2007 MITSUBISHI LANCER EVOLUTION brakes

00
11
12
13
14
15
16
17
21
22
25
26
27
31
32
33
34
35
36
37
42
51
52
54
55
General........................
Engine .........................
Engine Lubrication .............
Fuel ...........................
Engine Cooling .................
Intake and Exhaust ............
Engine Electrical ...............
Engine and Emission Control ....
Clutch .........................
Manual Transmission ...........
Propeller Shaft .................
Front Axle ......................
Rear Axle ......................
Wheel and Tyre .................
Power Plant Mount ..............
Front Suspension ...............
Rear Suspension ...............
Service Brakes .................
Parking Brakes .................
Steering ........................
Body ...........................
Exterior ........................
Chassis Electrical ..............
Electrical Wiring ................
Body Repair ....................
WORKSHOP
MANUAL
FOREWORD
This Workshop Manual contains procedures for
service mechanics, including removal, disassembly,
inspection, adjustment, reassembly and
installation. Use the following manuals in
combination with this manual as required.
TECHNICAL INFORMATION MANUAL N0104CT9A
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.
The EVOLUTION-VII is sold exclusively through
RALLIART Inc. Since the EVOLUTION-VII is a
rally-based model, it will not be warranted and will
not be homologated for general production.
Therefore, any service matters on the
EVOLUTION-VII should be inquired to RALLIART
Inc. as usual.
EMitsubishi Motors Corporation May 2001
Interior and Supplemental
Restraint System (SRS) ........
Heater, Air Conditioner and
Ventilation .....................

BASIC BRAKE SYSTEM 35A.........................................
ANTI-SKID BRAKING SYSTEM (ABS) <4WD> 35B......................
35A-1
SERVICE BRAKES
CONTENTS

BASIC BRAKE SYSTEM -General Information35A-3
GENERAL INFORMATION
The brake system offers high dependability and durability along with improved braking performance and
brake sensitivity.
SERVICE PRECAUTION
Take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched.
SPECIFICATIONS
ItemsSpecifications
Master cylinderTypeTandem type
I.D. mm26.9
Brake boosterTypeVacuum type, tandem
Effective dia. of power cylinder mm205 + 230
Boosting ratio4.5 (Pedal depressing force: 230 N)
Rear wheel hydraulic
controlmethod
Vehicles with ABS Electronic brake-force distribution (EBD)
control methodVehicles without ABS Proportioning valves
Proportioning valves
VehicleswithoutABS
TypeSingle type¢2
Decompression ratio0.25
Front brakes
RS(standard)
TypeFloating caliper, 2 piston, ventilated disc
Disc effective dia.¢thickness mm227¢24
Wheel cylinder I.D. mm42.9 (¢2)
Pad thickness mm10.0
Clearance adjustmentAutomatic
Front brakes
Type4 opposed piston, ventilated disc

Disc effective dia.¢thickness mm263¢32
Wheel cylinder I.D. mm40.0 (¢2), 46.0 (¢2)
Pad thickness mm10.0
Clearance adjustmentAutomatic
Rear brakes
RS(standard)
TypeFloating caliper, 1 piston, ventilated disc
Disc effective dia.¢thickness mm237¢20
Wheel cylinder I.D. mm34.9
Pad thickness mm10.0
Clearance adjustmentAutomatic
Rear brakes
Type2 opposed piston, ventilated disc

Disc effective dia.¢thickness mm252¢22
Wheel cylinder I.D. mm40.0 (¢2)
Pad thickness mm9.0
Clearance adjustmentAutomatic
Brake fluidDOT3 or DOT4

BASIC BRAKE SYSTEM -On-vehicle Service35A-13
(5) Apply repair kit grease to the portions of the pads
indicated on the left. At this time, make sure that
the grease will not be applied to any other surfaces.
(6) Mount the pads to the caliper so that its side with
the wear indicator is on the outside of the vehicle.
With the rear pads, ensure that the arrow on the
pad faces in the same direction as the brake disc
turns when the vehicle moves forward.
(7) Holding the cross spring with one hand, fit pins in
the caliper.
(8) Using a spring balance, measure the turning sliding
resistance of the hub in the forward direction.
(9) Find the brake disc drag force [the difference in
measurements taken in step(3) and in step(8)].
Standard value: 69 N or less
DISC BRAKE ROTOR CHECK
Caution
When servicing disc brakes, it is necessary to exercise caution to keep the disc brakes within
the allowable service values in order to maintain normal brake operation.
Before re-finishing or re-processing the brake disc surface, the following conditions should be checked.
Inspection itemsRemarks
Scratches, rust, saturated lining materials
and wearDIf the vehicle is not driven for a certain period, the sections of
the discs that are not in contact with lining will become rusty, causing
noise and shuddering.
DIf grooves resulting from excessive disc wear and scratches are
not removed prior to installing a new pad assembly, there will
momentarily be inappropriate contact between the disc and the
lining (pad).
Run-out or driftExcessive run-out or drift of the discs will increase the pedal depression
resistance due to piston knock-back.
Change in thickness (parallelism)If the thickness of the disc changes, this will cause pedal pulsation,
shuddering and surging.
Inset or warping (flatness)Overheating and improper handling while servicing will cause inset or
warping.
Front Rear
Cross
spring
Pins

ABS <4WD> -General Information35B-2
GENERAL INFORMATION
ABS has been adopted as optional equipment in
RS-IIto maintain directional stability and steering
performance during sudden braking or braking on
slippery road surfaces.
The ABS control method is a 4-sensor, 4-channel
method which provides independent control for all
wheels.
Following system for Lancer EVOLUTION-VII has
been modified from Lancer EVOLUTION-VI Tommi
Makinen Edition.DBy adding lateral G sensor, longitudinal G
sensor and steering wheel sensor, optimized
ABS control at the time of cornering.
DBy inputting parking brake switch signal to
ABS-ECU with pulling parking brake lever, ABS
control has been optimized.
DABS-ECU outputs ABS signal to 4WD-ECU.
DG sensor (lateral), steering wheel sensor and
parking brake switch have been added to the
diagnosis and service data.
DABS-ECU connector has been changed.
EBD CONTROL
In ABS, electronic control method is used by which
the rear wheel brake hydraulic pressure during
braking is regulated by rear wheel control solenoid
valves in accordance with the vehicle’s rate of
deceleration and the front and rear wheel slippage
which are calculated from the each wheel speed
sensor’s signal. EBD control is a control system
which provides a high level of control for both vehicle
braking force and vehicle stability. The system has
the following features:
DBecause the system provides the optimum rear
wheel braking force regardless of the vehicleladen condition and the condition of the road
surface, the system reduces the required pedal
depression force, particularly when the vehicle
is heavily laden or driving on road surfaces
with high frictional coefficients.
DBecause the duty placed on the front brakes
has been reduced, the increases in pad
temperature can be controlled to improve the
wear resistance characteristics of the pad,
during front brakes applying.
DControl valves such as the proportioning valve
are no longer required.
SPECIFICATIONS
ItemSpecifications
ABS control method4-sensor, 4-channel
No. of ABS rotor teethFront43
Rear43
ABS speed sensorTypeMagnet coil typep
Gap between sensor and rotor mm0.85 / 0.60 (non-adjustable type)

ABS <4WD> -On-vehicle Service35B-28
SymptomRemedy Probable causes
Noisy or disturbed waveformOpen circuit in sensorReplace sensor
Open circuit in harnessCorrect harness
Incorrectly mounted wheel speed sensorMount correctly
ABS rotor with missing or damaged teethReplace ABS rotor
Caution
Because the wheel speed sensor cables move together with the front and rear suspension, they
vibrate greatly when driving over poor road surfaces. As a result, the sensor harnesses should also
be shaken when monitoring of output waveforms of the wheel speed sensors in order to simulate
conditions such as driving over poor road surfaces.
HYDRAULIC UNIT CHECK
1. Jack up the vehicle and support the vehicle with rigid racks placed at the specified jack-up points
or place the wheels which are checked on the rollers of the braking force tester.
Caution
(1) The roller of the braking force tester and the tyre should be dry during testing.
(2) When testing the front brakes, apply the parking brake, and when testing the rear brakes,
stop the front wheels by chocking them.
2. Turn the ignition key to the “LOCK” (OFF) position and set the MUT-II.
Caution
Turn the ignition key to the “LOCK” (OFF) position before connecting or disconnecting the
MUT-II.
3. After checking that the shift lever is in neutral, start the engine.
4. Use the MUT-IIto force-drive the actuator.
NOTE
(1) During the actuator test, the ABS warning lamp will illuminate and the anti-skid control will be
cancelled.
(2) When the ABS has been interrupted by the fail-safe function, the MUT-IIactuator testing cannot
be carried out.
5. Turn the wheel by hand and check the change in braking force when the brake pedal is depressed.
When using the braking force tester, depress the brake pedal until the braking force is at the following
values, and check that the braking force decreases when the actuator is force-driven.
Front wheel785 - 981 N
Rear wheel588 - 784 N

36-1
PARKING BRAKES
CONTENTS
GENERAL INFORMATION 2..................
SERVICE SPECIFICATIONS 2.................
LUBRICANTS 2..............................
ON-VEHICLE SERVICE 3.....................
Parking Brake Lever Stroke Check and
Adjustment 3..................................Parking Brake Switch Check 3..................
Lining Running-In 4............................
PARKING BRAKE LEVER 5..................
PARKING BRAKE CABLE 6..................
PARKING BRAKE DRUM 7...................

PARKING BRAKES -General Information/Service Specifications/Lubricants36-2
GENERAL INFORMATION
The parking brake is of a mechanical control type
acting on the rear wheels. A lever is used to apply
the parking brake.
CONSTRUCTION DIAGRAM
Parking brake lever
Parking brake lever
SERVICE SPECIFICATIONS
ItemsStandard valueLimit
Parking brake lever stroke5 - 7 notches-
Rear brake lining thickness mm2.81.0
Rear drum inside diameter mm168.0169.0
LUBRICANTS
ItemsSpecified lubricants
Backing plateMultipurpose grease
Shoe and lining assembly
Adjuster