height adjustment MITSUBISHI LANCER EVOLUTION 2007 Service Repair Manual

CLUTCH -General Information/Service Specifications/Lubricants/On-vehicle Service21A-3
GENERAL INFORMATION
The clutch is a dry single-disc, diaphragm type;
hydraulic pressure is used for the clutch control.
SERVICE SPECIFICATIONS
ItemsStandard value
Clutch pedal height mm202.1 - 206.1
173.5 - 177.5
Clutch pedal clevis pin play mm1-3
Clutch pedal free play mm4-13
Distance between the clutch pedal and the toeboard
when the clutch is disengaged mm114.3 or more
100 or more
LUBRICANTS
ItemsSpecified lubricantsQuantity
Clutch fluidBrake fluid DOT3 or DOT4As required
Push rod assemblyRubber grease
Boot
Release cylinder push rodMITSUBISHI genuine grease Part No.
0101011
ON-VEHICLE SERVICE
CLUTCH PEDAL INSPECTION AND
ADJUSTMENT
1. Turn up the carpet, etc. under the clutch pedal.
2. Measure the clutch pedal height and the clutch pedal
clevis pin play.
Standard value (A):
202.1 - 206.1 mm
173.5 - 177.5 mm
Standard value (B): 1 - 3 mm
Clutch pedal height

A
A
Clutch pedal
stopper
Clutch pedal clevis pin play
B

CLUTCH -On-Vehicle Service21A-4
3. If the height of the clutch pedal is outside the standard
value, loosen the setting nut to adjust the pedal height
to the standard value.
Caution
Do not push in the master cylinder push rod at this
time, otherwise the clutch will not operate properly.
4. After completing the adjustments, confirm that the clutch
pedal free play (measured at the face of the pedal pad)
and the distance between the clutch pedal (the face of
the pedal pad) and the clutch pedal stopper or toeboard
when the clutch is disengaged are within the standard
value ranges.
Standard value (C): 4 - 13 mm
Standard value (D):
114.3 mm or more
100 mm or more
5. If the clutch pedal free play and the distance between
the clutch pedal and the clutch pedal stopper or toeboard
when the clutch is disengaged do not agree with the
standard values, it is probably the result of either air in
the hydraulic system or a faulty master cylinder, clutch
cylinder or clutch. Bleed the air, or disassemble and inspect
the master cylinder, clutch cylinder or clutch.
6. Turn back the carpet, etc.
BLEEDING
Specified fluid: Brake fluid DOT 3 or DOT 4
Caution
Use the specified brake fluid. Avoid using a mixture
of the specified fluid and other fluid.
CLUTCH PEDAL POSITION SWITCH
ADJUSTMENT
1. Adjust the clutch pedal. (Refer to P. 21A-3).
2. Disconnect the connector from clutch pedal position
switch.
3. Loosen the clutch pedal position switch by rotating approx.
quarter turn to counterclockwise.
4. Fix the clutch pedal in full stroke.
Clutch pedal Setting nut
13±2 N·m
Clutch pedal clevis pin play
C


Clutch
pedal
stopper
D D

REAR AXLE -Special Tools27B-7
Tool UseName Number
MB990850End yoke holderDRemoval of the self-locking nut
DAdjustment of the drive pinion turning
torque
MB990339Bearing pullerDrive pinion rear bearing inner race removal
MB990648Bearing remover
B A
MB990835
A: MB990836
B: MB990392Drive pinion setting
gauge set
A: Drive pinion
gauge assem-
bly
B: Cylinder
gaugeAdjustment of drive pinion height
MB990988Side gear holding
tool setMeasurement of clutch plate preload (vehicles
with mechanical LSD)
MB990728Side & rear bearing
inner race installerPress-fitting of drive pinion rear bearing inner
race
MB990727Oil seal installerPress-fitting of drive pinion oil seal
MB990813Ta pRemoval of adhesive

REAR AXLE -Differential Carrier 27B-40
2. Insert the brass between the differential carrier and the
differential case, and then rotate the companion flange
by hand (once in the normal direction, and then once
in the reverse direction) while applying a load to the drive
gear so that the revolution torque (approximate 2.5 -
3.0 N·m) is applied to the drive pinion.
Caution
If the drive gear is rotated too much, the tooth contact
pattern will become unclear and difficult to check.
3. Check the tooth contact condition of the drive gear and
drive pinion.
Standard tooth contact patternProblemSolution
1 Narrow tooth side
2 Drive-side tooth surface (the
side applying power during
forward movement)
3 Wide tooth side
4 Coast-side tooth surface (the
side applying power during
reverse movement)
1
2
34
Tooth contact pattern resulting from
excessive pinion height
The drive pinion is positioned too far
from the centre of the drive gear.
1 2
34
Increase the thickness of the drive
pinion rear shim, and position the
drive pinion closer to the centre of the
drive gear. Also, for backlash adjust-
ment, position the drive gear farther
from the drive pinion.
1 2
34
Tooth contact pattern resulting from
insufficient pinion height
The drive pinion is positioned too
close to the centre of the drive gear.
1 2
34
Decrease the thickness of the drive
pinion rear shim, and position the
drive pinion farther from the centre of
the drive gear. Also, for backlash
adjustment, position the drive gear
closer to the drive pinion.
1
2
34
NOTE
Checking the tooth contact pattern is the way to
confirm that the adjustments of the pinion height
and backlash have been done properly. Continue
to adjust the pinion height and backlash until the
tooth contact pattern resembles the standard
pattern.If, even after adjustments have been made, the
correct tooth contact pattern cannot be obtained,
it means that the drive gear and the drive pinion
have become worn beyond the allowable limit.
Replace the gear set.
MB990939

REAR AXLE -Differential Carrier 27B-43
REASSEMBLY
11
14
26
25
1310
6
124
7
24
21
18
17
15
2019
9
3
8
5
2
1
22
23
16
191820
5
17
15
84±4 N·m
186±29 N·m64±4 N·m
49±9 N·m
37±2 N·m
36±5 N·m
Final drive gear set
Reassembly steps
1. Differential carrier
"AA2. Oil seal
"BA3. Drive pinion rear bearing outer race
"CA4. Drive pinion front bearing outer race
"DADDrive pinion height adjustment
5. Drive pinion
6. Drive pinion rear shim (For adjusting
drive pinion height)
7. Drive pinion rear bearing inner race
8. Drive pinion spacer
"EADDrive pinion turning torque adjustment
9. Drive pinion front shim (For adjusting
drive pinion preload)
10. Drive pinion assembly
11. Drive pinion front bearing inner race
"EA12. Oil seal13. Companion flange
14. Washer
15. Self-locking nut
16. Limited slip differential case assembly
"FA17. Drive gear
"GA18. Side bearing inner race
19. Side bearing outer race
20. Side bearing spacer
21. Differential case assembly
"HA22. Bearing cap
23. Vent plug
24. Differential cover assembly
25. Drain plug
26. Filler plug
"HADFinal drive gear backlash adjustment

REAR AXLE -Differential Carrier 27B-45
"BADRIVE PINION REAR BEARING OUTER RACE
PRESS-FITTING
"CADRIVE PINION FRONT BEARING OUTER RACE
PRESS-FITTING
"DADRIVE PINION HEIGHT ADJUSTMENT
Adjust the drive pinion height by the following procedures:
1. Apply multipurpose grease to the washer of special tool.
2. Install special tool and drive pinion front and rear bearing
inner races to the gear carrier in the sequence shown
in the illustration.
3. Tighten the nut of special tool a little at a time while
measuring the turning torque of the drive pinion. Then
confirm the turning torque (without the oil seal) is at the
standard value.
Standard value:
Bearing typeTurning torque
New0.88 - 1.17 N·m
Caution
Take care not to fit gear oil on the bearing.
NOTE
The special tool can not rotate, move several times in
moving area, after rotating the bearing, measure the
torque.
MB990938
MB990935
MB990938
MB990932
MB990836
(MB990835)
MB990836
MB990326 MB990685
MB990836

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

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