2007 MITSUBISHI LANCER EVOLUTION service

POWER PLANT MOUNT - Crossmember32-8
CROSSMEMBER
REMOVAL AND INSTALLATION
Caution
1. Before removing the steering wheel and air bag module assembly, always refer to GROUP
52B - Service Precautions, Air bag Module and Clock Spring. Also, set the front wheels so
that they are facing straight forward, and remove the ignition key. If you fail to do this, the
SRS clock spring will be damaged, causing the SRS air bag to be inoperative and serious
injury.
2. *
1: Indicates parts which should be initially tightened, and then fully tightened after placing
the vehicle horizontally and loading the full weight of the engine on the vehicle body.
3. *
2: Indicates parts which should be temporarily tightened, and then fully tightened with the
vehicle on the ground in the unladen condition.
Caution
If the vehicle is equipped the Brembo disc brake, during maintenance, take care not to contact
the parts or tools to the caliper because the paint of caliper will be scratched.
Pre-removal Operations
DUnder Cover Removal
(Refer to GROUP 51 - Front Bumper.)
DCentermember, Crossmember Bar Removal
(Refer to P.32-6.)
DFront Exhaust Pipe Removal
(Refer to GROUP 15.)
DSteering Wheel Air Bag Module Assembly Removal
(Refer to GROUP 37A.)
DPower Steering Fluid Draining
(Refer to GROUP 37A - On-vehicle Service.)Post-installation Operations
DCentermember, Crossmember Bar Installation
(Refer to P.32-6.)
DFront Exhaust Pipe Installation
(Refer to GROUP 15.)
DSteering Wheel Air Bag Module Assembly
Installation (Refer to GROUP 37A.)
DPower Steering Fluid Supplying
(Refer to GROUP 37A - On-vehicle Service.)
DPower Steering Fluid Line Bleeding
(Refer to GROUP 37A - On-vehicle Service.)
DPress the dust cover with a finger to check whether
the dust cover is cracked or damaged.
DChecking Steering Wheel Position with Wheels
Straight Ahead
DFront Wheel Alignment Check and Adjustment
(Refer to GROUP 37A - On-vehicle Service.)
DUnder Cover Installation
(Refer to GROUP 51 - Front Bumper.)

POWER PLANT MOUNT - Crossmember32-11
REMOVAL SERVICE POINTS
AA"LOWER ARM ASSEMBLY REMOVAL
Lift the transmission with a transmission jack, and then
withdraw the front mounting bolt on the left lower arm
assembly.
AB"TIE ROD END AND KNUCKLE DISCONNECTION
Caution
1. The thread on the ball joint may be damaged. Do
not remove the tie rod end mounting nut from the
ball joint.Just loosen the nut. For this operation, use
the special tool.
2. Suspend the special tool with a cord to prevent it
from dropping.
AC"CROSSMEMBER ASSEMBLY REMOVAL
Retain the crossmember with a transmission jack, and then
remove the crossmember mounting bolt.
INSTALLATION SERVICE POINT
"AASTABILIZER BAR INSTALLATION
Align the identification colour on the left side of the stabilizer
bar with the right end of the bushing.
INSPECTION
DCheck the crossmember for cracks and damage.
Wooden block
Transmission jack
Mounting bolt
Cord
Ball joint
MB990635
MB991113 or
MB991406
Nut
Wooden
block
Transmission
jack
Identification
colourOutside of
vehicle
BushingFixture

33A-1
FRONT
SUSPENSION
CONTENTS
GENERAL INFORMATION 2..................
SERVICE SPECIFICATIONS 3.................
SPECIAL TOOLS 3...........................
ON-VEHICLE SERVICE 4.....................
Wheel Alignment Check and Adjustment 4.......Ball Joint Dust Cover Check 5..................
STRUT ASSEMBLY 6.........................
LOWER ARM ASSEMBLY 9..................
STABILIZER BAR 12.........................
CROSSMEMBER BAR 15.....................

FRONT SUSPENSION -Service Specifications/Special Tools33A-3
SERVICE SPECIFICATIONS
ItemsStandard value
Toe-inAt the centre of tyre tread mm0±2
Toe-angle (per wheel)0_00’±05’
Toe-out angle on turns (inner wheel when outer wheel at 20_)22_00’±1_30’
Steering angleInner wheel31_45’±1_30’
Outer wheel (for reference)27_15’
Camber (Selectable from 2 options)-1_00’±30’* or - 2_00’±30’*
Caster3_55’±30’*
Kingpin inclination13_45’±1_30’
Lower arm ball joint rotation starting torque N·m0.5 - 3.4
Lower arm pillow ball bushing rotation starting torque N·m0.5 - 3.0
NOTE
*: difference between right and left wheels: less than 30’
SPECIAL TOOLS
ToolsNumberNameUse
B
A
A: MB991237
B: MB991238A: Spring
compressor
body
B: Arm setCoil spring compression
BAMB991680
A: MB991681
B: MB991682Wrench set
A: Wrench
B: SocketStrut assembly disassembly and reassembly
MB991006Preload socketLower arm ball joint rotation starting torque
measurement
MB990326Preload socketLower arm pillow ball bushing rotation starting
torque measurement

FRONT SUSPENSION -Special Tools/On-vehicle Service33A-4
Tools UseName Number
MB990800Ball joint remover &
installerLower arm ball joint dust cover press-in
MB990651BarLower arm pillow ball bushing removal and
press-fitting
MB990816Bushing remover &
installer base
MB991576Base
MB990635,
MB991113 or
MB991406Steering linkage
pullerTie rod end and knuckle disconnection
ON-VEHICLE SERVICE
WHEEL ALIGNMENT CHECK AND
ADJUSTMENT
Measure the wheel alignment with the vehicle parked on a
level surface.
The front suspension, steering system, and wheels should be
serviced to normal condition prior to measurement of wheel
alignment.
TOE-IN
Standard value:
At the centre of tyre tread 0±2mm
Toe angle (per wheel) 0_00’±05’
1. Adjust the toe-in by undoing the clip and lock nut, and
turning the left and right tie rod turnbuckles by the same
amount (in opposite directions).
NOTE
The toe will move out as the left turnbuckle is turned
toward the front of the vehicle and the right turnbuckle
is turned toward the rear of the vehicle.
2. Install the clip and tighten the lock nut to the specified torque.
Clip
Lock nut

FRONT SUSPENSION -On-vehicle Service33A-5
Tightening torque: 52±2 N·m
3. Confirm that the toe-in is at the standard value.
4. Use a turning radius gauge to check that the steering
angle is at the standard value.
Standard value:
Inner wheels31_45’±1_30’
Outer wheels (for reference)27_15’
TOE-OUT ANGLE ON TURNS
To check the steering linkage, especially after the vehicle
has been involved in an accident or if an accident is presumed,
it is advisable to check the toe-out angle on turns in addition
to the wheel alignment.
Conduct this test on the left turn as well as on the right turn.
Standard value:
ItemsSpecifications
Toe-out angle on turns
(inner wheel when outer wheel at 20_)22_00’±1_30’
CAMBER, CASTER AND KINGPIN INCLINATION
Standard value:
ItemsSpecifications
Camber
(Selectable from 2 options)-1_00’±30’* or - 2_00’±30’*
Caster3_55’±30’*
Kingpin inclination13_45’±1_30’
NOTE
1. *: difference between right and left wheels must be less
than 30’
2. Caster and kingpin inclination are preset at the factory
and cannot be adjusted.
SELECTION THE CAMBER
Select the camber by the installation direction of the allow
of the connecting bolt of the strut assembly and the knuckle.
D-1
_00’±30’: Install the bolt turning the allow to the direction
of vehicle inside.
D-2
_00’±30’: Install the bolt turning the allow to the direction
of vehicle outside.
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
lower arm assembly.
NOTE
Cracks or damage of the dust cover may cause damage
of the ball joint.

FRONT SUSPENSION -Strut Assembly33A-7
DISASSEMBLY AND REASSEMBLY
60±10 N·m
3
2
1
5
6
7
8
9
4
3
Disassembly steps
1. Dust cover
AA""AA2. Self-locking nut
3. Strut insulator assembly
4. Upper spring seat assembly
5. Bump rubber6. Dust cover
7. Coil spring
8. Lower spring pad
AB"9. Strut assembly
DISASSEMBLY SERVICE POINTS
AA"SELF-LOCKING NUT REMOVAL
1. Use the special tools to compress the coil spring.
Caution
(1) Do not tighten the special tool bolt too tight. The
special tool will be broken if the allowable
tightening torque of 74 N·m is exceed.
(2) Install the special tools evenly, and so that the
maximum length will be attained within the
installation range.
(3) Do not use an impact wrench as it will cause the
bolt of the special tool to be seized.
2. Using the special tools, loosen the self-locking nut.
Caution
To prevent the piston rod lock nut inside the strut
from loosening, do not use an impact wrench when
the self-locking nut is loosened.
MB991237
MB991238
MB991681
MB991682

FRONT SUSPENSION -Strut Assembly33A-8
AB"STRUT ASSEMBLY REMOVAL
To discard the strut assembly, place the assembly horizontally
with its piston rod extended. Then drill a hole approx. 3 mm
in diameter at the location shown in the illustration and
discharge the gas.
Caution
The gas itself is harmless but it may issue out of the
hole together with chips generated by the drill. Therefore,
be sure to wear goggles.
REASSEMBLY SERVICE POINT
"AASELF-LOCKING NUT INSTALLATION
1. Ensure that the bearing is seated correctly.
2. Install the special tool to the strut assembly same as
its removal.
3. While the coil spring is being compressed by the special
tools, provisionally tighten the self-locking nut.
Caution
Do not use an impact wrench as it will cause the
bolt of the special tool to be seized.
4. Align the hole in the strut assembly lower spring seat
with the hole in the upper spring seat.
NOTE
Using a pipe as shown facilitates the alignment.
5. Correctly align both ends of the coil spring with the grooves
in the spring seat, and then loosen the special tools.
6. Using the special tools, tighten the self-locking nut to the
specified torque.
Specified torque: 60±10 N·m
Caution
To prevent the piston rod lock nut inside the strut
from loosening, do not use an impact wrench when
the self-locking nut is tightened.
7. After tightening self-locking nut, fill the multi purpose
greese to the bearing part of strut insulator.
Pipe
MB991681
MB991682