rear MITSUBISHI LANCER EVOLUTION 2007 Service Repair Manual

PARKING BRAKES -Parking Brake Drum36-8
REMOVAL SERVICE POINT
AA"REAR BRAKE CALIPER ASSEMBLY REMOVAL
Remove the rear brake caliper assembly and support it with
wire or similar.
CAUTION: Brembo disc brake
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.
INSTALLATION SERVICE POINTS
"AAADJUSTER ASSEMBLY INSTALLATION
Install the adjuster assembly so that the shoe adjusting bolt
of left hand wheel is attached towards the rear of the vehicle,
and the shoe adjusting bolt of right hand wheel is towards
the front of the vehicle.
"BASHOE-TO-ANCHOR SPRING INSTALLATION
Install the shoe-to-anchor springs in the order shown in the
illustration.
NOTE
The figure shows the left wheel; for the right wheel, the position
is symmetrical.
INSPECTION
BRAKE LINING AND BRAKE DRUM CHECK
1. Measure the thickness of the brake lining at several places.
Standard value: 2.8 mm
Limit: 1.0 mm
2. If the thickness of the brake lining has worn down to
the limit value or more, replace the shoe and lining
assemblies on both sides of the vehicle.
3. Measure the inside diameter of the brake disc in two
places or more.
Standard value: 168.0 mm
Limit: 169.0 mm
4. If the inside of the brake disc has worn down to the
limit value or more, or if it is excessively worn on one
side, replace the brake disc.
Shoe adjusting
bolt
Rear side
of the ve-
hicle
A14N0009
12
Paint

STEERING - Power Steering Gear Box and Linkage37A-16
POWER STEERING GEAR BOX AND LINKAGE
REMOVAL AND INSTALLATION
Caution: SRS
Before removing steering gear box, refer to GROUP 52B. 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.
Caution
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.
Pre-removal Operation
DClock Spring Removal (Refer to GROUP 52B.)
DPower Steering Fluid Draining (Refer to P.37A-9.)Post-installation Operation
DClock Spring Installation (Refer to GROUP 52B.)
DPower Steering Fluid Supplying and bleeding
(Refer to P.37A-9.)
DChecking Steering Wheel Position with Wheels
Straight Ahead

17
6
3 4
57±7 N·m5
8
70±10 N·m
2
15±3 N·m
9
10
12±2 N·m 12±2 N·m
70±10 N·m
Removal steps
1. Crossmember
(Refer to GROUP 32.)
DRear roll stopper(Refer to GROUP 32.)
2. Joint cover grommet
3. Return hose
4. Return tube5. O ring
6. Return tube
7. Eye bolt
8. Pressure hose assembly
9. Clamp
10. Steering gear and linkage

STEERING - Power Steering Oil Hoses37A-31

Pre-removal and Post-installation Operation
Power Steering Fluid Draining and Refilling (Refer to
P.37A-9.)
12±2 N·m
17
16
15
12
18±3 N·m
Crossmember
1
57±7 N·m
9
8 47
32 5
12±2 N·m15±3 N·m
18±2 N·m 12±2 N·m
49±10 N·m
52±7 N·m*
12±2 N·m
6
10
11
167±10 N·m
14 13
18
12±2 N·m
12±2 N·m
Removal steps
1. Oil reservoir
"BA2. Suction hose
3. Return hose
4. Return hose
5. Return tube
DStrut tower bar (Refer to GROUP 42.)
6. Return hose
DClock spring (Refer to GROUP 52B.)
DCrossmember bar
(Refer to GROUP 33A.)
DCenter member (Refer to GROUP 32.)
DFront exhaust pipe
(Refer to GROUP 15.)
7. Steering gear and joint connecting
bolt8. Rear roll stopper connecting bolt
9. Rear roll stopper
(Refer to GROUP 32.)
AA"10. Eye bolt
11. Gasket
"BA12. Pressure hose assembly
"AA13. O ring
14. Return hose
15. Return tube
AA"16. Return tube
17. O ring
DFront bumper (Refer to GROUP 51.)
DIntercooler (Refer to GROUP 15.)
18. Cooler tube assembly

STEERING - Power Steering Oil Hoses37A-32

Pre-removal and Post-installation Operation
Power Steering Fluid Draining and Refilling (Refer to
P.37A-9.)
12±2 N·m
15
12
18±3 N·m
Crossmember
1
57±7 N·m
9
8 4
7
32 5
12±2 N·m
15±3 N·m
18±2 N·m 12±2 N·m
49±10 N·m
52±7 N·m*
12±2 N·m
6
10
11
167±10 N·m
14
13
12±2 N·m
Removal steps
1. Oil reservoir
"BA2. Suction hose
3. Return hose
4. Return hose
5. Return tube
DStrut tower bar (Refer to GROUP 42.)
6. Return hose
DClock spring (Refer to GROUP 52B.)
DCrossmember bar
(Refer to GROUP 33A.)
DCenter member (Refer to GROUP 32.)
DFront exhaust pipe
(Refer to GROUP 15.)7. Steering gear and joint connecting
bolt
8. Rear roll stopper connecting bolt
AA"9. Eye bolt
10. Gasket
"BA11. Pressure hose assembly
"AA12. O ring
AA"13. Return tube
14. O ring
DFront bumper (Refer to GROUP 51.)
DIntercooler (Refer to GROUP 15.)
15. Cooler tube assembly

42-1
BODY
CONTENTS
HOOD2 .................................
ON-VEHICLE SERVICE 2..................
Adjustment of Clearance around Hood 2......
Adjustment of Alignment of Hood Stepped
Portion and Hood Striker 2..................
Adjustment of Hood Height 2.................
HOOD 3..................................
FENDER4 ..............................
SPECIAL TOOL 4.........................
FENDER 5................................
FUEL FILLER DOOR7 .................
STRUT TOWER BAR AND REAR END
CROSS BAR8 ...........................
WINDOW GLASS9 .....................
ADHESIVE 9..............................
SPECIAL TOOLS 9........................
WINDOW REPAIR 9.......................
WINDSHIELD 11...........................
REAR WINDOW GLASS 16................
DOORS19 ..............................
SERVICE SPECIFICATIONS 19.............ADHESIVES 19............................
SPECIAL TOOLS 19.......................
TROUBLESHOOTING 20...................
ON-VEHICLE SERVICE 20.................
Door Adjustment 20.........................
Door Window Glass Adjustment 21...........
Adjustment and Replacement during Power
Window Malfunction 22......................
Power Window Safety Mechanism Check 22..
Power Window Timer Function Check 22......
Door Outside Handle Looseness Check 23....
Power Window Operation Current Check 23...
Circuit Breaker Check 23....................
Power Window Check 23....................
Door Inside Handle Looseness Check and
Adjustment 24...............................
DOOR ASSEMBLY 25......................
DOOR TRIM AND
WATERPROOF FILM 27....................
DOOR GLASS AND REGULATOR 32.......
DOOR HANDLE AND LATCH 35...........
WINDOW GLASS RUNCHANNEL AND
DOOR OPENING WEATHERSTRIP 38.......
TRUNK LID41 ..........................

BODY -Fuel Filler Door42-7
FUEL FILLER DOOR
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operations
DRear Seat Removal and Installation. (Refer to GROUP
52A.)
DFront Scuff Plate (Driver’s Side), Rear Scuff Plate(Driver’s Side), Center Pillar Lower Trim (Driver’s
Side), Quarter Trim (Driver’s Side) Removal and
Installation (Refer to GROUP 52A – Trim.)
5
1
3 4 3
2
5.0±1.0 N·m
Adjustment of clearance around
fuel filler door
Removal steps
1. Fuel filler door panel assembly
2. Clip
3. Fuel filler door hook assembly4. Fuel filler door lock release cable
5. Fuel filler door lock release handle

BODY -Strut Tower Bar and Rear End Cross Bar42-8
STRUT TOWER BAR AND REAR END CROSS BAR
REMOVAL AND INSTALLATION
44±5 N·m
Strut tower bar
Rear end cross bar

BODY -Window Glass42-9
WINDOW GLASS
ADHESIVE
ItemsSpecified adhesive
Windshield3M ATD Part No. 8609 Super Fast Urethane Auto Glass Sealant or
il tRear window glass
p
equivalent
SPECIAL TOOLS
ToolNumberNameUse
MB990480Window glass
holderRemoval and Installation of Window Glass
MB990784Ornament removerRear Window Lower Molding Removal
WINDOW REPAIR
The following glass parts are installed with a liquid urethane
adhesive method:
DWindshield
DRear window glass
ITEMS NEEDED
NameRemarks
Adhesive3M ATD Part No. 8609 Super Fast Urethane Auto Glass Sealant or
equivalent
Primer3M ATD Part No. 8608 Super Fast Urethane Primer or equivalent
SpacersAvailable as service part
DamAvailable as service part
Anti-rust solvent (or Tectyl 506T...Valvoline Oil
Company)For rust prevention
Isopropyl alcoholFor grease removal from bonded surface
Steel piano wireDia. y length...0.6mm 1m For cutting adhesive
Adhesive gunFor pressing-out adhesive

BODY -Window Glass42-16
REAR WINDOW GLASS
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operations
DRear Pillar Trim Removal and Installation
(Refer to GROUP 52A.)
DHeadlining Removal and Installation
DRear Shelf Trim Removal and Installation
(Refer to GROUP 52A.)DHigh Mount Stop Lamp Assembly Removal and
Installation (Refer to GROUP 54A)
Section A - A
1
1
9 810
7
7
3
Apply the primer and
adhesive along the fictitious
lines (seal line) between
each of the marks.
Mark
Seal line center
Primer B
B
6
2
3
2
4
2
A
Section B - B
42
Sealant: 3M ATD Part No. 8609 Super Fast Urethane Auto Glass Sealant or equivalent
4
5
A
Removal steps
DRoof drip molding
(Refer to GROUP 51.)
AA""BA1. Rear window lower molding
2. Clip
3. Grommet A
4. Grommet B5. Grommet C
6. Connecting the harness connector
AB""AA7. Rear window glass
"AA8. Rear window upper molding
"AA9. Window dam
"AA10. Glass stopper

BODY -Window Glass42-17
REMOVAL SERVICE POINTS
AA"REAR WINDOW LOWER MOLDING REMOVAL
Pry the rear window lower molding off with the special tool.
Caution
Do not use a deformed molding.
AB"REAR WINDOW GLASS REMOVAL
Remove the rear window glass in the same manner as for
the windshield. (Refer to P42-12.)
INSTALLATION SERVICE POINTS
"AAGLASS STOPPER/WINDOW DAM/REAR WINDOW
UPPER MOLDING/REAR WINDOW GLASS
INSTALLATION
1. When replacing the rear window glass, first align it with
the body, and then matchmark them.
2. Use isopropyl alcohol to clean the inside edge of the
rear window glass and the body flange.
3. Use a primer dampened sponge to apply the primer to
the specified area around the rear window glass and
the body evenly.
4. After applying the primer, let it dry for at least 3 minutes.
Caution
(1) The primer strengthens the adhesive effect, so
that be sure to apply it. However, a too thick
application will weaken the adhesive effect.
(2) Never touch the primer-applied surface.
5. Position the glass stopper and the window dam in the
specified position, ensuring that there are no bends or
warpages inside the rear window glass.
MB990784