suspension MITSUBISHI LANCER EVOLUTION IV 1998 Workshop Manual

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General . . . . . . . . . . . . . . . . . . . . . . . .
Engine . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Lubrication . . . . . . . . . . . . .
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Cooling . . . . . . . . . . . . . . . . .
Intake and Exhaust . . . . . . . . . . . .
Engine Electrical . . . . . . . . . . . . . . .
Engine and Emission Control . . . .
Clutch . . . . . . . . . . . . . . . . . . . . . . . . .
Manual Transmission . . . . . . . . . . .
Front Axle . . . . . . . . . . . . . . . . . . . . . .
Rear Axle . . . . . . . . . . . . . . . . . . . . . .
Power Plant Mount . . . . . . . . . . . . . .
Front Suspension . . . . . . . . . . . . . . .
Rear Suspension . . . . . . . . . . . . . . .
Service Brakes . . . . . . . . . . . . . . . . .
Parking Brakes . . . . . . . . . . . . . . . . .
Steering . . . . . . . . . . . . . . . . . . . . . . . .
Body . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exterior . . . . . . . . . . . . . . . . . . . . . . . .
Chassis Electrical . . . . . . . . . . . . . .
Electrical Wiring . . . . . . . . . . . . . . . .
WORKSHOP MANUAL
FOREWORD
This Workshop Manual contains procedures for
service mechanics, including removal, disassembly,
inspection, adjustment, reassembly and
installation. Figures taken from registration
documents are given in metric units only. All other
figures are given in SI units with metric units in
brackets. Use the following manuals in combination
with this manual as required.
TECHNICAL INFORMATION MANUAL
N9806CNCP9
All information, illustrations and product
descriptions contained in this manual are current
as at the time of publication. We, however, reserve
the right to make changes at any time without prior
notice or obligation.
July 1998
EVOLUTION-IV
EVOLUTION-V

REAR AXLE – Special Tools / Troubleshooting 27-5
MB990988NumberNameO.D. mm
1MB990551Box–
2MB990989Base–
3(MB990990)Tool A25
(MB990991)Tool B28
(MB990992)Tool C31
MB990925
Brass bar
Bar (one-touch type)Toolbox
Installer adapter
Tool number (MB990925)O.D. mmTool number (MB990925)O.D. mm
AMB99092639.0AMB99093363.5
MB99092745.0MB99093467.5
MB99092849.5MB99093571.5
MB99092951.0MB99093675.5
MB99093054.0MB99093779.0
MB99093157.0BMB990938–
MB99093261.0CMB990939–
TROUBLESHOOTING
1. BASIC TROUBLESHOOTING CONDITIONS
Before starting the troubleshooting procedure, make sure that the following items have been checked
okay.

The correct steering wheel has been properly installed in the neutral position of the steering column
shaft.

Tire and wheel sizes are correct with correct specifications. Inflation pressure, balance, and wear
conditions are okay.

Wheel alignment is correct.

The engine, suspension, and other parts have not been remodeled so as to affect the AYC system.
2. DIAGNOSIS FUNCTION
READING THE DIAGNOSIS CODE
Read the diagnosis code using AYC warning lamp.

REAR AXLE – On-vehicle Service 27-32
Waveform Observation Points
SymptomProbable causeAction
Waveform amplitude is too small, or no
waveform.Defective speed sensorReplace sensor.
Waveform amplitude varies greatly. (No
problem ifthe smallest amplitude is 100
Excessive axle hub lateral and radial runoutReplace hub.
problem if the smallest amplitude is 100
mV or more)Poor AYC-ECU groundingRepair.
Noise on waveform or disturbed
waveform
Open-circuited sensorReplace sensor.
waveform
Open-circuited harnessRepair harness.
Improperly mounted speed sensorCorrect sensor installation.
Missing or collapsed rotor toothReplace rotor.
Caution
Since the speed sensor cable follows the movement of the front or rear suspension, it may be
open-circuited only when the vehicle is run on rough roads and not on ordinary road. The speed
sensor output voltage waveform should therefore be checked also by rocking the sensor harness
so that driving on rough roads may be simulated.
8. 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 fusible link from the engine compartment
relay box to make AYC inactive before attempting to start
the vehicle. When the fusible link is removed, the AYC warning
lamp lights up. After the battery has been recharged, fit the
fusible link back again and start the engine to ensure that
the AYC warning lamp is off.AYC fusible link

33A-1
FRONT
SUSPENSION
CONTENTS
SERVICE SPECIFICATIONS 2. . . . . . . . . . . . . .
SPECIAL TOOLS 2. . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE 3. . . . . . . . . . . . . . . . . .
Wheel Alignment Check and Adjustment
3. . . . . . . . . . . . . . . . . . . . . . . . .
STRUT ASSEMBLY 4. . . . . . . . . . . . . . . . . . . . . .
LOWER ARM 5. . . . . . . . . .
LOWER ARM 7. . . . . . . . . . .
STABILIZER BAR 9. . . . . . . . . . . . . . . . . . . . . . . .

FRONT SUSPENSION – Service Specifications / Special Tools33A-2
SERVICE SPECIFICATIONS

ItemsStandard value
Toe-in mm–3
3
Camber–1
00’ ± 30’
(difference between right and left wheel: less than 30’)
Caster3
50’ ± 30’
(difference between right and left wheel: less than 30’)
Kingpin inclination13
25’
Lower arm ball joint rotation starting torque Nm {kgfcm}2.0 – 8.8 {20 – 90}

Same as EVOLUTION-IV except for following.
ItemsStandard value
Camber (selectable from 2 options)–1
00’ ± 30’ or –2
00’ ± 30’
(difference between right and left wheel: less than 30’)
Caster3
54’ ± 30’
(difference between right and left wheel: less than 30’)
Kingpin inclination14
18’
SPECIAL TOOLS
ToolNumberNameUse
A
BA: MB991237
B: MB991238A: Spring
compressor
body
B: Arm setCoil spring compression
MB991006Preload socketLower arm ball joint rotation starting torque
measurement

FRONT SUSPENSION – On-vehicle Service33A-3
ON-VEHICLE SERVICE
WHEEL ALIGNMENT CHECK AND
ADJUSTMENT
Use the conventional procedures to measure wheel alignment.
1. CAMBER
Standard value:
–1
00’ ± 30’ (difference between right and left
wheel: less than 30’) or
–2
00’ ± 30’ (difference between right and left
wheel: less than 30’)
Select the camber angle as follows.
If the arrow on the bolt that couples the strut assembly
to knuckle faces inboard → –1
00’ ± 30’.
If the arrow on the bolt that couples the strut assembly
to knuckle faces outboard → –2
00’ ± 30’.
2. CASTER
Standard value: 3
54’ ± 30’ (difference between right
and left wheel: less than 30’)
NOTE
The suspension system is designed so as to retain the
preset caster value, requiring no adjustment for caster.

Bolt coupling strut
assembly to
knuckle

FRONT SUSPENSION – Strut Assembly33A-4
STRUT ASSEMBLY
REMOVAL AND INSTALLATION
Post-installation Operation
Front Wheel Alignment Adjustment
(Refer to P.33A-3.)
12 3
4
5
6 7
Unit: Nm {kgfm}
44 {4.5}
108 – 127
{11.0 – 13.0}
Removal steps
1. Brake hose clamp
2. Front speed sensor bracket

3. Flange nut4. Strut tower bar
5. Plain washer
A6. Bolts
7. Strut assembly
REMOVAL SERVICE POINT
ABOLTS REMOVAL
(1) Suspend the lower arm from the vehicle with wire.
(2) Remove the strut and knuckle connection.

FRONT SUSPENSION – Lower Arm 33A-5
LOWER ARM
REMOVAL AND INSTALLATION
Post-installation Operation
(1) Push the Dust Cover of the Lower Arm and Stabilizer
Link Ball Joint with a Finger to Check for Possible
Cracks or Damage.
(2) Wheel Alignment Check and Adjustment
12
3
45
6
Unit: Nm {kgfm}
39 {4.0}113 {11.5}
Molybdenum disulfide-base chassis
grease:
SHOWA SHELL SEKIYU SUNLITE
MB2, NISSEKI CLAKNOCK FL, or
equivalent
137 {14.0}
88 {9.0} 106 {10.8}*
6
Removal steps
1. Stabilizer link mounting nut
A2. Lower arm to knuckle coupling bolt
3. Bolt
4. Stabilizer bracket
A5. Bushing assembly
6. Lower arm assemblyCaution
The part marked with * should be first temporarily
tightened, then torqued to specification with the
vehicle on the ground in unloaded condition.
NOTE
Follow the conventional procedures for removal service
points.

FRONT SUSPENSION – Lower Arm 33A-6
INSTALLATION SERVICE POINT
ABUSHING ASSEMBLY INSTALLATION
Install the bushing assembly to the lower arm assembly with
a relative angle as shown and tighten the self-locking nut
to the specified torque.
Tightening torque: 137 Nm {14.0 kgfm}
INSPECTION
BALL JOINT ROTATION STARTING TORQUE
Use the conventional procedures except the special tool used
and the standard value as given below.
Standard value: 2.0 – 8.8 Nm {20 – 90 kgfcm}
LOWER ARM BALL JOINT DUST COVER
REPLACEMENT
Replace the dust cover by using the conventional procedure
only if it has been inadvertently damaged during servicing.
After the dust cover has been replaced with a new one, push
it with a finger to check for possible cracks or damage.
Bushing assembly
Lower arm assembly
MB991006

FRONT SUSPENSION – Lower Arm 33A-7
LOWER ARM
REMOVAL AND INSTALLATION
Caution
To prevent bushing from being galled, the part
marked with * should be first temporarily tightened,
then torqued to specification with the vehicle on
the ground in unloaded condition.Post-installation Operation
(1) Push the Dust Cover of the Lower Arm and Stabilizer
Link Ball Joint with a Finger to Check for Possible
Cracks or Damage.
(2) Wheel Alignment Check and Adjustment
(Refer to P.33A-3.)
12
3
456
Unit: Nm {kgfm} Molybdenum disulfide-base chassis
grease:
SHOWA SHELL SEKIYU SUNLITE
MB2, NISSEKI CLAKNOCK FL, or
equivalent
39 {4.0}108 {11.0}
137 {14.0}
88 {9.0} 106 {10.8}*
6
Removal steps
1. Stabilizer link mounting nut
AB2. Lower arm to knuckle coupling bolt
3. Bolt
4. Stabilizer bracket
A5. Bushing assembly
6. Lower arm assemblyNOTE
Follow the conventional procedures for removal service
points.