service MITSUBISHI LANCER EVOLUTION 2007 Service Repair Manual

STEERING -Steering Shaft37A-15
DISASSEMBLY AND REASSEMBLY
1
2
3 4
5 6
7
Disassembly steps
AA""AA1. Special bolt
"AA2. Steering lock bracket
"AA3. Steering lock cylinder assembly
4. Snap ring5. Steering shaft assembly
6. Tilt spring
7. Steering column assembly
DISASSEMBLY SERVICE POINT
AA"SPECIAL BOLT REMOVAL
1. Drill in the special bolt a hole deep enough for the tap
to stand.
2. Remove the special bolt with a left-hand tap.
REASSEMBLY SERVICE POINT
"AASTEERING LOCK CYLINDER ASSEMBLY/
STEERING LOCK BRACKET/SPECIAL BOLT
INSTALLATION
1. When installing the steering lock cylinder assembly and
steering lock bracket to the steering column assembly,
temporarily install the steering lock in alignment with the
column boss.
2. Check that the steering lock works properly. Then, tighten
the special bolts until the heads twists off.
Steering lock
bracket
Steering lock body
Special boltLeft-hand tap

STEERING - Power Steering Gear Box and Linkage37A-18
TIE ROD SWING RESISTANCE CHECK
1. Swing the tie rod 10 times hardly.
2. With the tie rod end downwards as shown, use a spring
scale to measure swing resistance (swing torque).
Standard value: 8 - 27 N (1.5 - 4.9 N·m)
3. If the measured value is above the standard value, replace
the tie rod.
4. If below, check the ball joint for looseness or ratcheting.
The tie rod is still serviceable when the ball joint swings
smoothly.
TIE ROD END 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. (Refer to P.37A-19, 20.)
NOTE
A cracked or damaged dust cover may damage the ball
joint. Replace the dust cover when it is damaged during
service work.

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-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-28
3. See that the crimped width (A) meets the standard value.
Standard value (A): 2.4-2.8 mm

Readjust the dimension (W) of step (1) to the value
calculated by the following equation, and repeat step
(2).
W = 5.5 mm-A [Example: If (A) is 2.9 mm, (W)
is 2.6 mm.]

Remove the bellows band, readjust the dimension
(W) of step (1) to the value calculated by the following
equation, and use a new bellows band to repeat steps
(2) to (3).
W = 5.5 mm-A [Example: If (A) is 2.3 mm, (W)
is 3.2 mm.]
"NATIE ROD END/LOCKING NUT INSTALLATION
Screw in the tie rod end until the dimension shown is achieved.
Then, temporarily tighten with the locking nut.
NOTE
The locking nut must be tightened securely only after the
power steering gear box and linkage are installed to the vehicle
and toe-in is adjusted.
"OAGEAR MOUNTING RUBBER INSTALLATION
Install the gear mounting rubber to the rack housing so that
the distance is as shown in the illustration.
TIE ROD END BALL JOINT DUST COVER
REPLACEMENT
Only when the dust cover is damaged accidentally during
service work, replace the dust cover as follows:
1. Apply grease to the inside of the dust cover.
2. Drive in the dust cover with special tool until it is fully
seated.
3. Check the dust cover for cracks or damage by pushing
it with finger.
A
Edge of bellows
assembly grooveLocking nut
184 mm
220 mm
MB990776

STEERING - Power Steering Oil Pump37A-29
POWER STEERING OIL PUMP
REMOVAL AND INSTALLATION
Caution
After temporary tightening all bolts in * part, tighten in specific torque.
Pre-removal Operation
Power Steering Fluid Draining (Refer to P.37A-9.)Post-installation Operation
DPower Steering Fluid Supplying and Bleeding
(Refer to P.37A-9.)
DDrive Belt Tension Adjusting
(Refer to GROUP 11A – On-vehicle Service.)
22±4 N·m
8
40±5 N·m 18±3 N·m
3
45
2
5
22±4 N·m*
1 7
6
40±5 N·m* 22±4 N·m
Removal steps
1. Pressure switch connector
2. Drive belt (Refer to GROUP 11A.)
"BA3. Suction hose connection
"BA4. Pressure hose connection"AA5. O ring
6. Heat protecter
7. Oil pump assembly
8. Power steering pump bracket
INSTALLATION SERVICE POINTS
"AAO-RING INSTALLATION
No.ID×Width mm
111.0×1.9
213.0×1.9
21

STEERING - Power Steering Oil Pump/Power Steering Oil Hoses37A-30
"BAPRESSURE HOSE ASSEMBLY/SUCTION HOSE
REMOVAL
Install the pressure hose assembly and suction hose as
illustrated.
DISASSEMBLY AND REASSEMBLY
21±3 N·m
3
4
2 1
39±5 N·m
: Automatic transmission fluid DEXRONII
NOTE
Disassembly steps
1. Suction connector
2. O-ring3. Connector
4. Gasket
POWER STEERING OIL HOSES
REMOVAL AND INSTALLATION
Caution
1. Before removing the clock spring, always see GROUP 52B - Caution for Service and Air Bag
Module Clock Spring
2. 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.
3. On the tightening section indicated in the mark (*), lightly tighten the nut first, and then finally
tighten it with the engine weight applied on the body.
Suction hose
Pressure hose
assembly
Marking
Notch

STEERING - Power Steering Oil Hoses37A-33
REMOVAL SERVICE POINT
AA"EYE BOLT/RETURN TUBE REMOVAL
1. Loosen the crossmember mounting bolts and nuts, and
lower the crossmember to a position so that the eye bolts
or return tube at the steering gear side can be removed.
NOTE
In this case, do not remove the crossmember
mounting bolts and nuts.
2. Remove the eye bolts or return tube.
INSTALLATION SERVICE POINTS
"AAO RING INSTALLATION
No.ID×Width mm
111.0×1.9
213.0×1.9
"BAPRESSURE HOSE ASSEMBLY/SUCTION HOSE
INSTALLATION
Install the pressure hose assembly and suction hose as
illustrated.
1
2
Suction hose
Pressure hose
assembly
Marking
Notch

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 -Hood42-2
HOOD
ON - VEHICLE SERVICE
ADJUSTMENT OF CLEARANCE AROUND
HOOD
ADJUSTMENT OF ALIGNMENT OF HOOD
STEPPED PORTION AND HOOD STRIKER
ADJUSTMENT OF HOOD HEIGHT
With the marker as guide, turn the hood bumper to adjust
the hood height. The hood bumper height changes approx.
3mm (new hood bumper with one complete turn).
A
A
Section A-A
16.3 mmHood
Hood bumper