oil 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

BASIC BRAKE SYSTEM -Disc Brake35A-21
INSTALLATION SERVICE POINT
"AADISC BRAKE ASSEMBLY INSTALLATION

1. In order to measure the brake drag force after pad
installation, measure the rotary-sliding resistance of the
hub by the following procedure with the pads removed.
(1) Withdraw the drive shaft. (Refer to GROUP 26, 27.)
(2) Attach the special tool to the front hub assembly as
shown in the illustration, and tighten it to the specified
torque.
Tightening torque:
245±29 N·m , 225±25 N·m
(3) Use a spring balance to measure the rotary-sliding
resistance of the hub in the forward direction.
2. Install the caliper support to the knuckle, and then
assemble the pad and the clip to the caliper support.
Caution
Do not contaminate the friction surfaces of the pads
and brake discs by any oil or grease.
3. Clean the piston and insert it into the cylinder with the
special tool.
4. Be careful that the piston boot does not become caught,
when lowering the caliper assembly and install the guide
pin to the caliper.
5. Start the engine, and then depress the brake pedal two
or three times strongly. Then stop the engine.
6. Turn the brake disc forward 10 times.
7. Use a spring balance to measure the rotary-sliding
resistance of the hub in the forward direction.
8. Calculate the drag force of the disc brake [difference
between the values measured at steps 1 and 7].
Standard value:
51 N or less , 69 N or less
9. If that drag force exceeds the standard value, disassemble
the piston assembly. Then check the piston for
contamination or rust, and confirm if the piston or the
piston seal is deteriorated, and if the slide pins slide
smoothly.

1. Find the drag force of the disc brake. (Refer to P.35A-13.)
Standard value: 69 N or less
2. If that drag force exceeds the standard value, disassemble
the piston assembly. Then check the piston for
contamination or rust, and confirm if the piston or the
piston seal is deteriorated.MB990998
Bolt


MB990998Bolt
MB990520

ABS <4WD> -General Information35B-2
GENERAL INFORMATION
ABS has been adopted as optional equipment in
RS-IIto maintain directional stability and steering
performance during sudden braking or braking on
slippery road surfaces.
The ABS control method is a 4-sensor, 4-channel
method which provides independent control for all
wheels.
Following system for Lancer EVOLUTION-VII has
been modified from Lancer EVOLUTION-VI Tommi
Makinen Edition.DBy adding lateral G sensor, longitudinal G
sensor and steering wheel sensor, optimized
ABS control at the time of cornering.
DBy inputting parking brake switch signal to
ABS-ECU with pulling parking brake lever, ABS
control has been optimized.
DABS-ECU outputs ABS signal to 4WD-ECU.
DG sensor (lateral), steering wheel sensor and
parking brake switch have been added to the
diagnosis and service data.
DABS-ECU connector has been changed.
EBD CONTROL
In ABS, electronic control method is used by which
the rear wheel brake hydraulic pressure during
braking is regulated by rear wheel control solenoid
valves in accordance with the vehicle’s rate of
deceleration and the front and rear wheel slippage
which are calculated from the each wheel speed
sensor’s signal. EBD control is a control system
which provides a high level of control for both vehicle
braking force and vehicle stability. The system has
the following features:
DBecause the system provides the optimum rear
wheel braking force regardless of the vehicleladen condition and the condition of the road
surface, the system reduces the required pedal
depression force, particularly when the vehicle
is heavily laden or driving on road surfaces
with high frictional coefficients.
DBecause the duty placed on the front brakes
has been reduced, the increases in pad
temperature can be controlled to improve the
wear resistance characteristics of the pad,
during front brakes applying.
DControl valves such as the proportioning valve
are no longer required.
SPECIFICATIONS
ItemSpecifications
ABS control method4-sensor, 4-channel
No. of ABS rotor teethFront43
Rear43
ABS speed sensorTypeMagnet coil typep
Gap between sensor and rotor mm0.85 / 0.60 (non-adjustable type)

37A-1
STEERING
CONTENTS
GENERAL INFORMATION 2..................
SERVICE SPECIFICATIONS 4.................
LUBRICANTS 4..............................
SEALANT 4..................................
SPECIAL TOOLS 4...........................
ON-VEHICLE SERVICE 7.....................
Steering Wheel Free Play Check 7..............
Steering Angle Check 7........................
Tie Rod End Ball Joint Turning Torque Check 7..
Stationary Steering Effort Check 8...............
Checking Steering Wheel Return to Centre 8.....
Drive Belt Tension Check 8.....................Power Steering Fluid Level Check 9.............
Power Steering Fluid Replacement 9.............
Power Steering System Bleeding 9..............
Oil Pump Pressure Test 10.....................
Power Steering Oil Pressure Switch Check 11....
Ball Joint Dust Cover Check 11.................
STEERING WHEEL* 12.......................
STEERING SHAFT* 14.......................
POWER STEERING GEAR BOX AND
LINKAGE* 16................................
POWER STEERING OIL PUMP 29............
POWER STEERING OIL HOSES 30...........
WARNINGS REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM (SRS) EQUIPPED VEHICLES
WARNING!
(1) Improper service or maintenance of any component of the SRS, or any SRS-related component, can lead to personal
injury or death to service personnel (from inadvertent firing of the air bag) or to the driver and passenger (from rendering
the SRS inoperative).
(2) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized
MITSUBISHI dealer.
(3) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B - Supplemental
Restraint System (SRS) before beginning any service or maintenance of any component of the SRS or any SRS-related
component.
NOTE
The SRS includes the following components: SRS-ECU, SRS warning lamp, air bag module, clock spring and interconnecting
wiring. Other SRS-related components (that may have to be removed/installed in connection with SRS service or maintenance) are
indicated in the table of contents by an asterisk (*).

STEERING -General Information37A-2
GENERAL INFORMATION
The system has been equipped with the MOMO
leather 3-spoke-type steering wheel with built-in
SRS airbag.
The steering column is equipped with tilt steering
mechanism.
The power steering is an integral rack and piniontype that combines the steering gear and linkage
into one light-weight and compact assembly.
The steering system uses a vane oil pump with
a fluid flow control system, so that steering effort
varies with engine speed.
ItemLancer EVOLUTION-
Steering wheelTypeMOMO 3-spoke typeg
Outside diameter mm380 ,
365
Maximum number of turns2.1
Steering columnColumn mechanismTilt steering
Power steering typeIntegral type
Oil pumpTypeVariable capacity type (vane pump)pp
Basic discharge amount cm3/rev.9.6
Relief pressure MPa8.3 - 9.0
Reservoir typeSeparate type
Pressure switchEquipped
Steering gear and linkageTypeRack and pinionggg
Stroke ratio (Rack stroke/Steering wheel
Maximum turning radius)68.61
Rack stroke mm146
Steering angleInner wheel32°gg
Outer wheel (for reference)27°
Power steering fluidSpecified lubricantsAutomatic transmission fluid DEXRON IIg
Quantity LApproximately 1.0

STEERING -General Information37A-3
CONSTRUCTION DIAGRAM
Reservoir tank
Reservoir tank

Steering gear and linkage Return hose
Suction hose
Pressure hoseSteering wheel
Steering column and shaft
Oil pump
assembly

Steering gear
and linkage Return hose
Suction hose
Pressure hoseSteering wheel
Steering column and shaft
Oil pump
assembly
Cooler tube
Cooler tube

STEERING -Service Specifications/Lubricants/Sealant/Special Tools37A-4
SERVICE SPECIFICATIONS
ItemsStandard valueLimit
Steering wheel free play mmwhen engine running-30 or less
with engine stopped0-10-
Steering angleInner wheel31_45’±1_30’-
Outer wheel 27_15’-
Ball joint turning torque N·m1.0 - 3.0-
Stationary steering effort NSteering effort32 or less-
Fluctuation allowance6.0 or less-
Oil pump relief pressure MPa8.4 - 9.0-
Pressure under no-load conditions MPa0.2 - 0.8-
Steering gear retention hydraulic pressure MPa8.4 - 9.0-
Oil pressure switch operating
pressureMPa
OFF→ON1.8 - 2.4-
pressure MPaON→OFF1.0 - 2.4-
Total pinion torque N·mTotal rotation torque0.8 - 1.8-
Torque variation0.49 or less-
Tie rod joint swing resistance N (Tie rod joint swing torque N·m)8 - 27 (1.5 - 4.9)-
Opening dimension of special tool (MB991561) mm2.9-
Band crimped width mm2.4 - 2.8-
LUBRICANTS
ItemsSpecified lubricantQuantity
Power steering fluidAutomatic transmission fluid DEXRONIIApprox. 1.0 L
Tie rod bellowsSilicone greaseAs required
Pinion and valve assemblyRepair kit greaseAs required
Rack assembly
SEALANT
ItemsSpecified sealantRemarks
Toe boad (steering shaft cover
mounting bolt hole)3M ATD Part No. 8513 or equivalentDrying sealant
Rack support cover end plug3M ATD Part No. 8661, 8663 or equivalentSemi-drying sealant
SPECIAL TOOLS
ToolNumberNameUse
MB990635,
MB991113 or
MB991406Steering linkage
pullerDisconnection of tie rod end

STEERING -Special Tools37A-5
Tool UseName Number
MB991006Preload socketMeasurement of the total pinion torque
MB990326Preload socketMeasurement of the ball joint turning torque
MB990993Power steering oil
pressure gauge
adapter (pump
side)Measurement of oil pressure
MB990994Power steering oil
pressure gauge
adapter (hose
side)
MB990662Oil pressure gauge
assemblyMeasurement of oil pressure
MB991204Torque wrench
socketDAdjustment of rack support
DRemoval of rack support cover
MB990784Ornament removerRemoval of steering wheel cover

MB990803Steering wheel
pullerDisconnection of the steering wheel
MB991199Oil seal and
bearing installerDPress fitting of rack housing bearing
DTo press in the oil seal for the rack

STEERING -Special Tools37A-6
Tool UseName Number
MB991197Bar (long type)DPress fitting of rack housing bearing
DTo press in the oil seal for the rack
MB991214Rack installerRack installation
MB990925Bearing and oil
seal installer setInstallation of the oil seal and bearing
(Refer to GROUP 26 - Special Tools.)
MB991120Needle bearing
pullerRemoval of rack housing needle bearing
MB991203Oil seal and
bearing installerTo press in the valve housing oil seal and
bearing
MB991317Seal ring installerCompression of the seal rings after
replacement of the pinion seal rings
MB990941Torque tube
bearing installerInstallation of valve housing oil seal
MB991561Boot band crimp-
ing toolInstallation of bellows band
MB990776Front axle baseInstallation of dust cover for tie rod end ball joint

STEERING -On-vehicle Service37A-8
2. Move ball joint stud several times and install nut on stud.
Measure ball joint turning torque with special tool.
Standard value: 1.0 - 3.0 N·m
3. When the turning torque exceeds the standard value,
replace tie rod end.
4. When the turning torque is under the standard value,
check ball joint for end play or ratcheting. If none of these,
the joint is still serviceable.
STATIONARY STEERING EFFORT CHECK
1. With the vehicle stopped on a flat, paved surface, turn
the steering wheel to the straight ahead position.
2. Start the engine and set it to 1,000±100 r/min.
3. Attach a spring balance to the outer circumference of
the steering wheel and measure the steering force
required to turn the steering wheel from the straight ahead
position to the left and right (within a range of 0.9 turns).
Also check to be sure that there is no significant fluctuation
of the required steering force.
Standard value:
Steering effort32 N or less
Fluctuation allowance6.0 N or less
4. If the standard values are not met, check and adjust
the related parts.
CHECKING STEERING WHEEL RETURN TO
CENTRE
To make this test, conduct a road test and check as follows.
1. Make both gradual and sudden turns and check the
steering “feeling” to be sure that there is not difference
in the steering force required and the wheel return between
left and right turns.
2. At a speed of 35 km/h, turn the steering wheel 90_and
release the steering wheel after 1 or 2 seconds. If the
steering wheel then returns 70_or more, the return can
be judged to be satisfactory.
NOTE
There will be a momentary feeling or “heaviness” when
the wheel is turned quickly, but this is not abnormal. (This
is because the oil pump discharge amount is especially
apt to be insufficient during idling.)
DRIVE BELT TENSION CHECK
Refer to GROUP 11A - On-vehicle Service.
MB990326
70_70_