torque MITSUBISHI LANCER EVOLUTION VI 1999 Owner's Guide

REAR AXLE – On-vehicle Service <Vehicles with AYC>27-36
(2) While this function is being disabled by the fail-safe
function, the forced activation of the hydraulic unit
can not be executed.
6. Check to ensure that the hydraulic pressure generated
by the hydraulic unit conforms to the standard value.
Standard value: 1.0 – 1.6 MPa
NOTE
During checking the hydraulic pressure, occasionally
replenish the oil reservoir with fluid so that it does not
become empty.
7. Check the hydraulic pressure of the clutch right side by
repeating the steps (4) through (6). At this time, however,
the special tool must be connected to the R port and
the blind plug or the R port of the removed hydraulic
unit hose assembly must be attached to the L port. Further,
the MUT-II must be operated in the forced activation mode
Item No. 14 (clutch right side operation check mode).
8. If the measured value exceeds the standard value, replace
the hydraulic unit.
9. Connect the hydraulic unit hose assembly to the hydraulic
unit and to the torque transfer differential and tighten
the flare nuts to the specified torque.
Specified torque: 34 Nm
10. Pour the specified fluid in the oil reservoir up to the MAX
mark. Then, bleed the system.
Specified fluid: Dia Queen ATF SP II or equivalent
Fluid amount used: Approx. 1

DIFFERENTIAL CARRIER OIL SEAL
REPLACEMENT
DIFFERENTIAL
1. Remove the drive shaft.
2. Remove the oil seal from the differential carrier.
3. Using the special tool, drive a new oil seal all the way
into position.
4. Coat the oil seal lips and the drive shaft surface in contact
with the oil seal with multi-purpose grease.
5. Replace the drive shaft circlip with a new one and mount
the drive shaft to the differential carrier.
6. Check for correct wheel alignment.
TORQUE TRANSFER MECHANISM
1. Remove the drive shaft.
2. Remove the oil seal from the differential carrier.
3. Using the special tool, drive a new oil seal all the way
into position.
4. Coat the oil seal lips and the drive shaft surface in contact
with the oil seal with the specified grease.
Specified grease: Vaseline
5. Replace the drive shaft circlip with a new one and mount
the drive shaft to the differential carrier.
6. Check for correct wheel alignment.
MB990938
MB991115
MD998829
MD998812
MD998813

FRONT SUSPENSION – General / Lower Arm <EVOLUTION-VI>33A-1
GROUP 33A
FRONT SUSPENSION
GENERAL
OUTLINE OF CHANGE

The installation method of the ball joint between the knuckle and the lower arm has been changed,
and accordingly the removal and installation procedures of the lower arm have been revised.
<EVOLUTION-VI>
LOWER ARM <EVOLUTION-VI>
REMOVAL AND INSTALLATION
Caution
The part marked with * should be first temporarily tightened, then torqued to specification with the vehicle
on the ground in unloaded condition.
Post-installation Operation

Push the Dust Cover of the Lower Arm and Stabilizer Link Ball Joint with a Finger to Check for Possible Cracks or Damage.

Wheel Alignment Check and Adjustment
1
2
3
4
5
6
39 Nm
106 Nm*
5
98 – 118 Nm
74 – 87 Nm88 Nm
137 Nm
Removal steps
1. Stabilizer link mounting nut
2. Bolt
3. Stabilizer bracket
A4. Bushing assembly
5. Lower arm assembly6. Lower arm bracket assembly
NOTE
Follow the conventional procedures for installation service
points.

STEERING – Power Steering Gear Box37A-6
REMOVAL SERVICE POINTS
ATIE-ROD END AND KNUCKLE DISCONNECTION
Caution
1. In order not to damage the ball joint thread, the tie
rod end mounting nut must be only loosened but not
removed from the ball joint. Be sure to use the special
tool.
2. Tie the special tool with a cord so as not to fall off.
BGEAR BOX ASSEMBLY REMOVAL
Caution
Do not damage the bellows and the tie-rod end dust cover
when removing the gear box assembly.
INSPECTION

Check the rubber parts for cracks and breakage.
GEAR BOX TOTAL PINION TORQUE
Using the special tools, rotate the pinion gear at the rate
of one rotation in approximately 4 to 6 seconds to check
the total pinion torque.
Standard value: 0.9 – 1.7 Nm
[Change in torque: 0.4 Nm]
Caution
When holding the steering gear box assembly in a vice,
secure its mounting positions. If it is secured in any other
places, the gear housing may become deformed or
damaged.
NOTE
When measuring, remove the bellows from the rack housing.
Measure the pinion torque through the whole stroke of the
rack.
If the measured value is not within the standard range, first
adjust the rack support cover, and then check the total pinion
starting torque again.
Cord
Ball joint
NutMB990635 or
MB991113
MB991006

STEERING – Power Steering Gear Box37A-7
If the total pinion starting torque cannot be adjusted to within
the standard range by adjusting the rack support cover, check
the rack support cover, rack support spring, rack support
and replace any parts if necessary.
CHECK THE TIE ROD FOR SWING RESISTANCE
1. Give 10 hard swings to the tie rod.
2. Measure the tie rod swing resistance with a spring balance.
Standard value: 5–18 N [1.5–4.9 Nm]
3. If the measured value exceeds the standard value, replace
tie rod.
4. Even if the measured value is below the standard value,
the tie rod which swings smoothly without excessive play
may be used.

STEERING – Power Steering Gear Box37A-8
DISASSEMBLY AND REASSEMBLY
Steering gear seal set
Flare nut
1
3 4
5
6 7
8
910
11
12 13 14
15 17
1921
24
25
26 29
32
33
35
2
22
3416
27
28 31
3013 Nm
1
20
36 3718
25 Nm
49 – 59 Nm
88 Nm27
28
309 20
62
9 6 35
59 Nm
15
59 Nm
21 Nm
2
311823 23
Disassembly steps
1. Feed pipe
2. O-ring
N3. Tie-rod end locking nut
N4. Tie-rod end
5. Bellows clip
M6. Bellows band
7. Bellows
L8. Tie-rod
L9. Tab washer
K
Total pinion torque adjustment
10. Locking nut
A11. Rack support cover
12. Rack support spring
13. Rack support
J14. End plug
15. Self-locking nut
16. Bolt
17. Valve assembly
BI18. Oil sealB19. Pinion and valve assembly
CH20. Seal ring
21. Valve housing assembly
DG22. Ball bearing
DG23. Oil seal
EF24. Circlip
F25. Rack stopper
FE26. Rack bushing
GE27. Oil seal
28. O-ring
FD29. Rack
30. Piston ring
31. O-ring
32. Rack housing assembly
HC33. Ball bearing
IC34. Needle roller bearing
JB35. Oil seal
36. Gear housing mounting bushing
A37. Gear housing mounting rubber

STEERING – Power Steering Gear Box37A-14
2. Apply a coating of the specified fluid to the outside of
the ball bearing. Using the special tools, press the ball
bearing into the valve housing.
Specified fluid:
Automatic transmission fluid
DEXRON or DEXRON II
HSEAL RING INSTALLATION
1. Kneed the seal ring to soften it.
2. Apply the specified fluid to the seal ring, and install to
the rack groove.
Specified fluid:
Automatic transmission fluid
DEXRON or DEXRON II
3. Insert the tapered side of the special tool from the pinion
gear side, and compress the seal ring.
IOIL SEAL INSTALLATION
Use the special tool to press the oil seal into the valve housing.
The upper surface of the oil seal should project outwards
approx. 1 mm from the housing edge surface.
Caution
If the oil seal is flush with or lower than the housing
edge, it will cause oil leaks and require reassembly.
JEND PLUG INSTALLATION
1. Apply the specified sealant to the threaded part of the
end plug.
Specified sealant:
3M ATD Part No.8661 or equivalent
2. Secure the threaded portion of the end plug at two places
by using a punch.
KTOTAL PINION TORQUE ADJUSTMENT
1. Position the rack at its centre. Tighten the rack support
cover to 15 Nm.
2. In neutral position, rotate the pinion shaft clockwise one
turn/4 – 6 seconds with the special tool. Return the rack
support cover 30 – 60 and adjust torque to the standard
value.
Ball bearingMB990938
MB991203
Pinion gearMB991317
Tapered side
Approx. 1 mmMB990941
End plug
SealantEnd plug
MB991006

STEERING – Power Steering Gear Box37A-15
3. Using the special tools, rotate the pinion gear at the rate
of one rotation in approximately 4 to 6 seconds to check
the total pinion torque.
Standard value: 0.9 – 1.7 Nm
[Change in torque: 0.4 Nm]
Caution
(1) When adjusting, set the standard value at its
highest value.
(2) Assure no ratcheting or catching when operating
the rack towards the shaft direction.
NOTE
When it cannot be adjusted within the specified return
angle, check or replace the rack support cover
components.
4. After adjusting, lock the rack support cover with lock nut.
LTAB WASHER / TIE-ROD INSTALLATION
After installing the tie-rod to the rack, fold the tab washer
end (2 locations) to the tie-rod notch.
MBELLOWS BAND INSTALLATION
1. Turn the adjusting bolt of the special tool to adjust the
opening dimension (W) to the standard value.
Standard value (W): 2.9 mm
<When more than 2.9 mm>
Screw in the adjusting bolt.
<When less than 2.9 mm>
Loosen the adjusting bolt.
NOTE
(1) The dimension (W) is adjusted by approx. 0.7 mm
per one turn.
(2) Do not turn the adjusting bolt more than one turn.
MB991006
MB991561
Stopper
Adjusting bolt W

BODY – SunroofBODY – Sunroof42-9
SUNROOF
SERVICE SPECIFICATIONS
ItemsStandard value
Roof lid glass operating current A (at 20C)7 or less
Sunroof motor clutch slippage torque Nm4.7 – 6.2
SEALANT
ItemSpecified sealant
Rail cover assembly3M ATD Part No.8531 or 3M Part No.8646 or equivalent
TROUBLESHOOTING
INSPECTION CHART FOR TROUBLE SYMPTOMS
Trouble symptomInspection procedureReference page
The sunroof can not be operated when the ignition switch is in
ON position.142-9
The motor does not reverse its direction when a load of 140 N
or more is applied while the sunroof is closing.242-11
The timer does not operate for 30 seconds after the ignition
switch is turned to OFF.342-11
Opening or closing of the sunroof is possible for 30 seconds
after turning the ignition switch to OFF, but the timer function
is not extended when the driver’s side door is opened within this
period.442-11
INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS
Inspection Procedure 1
The sunroof can not be operated when the ignition switch
is in ON position.
Probable cause
One of the following items may be defective.

Sunroof switch

Sunroof motor

Sunroof-ECU power supply circuit

Earth circuit
Malfunction of sunroof switch

Malfunction of sunroof motor

Malfunction of sunroof-ECU

Malfunction of wiring harness or connector

CHASSIS ELECTRICAL – Combination Meters54-30
ENGINE COOLANT TEMPERATURE GAUGE UNIT
CHECK
1. Bleed the engine coolant.
2. Remove the engine coolant temperature gauge unit.
3. Immerse the unit in 70C water to measure the resistance.
Standard value: 104 ±13.5 Ω
4. After checking, apply the specified adhesive around the
thread of engine coolant temperature gauge unit. Then,
tighten the unit to the specified torque.
Specified sealant:
3M Adhesive Nut Locking No. 4171 or equivalent
5. Add engine coolant.
COMBINATION METERS
REMOVAL AND INSTALLATION
2 1
3
Vehicle speed sensor removal
steps

Battery and battery tray

Air cleaner assembly
1. Vehicle speed sensorCombination meter removal steps
2. Meter bezel
3. Combination meter
ThermometerCircuit tester
10 – 12 Nm