ABS MITSUBISHI LANCER EVOLUTION 2007 Service Manual PDF

FRONT SUSPENSION -General Information33A-2
GENERAL INFORMATION
The front suspension is a McPherson strut with
coil spring. The shock absorber is gas-filled
hydraulic double-acting type.
COIL SPRING
ItemRS ,
RS-IIRS
Wire diameter·average
diameter·free length mm14·155·28114·155·275
CONSTRUCTION DIAGRAM
Stabilizer barCoil spring
Strut assembly
(shock absorber) Crossmember
Lower armStrut insulator
Stabilizer link
Crossmember bar
Lower arm bushing
(pillow ball bushing with rubber)

FRONT SUSPENSION -Strut Assembly33A-6
STRUT ASSEMBLY
REMOVAL AND INSTALLATION
Post-installation Operation
Wheel alignment check and adjustment (Refer to
P.33A-4.)
44±5N·m
3
21
167±9N·m
4
5
Removal steps
1. Front wheel speed sensor harness
bracket
2. Brake hose bracket3. Knuckle connection
4. Strut mounting nut
5. Strut assembly

BASIC BRAKE SYSTEM 35A.........................................
ANTI-SKID BRAKING SYSTEM (ABS) <4WD> 35B......................
35A-1
SERVICE BRAKES
CONTENTS

35A-2
BASIC BRAKE
SYSTEM
CONTENTS
GENERAL INFORMATION 3..................
SERVICE SPECIFICATIONS 5.................
LUBRICANTS 6..............................
SEALANT 6..................................
SPECIAL TOOLS 6...........................
ON-VEHICLE SERVICE 7.....................
Brake Pedal Check and Adjustment 7............
Brake Booster Operating Test 8.................
Check Valve Operation Check 9.................
Proportioning Valve Function Test
9......................Bleeding 10....................................
Brake Fluid Level Sensor Check 11.............
Disc Brake Pad Check and Replacement 11......
Disc Brake Rotor Check 13.....................
Brake Disc Thickness Check 14.................
Brake Disc Run-out Check and Correction 14....
BRAKE PEDAL 16...........................
PROPORTIONING VALVE, MASTER
CYLINDER AND BRAKE BOOSTER 17........
Master Cylinder 19.............................
DISC BRAKE 20.............................

BASIC BRAKE SYSTEM -General Information35A-3
GENERAL INFORMATION
The brake system offers high dependability and durability along with improved braking performance and
brake sensitivity.
SERVICE PRECAUTION
Take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched.
SPECIFICATIONS
ItemsSpecifications
Master cylinderTypeTandem type
I.D. mm26.9
Brake boosterTypeVacuum type, tandem
Effective dia. of power cylinder mm205 + 230
Boosting ratio4.5 (Pedal depressing force: 230 N)
Rear wheel hydraulic
controlmethod
Vehicles with ABS Electronic brake-force distribution (EBD)
control methodVehicles without ABS Proportioning valves
Proportioning valves
VehicleswithoutABS
TypeSingle type¢2
Decompression ratio0.25
Front brakes
RS(standard)
TypeFloating caliper, 2 piston, ventilated disc
Disc effective dia.¢thickness mm227¢24
Wheel cylinder I.D. mm42.9 (¢2)
Pad thickness mm10.0
Clearance adjustmentAutomatic
Front brakes
Type4 opposed piston, ventilated disc

Disc effective dia.¢thickness mm263¢32
Wheel cylinder I.D. mm40.0 (¢2), 46.0 (¢2)
Pad thickness mm10.0
Clearance adjustmentAutomatic
Rear brakes
RS(standard)
TypeFloating caliper, 1 piston, ventilated disc
Disc effective dia.¢thickness mm237¢20
Wheel cylinder I.D. mm34.9
Pad thickness mm10.0
Clearance adjustmentAutomatic
Rear brakes
Type2 opposed piston, ventilated disc

Disc effective dia.¢thickness mm252¢22
Wheel cylinder I.D. mm40.0 (¢2)
Pad thickness mm9.0
Clearance adjustmentAutomatic
Brake fluidDOT3 or DOT4

BASIC BRAKE SYSTEM -General Information35A-4
CONSTRUCTION DIAGRAM

Brake booster*
Rear disc brake
Parking brake
Front disc brake Master cylinder*Hydraulic unit*

Brake booster*
Rear disc brake
Parking brake
Front disc brake Master cylinder and
proportioning valves*
NOTE
For R.H. drive vehicles, only the position indicated by the * is symmetrical.

BASIC BRAKE SYSTEM -Service Specifications35A-5
SERVICE SPECIFICATIONS
ItemsStandard valueLimit
Brake pedal height mm169.1 - 172.1-
Brake pedal play mm3-8-
Brake pedal to floorboard clearance when the brake pedal is depressed mm90 or more-
Brake booster push rod protrusion amount mm8.98 - 9.23-
Proportioning valve

Split point MPa2.70 - 3.19-

Output fluid pressure MPa 3.68 - 4.17-
Output fluid pressure difference between left and right MPa-0.49
Front disc brake

Pad thickness mm10.02.0

Discthicknessmm24 022 4Discthickness mm24.022.4
Disc run-out mm-0.03
Drag force N51 or less-
Brembo front disc brake

Pad thickness mm10.02.0

Discthicknessmm32 029 8Discthickness mm32.029.8
Disc run-out mm-0.03
Drag force N69 or less-
Rear disc brake

Pad thickness mm10.02.0

Discthicknessmm20 018 4Discthickness mm20.018.4
Disc run-out mm-0.03
Drag force N69 or less-
Brembo rear disc brake

Pad thickness mm9.02.0

Discthicknessmm22 020 4Discthickness mm22.020.4
Disc run-out mm-0.03
Drag force N69 or less-
Front wheel bearing axial play mm-0.06
Rear wheel bearing axial play mm-0.05

BASIC BRAKE SYSTEM -On-vehicle Service35A-9
CHECK VALVE OPERATION CHECK
1. Remove the vacuum hose. (Refer to P.35A-17.)
Caution
The check valve should not be disassembled from
the vacuum hose as they are united as one part.
2. Check the operation of the check valve by using a vacuum
pump.
Vacuum pump
connectionAccept/reject criteria
Connection at the brake
booster side (A)A negative pressure (vacuum) is
created and held.
Connection at the intake
manifold side (B)A negative pressure (vacuum) is
not created.
Caution
If the check valve is defective, always replace it as
an assembly unit together with the vacuum hose.
PROPORTIONING VALVE FUNCTION TEST

Caution
The proportioning valves are installed independently for
the right and left brake lines. Always measure each valve.
1. Connect two pressure gauges to the output port of the
master cylinder and output port of the proportioning valve.
2. Bleed the brake line and the pressure gauges. (Refer
to P.35A-10.)
3. Depress the brake pedal gradually. Then check that the
split point, where the output fluid pressure begins to drop
in proportion to the output fluid pressure, is at the standard
value.
Standard value: 2.70 - 3.19 MPa
4. Depress the brake pedal more strongly than at the above
step. Then check that the output fluid pressure is at the
standard value when the input fluid pressure is 6.86 MPa.
Standard value: 3.68 - 4.17 MPa
5. Measure each output fluid pressure at both valves, and
check that the difference between the two is at the limit
value or less.
Limit: 0.49 MPa
6. If the measured pressure exceeds the limit, replace the
proportioning valve.
ValveSpring
Booster
sideA
B
Intake
manifold
side
Pressure gauge (A)
Proportioning valve
Output port
Output port
Pressure gauge (B)
gauge (B)>
Input pressure
Output
pressureSplit point

BASIC BRAKE SYSTEM -On-vehicle Service35A-10
BLEEDING
Caution
Specified brake fluid: DOT3 or DOT4
Always use the specified brake fluid. Avoid using a
mixture of the specified brake fluid and other fluid.
MASTER CYLINDER BLEEDING
The master cylinder used has no check valve, so if bleeding
is carried out by the following procedure, bleeding of air from
the brake pipeline will become easier. (When brake fluid is
not contained in the master cylinder.)
1. Fill the reserve tank with brake fluid.
2. Keep the brake pedal depressed.
3. Have another person cover the master cylinder outlet
with a finger.
4. With the outlet still closed, release the brake pedal.
5. Repeat steps 2 - 4 three or four times to fill the inside
of the master cylinder with brake fluid.
BREMBO DISC BRAKE BLEEDING
Caution
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.
Connect a vinyl tube to the outer end of the air bleeder screw
to bleed the circuit of air. Then, connect the vinyl tube to
the inner end and bleed the circuit of air. Except for these,
the conventional procedures shall be followed. After the circuit
has been bled of air, tighten both air bleeder screws securely.
BRAKE PIPE LINE BLEEDING
Bleed the air in the sequence shown in the figure.
Air bleeder screw
( ): R.H. drive vehicles
4 (2)
1 (3)
2 (4)
3 (1)
( ): R.H. drive vehicles
4, 6 (1, 3)
2 (5)
1, 3 (4, 6)
5 (2)
Vehicles with ABS
Vehicles without ABS

BASIC BRAKE SYSTEM -Brake Pedal/Proportioning Valve,
Master Cylinder and Brake Booster35A-17
INSPECTION
STOP LAMP SWITCH CHECK
1. Connect an ohmmeter between the stop lamp switch
connector terminals.
2. There should be no continuity between the terminals when
the plunger is pushed in as shown. There should be
continuity when it is released.
PROPORTIONING VALVE, MASTER CYLINDER AND BRAKE
BOOSTER
REMOVAL AND INSTALLATION
Pre-removal Operation
DAir Intake Hose and Air Cleaner Removal

DStrut Tower Bar Removal (Refer to GROUP 42.)
DBrake Fluid DrainingPost-installation Operation
DBrake Fluid Supplying and Air Bleeding
(Refer to P.35A-10.)
DBrake Pedal Adjustment (Refer to P.35A-7.)
DAir Intake Hose and Air Cleaner Installation

DStrut Tower Bar Installation (Refer to GROUP 42.)
510
11 3
12 4
14
15±2N·m 15±2N·m
22±3N·m
10±2N·m
13 2
8
14±3N·m
519

9
15±2N·m
5
Proportioning valves

67
30±5N·m
9
15
16±1N·m

9
15
16±1N·m
Vacuum hose, fitting
Specified Sealant: 3M ATD
Part No.8661, 8663 or
equivalent
15
Fitting
4mm
No continuityContinuity