stop start MITSUBISHI LANCER EVOLUTION 2007 Service Owner's Manual

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> -Troubleshooting35B-15
INSPECTION CHART FOR TROUBLE SYMPTOMS
Trouble symptomsInspection procedure
No.Reference page
Communication between the MUT-IIand the whole system is not
possible.135B-16
Communication between the MUT-IIand the ABS-ECU is not possible.235B-17
When the ignition key is turned to “ON” (engine stopped), the ABS
warning lamp does not illuminate.335B-18
Even after the engine is started, the ABS warning lamp remains
illuminated.435B-18
In the inspection with MUT-II service data, the parking brake switch is not
turned ON or turn OFF.535B-19
The neutral position learning of the steering wheel sensor is not finished.635B-20
Faulty ABS operation735B-21
Caution
1. If steering movements are made when driving at high speed, or when driving on road surfaces
with low frictional resistance, or when passing over bumps, the ABS may operate even though
sudden braking is not being applied. Because of this, when getting information from the customer,
check if the problem occurred while driving under such conditions as these.
2. During ABS operation, the brake pedal may vibrate or may not be able to be depressed. Such
phenomena are due to intermittent changes in hydraulic pressure inside the brake line to prevent
the wheels from locking and is not an abnormality.

ABS <4WD> -Troubleshooting35B-18
Inspection Procedure 3
When the ignition key is turned to “ON” (engine stopped),
the ABS warning lamp does not illuminate.
Probable cause
The cause may be an open circuit in the lamp power supply circuit, a blown lamp,
or an open circuit between the ABS warning lamp and the earth.DBlown fuse
DBurn out ABS warning lamp bulb
DMalfunction of combination meter
DMalfunction of wiring harness or connector
DMalfunction of hydraulic unit and ABS-ECU
NO
NG
Replace the ABS warning lamp bulb.
Check the harness wire.
DBetween combination meter and ABS-ECU
DBetween ignition switch (IG1) and combination meter
DBetween combination meter and earth
Replace the hydraulic unit and ABS-ECU.
OKNG
OK
Check the following connectors:
B-123, C-01, C-29 , C-128, C-210, C-213
OK
Check whether the ABS warning lamp bulb is burnt out.
Does the ABS warning lamp illuminate when the ABS-ECU
connector B-123 is disconnected and the ignition switch is turned
to ON?YES
Repair
Replace the combination meter. (Refer to GROUP 54A.)NG
Repair
Inspection Procedure 4
Even after the engine is started, the ABS warning lamp
remains illuminated.
Probable cause
The cause is probably a short-circuit in the ABS warning lamp illumination circuit.DMalfunction of combination meter
DMalfunction of wiring harness (short circuit)
DMalfunction of hydraulic unit and ABS-ECU
NOTE
This trouble symptom is limited to cases where communication with the MUT-IIis possible (ABS-ECU
power supply is normal) and the diagnosis code is a normal diagnosis code.
YES
NG
Check the harness wire.
DBetween combination meter and ABS-ECU
Replace the hydraulic unit and ABS-ECU.
OK
NG
OK
Check the trouble symptom.
Does the ABS warning lamp stay illuminated when the ABS-ECU
connector B-123 is disconnected and the ignition switch is turned
to ON?NO
Repair
Replace the combination meter. (Refer to GROUP 54A.)NG
Repair
Check the following connectors:B-123, C-01, C-128

ABS <4WD> -Troubleshooting35B-25
Terminal No. Normal conditionChecking requirements Check item
10ABS-ECU power
supply
Ignition switch: ONSystem voltage
supply
Ignition switch: START or ACC0V
11Solenoid valve power
supplyAlwaysSystem voltage
14Lateral G sensor inputIgnition switch: ON2.4 - 2.6 V (horizontal position)
15Longitudinal G sensor
earthAlways0V
17Steering wheel sensor
(ST-2) inputIgnition
switch: ONSteering wheel: Turn
laterallyVariation in the voltage value 0.8 -
2.1 V and 2.7 - 4.4 V
18Wheel speed sensor
(front right) outputMoving forward slowly0-5V
19Stop lamp monitor
input
Ignition
switch:ON
Stop lamp switch: ONSystem voltage
inputswitch:ON
Stop lamp switch: OFF1 V or less
20Wheel speed sensor
(rear left) outputMoving forward slowly0-5V
21Wheel speed sensor
(rear right) outputMoving forward slowly0-5V
24Lateral G sensor earthAlways0V
25Longitudinal G sensor
inputIgnition switch: ON2.4 - 2.6 V (horizontal position)
26Steering wheel sensor
(ST-1) inputIgnition
switch: ONSteering wheel: Turn
laterallyVariation in the voltage value 0.8 -
2.1 V and 2.7 - 4.4 V
27ABS warning lamp
transistor outputIgnition
switch: ONWhen the lamp is
switched off1 V or less
When the lamp is
illuminated7 V or more
32Wheel speed sensor
(front left) outputMoving forward slowly0-5V
33Motor power supplyAlwaysSystem voltage

ABS <4WD> -On-vehicle Service35B-28
SymptomRemedy Probable causes
Noisy or disturbed waveformOpen circuit in sensorReplace sensor
Open circuit in harnessCorrect harness
Incorrectly mounted wheel speed sensorMount correctly
ABS rotor with missing or damaged teethReplace ABS rotor
Caution
Because the wheel speed sensor cables move together with the front and rear suspension, they
vibrate greatly when driving over poor road surfaces. As a result, the sensor harnesses should also
be shaken when monitoring of output waveforms of the wheel speed sensors in order to simulate
conditions such as driving over poor road surfaces.
HYDRAULIC UNIT CHECK
1. Jack up the vehicle and support the vehicle with rigid racks placed at the specified jack-up points
or place the wheels which are checked on the rollers of the braking force tester.
Caution
(1) The roller of the braking force tester and the tyre should be dry during testing.
(2) When testing the front brakes, apply the parking brake, and when testing the rear brakes,
stop the front wheels by chocking them.
2. Turn the ignition key to the “LOCK” (OFF) position and set the MUT-II.
Caution
Turn the ignition key to the “LOCK” (OFF) position before connecting or disconnecting the
MUT-II.
3. After checking that the shift lever is in neutral, start the engine.
4. Use the MUT-IIto force-drive the actuator.
NOTE
(1) During the actuator test, the ABS warning lamp will illuminate and the anti-skid control will be
cancelled.
(2) When the ABS has been interrupted by the fail-safe function, the MUT-IIactuator testing cannot
be carried out.
5. Turn the wheel by hand and check the change in braking force when the brake pedal is depressed.
When using the braking force tester, depress the brake pedal until the braking force is at the following
values, and check that the braking force decreases when the actuator is force-driven.
Front wheel785 - 981 N
Rear wheel588 - 784 N

STEERING -On-vehicle Service37A-7
ON-VEHICLE SERVICE
STEERING WHEEL FREE PLAY CHECK
1. With engine running (hydraulic operation), set front wheels
straight ahead.
2. Measure the play on steering wheel circumference before
wheels start to move when slightly moving steering wheel
in both directions.
Limit: 30 mm or less
3. When play exceeds the limit, check for play on steering
shaft connection and steering linkage. Correct or replace.
4. If the free play still exceeds the limit value, set steering
wheel straight ahead with engine stopped. Load 5 N
towards steering wheel circumference and check play.
Standard value: 0 - 10 mm
5. If the play exceeds the standard value, remove steering
gear box and check total pinion torque. (Refer to
P.37A-17.)
STEERING ANGLE CHECK
1. Locate front wheels on turning radius gauge and measure
steering angle.
Standard value:
Inner wheel31_45’±1_30’
Outer wheel27_15’
2. When the angle is not within the standard value, the
toe-in is probably incorrect. Adjust the toe-in.
Standard value: 0±2mm
Adjust the toe-in by undoing the clip and lock nut, and
turning the left and right tie rod turnbuckles by the same
amount (in opposite directions).
3. Recheck the steering angle.
TIE ROD END BALL JOINT TURNING TORQUE
CHECK
1. Disconnect tie rod and knuckle with special tool.
Caution
(1) Loosen the nut of the special tool, but do not
remove it. If it is removed, the ball joint thread
may be damaged.
(2) Tie the special tool with a cord so as not to fall
off.
Clip
Lock nut
Cord
Ball jointNutMB990635,
MB991113 or
MB991406

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_

STEERING -On-vehicle Service37A-9
POWER STEERING FLUID LEVEL CHECK
1. Park the vehicle on a flat, level surface, start the engine,
and then turn the steering wheel several times to raise
the temperature of the fluid to approximately 50 - 60_C.
2. With the engine running, turn the wheel all the way to
the left and right several times.
3. Check the fluid in the oil reservoir for foaming or milkiness.
Check the difference of the fluid level when the engine
is stopped, and while it is running. If the change of the
fluid level is 5 mm or more, air bleeding should be done.
POWER STEERING FLUID REPLACEMENT
1. Raise the front wheels on a jack, and then support them
with rigid racks.
2. Disconnect the return hose connection.
3. Connect a vinyl hose to the return hose, and drain the
oil into a container.
4. Disconnect the ignition coil connectors. (Refer to
GROUP16 - Ignition System.)
5. While operating the starting motor intermittently, turn the
steering wheel all the way to the left and right several
times to drain all of the fluid.
6. Connect the return hoses securely, and then secure it
with the clip.
7. Fill the oil reservoir with specified fluid up to the lower
position of the filter, and then bleed air.
Specified fluid:
Automatic transmission fluid DEXRONII
Caution
Do not use ATF-SPIIM and ATF-SPIII.
POWER STEERING SYSTEM BLEEDING
1. Jack up the vehicle and support the front wheels with
rigid racks.
2. Disconnect the ignition coil connectors. (Refer to
GROUP16 - Ignition System.)
3. Cranking the engine with the starter several times
intermittently (during 15 to 20 seconds), turn the steering
wheel left and right fully five or six times.
Caution
(1) During the bleeding, refill the fluid so that the
level never falls below the lower position of the
filter.
(2) Be sure to bleed air only while cranking. If the
bleeding is done with the engine running, the air
will be broken up and absorbed into the fluid.
4. Connect the ignition coil connectors and idle the engine.
5. Turn the steering wheel left and right fully until no bubbles
comes out in the oil reservoir.
6. See that the fluid is not milky and that the fluid level
is up to the specified position on the level gauge.
7. See that the fluid level changes little when the steering
wheel is turned left and right.
8. Check difference in fluid levels between the engine
stopped and running.
Fluid level change: Within 5 mm
While engine
runningWhile engine
stopped
Return hose
Vinyl hose

STEERING -On-vehicle Service37A-10
9. If the level changes more than 5 mm, the air is badly
bled. So, bleed air again.
Caution
(1) If the fluid level rises suddenly after the engine
is stopped, the bleeding is incomplete.
(2) Incomplete bleeding causes abnormal noises
from the pump and the flow-control valve. This
could lessen the life of the pump and the other
parts.
OIL PUMP PRESSURE TEST
1. Disconnect the pressure hose from the oil pump, and
then connect the special tools.
2. Bleed the air, and then turn the steering wheel several
times while the vehicle is not moving so that the
temperature of the fluid rises to approximately 50 - 60_C.
3. Start the engine and idle it at 1,000±100 r/min.
4. Fully close the shut-off valve of the pressure gauge and
measure the oil pump relief pressure to confirm that it
is within the standard value range.
Standard value: 8.4 - 9.0 MPa
5. If the standard value is not met, the oil pump is defective.
So, replace the oil pump. Then, measure oil pressure
again.
6. With the pressure gauge shut - off valve fully open, check
the hydraulic pressure in unladen condition.
Standard value: 0.2 - 0.8 MPa
7. If the standard value is not met, the oil line or steering
gear is probably defective. So, repair and measure oil
pressure again.
8. Turn the steering wheel fully either left or right and check
the retention hydraulic pressure.
Standard value: 8.4 - 9.0 MPa
9. If the pressure is below the standard value, disassemble
and reassemble the steering gear. If above, replace the
oil pump. Then, measure oil pressure again.
10. Remove the special tools, and tighten the pressure hose
to the specified torque.
Tightening torque: 18±3 N·m
11. Bleed the system.
Fluid level change: Within 5 mm
While engine
runningWhile engine
stopped
Temperature
gaugePressure
gauge
(MB990662)Shut-off valve
Oil
pumpOil reservoir
Adapter
(MB990994)
Adapter
(MB990993)

SWS -Troubleshooting54B-7
TROUBLE SYMPTOM CHART
Trouble symptomInspection
procedureReference
page
No communication with MUT-IIA-154B-10
BuzzersLights left ON reminder warning function not working normally.B-154B-10
Central lockingCentral door locking system not working at all.C-154B-11g
Some doors not locking or unlocking.C-254B-11
Power windowPower windows not working at all.D-154B-12
Power windows are not operated with the power window main
switch.
Driver’s power window not responding to power window main
switch.D-254B-13
Windows not responding to passenger or rear power window
switches.D-354B-14
Passenger or rear power windows not responding to power window
main switch.D-454B-15
Power window timer function not working normally.D-554B-15
While the window is winding up, it suddenly starts coming down
again.D-654B-16
Safety mechanism (to prevent jamming of fingers, etc.) not
working.D-754B-16
Windshield wipers
dh
The windshield wipers do not work at all.E-154B-17p
and washerThe windshield wipers only operate at LO speed (though the wipers
and washer can be switched OFF).E-254B-17
The windshield wipers do not respond to any switch position.E-354B-18
The windshield wipers do not stop in the normal predetermined
position.E-454B-18
The windshield washer does not work at all.E-554B-19
Windshield wipers are not operated with the switch in INT,
WASHER and MIST positions, and operated in a low mode with the
switch in Lo and Hi positions.E-654B-19
Headlamps, tail lampsExcept for lighting switch“OFF,” the headlamps only respond to the
“low-beam” position.
F-154B-20
The tail lamps do not work.F-254B-20
The headlamps (low-beam) do not light.F-354B-21
The headlamps (high-beam) do not light.F-454B-21
The headlamps (low or high-beam) do not work when the passing
switch is ON.F-554B-22
The headlamp automatic cut-off function is not working normally.F-654B-22
Rear fog lampRear fog lamp is not properly illuminated.G-154B-23
Flasher timerThe turn signal lamps do not light.H-154B-24
The hazard warning lamps do not light up.H-254B-24
Room lampsThe room lamps do not come ON or OFF normally.I-154B-25