lock MITSUBISHI LANCER EVOLUTION 2007 Service Repair Manual

FRONT SUSPENSION -Strut Assembly33A-8
AB"STRUT ASSEMBLY REMOVAL
To discard the strut assembly, place the assembly horizontally
with its piston rod extended. Then drill a hole approx. 3 mm
in diameter at the location shown in the illustration and
discharge the gas.
Caution
The gas itself is harmless but it may issue out of the
hole together with chips generated by the drill. Therefore,
be sure to wear goggles.
REASSEMBLY SERVICE POINT
"AASELF-LOCKING NUT INSTALLATION
1. Ensure that the bearing is seated correctly.
2. Install the special tool to the strut assembly same as
its removal.
3. While the coil spring is being compressed by the special
tools, provisionally tighten the self-locking nut.
Caution
Do not use an impact wrench as it will cause the
bolt of the special tool to be seized.
4. Align the hole in the strut assembly lower spring seat
with the hole in the upper spring seat.
NOTE
Using a pipe as shown facilitates the alignment.
5. Correctly align both ends of the coil spring with the grooves
in the spring seat, and then loosen the special tools.
6. Using the special tools, tighten the self-locking nut to the
specified torque.
Specified torque: 60±10 N·m
Caution
To prevent the piston rod lock nut inside the strut
from loosening, do not use an impact wrench when
the self-locking nut is tightened.
7. After tightening self-locking nut, fill the multi purpose
greese to the bearing part of strut insulator.
Pipe
MB991681
MB991682

FRONT SUSPENSION -Lower Arm Assembly33A-10
REMOVAL SERVICE POINT
AA"LOWER ARM AND CROSSMEMBER
DISCONNECTION
Lift the transmission with a transmission jack, and then
withdraw the front mounting bolt on the left lower arm
assembly.
INSPECTION
LOWER ARM BALL JOINT ROTATION STARTING
TORQUE CHECK
1. After shaking the ball joint stud several times, use the
special tool to measure the rotation starting torque of
the lower arm ball joint.
Standard value: 0.5 - 3.4 N·m
2. When the measured value exceeds the standard value,
replace the lower arm assembly.
3. When the measured value is lower than the standard
value, check that the lower arm ball joint turns smoothly
without excessive play. If there is no excessive play, the
ball joint can be reused.
PILLOW BALL BUSHING ROTATION STARTING
TORQUE CHECK
1. Insert the bolt to the lower arm pillow ball bushing, in
the opposite direction, insert the washer then install the
nut. After rotating the inner sleeve (contained washer)
several times, measure the rotation starting torque of
the lower arm pillow ball bushing using special tool.
Standard value: 0.5 - 3.0 N·m
2. When the measured value exceeds the standard value,
replace the pillow ball bushing.
3. When the measured value is lower than the standard
value, check that the lower arm pillow ball bushing turns
smoothly without excessive play. If there is no excessive
play, the pillow ball bushing can be reused.
LOWER ARM 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
lower arm assembly.
NOTE
If the dust cover is cracked or damaged, it is possible
that there may also be damage to the ball joint.
When it is damaged during service work, replace the
dust cover.
Wooden block
Transmission jack
Mounting Bolt
Pillow ball
bushing
MB991006
Pillow ball bushing
Ball joint
Ball joint
MB990326

FRONT SUSPENSION -Lower Arm Assembly/Stabilizer Bar33A-12
3. Use the special tools to press in the bushing until its
outer tube is flush with the lower arm assembly surface.
STABILIZER BAR
REMOVAL AND INSTALLATION
Caution
1. Before removing the steering wheel and air bag module assembly, refer to GROUP 52B - Service
Precautions and Air Bag Module and Clock Spring. Also, put the front wheels in straight-ahead
position. Failure to do so may damage the SRS clock spring and render the SRS air bag
inoperative, which results serious driver injury.
2. If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to
contact the parts or tools to the caliper because the paint of caliper will be scratched. And
if there is brake fluid on the caliper, wipe out quickly.
3. To prevent bushings from breakage, the parts indicated by * should be temporarily tightened,
and then fully tightened with the vehicle on the ground in the unladen condition.
Lower arm
assembly
MB990651
MB991576
MB991816
Outer tube

FRONT SUSPENSION -Stabilizer Bar33A-13
Pre-removal Operation
DSteering Wheel and Air Bag Module Assembly
Removal (Refer to GROUP 37A.)
DClock Spring Removal (Refer to GROUP 52B.)
DCrossmember Bar Removal (Refer to P.33A-15.)
DCentermember Removal (Refer to GROUP 32.)
DFront Exhaust Pipe Removal (Refer to GROUP 15.)Post-installation Operation
DFront Exhaust Pipe Installation (Refer to GROUP
15.)
DCentermember Installation (Refer to GROUP 32.)
DCrossmember Bar Installation (Refer to P.33A-15.)
DClock Spring Installation (Refer to GROUP 52B.)
DSteering Wheel and Air Bag Module Assembly
Installation (Refer to GROUP 37A.)
DCheck the Dust Cover for Cracks or Damage by
Pushing it with Finger.
DChecking Steering Wheel Position with Wheels
Straight Ahead
DFront Wheel Alignment Check and Adjustment
(Refer to P.33A-4.)
3
4
10
21±4N·m
51
1
2
25±5N·m
18±2N·m
108±10 N·m
52±7N·m*
49±10 N·m
167±9N·m
7
8
9
6
39±5N·m
39±5N·m
Removal steps
1. Stabilizer link
2. Stabilizer bracket
3. Lower arm and knuckle connection
AA"4. Tie rod end and knuckle connection
5. Steering shaft cover6. Steering gear and joint connecting bolt
7. Rear roll stopper connecting bolt
AB""AA8. Fixture
AB""AA9. Bushing
AB""AA10. Stabilizer bar

FRONT SUSPENSION -Stabilizer Bar33A-14
REMOVAL SERVICE POINTS
AA"TIE ROD END AND KNUCKLE DISCONNECTION
Caution
1. To prevent the ball joint thread from damage, 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. Support the special tool with a cord to prevent it from
coming off.
AB"FIXTURE/BUSHING/STABILIZER BAR REMOVAL
Carry out the following operations to ensure working space
in order to remove the fixture, the bushing and the stabilizer
bar.
1. Use a transmission jack to hold the crossmember, and
then remove the crossmember mounting nuts and bolts.
2. Lower the crossmember until the fixture, the bushing and
the stabilizer bar can be removed.
Caution
Be careful not to lower the crossmember excessively,
otherwise the power steering return hose bracket may
deform.
INSTALLATION SERVICE POINT
"AASTABILIZER BAR/BUSHING/FIXTURE
INSTALLATION
Align the stabilizer bar identification mark with the right end
of the bushing.
Cord
Ball jointNut
MB991406,
MB990635 or
MB991113
Transmission jack
Woodenblock
Identification colour
BushingFixture
Outside of
vehicle

BASIC BRAKE SYSTEM -Lubricants/Sealant/Special Tools35A-6
LUBRICANTS
ItemsSpecified LubricantQuantity
Brake fluidDOT3 or DOT4As required
Piston, wheel cylinder body
Piston boot, piston seal, shimRepair kit grease
Guide pin, lock pin, pin boot
Pad assembly
SEALANT
ItemsSpecified sealantRemarks
Fitting3M ATD Part No. 8661, 8663 or equivalentSemi-drying sealant
SPECIAL TOOLS
ToolNumberNameUse
MB991568Push rod adjusting
socketAdjustment of the brake booster push rod
protrusion amount
AMB990964
A: MB990520Brake tool setPushing-in of the disc brake piston
DDisc brake piston pushing-in
MB990998Front hub remover
and installerProvisional holding of the wheel bearing

BASIC BRAKE SYSTEM -On-vehicle Service35A-7
ON-VEHICLE SERVICE
BRAKE PEDAL CHECK AND ADJUSTMENT
BRAKE PEDAL HEIGHT
1. Turn up the carpet, etc. under the brake pedal.
2. Measure the brake pedal height as illustrated.
Standard value (A): 169.1 - 172.1 mm
3. If the brake pedal height is not within the standard value,
follow the procedure below.
(1) Disconnect the stop lamp switch connector.
(2) Loosen the stop lamp switch by turning it approx.
1/4 turns anticlockwise.
(3) Remove the brake booster. (Refer to P.35A-17.)
NOTE
With the master cylinder and brake pipe connected,
remove the brake booster only.
(4) Adjust the brake pedal height by turning the clevis.
NOTE
When the clevis is turned 180_, the pedal hight is
changed approximately 2.4 mm.
(5) Install the brake booster. (Refer to P.35A-17.)
(6) Measure brake pedal height, and ensure that the
measured value is within the specified value. When
it is out of the specified value, repeat Step (3) - (6).
(7) Insert the stop lamp switch until it’s thread part touches
the stopper. Then lock the stop lamp switch by turning
it approx. 1/4 turns clockwise, and confirm that the
clearance between the switch plunger and the stopper
is as shown.
(8) Connect the connector at the stop lamp switch.
Caution
Check that the stop lamp does not illuminate when
the brake pedal is not depressed.
4. Return the carpet, etc.
BRAKE PEDAL FREE PLAY
1. 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.
Standard value (B):3–8mm
A
Clevis
Stopper
0.5 - 1.0 mm
B

BASIC BRAKE SYSTEM -ProportioningValve,MasterCylinder
and Brake Booster35A-18
Master cylinder removal steps
1. Clutch hose connection
2. Brake fluid level sensor connector
3. Reservoir cap assembly
4. Brake fluid level sensor
5. Brake pipe connection
6. Proportioning valve

7. O ring
8. Master cylinder
Proportioning valve removal steps

5. Brake pipe connection
6. Proportioning valve
7. O ring
Brake booster removal steps
1. Clutch hose connection
2. Brake fluid level sensor connector5. Brake pipe connection
8. Master cylinder
"BADPush rod protrusion amount check and
adjustment
"AA9. Vacuum hose
(With built-in check valve)
10. Snap pin
11. Pin assembly
12. Clevis
DRemove A/C liquid pipe B
from the
retaining clip.(Refer to GROUP 55A
- Refrigerant Line.)
13. Brake booster
14. Sealer
Fitting removal steps
"AA9. Vacuum hose
(With built-in check valve)
15. Fitting
INSTALLATION SERVICE POINTS
"AAVACUUM HOSE CONNECTION
Insert the vacuum hose to the brake booster with its paint
mark facing upward, and then secure the hose by using the
hose clip.
"BAPUSH ROD PROTRUSION AMOUNT CHECK AND
ADJUSTMENT
1. Measure dimension (A).
Standard value (A) : 8.98 - 9.23 mm
NOTE
When a negative pressure of 66.7 kPa is applied to the
brake booster, the push rod should protrude 10.27 – 10.53
mm.
Block gauge Measuring distance A
A

BASIC BRAKE SYSTEM -Disc Brake35A-22
DISASSEMBLY AND REASSEMBLY
Front
9
11
1213
4 1
2
4
5
6 89
Brake caliper kit Pad set Seal and boot kit
55 2
3
5
110
8
76
3
9 12
97
Clip set
14
Shim set
11
6
106 31414
14
13
7
74±10 N·m
74±10 N·m 7.9±0.9 N·m
5
57Grease
Disassembly steps
"AA1. Guide pin
"AA2. Lock pin
3. Bushing
4. Caliper support (including pad, clip,
and shim)
5. Pin boot
6. Boot ring
AA"7. Piston bootAA"8. Piston
AB"9. Piston seal
10. Caliper body
11. Pad and wear indicator assembly
12. Pad assembly
13. Outer shim
14. Clip

BASIC BRAKE SYSTEM -Disc Brake35A-24
Rear
11
1213
4 1
25
6 89
Brake caliper kit Pad set Seal and boot kit
55
2
3
5 1108
76
39 12
97
Clip set
14
Shim set
11
10
6 31414
14
13
44±5 N·m
7.9±0.9 N·m
5
57Grease
4
Disassembly steps
"AA1. Guide pin
"AA2. Lock pin
3. Bushing
4. Caliper support (including pad, clip,
and shim)
5. Pin boot
6. Boot ring
AA"7. Piston bootAA"8. Piston
AB"9. Piston seal
10. Caliper body
11. Pad and wear indicator assembly
12. Pad assembly
13. Outer shim
14. Clip