1998 MITSUBISHI LANCER EVOLUTION IV ECU

REAR AXLE – Drive Shaft27-38
INSTALLATION SERVICE POINTS
ADRIVE SHAFT INSTALLATION
Caution
Use care not to allow the drive shaft splines to damage
the oil seal of the differential carrier.
BDRIVE SHAFT NUT INSTALLATION
(1) Install the washer on the drive shaft in the direction shown
on the left.
(2) Using the special tool, tighten the drive shaft nut to the
specified torque.
Caution
Before torquing the drive shaft nut to specification,
do not apply vehicle weight to the wheel bearing.
(3) If, at this time, the split pin holes are not aligned, tighten
the nut further (within 255 Nm {26.0 kgf
m}), insert the
split pin in the first matching holes, and bend it securely.
Washer
MB990767196 – 255 Nm
{20.0 – 26.0 kfg
m}

REAR AXLE – LSD Case Assembly 27-46
LSD CASE ASSEMBLY
DISASSEMBLY AND REASSEMBLY
1
2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20
Differential gear set
1011
1110
Disassembly steps
CLSD differential torque check
AB1. Screw
2. Differential case A
3. Spring plate
4. Friction plate
5. Friction disc
6. Friction plate
7. Friction disc
8. Friction plate
9. Pressure ring
10. Side gear11. Pinion gear
12. Pinion shaft
13. Pressure ring
14. Friction plate
15. Friction disc
16. Friction plate
17. Friction disc
18. Friction plate
19. Spring plate
A20. Differential case B
DISASSEMBLY SERVICE POINT
ASCREW REMOVAL
(1) Check out the alignment marks.
(2) Loosen a uniform amount little by little the screws securing
differential case A to B.
(3) Separate differential case B from differential case A and
remove their components.
Keep the removed spring plates, friction plates, and friction
discs organized in the order of removal and for right and
left use.

REAR AXLE – Sensor Relay / AYC-ECU27-53
INSPECTION
1. LONGITUDINAL AND LATERAL ACCELERATION
SENSOR CHECK
Refer to GROUP 35B – Acceleration Sensor.
2. AYC RELAY CONTINUITY CHECK
Battery voltageTerminal No.
1345
When not energized
When energized
AYC-ECU
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
Front Floor Console Removal and Installation
Unit: Nm {kgf
m}
5 {0.5}
AYC-ECU
5 {0.5}

FRONT SUSPENSION – Stabilizer Bar33A-9
STABILIZER BAR
REMOVAL AND INSTALLATION
Pre-removal Operation
Crossmember RemovalPost-installation Operation
(1) Crossmember Installation
(2) Check the Stabilizer Link Ball Joint Dust Cover for
Cracks or Damage by Pushing it with Finger.
1
23
4
5
Unit: Nm {kgfm}
22 {2.2}
SHOWA SHELL SEKIYU
VARIANT R-2 or equivalent
39 {4.0}
39 {4.0}
1
Removal steps
1. Stabilizer link
2. Stabilizer bar bracket
A3. Fixture
A4. Bushing
5. Stabilizer bar
INSTALLATION SERVICE POINT
AFIXTURE / BUSHING INSTALLATION
Install the stabilizer bar so that the identification mark is
positioned at left. Fit the bushing so that the mark may protrude
about 10 mm from the inner end of the bushing, then secure
it with the fixture.Approx. 10 mm

REAR SUSPENSION – Rear Suspension Assembly34-5
REMOVAL SERVICE POINTS
ABRAKE CALIPER ASSEMBLY REMOVAL
Remove the brake caliper assembly and secure it with a
wire.
BPROPELLER SHAFT DISCONNECTION
(1) Make an alignment mark on the differential carrier
companion flange and propeller shaft flange yoke.
(2) Remove the mounting bolts and nuts of the differential
carrier and propeller shaft.
CCROSSMEMBER MOUNTING BOLT REMOVAL
Support the differential case with a garage jack or transmission
jack and then remove the crossmember mounting bolt.
INSTALLATION SERVICE POINTS
ACROSSMEMBER MOUNTING BOLT
INSTALLATION
Tighten the mounting bolts in the numerical order shown.
NOTE
To ensure both good installation accuracy and ease of
installation, the crossmember mounting holes have different
diameters between front and rear. This is the reason for
specifying the tightening sequence of the mounting bolts.
BPROPELLER SHAFT CONNECTION
Align the alignment mark on the differential carrier with that
of the propeller shaft at installation.
Caution
Oil or grease on the threads of the mounting bolt or nut
can allow the bolt or nut to come loose. Be sure to
degrease the threads before installation.
Bolt size (thread dia. × length mm)
1 to 3: Flange bolt (with washer) 12 × 70
4: Flange bolt (with washer) 12 × 152
5: Bolt (with spring washer + washer) 12 × 105 Front of vehicle
13
3
44
2
55

REAR SUSPENSION – Stabilizer Bar34-16
STABILIZER LINK BALL JOINT DUST COVER
REPLACEMENT
Only when the dust cover is damaged accidentally during
service work, replace the dust cover as follows:
(1) Remove the clip ring and the dust cover.
(2) Apply the specified grease to the lip and inside of the
dust cover.
Specified grease:
SHOWA SHELL SEKIYU VARIANT R-2 or
equivalent
(3) Wrap plastic tape on the stabilizer link threads as shown
in the illustration, and then install the dust cover to the
stabilizer link.
(4) Secure the dust cover with the clip ring.
When installing the clip ring, align the ends at a 90

angle from the axis of the stabilizer link.
(5) Check the dust cover for cracks or damage by pushing
it with finger.
Clip ring
Clip ring ends (180
on
opposite side also possible)

BASIC BRAKE SYSTEM – General / On-vehicle Service35A-2
GENERAL
OUTLINE OF CHANGE

The service procedures for left-hand drive vehicles have been established as described below.

The service procedures for the front and rear disc brakes have been changed since they had been
replaced by a different type.
ON-VEHICLE SERVICE
BRAKE PEDAL CHECK AND ADJUSTMENT

1. Turn up the carpet, etc under the brake pedal.
2. Measure the brake pedal height as illustrated. If the brake
pedal height is not within the standard value, follow the
procedure below.
Standard value: 163.5 –166.5 mm
(1) Disconnect the stop lamp switch connector.
(2) Adjust the brake pedal height by turning the operating
rod with pliers (with the operating rod lock nut
loosened), until the correct brake pedal height is
obtained.
(3) Secure by tightening the lock nut of the operating
rod.
(4) Push the stop lamp switch in the direction of the
pedal stroke until it stops. (The switch will slide if
it is pushed firmly.)
(5) Lift up the pedal until the operating rod is fully
extended, and then slide the stop lamp switch back
to the required position. Adjust the position of the
switch by turning it until the distance shown in the
illustration is correct.
(6) Connect the connector of the stop lamp switch.
(7) Check that the stop lamp is not illuminated with the
brake pedal unpressed.
3. 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 range.
Standard value: 3 – 8 mmOperating
rod
Operating
rod lock nutStop lamp
switch
Pedal down
Pedal up
Lock nut
Lock nut
Outer case
0.5 – 1.0 mm

BASIC BRAKE SYSTEM – Master Cylinder and Brake Booster35A-6
INSTALLATION SERVICE POINTS
AVACUUM HOSE CONNECTION
Insert securely and completely until the vacuum hose at the
engine side contacts the edge of the hexagonal part of the
fitting, and then secure by using the hose clip.
BCLEARANCE ADJUSTMENT BETWEEN BRAKE
BOOSTER PUSH ROD AND PRIMARY PISTON
Calculate clearance A from the B, C and D measurements.
A = B – C – D
Standard value: 0.65–0.85 mm
If the clearance is not within the standard value range, adjust
by changing the push rod length by turning the screw of
the push rod.
Measuring
distance BMeasuring
distance D
Block
gaugeB
AC
D