2005 MITSUBISHI LANCER EVOLUTION IX Workshop Manual

REAR AXLE – GENERAL, DIFFERENTIAL CARRIER 27B-1
SECTION 27B
REAR AXLE
CONTENTS
General........................................................1 Differential carrier AYC system> ..............................................1
General
The tightening torque for the flare nut which joins the fuel pressure unit hose ASSY and the differential carrier ASSY, has been
changed. Other servicing guidelines remain unchanged.
Differential carrier
Removal and fitting
Note
*1: When the screw is dry.
*2: When the screw is lubricated.
NEWOLDfuel pressure unit hose ASSY
differential carrier ASSY

TYRES AND WHEELS – GENERAL, ON-VEHICLE SERVICING
31-1
SECTION 31
WHEELS AND TYRES
CONTENTS
General........................................................1
On-vehicle servicing ..................................1Removal of emergency puncture repairing agent ....1
Disposal of emergency puncture repairing agent ....2
General
The following servicing guidelines have been prepared now that vehicles are supplied with an emergency puncture repair kit.
On-vehicle servicing
Removal of emergency puncture repairing
agent
When repairing or replacing a tyre which has been treated using the
puncture repair kit, remove the emergency puncture repairing agent
(henceforth, repairing agent) from the tyre, in accordance with the
guidelines below.
Note
When removing the repairing agent, a container (the empty bottle
which contained the repairing agent), and the insertion hose and the
extraction hose from the emergency puncture repair kit, are needed.
Caution
1. Carry out the operation in a well-ventilated, airy place.
2. Take appropriate measures in order to prevent repairing
agent; getting onto the skin, being inhaled, coming into
contact with clothing, or getting into the eyes.
3. After the job has been completed, wash hands and face
thoroughly.
1. Remove the wheel from the vehicle, and remove the air from the
tyre.
2. Cut away the rubber part of the valve using a cutter-knife.
3. Attach the injection hose to the empty repairing agent bottle, and
then attach the extraction hose onto the injection hose.
empty bottle of
repairing agentinjection
hoseextraction
hose
valve

TYRES AND WHEELS – ON-VEHICLE SERVICING31-2
4. Put the tyre on a raised surface and tilt it to an angle. Insert the
extraction hose through the hole made by removing the valve,
so that the tip of the hose is submerged in the repairing agent.
5. Hold the bottle so that it is, as far as possible, below the tyre,
and suck the repairing agent out of the tyre by squeezing the
bottle by hand. Repeat this operation 2 or 3 times, so that as
much of the repairing agent as possible is removed.
6. After the repairing agent has been extracted, remove the tyre
from the wheel. Remove any repairing agent stuck onto the
tyre, and if the place from which air is escaping can be
identified, carry out a normal repair procedure. If the place from
which air is escaping cannot be identified, replace the tyre.
Disposal of emergency puncture repairing
agent
Dispose of the repairing agent extracted from the tyre, and any
unused agent which has exceeded its use-by date, in the same way
that used oil is discarded.
Note
The use-by date is printed on the bottle of repairing agent (about 3
years from the date of purchase)
Caution
The repairing agent includes propylene glycol which must be
handled as industrial waste.
extraction hose
raised surface
repairing
agent
extraction hose
injection hose
bottle

FRONT SUSPENSION – GENERAL, SPECIAL TOOLS, STRUT ASSY
33-1
SECTION 33
FRONT SUSPENSION
CONTENTS
General........................................................1
Special tools ...............................................1Strut ASSY ..................................................1
General
The guidelines for the dismantling and assembly of the front suspension have been changed due to changes made to the
shape of the Bilstein shock absorbers.
Special tools
ToolNumberNameFunction
A: MB991237
B: MB991238A. Spring compressor body
B. Arm setDismantling and assembling
the strut ASSY
MB991680
A: MB991681
B: MB991682Wrench set
A. Wrench
B. Socket
Strut ASSY
Dismantling guidelines
 
A


Removal of the self-locking nut
1. Use the following special tools to compress the coil spring.
• Spring compressor body (MB991237)
• Arm set (MB991238)
Caution
(1) In order to completely compress the coil spring, ensure that
the special tool is fixed when at its greatest possible
extension and that it is fixed evenly to the coil spring.
(2) Do not use an impact wrench, because there is a danger
that the special tool may be damaged.

FRONT SUSPENSION – STRUT ASSY33-2
pipe
2. Use the following tools to loosen the self-locking nut.
•Wrench (MB991681)
•Socket (MB991682)
Caution
Do not use an impact wrench when loosening the self-
locking nut, because there is a danger that the lock nut on
the piston rod inside the strut, may work loose.
Assembly guidelines



A 

Fitting the self-locking nut
1. Check that the bearing has completely slotted in.
2. When the coil spring has been compressed using the special
tool, provisionally tighten the self-locking nut.
Caution
Do not use an impact wrench because there is a danger that
the special tool may be damaged.
3. Align the holes in the lower spring plate and the upper spring
plate of the strut ASSY.
Note
This operation can be easily performed by using a pipe to align
the holes.
4. Line up the two ends of the coil spring with the slots in the
spring plate, and loosen the special tool.
5. Use the following special tools to tighten the self-locking nut to
the specified tightening torque.
•Wrench (MB991681)
•Socket (MB991682)
Tightening torque: 60 ± 10 N·m
Caution
Do not use an impact wrench when loosening the self-
locking nut, because there is a danger that the lock nut on
the piston rod inside the strut, may work loose.

BODY – GENERAL, WINDOW GLASS CHANNEL, DOOR-OPENING WEATHER STRIP42-1
SECTION 42
BODY
CONTENTS
General........................................................1 Window glass channel, door-opening
weather strip ...........................1
General
Servicing guidelines have been amended in conjunction with the changes listed below. Other servicing guidelines remain
unchanged.
•Addition of front door opening inner lower weather strip
•Addition of front and rear door opening inner weather strip
Window glass channel, door-opening weather strip

Removal and fitting

Note
: position of clips
Cross section A – A
front door trim
clip
Removal of the front door opening inner
lower weather strip
1. Front door opening inner lower weather
strip
Procedure for removing the front door
opening inner weather strip
•Front scuff plate
•Cowl side trim
•Lower centre pillar trim2. Front door opening inner weather strip
Procedure for removing the rear door
opening inner weather strip
•Rear scuff plate
•Lower centre pillar trim
3. Rear door opening inner weather strip