brake MITSUBISHI LANCER EVOLUTION 2007 Service Manual PDF

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

FRONT SUSPENSION -Lower Arm Assembly33A-9
LOWER ARM ASSEMBLY
REMOVAL AND INSTALLATION
Caution
1. 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. And
if there is brake fluid on the caliper, wipe out quickly.
2. *: To prevent bushings from breakage, the parts indicated by * should be temporarily tightened,
and then fully tightened with the vehicle on the ground in the unladen condition.
Post-installation Operation
DCheck the dust cover for cracks or damage by
pushing it with finger.
DWheel alignment check and adjustment
(Refer to P.33A-4.)
72
5
186±10 N·m*
3167±9N·m
5
1
3
4
108±10 N·m
39±5N·m
39±5N·m
Removal steps
1. Stabilizer link nut
2. Lower arm and knuckle connection
AA"3. Lower arm and crossmember
connection4. Stabilizer bracket
5. Lower arm assembly

FRONT SUSPENSION -Lower Arm Assembly/Stabilizer Bar33A-12
3. Use the special tools to press in the bushing until its
outer tube is flush with the lower arm assembly surface.
STABILIZER BAR
REMOVAL AND INSTALLATION
Caution
1. Before removing the steering wheel and air bag module assembly, refer to GROUP 52B - Service
Precautions and Air Bag Module and Clock Spring. Also, put the front wheels in straight-ahead
position. Failure to do so may damage the SRS clock spring and render the SRS air bag
inoperative, which results serious driver injury.
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. And
if there is brake fluid on the caliper, wipe out quickly.
3. To prevent bushings from breakage, the parts indicated by * should be temporarily tightened,
and then fully tightened with the vehicle on the ground in the unladen condition.
Lower arm
assembly
MB990651
MB991576
MB991816
Outer tube

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 -Lubricants/Sealant/Special Tools35A-6
LUBRICANTS
ItemsSpecified LubricantQuantity
Brake fluidDOT3 or DOT4As required
Piston, wheel cylinder body
Piston boot, piston seal, shimRepair kit grease
Guide pin, lock pin, pin boot
Pad assembly
SEALANT
ItemsSpecified sealantRemarks
Fitting3M ATD Part No. 8661, 8663 or equivalentSemi-drying sealant
SPECIAL TOOLS
ToolNumberNameUse
MB991568Push rod adjusting
socketAdjustment of the brake booster push rod
protrusion amount
AMB990964
A: MB990520Brake tool setPushing-in of the disc brake piston
DDisc brake piston pushing-in
MB990998Front hub remover
and installerProvisional holding of the wheel bearing

BASIC BRAKE SYSTEM -On-vehicle Service35A-7
ON-VEHICLE SERVICE
BRAKE PEDAL CHECK AND ADJUSTMENT
BRAKE PEDAL HEIGHT
1. Turn up the carpet, etc. under the brake pedal.
2. Measure the brake pedal height as illustrated.
Standard value (A): 169.1 - 172.1 mm
3. If the brake pedal height is not within the standard value,
follow the procedure below.
(1) Disconnect the stop lamp switch connector.
(2) Loosen the stop lamp switch by turning it approx.
1/4 turns anticlockwise.
(3) Remove the brake booster. (Refer to P.35A-17.)
NOTE
With the master cylinder and brake pipe connected,
remove the brake booster only.
(4) Adjust the brake pedal height by turning the clevis.
NOTE
When the clevis is turned 180_, the pedal hight is
changed approximately 2.4 mm.
(5) Install the brake booster. (Refer to P.35A-17.)
(6) Measure brake pedal height, and ensure that the
measured value is within the specified value. When
it is out of the specified value, repeat Step (3) - (6).
(7) Insert the stop lamp switch until it’s thread part touches
the stopper. Then lock the stop lamp switch by turning
it approx. 1/4 turns clockwise, and confirm that the
clearance between the switch plunger and the stopper
is as shown.
(8) Connect the connector at the stop lamp switch.
Caution
Check that the stop lamp does not illuminate when
the brake pedal is not depressed.
4. Return the carpet, etc.
BRAKE PEDAL FREE PLAY
1. With the engine stopped, depress the brake pedal two
or three times, After eliminating the vacuum in the power
brake booster, press the pedal down by hand, and confirm
that the amount of movement before resistance is met
(the free play) is within the standard value.
Standard value (B):3–8mm
A
Clevis
Stopper
0.5 - 1.0 mm
B