LANCER EVOLUTION IV 1998 Owner's Guide

REAR AXLE – Torque Transfer Differential <Vehicles with AYC>27-43
TORQUE TRANSFER DIFFERENTIAL <VEHICLES WITH AYC>
DISASSEMBLY AND REASSEMBLY
1 23
4 5
6
7 891011
12 1314
Unit: Nm {kgf
m}
186 {19.0}4
49 {5.0}
49 {5.0}9 {0.9}9 {0.9} 49 {5.0}
3
Disassembly steps
1. Drain plug
2. Packing
3. Filler plug
4. Gasket
5. Vent plug
6. Bleeder screw
7. Cover
A8. Self-locking nut
9. Washer
10. Companion flange11. Oil seal
B12. Oil seal
A13. Oil seal
14. Differential carrier assembly
Caution
(1) The differential carrier assembly is non-main-
tainable.
(2) No foreign matter should be allowed inside and
at the joints of the differential carrier assembly.

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>27-48
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

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

REAR SUSPENSION – On-vehicle Service34-3
ON-VEHICLE SERVICE
1. REAR WHEEL ALIGNMENT CHECK AND
ADJUSTMENT
(1) The rear suspension and wheels should be serviced to
the normal condition prior to measurement of wheel
alignment.
(2) Measure the wheel alignment with the vehicle parked
on level ground.
1-1 CAMBER
Standard value: –1
00’ ± 30’
(The difference between the left and right wheels
should be 30’ or less.)
NOTE
For vehicles equipped with aluminium wheels, measure the
camber using a compensator. If no compensator is available,
measure the camber after tightening the special tool
(MB991004) to the specified torque 196 – 255 Nm {20.0
– 26.0 kgf
m}.
Caution
Never subject the wheel bearings to the full vehicle load
when the flange nuts/drive shaft nuts are loosened.
If outside the standard value, adjust by the following
procedure.
(1) Adjust by turning the camber adjusting bolt (mounting
bolt for the lower arm and rear crossmember).
Left wheel: clockwise + camber
Right wheel: clockwise – camber
The scale has gradations of approximately 14’.
(2) After adjusting the camber, be sure to adjust the toe-in.
1-2 TOE-IN
Standard value:
At the centre of tyre tread 3 ± 2 mm
If outside the standard value, adjust by the following
procedure.
(1) Be sure to adjust the camber before adjusting the toe-in.
(2) Adjust by turning the toe adjusting bolt (inner mounting
bolt toe control arm).
LH: Turning clockwise → toe-in direction
RH: Turning clockwise → toe-out direction
The scale has gradations of approximately 3.3 mm (single
side toe angle equivalent to 19’).
2. BALL JOINT DUST COVER CHECK
(1) Check the dust cover for cracks or damage by pushing
it with finger.
(2) If the dust cover is cracked or damaged, replace the
appropriate suspension arm assembly or stabilizer link.
NOTE
Cracks or damage of the dust cover may cause damage
of the ball joint.
Compensator
Camber adjusting bolt
Lower arm
Toe-in adjusting bolt
Control link

BASIC BRAKE SYSTEM 35A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ANTI-LOCK BRAKING SYSTEM (ABS) 35B. . . . . . . . . . . . . . . . . . . . . .
35-1
SERVICE BRAKES
CONTENTS

BASIC BRAKE SYSTEM – General / On-vehicle Service35A-2
GENERAL
OUTLINE OF CHANGE

The service procedures for left-hand drive vehicles have been established as described below.

The service procedures for the front and rear disc brakes have been changed since they had been
replaced by a different type. <EVOLUTION-VI with BREMBO braking system>
ON-VEHICLE SERVICE
BRAKE PEDAL CHECK AND ADJUSTMENT
<L.H. DRIVE VEHICLES>
1. Turn up the carpet, etc under the brake pedal.
2. Measure the brake pedal height as illustrated. If the brake
pedal height is not within the standard value, follow the
procedure below.
Standard value: 163.5 –166.5 mm
(1) Disconnect the stop lamp switch connector.
(2) Adjust the brake pedal height by turning the operating
rod with pliers (with the operating rod lock nut
loosened), until the correct brake pedal height is
obtained.
(3) Secure by tightening the lock nut of the operating
rod.
(4) Push the stop lamp switch in the direction of the
pedal stroke until it stops. (The switch will slide if
it is pushed firmly.)
(5) Lift up the pedal until the operating rod is fully
extended, and then slide the stop lamp switch back
to the required position. Adjust the position of the
switch by turning it until the distance shown in the
illustration is correct.
(6) Connect the connector of the stop lamp switch.
(7) Check that the stop lamp is not illuminated with the
brake pedal unpressed.
3. With the engine stopped, depress the brake pedal two
or three times. After eliminating the vacuum in the power
brake booster, press the pedal down by hand, and confirm
that the amount of movement before resistance is met
(the free play) is within the standard value range.
Standard value: 3 – 8 mmOperating
rod
Operating
rod lock nutStop lamp
switch
Pedal down
Pedal up
Lock nut
Lock nut
Outer case
0.5 – 1.0 mm

BASIC BRAKE SYSTEM – Master Cylinder and Brake Booster35A-6
INSTALLATION SERVICE POINTS
AVACUUM HOSE CONNECTION
Insert securely and completely until the vacuum hose at the
engine side contacts the edge of the hexagonal part of the
fitting, and then secure by using the hose clip.
BCLEARANCE ADJUSTMENT BETWEEN BRAKE
BOOSTER PUSH ROD AND PRIMARY PISTON
Calculate clearance A from the B, C and D measurements.
A = B – C – D
Standard value: 0.65–0.85 mm
If the clearance is not within the standard value range, adjust
by changing the push rod length by turning the screw of
the push rod.
Measuring
distance BMeasuring
distance D
Block
gaugeB
AC
D

35B-1
ANTI-LOCK
BRAKING
SYSTEM (ABS)
CONTENTS
TROUBLESHOOTING 2. . . . . . . . . . . . . . . . . . . .
1. Inspection Chart for Diagnosis Codes 2. . .
2. Inspection Procedure for Diagnostic
Trouble Codes 3. . . . . . . . . . . . . . . . . . . . . . . .
3. Inspection Chart for Trouble Symptoms 11
4. Inspection Procedure for Trouble
Symptoms 12. . . . . . . . . . . . . . . . . . . . . . . . . . .
5. Check at ABS-ECU Terminals 15. . . . . . . . .
ON-VEHICLE SERVICE 17. . . . . . . . . . . . . . . .
Wheel Speed Sensor Output Voltage
Measurement <EVOLUTION-V> 17. . . . . . . . . . .
LATERAL ACCELERATION SENSOR 17. . .
WHEEL SPEED SENSOR 18. . . . . . . . . . . . . .

ABS – Troubleshooting35B-3
2. INSPECTION PROCEDURE FOR DIAGNOSTIC TROUBLE CODES
Code Nos.11, 12, 13 and 14: Wheel speed sensor
(open circuit or short circuit)Probable cause
Code Nos.21, 22, 23 and 24: Wheel speed sensor
Code Nos 11, 12, 13 and 14 are output if the ABS-ECU detects an open circuit or
short-circuit in the (+) wire or (–) wire in any one of the four wheel speed sensors.
Malfunction of wheel speed sensor

Malfunction of wiring harness or connector

Malfunction of ABS-ECU
Code Nos.21, 22, 23 and 24 are output in the following cases.

When there is no input from any one of the four wheel speed sensors when travelling
at 8 km/h or more, even though open circuit can not be verified.

When a chipped or blocked-up ABS rotor is detected and if the anti-lock system
operates continuously because a malfunctioning sensor or a warped ABS rotor
is causing sensor output to drop.
Malfunction of wheel speed sensor

Malfunction of wiring harness or connector

Too much gap between the sensor and the rotor

Malfunction of ABS-ECU

Malfunction of wheel bearing
NG
Check the harness wire, and repair
if necessary.

Between each wheel speed sensor
and ABS-ECU
NG
Replace the ABS-ECU.
OK
Check the trouble symptom.
OK
Check the following connector:
B-24NG
Repair
NG
Repair
OK
Wheel bearing check
OK
ABS rotor check
OK
Wheel speed sensor output voltage
check (Refer to P.35B-17.)NGWheel speed sensor checkNG
Replace
OK
Check the following connectors:
B-24, B-52, B-17, A-26, A-50, D-04,
D-14, D-19OKCheck the trouble symptom.
OK
Measure at the ABS-ECU connector
B-24.

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

Resistances between 8 and 21,
10 and 19, 7 and 20, 9 and 22
OK:1.4 – 1.8 kΩNGWheel speed sensor check
(Refer to P.35B-29.)NG
Replace
Wheel speed sensor installation checkNG
Replace
NG
Replace