1998 MITSUBISHI LANCER EVOLUTION IV tow

ENGINE ELECTRICAL – Charging System16-2
CHARGING SYSTEM
ALTERNATOR
REMOVAL AND INSTALLATION
Pre-removal Operation
(1) Under Cover Removal
(2) Engine Mount Removal
(3) Strut Tower Bar RemovalPost-installation Operation
(1) Strut Tower Bar Installation
(2) Engine Mount Installation
(3) Under Cover Installation
(4) Drive Belt Tension Adjustment
(Refer to GROUP 11 – On-vehicle Service.)
Unit: Nm {kgf
m}
44 {4.5}
7 3
2
6
15 4
24 {2.4} 22 {2.2} 9 {0.9}12 – 15
{1.2 – 1.5}10 – 13
{1.0 – 1.3}
12 {1.2}
Removal steps

A1. Drive belt (Power steering, A/C)

B2. Delivery pipe, injector and pressure
regulator assembly
3. Oil level gauge guide4. Pressure hose connection

C5. Alternator
6. Water pump pulley
7. Alternator brace

MANUAL TRANSMISSION – Transmission Assembly22A-9
REMOVAL SERVICE POINTS
ACLUTCH RELEASE BEARING SEPARATION
(1) Remove the cover from the service hole in the clutch
housing.
(2) While pushing the release fork by hand in the direction
A, insert a flap-tip screwdriver between the release bearing
and the wedge collar.
Caution
Be sure to push the release fork in the direction A
before inserting a screwdriver.
(3) Separate the release bearing from the wedge collar by
prying with the screwdriver (turning the screwdriver grip
90).
NOTE
The release fork is forced to move fully in the direction
B by the return spring as soon as it is separated from
the wedge collar.
Caution
If it is hard to turn the screwdriver (to pry off the
release bearing), remove the screwdriver once and
repeat the above procedure after pushing the release
fork fully in the direction A two to three times. Forcibly
prying can cause the release bearing to be damaged.
BDRIVE SHAFT / DRIVE SHAFT
DISCONNECTION
(1) To disconnect the left-hand drive shaft, insert a lever
as shown and pry out the shaft from the transmission.
To disconnect the right-hand drive shaft, apply a lever
and a hammer as shown and lever out the shaft from
the transfer assembly using the hammer as a fulcrum.
NOTE
Remove the drive shafts with the hub and knuckle
attached.
Caution
Do not attempt to pull out the drive shaft from the
BJ in this stage since it can cause the TJ to be
damaged. Be sure to remove the drive shaft first from
the transmission side using a lever.
(2) Suspend the removed drive shaft with a wire so that
there are no sharp bends in any of the joints.
COUTPUT SHAFT REMOVAL
(1) Use the special tools (MB991612, MB990211) to remove
the output shaft.
(2) Use a shop towel to cover the transmission case not
to let foreign material get into it.
Service hole
Release fork
Wedge collar
Release bearing
Trans-
mission
side
Lever
Projection
Hammer
Lever
Output shaft
Transmission caseMB990211
MB991612

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.

REAR SUSPENSION – Stabilizer Bar34-15
INSTALLATION SERVICE POINT
ASTABILIZER BAR / BUSHING / STABILIZER BAR
BRACKET INSTALLATION
Position the stabilizer bar such that the identification mark
may protrude toward the vehicle center as shown in the figure,
and tighten first the stabilizer bar bracket mounting bolt 1
then the mounting bolt 2.
INSPECTION
1. STABILIZER LINK BALL JOINT TURNING TORQUE
CHECK
(1) After shaking the ball joint stud several times, install the
nut to the stud and use the special tool to measure the
turning torque of the ball joint.
Standard value: 1.7 – 3.1 Nm {17 – 32 kgf
cm}
(2) When the measured value exceeds the standard value,
replace the stabilizer link.
(3) When the measured value is lower than the standard
value, check that the ball joint turns smoothly without
excessive play. If so, it is possible to use that ball joint.
2. STABILIZER LINK BALL JOINT DUST COVER
CHECK
(1) Check the dust cover for cracks or damage by pushing
it with finger.
(2) If the dust cover is cracked or damaged, replace the
stabilizer link.
NOTE
Cracks or damage of the dust cover may cause damage
of the ball joint. When it is damaged during service work,
replace the dust cover.
Approx. 10 mm
2
2
1
MB990326

PARKING BRAKE – Parking Brake Cable36-6
REMOVAL SERVICE POINTS
AREAR BRAKE CALIPER ASSEMBLY REMOVAL
Remove the rear brake caliper assembly and support it with
wire or similar.
BSHOE HOLD-DOWN CUP REMOVAL
Extend the shoe and lining assembly, and remove the shoe
hold-down cup.
INSTALLATION SERVICE POINTS
AADJUSTER INSTALLATION
Install the adjuster so that the shoe adjusting bolt of left hand
wheel is attached towards the front of the vehicle, and the
shoe adjusting bolt of right hand wheel is towards the rear
of the vehicle.
BSHOE-TO-ANCHOR SPRING INSTALLATION
Install the shoe-to-anchor springs in the order shown in the
illustration.
Caution
The load on the respective shoe-to-anchor springs is
different, so the spring in the figure has been painted.
NOTE
The figure shows the left wheel; for the right wheel, the position
is symmetrical.
Shoe
hold-down
cup
Shoe adjusting
bolt
Rear
(Painted) 1
2

STEERING – Power Steering Gear & Linkage37A-6
JADJUSTMENT OF PINION TOTAL TURNING
TORQUE
(1) With special tool, tighten rack support cover to 15 Nm
{1.5 kgf
m}.
(2) Return rack support cover approx. 30
.
(3) Using the special tools, rotate the pinion shaft at the
rate of one rotation in approximately 4 to 6 seconds to
check that the turning torque and the torque fluctuation
confirm to the standard values.
Standard value:
Pinion total turning torque
0.9 – 1.7 Nm {9 – 17 kgf
cm}
Torque fluctuation 0.4 Nm {4 kgf
cm} or less
(4) If either the turning torque or the torque fluctuation
deviates from the standard value, turn back the rack
support cover within the range of 0 to 30
to adjust it
for the standard value.
Caution
1. When adjusting, set the standard value at its
highest value.
2. Assure no ratcheting or catching when operating
rack towards the axial direction.
3. Be sure to measure the turning torque through
the whole stroke of the rack.
NOTE
If the standard value cannot be obtained by turning back
the rack support cover within the specified angle range,
check rack support cover components and replace as
required.
NTIE ROD END / LOCK NUT INSTALLATION
Turn down the tie rod until the dimension shown in the
illustration is reached; then, temporarily tighten the lock nut.
NOTE
The lock nut is to be tightened to the specified torque after
toe-in has been adjusted with the steering gear & linkage
mounted in the vehicle.
MB990607
MB991006
End of groove in
which bellows fitsLock nut
197.2 mm
212.2 mm

EXTERIOR – Intercooler & Radiator Water Spray System 51-14
INSTALLATION SERVICE POINT
ACLIP / WATER SPRAY HOSE INSTALLATION
(1) Tape clips as illustrated.
(2) Tape the water spray hose as illustrated.
(3) Insert the clips positively into the mounting holes.
Washer
tank side
TapeConnect to radiator nozzle (RH).
Tape (secures three water hoses together)
Tape
Tape
Tape Tape so that the
clip faces toward
the front of vehicle.Connect to intercooler
nozzle (RH).
Connect to intercooler
nozzle (LH).
Tape so that the clip faces
toward the front of vehicle.Connect to radiator
nozzle (LH).
Section A – A Section B – B
Tape and secure so that the two
thin water spray hoses are located
above the thick water spray hose.Tape and secure so that the thin
water spray hose is located above
the thick water spray hose.
To intercooler
nozzle (RH)To intercooler
nozzle (LH)

Unit: mm
Fixing rangeFixing range
330 ± 550 ± 5+10
060
+10
050
60 ± 5

CHASSIS ELECTRICAL – Ignition Switch and Immobilizer System54-20
REMOVAL SERVICE POINTS
ASTEERING LOCK CYLINDER REMOVAL
1. Insert the key in the steering lock cylinder and turn it
to the “ACC” position.
2. Using a cross-tip (+) screwdriver (small) or a similar tool,
push the lock pin of the steering lock cylinder inward
and then pull the steering lock cylinder toward you.
INSPECTION
IGNITION SWITCH CONTINUITY CHECK
1. Remove the column cover lower and upper.
2. Disconnect the wiring connector from the ignition switch.
3. Operate the switch, and check the continuity between
the terminals.
Ignition key Terminal No.Ignition key
position
12356
LOCK
ACC
ON
START
IGNITION KEY RING ANTENNA CONTINUITY CHECK
Use a circuit tester to check the continuity between the
terminals.
Cross-tip (+)
screwdriver