oil MITSUBISHI LANCER EVOLUTION 2007 Service Repair Manual

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)

STEERING -On-vehicle Service37A-11
POWER STEERING OIL PRESSURE SWITCH
CHECK
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. The engine should be idling.
4. Disconnect the connection of the connector for the oil
pressure switch, and set an ohmmeter in position.
5. Gradually close the shut-off valve of the pressure gauge
and increase the hydraulic pressure, then check whether
or not the hydraulic pressure that activates the switch
is the standard value.
Standard value: 1.8 - 2.4 MPa
6. Gradually open the shut-off valve and reduce the hydraulic
pressure; then check whether or not the hydraulic pressure
that deactivates the switch is the standard value.
Standard value: 1.0 - 2.4 MPa
7. Remove the special tools, and then tighten the pressure
hose to the specified torque.
Tightening torque: 18±3 N·m
8. Bleed the system.
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
tie rod end.
NOTE
Cracks or damage of the dust cover may cause damage
of the ball joint.
Temperature
gaugeShut-off valve
Oil
pump
ReservoirAdapter
(MB990993)Pressure
gauge
(MB990662)
Adapter
(MB990994)

STEERING - Power Steering Gear Box and Linkage37A-19
DISASSEMBLY AND REASSEMBLY
31
30
28
11
10
8
97
5
6
29
2618
33
22
20
Flare nut
21
23
36
32 17
1615
14 13
12 3
19
Steering gear seal set
Repair kit grease35
23
21
19
8
1135
17
32 3129
2811
8 3
4 4
27 25
22±4 N·m
25±4 N·m59±10 N·m
88±10 N·m 52±2 N·m
13±3 N·m
1
2 4
23±2 N·m→-30_
59±10 N·m
34
24
4

Disassembly steps
"OA1. Gear mounting rubber cushion
2. Gear housing mounting bushing
3. Feed pipe
4. O-ring
"NA5. Lock nut
"NA6. Tie rod end
7. Clip
"MA8. Band
9. Bellows
"LA10. Tie rod
"LA11. Tab washer
"KADTotal pinion rotating torque adjustment
"JA12. Lock nut
AA""JA13. Rack support cover
14. Support spring
15. Rack support
"IA16. End plug
17. Lock nut18. Valve housing assembly
AB""HA19. Lower oil seal
AB"20. Pinion and valve assembly
AC""GA21. Seal ring
AD""FA22. Upper bearing
AD""FA23. Upper oil seal
24. Valve housing
AE""EA25. Circlip
AF"26. Rack stopper
AF""DA27. Rack bushing
AF""DA28. Oil seal
AF"29. O-ring
AF""CA30. Rack assembly
AC"31. Seal ring
32. O-ring
AG""BA33. Lower bearing
AH""BA34. Needle bearing
AI""AA35. Oil seal
36. Gear housing

STEERING - Power Steering Gear Box and Linkage37A-20
18
24
23
22
21
20
34
36
33
17
1615
14
13
123
19
3523
21
19
8
1135
17
31
3229
2811
8
3
4 4
31
32
27
29
28
26
25
1110
8
9
756
304
22±4 N·m
25±4 N·m
59±10 N·m
59±10 N·m
88±10 N·m
52±2 N·m
23±2 N·m→–30_
13±3 N·m
1 2
4
Flare nut
Steering gear seal set
Repair kit grease3
4

Disassembly steps
"OA1. Gear mounting rubber cushion
2. Gear housing mounting bushing
3. Feed pipe
4. O-ring
"NA5. Lock nut
"NA6. Tie rod end
7. Clip
"MA8. Band
9. Bellows
"LA10. Tie rod
"LA11. Tab washer
"KADTotal pinion rotating torque adjustment
"JA12. Lock nut
AA""JA13. Rack support cover
14. Support spring
15. Rack support
"IA16. End plug
17. Lock nut18. Valve housing assembly
AB""HA19. Lower oil seal
AB"20. Pinion and valve assembly
AC""GA21. Seal ring
AD""FA22. Upper bearing
AD""FA23. Upper oil seal
24. Valve housing
AE""EA25. Circlip
AF"26. Rack stopper
AF""DA27. Rack bushing
AF""DA28. Oil seal
AF"29. O-ring
AF""CA30. Rack assembly
AC"31. Seal ring
32. O-ring
AG""BA33. Lower bearing
AH""BA34. Needle bearing
AI""AA35. Oil seal
36. Gear housing

STEERING - Power Steering Gear Box and Linkage37A-22
DISASSEMBLY SERVICE POINTS
AA"RACK SUPPORT COVER REMOVAL
AB"LOWER OIL SEAL/PINION AND VALVE
ASSEMBLY REMOVAL
With a plastic hammer, lightly tap the pinion and valve
assembly in its spline to remove the lower oil seal and pinion
and valve assembly from the valve housing.
AC"SEAL RING REMOVAL
Cut the seal ring to remove from the pinion and valve assembly.
Caution
When cutting the seal ring, be careful not to damage
the pinion and valve assembly.
AD"UPPER BEARING/UPPER OIL SEAL REMOVAL
Using a socket, pull out the upper oil seal and bearing from
the valve housing.
AE"CIRCLIP REMOVAL
1. Turn the rack stopper clockwise until the circlip end comes
out of the slot in the rack housing.
2. Turn the rack stopper anticlockwise to remove the circlip.
Caution
Do not turn the rack stopper anticlockwise first.
Otherwise, the circlip will get caught in the slot in
the housing, which makes the rack stopper unable
to turn.MB991204
Socket
Circlip
Rack stopper

STEERING - Power Steering Gear Box and Linkage37A-23
AF"RACK STOPPER/RACK BUSHING/OIL SEAL/
O-RING/RACK ASSEMBLY REMOVAL
1. Remove the rack stopper, rack bushing, oil seal and O-ring
together by pulling out the rack gently.
2. Partially bend the oil seal to remove from the rack bushing.
Caution
Use care not to damage the oil seal press-fitting
surface of the rack bushing.
AG"LOWER BEARING REMOVAL
AH"NEEDLE BEARING REMOVAL
Caution
Do not open the special tool to much, otherwise it may
damage the inside surface of the valve housing.
AI"OIL SEAL REMOVAL
Use a pipe or the like to pull out the oil seal.
Rack bushing
Valve
housing
MB990925
(MB990939)
Lower
bearing
MB991120
Needle
bearing Valve
housing
Oil seal
Gear housing
Pipe

STEERING - Power Steering Gear Box and Linkage37A-24
REASSEMBLY SERVICE POINTS
"AAOIL SEAL INSTALLATION
"BANEEDLE BEARING/LOWER BEARING
INSTALLATION
"CARACK ASSEMBLY INSTALLATION
1. Apply repair kit grease to the teeth of the rack assembly.
Caution
Use care not to close the vent hole in the rack with
grease.
2. Cover the serrations of the rack assembly with the special
tool.
3. Apply specified fluid to the outer surfaces of the special
tool, seal ring and O-ring.
Specified fluid:
Automatic transmission fluid DEXRONII
Caution
Do not use ATF-SPIIM and ATF-SPIII.
4. Slowly insert the rack covered with the special tool from
the power cylinder side of the gear housing.
Caution
Carefully push in the rack with the oil seal centre
and the special tool end matched. This is to avoid
the retainer spring coming off.MB991197
Gear housing
Oil seal MB991199
Needle
bearingMB990925
(MB990938)
MB991202
Lower
bearing MB990925
(MB990938)
MB991202
Vent hole
Seal ring, O-ring
MB991214 Oil seal

STEERING - Power Steering Gear Box and Linkage37A-25
"DAOIL SEAL/RACK BUSHING INSTALLATION
1. Apply specified fluid to the outer surface of the oil seal.
Using the special tool, press in the oil seal until it is flush
with the bushing end face.
Specified fluid:
Automatic transmission fluid DEXRONII
Caution
Do not use ATF-SPIIM and ATF-SPIII.
2. Apply the specified fluid to the oil seal inner surface and
the O-ring.
Specified fluid:
Automatic transmission fluid DEXRONII
Caution
Do not use ATF-SPIIM and ATF-SPIII.
3. Wrap the rack end with plastic tape, and push the rack
bushing onto the rack.
"EACIRCLIP INSTALLATION
Align the mark on the rack stopper and the slot in the cylinder.
Then, insert the circlip into the rack stopper hole through
the cylinder hole. Turn the rack stopper clockwise and insert
the circlip firmly.
"FAUPPER OIL SEAL/UPPER BEARING
INSTALLATION
"GASEAL RING INSTALLATION
After installation, using the special tool or by hand, compress
seal rings that expand during installation.
MB990925
(MB990927)
Oil seal
O-ring
Rack
bushing
Rack bushingPlastic tape Rack
Slot
Circlip
SlotCirclip
MB991203MB991203 MB990925
(MB990938)
Upper oil
seal
MB990925
(MB990938)
Bearing
MB991317

STEERING - Power Steering Gear Box and Linkage37A-26
"HALOWER OIL SEAL INSTALLATION
Using the special tool, press the oil seal into the valve housing.
The upper surface of the oil seal must project outwards about
1 mm from the housing end surface.
Caution
When the oil seal is flush with or lower than the housing
edge, reassemble the components. Otherwise, oil leaks
will result.
"IAEND PLUG INSTALLATION
1. Apply specified sealant to the threaded section of the
end plug, and then install the end plug to the gear housing.
Specified fluid:
3M ATD Part No.8661, 8663 or equivalent
2. Use a punch to bend over the two tabs on the sides
of the end plug to stop the end plug from turning.
"JARACK SUPPORT COVER/LOCKING NUT
INSTALLATION
1. Apply specified sealant to the rack support cover thread.
Specified fluid:
3M ATD Part No.8661, 8663 or equivalent
2. Using the special tool, tighten the rack support cover
to 23±2 N·m.
3. Return the rack support cover by about 30_.
4. Tighten the locking nut to the specified torque, using
the special tool to prevent the rack support cover from
spinning.
"KAPINION TOTAL ROTATION TORQUE ADJUSTMENT
1. Using the special tool, measure total rotation torque by
turning the pinion gear at a speed of one rotation per
4 to 6 seconds.
Standard value:
Total rotation torque: 0.8-1.8 Nm
Torque fluctuation: 0.49 Nm or lessMB990941 Approx. 1 mmOil
seal
Housing
End plugEnd plug
MB991204
MB991006