service MITSUBISHI LANCER EVOLUTION 2007 Service Repair Manual

BASIC BRAKE SYSTEM -On-vehicle Service35A-15
3. Place a dial gauge approximately 5 mm from the outer
circumference of the brake disc, and measure the run-out
of the disc.
Limit: 0.03 mm or less
4. If the brake disc run-out exceeds the limit, correct it as
follows:
(1) Chalk phase marks on the wheel stud and the brake
disc, which run-out is excessive.
(2) Remove the brake disc. Then place a dial gauge
as shown, and measure the wheel bearing axial play
by pushing and pulling the wheel hub.
Limit: 0.06 mm , 0.05 mm
(3) If the wheel bearing axial play exceeds the limit,
disassemble the hub and knuckle assembly to check
each part.
(4) If the wheel bearing axial play does not exceed the
limit, dephase the brake disc and secure it. Then
recheck the brake disc run-out.
5. If the run-out cannot be corrected by changing the phase
of the brake disc, replace the brake disc or grind it with
the on-the-car type brake lathe ( “MAD, DL-8700PF” or
equivalent).
Caution
(1) After a new brake disc is installed, always grind
the brake disc with on-the-car type brake lathe.
If this step is not carried out, the brake disc run-out
exceeds the specified value, resulting in judder.
(2) When the on-the-car type lathe is used, first install
M12 flat washer on the stud bolt in the brake disc
side according to the figure, and then install the
adapter. If the adapter is installed with M12 flat
washer not seated, the brake disc rotor may be
deformed, resulting in inaccurate grinding.
(3) Grind the brake disc with all wheel nuts diagonally
and equally tightened to the specified torque 100
N·m. When all numbers of wheel nuts are not used,
or the tightening torque is excessive or not equal,
the brake disc rotor or drum may be deformed,
resulting in judder.
M12 flat washer
M12 flat washer

BASIC BRAKE SYSTEM -Brake Pedal35A-16
BRAKE PEDAL
REMOVAL AND INSTALLATION
Post-installation Operation
Brake Pedal Adjustment (Refer to P.35A-7.)
1
2
3
64 8
7 5
12±2 N·m
14±3 N·m
Removal steps
1. Harness connector
2. Stop lamp switch
3. Adjuster
4. Pedal stopper
5. Snap pin6. Pin assembly
7. Pedal pad
"AA8. Brake pedal and pedal support
member
INSTALLATION SERVICE POINT
"AABRAKE PEDAL AND PEDAL SUPPORT MEMBER
INSTALLATION
Tighten the brake booster mounting nuts (A), and then the
brake pedal mounting bolts (B).
NOTE
The pedal support member can not be positioned correctly
if the pedal mounting bolts (B) are tightened first as the their
holes are oblong holes.
AA
BB

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-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

BASIC BRAKE SYSTEM -Disc Brake35A-27
DISASSEMBLY SERVICE POINTS
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.
AA"PISTON BOOT/PISTON REMOVAL

Remove the piston boot by pumping in air slowly from the
brake hose connection. Be sure to use the handle of a plastic
hammer and adjust the height of the two pistons while so
that the pistons protrude evenly.
Caution
Do not remove one piston completely before trying to
remove the other piston, because it will become
impossible to remove the second piston.

Use a piece of wood to protect the caliper body outer side,
and then apply compressed air through the brake hose
connection hole to withdraw the piston and piston boot.
Caution
If air is blown into the caliper body suddenly, the piston
will pop out, causing damage to the caliper body. Be
sure to apply compressed air gradually.
AB"PISTON SEAL REMOVAL
1. Remove the piston seal with finger tip.
Caution
Do not use a flat-tipped screwdriver or other tool to
prevent damage to inner cylinder.
2. Clean piston surface and inner bore with trichloroethylene,
alcohol or the specified brake fluid.
Specified brake fluid: DOT3 or DOT4
REASSEMBLY SERVICE POINT
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.

35B-1
ANTI-SKID
BRAKING SYSTEM
(ABS) <4WD>
CONTENTS
GENERAL INFORMATION 2..................
SERVICE SPECIFICATIONS 3.................
LUBRICANTS Refer to GROUP 35A..........
SEALANT Refer to GROUP 35A..............
SPECIAL TOOLS 4...........................
TROUBLESHOOTING 4.......................
ON-VEHICLE SERVICE 26....................
Brake Pedal Check and Adjustment
Refer to GROUP 35A ..........................
Brake Booster Operating Test
Refer to GROUP 35A ..........................
Check Valve Operation Check
Refer to GROUP 35A ..........................
Bleeding Refer to GROUP 35A..................
Brake Fluid Level Sensor Check
Refer to GROUP 35A ..........................
Disc Brake Pad Check and
Replacement Refer to GROUP 35A..............Disc Brake Rotor Check Refer to GROUP 35A...
Brake Disc Thickness Check
Refer to GROUP 35A ..........................
Brake Disc Run-out Check and Correction
Refer to GROUP 35A ..........................
Wheel Speed Sensor Output Voltage Check
26 ............................................
Hydraulic Unit Check 28........................
Remedy for a Flat Battery 29...................
BRAKE PEDAL Refer to GROUP 35A........
MASTER CYLINDER AND BRAKE
BOOSTER Refer to GROUP 35A............
DISC BRAKE Refer to GROUP 35A..........
HYDRAULIC UNIT AND ABS-ECU 30.........
WHEEL SPEED SENSOR 33..................
G SENSORS AND STEERING WHEEL
SENSOR 35..................................

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)

ABS <4WD> -General Information/Service Specifications35B-3
CONSTRUCTION DIAGRAM
Stop lamp
switch*Parking brake
switch
Diagnosis
connector*
Wheel speed sensorWheel speed sensor Hydraulic unit
assembly*
(integrated with
the ABS-ECU) ABS warning lamp
Lateral G sensor
Longitudinal G sensor Steering
wheel
sensor*
NOTE
For R.H. drive vehicles, only the position indicated by the * is symmetrical.
SERVICE SPECIFICATIONS
ItemsStandard value
Wheel speed sensor internal resistance kΩ1.24 - 1.64
Wheel speed sensor insulation resistance kΩ100 or more
Lateral G sensor/Longitudinal G
sensoroutputvoltageV
On stationary vehicle2.4 - 2.6
sensor outputvoltageV
With front mark downward3.4 - 3.6

ABS <4WD> -Special Tools/Troubleshooting35B-4
SPECIAL TOOLS
ToolNumberNameUse
MB991502MUT-IIsub
assemblyFor checking of ABS
(Diagnosis code display when using the
MUT-II)
MB991529Diagnosis code
check harnessFor checking of ABS
(Diagnosis code display when using the ABS
warning lamp)
MB991348Test harness setFor checking of G sensor
TROUBLESHOOTING
STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING
Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points.
NOTES WITH REGARD TO DIAGNOSIS
1. The phenomena listed in the following table are not abnormal.
PhenomenonExplanation of phenomenon
System check soundWhen starting the engine, a thudding sound can sometimes be heard coming from inside
the engine compartment, but this is because the system operation check is being
performed, and is not an abnormality.
ABS operation sound1. Sound of the motor inside the ABS hydraulic unit operation. (whine)
2. Sound is the generated along with vibration of the brake pedal. (scraping)
3. When ABS operates, sound is generated from the vehicle chassis due to repeated
brake application and release.
(Thump: suspension; squeak: tyres)
System check soundWhen depressing the brake pedal during driving, a shock is sometime felt.
2. For road surfaces such as snow-covered roads and gravel roads, the braking distance for vehicles
with ABS can sometimes be longer than that for other vehicles. Accordingly, advise the customer
to drive safely on such roads by lowering the vehicle speed and not being too overconfident.
3. Diagnosis detection condition can vary depending on the diagnosis code.
Make sure that checking requirements listed in the “Comment” are satisfied when checking the trouble
symptom again.

ABS <4WD> -Troubleshooting35B-5
ABS WARNING LAMP INSPECTION
Check that the ABS warning lamp illuminates as follows.
1. When the ignition key is turned to “ON”, the ABS warning
lamp illuminates for approximately 3 seconds and then
switches off.
2. When the ignition key is turned to “START”, the ABS
warning lamp remains illuminated.
3. When the ignition key is turned from “START” back to
“ON”, the ABS warning lamp illuminates for approximately
3 seconds and then switches off.
NOTE
The ABS warning lamp may remain on until the vehicle
reaches a speed of several km/h. This is limited to cases
where diagnosis code Nos.21 to 24, 41 to 44, 53 or 55
have been recorded because of a previous problem
occurring. In this case, the ABS-ECU keeps the warning
lamp illuminated until the problem corresponding to that
diagnosis code can be detected.
4. If the illumination is other than the above, check the
diagnosis codes.
DIAGNOSIS FUNCTION
READING DIAGNOSIS CODES
Read a diagnosis code by the MUT-IIor ABS warning lamp.
(Refer to GROUP 00 - How to Use Troubleshooting/Inspection
Service Points.)
NOTE
Connect the MUT-IIto the diagnosis connector (16-pin).
ERASING DIAGNOSIS CODES
When using the MUT-II
Connect the MUT-IIto the diagnosis connector (16-pin) and
erase the diagnosis code.
Caution
Turn the ignition key to the “LOCK” (OFF) position before
connecting or disconnecting the MUT-II.
Not
illuminated
ABS
warn-
ing
lampIlluminated
Approx. 3 sApprox. 3 s
Ignition
switchSTARTON
ACC,
ABS warning lamp