light MITSUBISHI LANCER EVOLUTION 2007 Service Manual PDF

MANUAL TRANSMISSION OVERHAUL -Transmission22B-21
"GACONTROL HOUSING INSTALLATION
Apply sealant at the positions of the transmission case shown
in the illustration.
Sealant
Specified sealant:
MITSUBISHI genuine sealant Part No.MD997740 or
equivalent
Caution
Evenly squeeze out the agent so that it is not insufficient
or excessive.
"HASPEEDOMETER GEAR INSTALLATION
Apply transmission oil on the O-ring for the speedometer
gear.
Transmission oil
Specified oil:
MITSUBISHI genuine “DIA-QUEEN” multi gear oil
<75W/85W> or equivalent
"IASELECT LEVER INSTALLATION
Apply grease on the sliding section of the select lever shoe’s
control shaft.
Grease
Specified grease:
MITSUBISHI genuine grease Part No.0101011 or
equivalent
"JAO-RING INSTALLATION
Apply transmission oil on the O-ring.
Transmission oil
Specified oil:
MITSUBISHI genuine “DIA-QUEEN” multi gear oil
<75W/85W> or equivalent
INSPECTION
BACKUP LIGHT SWITCH
Check the continuity between the terminals.
ItemsContinuity
Switch pressedContinuity not established
Switch releasedContinuity established
Control shaft
Select
lever
shoe

REAR AXLE -Troubleshooting REAR AXLE -Troubleshooting 27B-14
INSPECTION CHART FOR TROUBLE SYMPTOMS
Trouble symptomInspection
procedure No.Reference
page
Communication between MUT-IIand the whole system is not possible.1Refer to
GROUP22
Communication between MUT-IIand 4WD-ECU is not possible.2
GROUP22.
3 ACD mode indicator lamps do not light up when the ignition key is turned to “ON”
(engine stationary).3
3 ACD mode indicator lamps remain lit up after the engine has started.4
AYC is inoperative.
Unable to start or accelerate on slippery road surfaces.527B-14
Rear tires are noisy during low-speed cornering.
Vehicle skews.627B-15
Noise is produced from the torque transfer differential during turning.727B-15
INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS
INSPECTION PROCEDURE 5
AYC is inoperative.
Unable to start or accelerate on slippery road surfaces.
Probable cause
The hydraulic oil level is probably low, there is an oil leak, the hydraulic unit is defective,
or the torque transfer differential is defective.DLow hydraulic oil level
DOil leak
DDefective hydraulic unit
DDefective torque transfer differential
NOTE
This symptom is limited only when the diagnosis code is correct.
NG
Replace the hydraulic unit. (Refer to
P.27B-61.)
NG
Add fluid. (Refer to P.27B-19.)
OKRepair
Check the trouble symptom.NO
Replace the torque transfer differential.
OK
Is foreign matter trapped in the hydrau-
lic line?YES
Repair
OK
Check the fluid level.
(Refer to P.27B-19.)Check the hydraulic pressure line for
leak.
OK
Add gear oil. (Refer to P.27B-16.)
OK
Check hydraulic pressure.
(Refer to P.27-21.)NGBleed the system of air.
(Refer to P.27-19.)
Check the gear oil level. (Refer to
P.27B-16.)NGCheck for oil leak.NG
Repair
Check the AYC for operation.
(Refer to P.27B-20.)Check the trouble symptom. OKOK
NGNormal
NGNG

REAR AXLE -On-vehicle Service27B-24
Torque transfer mechanism part
1. Remove the drive shaft. (Refer to P. 27B-29.)
2. Remove the oil seal from the differential carrier.
3. Using the special tool, drive a new oil seal all the way
into position.
4. Coat the oil seal lips and the drive shaft surface in contact
with the oil seal with the specified grease.
Specified grease: Vaseline
5. Replace the drive shaft circlip with a new one and mount
the drive shaft to the differential carrier. (Refer to P.
27B-29.)
6. Check for correct wheel alignment. (Refer to GROUP
34 – On-vehicle Service.)
ACTION WHEN BATTERY RUNS OUT
When the engine is started using a booster cable where the
battery has completely run down and you attempt to start
the vehicle without waiting for the battery to recover a certain
charge, the engine can misfire and you just cannot start to
move it. In such cases, charge the battery sufficiently; or,
remove the AYC battery cable from the battery fuse assembly
to make AYC inactive before attempting to start the vehicles.
When the battery cable is removed, the ACD mode indicator
lamp lights up. After the battery has been recharged, fit the
battery cable back again and start the engine to ensure that
the ACD mode indicator lamp is off.
MD998829
MD998813 MD998812
Battery fuse assembly
Battery cable
for AYC

BASIC BRAKE SYSTEM -On-vehicle Service35A-8
2. If the brake pedal play is not within the standard value,
check the following, and adjust or replace if necessary:
DExcessive play between the brake pedal and the clevis
pin, or between the clevis pin and the brake booster
operating rod
DBrake pedal height
DInstallation position of the stop lamp switch, etc.
CLEARANCE BETWEEN BRAKE PEDAL AND FLOOR
BOARD
1. Turn up the carpet etc. under the brake pedal.
2. Start the engine, depress the brake pedal with
approximately 500 N of force, and measure the clearance
between the brake pedal and the floorboard.
Standard value (C): 90 mm or more
3. If the clearance is outside the standard value, check for
air trapped in the brake line and thickness of the disc
brake pad and dragging in the parking brake.
Adjust and replace defective parts as required.
4. Return the carpet, etc.
BRAKE BOOSTER OPERATING TEST
For simple checking of the brake booster operation, carry
out the following tests:
1. Run the engine for one or two minutes, and then stop
it.
If the pedal depresses fully the first time but gradually
becomes higher when depressed succeeding times, the
booster is operating properly. If the pedal height remains
unchanged, the booster is defective.
2. With the engine stopped, step on the brake pedal several
times.
Then start the engine while the brake pedal is stepped
on.
If the pedal moves downward slightly, the booster is in
good condition. If there is no change, the booster is
defective.
3. With the engine running, step on the brake pedal and
then stop the engine.
Hold the pedal depressed for 30 seconds. If the pedal
height does not change, the booster is in good condition.
If the pedal rises, the booster is defective.
If the above three tests are okay, the booster performance
can be determined as good.
If one of the above three tests is not okay at least, the check
valve, vacuum hose, or booster will be defective.
C
Good No good
When engine is
stoppedWhen engine is
started
GoodNo good

STEERING -General Information37A-2
GENERAL INFORMATION
The system has been equipped with the MOMO
leather 3-spoke-type steering wheel with built-in
SRS airbag.
The steering column is equipped with tilt steering
mechanism.
The power steering is an integral rack and piniontype that combines the steering gear and linkage
into one light-weight and compact assembly.
The steering system uses a vane oil pump with
a fluid flow control system, so that steering effort
varies with engine speed.
ItemLancer EVOLUTION-
Steering wheelTypeMOMO 3-spoke typeg
Outside diameter mm380 ,
365
Maximum number of turns2.1
Steering columnColumn mechanismTilt steering
Power steering typeIntegral type
Oil pumpTypeVariable capacity type (vane pump)pp
Basic discharge amount cm3/rev.9.6
Relief pressure MPa8.3 - 9.0
Reservoir typeSeparate type
Pressure switchEquipped
Steering gear and linkageTypeRack and pinionggg
Stroke ratio (Rack stroke/Steering wheel
Maximum turning radius)68.61
Rack stroke mm146
Steering angleInner wheel32°gg
Outer wheel (for reference)27°
Power steering fluidSpecified lubricantsAutomatic transmission fluid DEXRON IIg
Quantity LApproximately 1.0

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 - 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 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

BODY -Window Glass42-10
HANDLING OF AUTO WINDOW SEALER
Keep the sealant in a cool place, not exposed to the direct
rays of the sun. Do not place any heavy article on the sealant
nor press it, otherwise it will become deformed. Avoid storing
the sealant for more than 6 months, because it will lose its
sealing effect.
BODY PINCH-WELD FLANGE SERVICING
Before servicing the body pinch-weld flange, remove old
adhesive completely. If the flange requires painting, bake
it after painting is completed.
WORKING PROCESS
Window glass installation procedure
Body side
Cleaning of adhesion surface
Cut off the residual adhesive until the
thickness is less than 2 mm. Clean
the adhesion surface with isopropyl al-
cohol, and let dry for 3 minutes or more.
Attaching of clip, spacer and dual
lock fastener
Attach the clip, spacer and dual lock
fastener to set the positions for the glass
to be installed.
Application of primer
Apply to the adhesion surface of the
body and let dry for 3 minutes or more.
Window glass side
Reusing the glassReplacing the glass
Cleaning of adhesion surface
Completely cut off all of the residual
adhesive. Clean the adhesion
surface with isopropyl alcohol, and
let dry for 3 minutes or more.Cleaning of adhesion surface
Clean off any dirt adhering to the adhe-
sion surface with isopropyl alcohol, and
let dry for 3 minutes or more.
Gluing of window spacer, glass stoppers and dual lock fastener
Glue the window spacer, glass stoppers and dual lock fastener along the standard position
on the glass outer circumference.
Application of primer
Apply sufficient primer evenly to the adhesion surface so that there is no patchiness. After
application, let dry for 3 to 30 minutes.
Application of adhesive
Within 30 minutes after applying the primer, apply the adhesive evenly all the way around
the inside edge of the glass.
Installing the glass
After applying the adhesive, lightly press the glass evenly so that it adheres
completely.
Cleaning
After removing any adhesive that is sticking out or adhering to the body or
glass with a spatula, etc., clean off with isopropyl alcohol.
Checking for water leaks
Carry out a shower test to check that no water will leak through.

BODY -Window Glass42-15
6. Install the windshield molding.
7. Within thirty minutes after the primer application, fill a
sealant gun with the adhesive, and then apply the
adhesive evenly around the windshield.
NOTE
Cut the tip of the sealant gun nozzle into a V shape
to simplify adhesive application.
8. After applying adhesive, align the mating marks on the
windshield and the body, and then lightly press the
windshield evenly so that it adheres completely.
9. After removing any adhesive that is sticking out or adhering
to the windshield or body with spatula, etc., clean with
isopropyl alcohol. Install the windshield molding before
the adhesive sets. After the windshield is installed, wait
until the adhesive sets.
10. Adhere the windshield to the body, and install the roof
drip molding (Refer to GROUP 51.) promptly before the
adhesive sets.
11. After adhering the windshield to the body, wait 30 minutes
or more, and then test for water leakage.
Caution
(1) Move the vehicle carefully.
(2) When testing for water leakage, do not pinch the
end of the hose to spray the water.
10 mm
15 mm