Power Steering - Evolution Mitsubishi Lancer Evolution VIII

GENERAL DESCRIPTION

Power steering has been adopted in all vehicles to make the steering system easier to handle.

1. MOMO leather-wrapped 3-spoke steering wheel is used.
2. The steering column has a shock absorbing mechanism and a tilt steering mechanism.
3. A rack and pinion steering gear is used for steering that feels more direct and for ample handling performance.
4. An oil pump responsive to engine RPM is used, which, with tuning for a rigid gear box mount, provides stable steering at high speeds.
5. The separate oil reservoir is rubber-mounted.

Scheme 191

INTRODUCTION TO POWER STEERING DIAGNOSIS

Hydraulic power steering is used for all vehicles. Faults in the power steering can include excessive play of the steering wheel, difficult steering wheel operation, noise, vibration, and oil leaks, etc. Possible causes of these faults can include problems in the gear box, oil pump or steering linkage.

POWER STEERING DIAGNOSIS TROUBLESHOOTING STRATEGY

Use these steps to plan your diagnostic strategy. If you follow them carefully, you will be sure that you have exhausted most of the possible ways to find a power steering fault.

1. Gather information from the customer.
2. Verify that the condition described by the customer exists.
3. Find the malfunction by following the Symptom Chart. Refer to «SYMPTOM CHART»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/manual-power-steering/#power-steering-evolution) .
4. Verify malfunction is eliminated.

Scheme 192

Scheme 193

1. STEP 1. Check for looseness at the steering shaft coupling section and at the steering wheel linkage. Q: Is there any looseness? YES: Repair or replace the part. Then go to Step 3 . NO: Go to Step 2.
2. STEP 2. Check the steering wheel free play. With the engine running (hydraulic operation), set the front wheels straight ahead. Measure the play on the steering wheel circumference before the wheels start to move when slightly moving the steering wheel in both directions. Limit: 30 mm (1.2 inch) If the free play exceeds the limit value, set the steering wheel straight ahead with the engine stopped. Apply approximately 5 N (1.1 pound) in one direction and check the play. Standard value (steering wheel play with engine stopped): 10 mm (0.4 inch) or less Q: Does the play exceed the standard value? YES: Remove the steering gear box (Refer to «REMOVAL AND INSTALLATION»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/manual-power-steering/#power-steering-evolution) ) and check the total pinion torque (Refer to «REMOVAL AND INSTALLATION»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/manual-power-steering/#power-steering-evolution) ). Then go to Step 3. NO: Go to Step 3.
3. STEP 3. Check the steering wheel play. Verify that the steering wheel play is not excessive. Q: Is the steering wheel play excessive? YES: Repeat to Step 1 . NO: The procedure is complete.

Scheme 194

1. STEP 1. Check the power steering oil pump drive belt tension. Refer to «8. DRIVE BELT (FOR GENERATOR, WATER PUMP AND POWER STEERING OIL PUMP (CHECK CONDITION)»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/oem-general-information/#general-evolution) . Q: Is the power steering oil pump drive belt tension within the standard value? YES: Go to Step 2. NO: Adjust the tension. (Refer to «8. DRIVE BELT (FOR GENERATOR, WATER PUMP AND POWER STEERING OIL PUMP (CHECK CONDITION)»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/oem-general-information/#general-evolution) ). Then go to Step 9 .
2. STEP 2. Check the drive belt for damage. Q: Is the drive belt damaged? YES: Replace the drive belt. Then go to Step 9 . NO: Go to Step 3.
3. STEP 3. Check the fluid level. Park the vehicle on a flat, level surface, and then start the engine. Turn the steering wheel several times to raise the temperature of the fluid to approximately 50 - 60°C (122 - 140°F). With the engine running, turn the wheel all the way to the left and right several times. Check the fluid in the oil reservoir for foaming or milkiness. Check the difference of the fluid level when the engine is stopped, and while it is running. Q: Is the check result OK? YES: Go to Step 4. NO: Bleed the air (Refer to «POWER STEERING SYSTEM AIR BLEEDING»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/manual-power-steering/#power-steering-evolution__power-steering-system-air-bleeding) ). Then go to Step 9 .
4. STEP 4. Check each hose for crushing or twisting. Q: Is any hose crushed or twisted? YES: Repair or replace the hose. Then go to Step 9 . NO: Go to Step 5.
5. STEP 5. Check for oil leaks. Q: Are there oil leaks? YES: Repair it. Then go to Step 9 . NO: Go to Step 6.
6. STEP 6. Check the wheel alignment (camber and caster). Refer to «FRONT WHEEL ALIGNMENT CHECK AND ADJUSTMENT»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/suspension-front/#front-suspension-evolution__front-wheel-alignment-check-and-adjustment) . Q: Is the alignment incorrect? YES: Repair it. Then go to Step 9 . NO: Go to Step 7.
7. STEP 7. Check the gear box rack piston seal for damage. Q: Is there damage? YES: Replace it. Then go to Step 9 . NO: Go to Step 8.
8. STEP 8. Check for excessive tie rod end ball joint breakaway torque. Refer to «TIE ROD END BALL JOINT BREAKAWAY TORQUE CHECK»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/manual-power-steering/#power-steering-evolution__tie-rod-end-ball-joint-breakaway) . Q: Is there fault? YES: Replace the part. Then go to Step 9. NO: Go to Step 9.
9. STEP 9. Check the steering wheel operation. Verify that the steering wheel operation is not difficult. Q: Is the steering wheel operation difficult? YES: Repeat from Step 1 . NO: The procedure is complete.

DIAGNOSIS

1. STEP 1. Check for proper oil pump and steering gear installation. Q: Is the oil pump and the steering gear installation correct? YES: Go to Step 2. NO: Repair it. Then go to Step 4 .
2. STEP 2. Check for interference of other parts with the steering column and the power steering hoses. Q: Is there interference? YES: Correct the interference. Then go to Step 4 . NO: Go to Step 3.
3. STEP 3. Check for noise from inside the oil pump or the steering gear. Q: Is there noise? YES: Replace the part. Then go to Step 4. NO: Go to Step 4.
4. STEP 4. Check for rattling noise. Confirm that no noise is generated. Q: Is there noise? YES: Repeat from Step 1 . NO: The procedure is complete.

Scheme 195

1. STEP 1. Check the fluid level. Park the vehicle on a flat, level surface, and then start the engine. Turn the steering wheel several times to raise the temperature of the fluid to approximately 50 - 60°C (122 - 140°F). With the engine running, turn the wheel all the way to the left and right several times. Check the fluid in the oil reservoir for foaming or milkiness. Check the difference of the fluid level when the engine is stopped, and while it is running. Q: Is the check result OK? YES: Go to Step 2. NO: Bleed the air (Refer to «POWER STEERING SYSTEM AIR BLEEDING»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/manual-power-steering/#power-steering-evolution__power-steering-system-air-bleeding) ). Then go to Step 3 .
2. STEP 2. Check for seizure in the oil pump. Q: Is there seizure? YES: Replace the part. Then go to Step 3. NO: Go to Step 3.
3. STEP 3. Retest the system. Confirm that no noise is generated. Q: Is there noise? YES: Repeat from Step 1 . NO: The procedure is complete.

1. STEP 1. Check the power steering oil pump drive belt tension. Refer to «8. DRIVE BELT (FOR GENERATOR, WATER PUMP AND POWER STEERING OIL PUMP (CHECK CONDITION)»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/oem-general-information/#general-evolution) . Q: Is the power steering oil pump drive belt tension within the standard value? YES: Go to Step 2. NO: Adjust the belt tension. (Refer to «8. DRIVE BELT (FOR GENERATOR, WATER PUMP AND POWER STEERING OIL PUMP (CHECK CONDITION)»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/oem-general-information/#general-evolution) ). Then go to Step 3 .
2. STEP 2. Check for seizure in the oil pump. Q: Is there seizure? YES: Replace the part. Then go to Step 3. NO: Go to Step 3.
3. STEP 3. Retest the system. Confirm that no noise is generated. Q: Is there noise? YES: Repeat from Step 1 . NO: The procedure is complete.

Scheme 196

1. STEP 1. Check the fluid level. Park the vehicle on a flat, level surface, and then start the engine. Turn the steering wheel several times to raise the temperature of the fluid to approximately 50 - 60°C (122 - 140°F). With the engine running, turn the wheel all the way to the left and right several times. Check the fluid in the oil reservoir for foaming or milkiness. Check the difference of the fluid level when the engine is stopped, and while it is running. Q: Is the check result OK? YES: Go to Step 2. NO: Bleed the air (Refer to «POWER STEERING SYSTEM AIR BLEEDING»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/manual-power-steering/#power-steering-evolution__power-steering-system-air-bleeding) ). Then go to Step 4 .
2. STEP 2. Check each hose for crushing or twisting. Q: Is any hose crushed or twisted? YES: Repair or replace the hose. Then go to Step 4 . NO: Go to Step 3.
3. STEP 3. Check the steering gear for damage. Q: Is there damage? YES: Repair or replace the part. Then go to Step 4. NO: Go to Step 4.
4. STEP 4. Retest the system. Confirm that no noise is generated. Q: Is there noise? YES: Repeat from Step 1 . NO: The procedure is complete.

1. STEP 1. Check the oil pump or oil pump bracket installation. Q: Is the oil pump or the oil pump bracket installation correct? YES: Go to Step 2. NO: Repair it. Then go to Step 3 .
2. STEP 2. Check the oil pump for damage. NOTE: If a slight "beat noise" is produced by the oil pump when the steering wheel is turned fully and held in that position, this is not a malfunction. Q: Is there damage? YES: Replace the oil pump. Then go to Step 3. NO: Go to Step 3.
3. STEP 3. Retest the system. Confirm that no noise is generated. Q: Is there noise? YES: Repeat from Step 1 . NO: The procedure is complete.

Scheme 197

Scheme 198

Scheme 199

1. STEP 1. Check for interference of the wheel and the vehicle body. If interfering, adjust the steering angle. Place the front wheel on a turning radius gauge and measure the steering angle. Standard value: If the steering angle is not within the standard value, adjust the toe-in. Standard value: 0 +/- 2 mm (0 +/- 0.08 inch) Adjust the toe-in by undoing the clip and jam 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 turnbuckles is turned toward the front of the vehicle and the right turnbuckle is turned toward the rear of the vehicle. Q: Is the steering angle normal? YES: Go to Step 2. NO: Adjust the steering angle. Then go to Step 3 .
2. STEP 2. Check the steering gear for damage. Q: Is there damage? YES: Repair or replace the part. Then go to Step 3. NO: Go to Step 3.
3. STEP 3. Retest the system. Confirm that no noise is generated. Q: Is there noise? YES: Repeat from Step 1 . NO: The procedure is complete.

INSPECTION PROCEDURE 9: VIBRATION

Note. A slight vibration may be felt when the stationary steering effort is made due to the condition of the road surface. To check whether the vibration actually exists or not, test-drive the vehicle on a dry concrete or asphalt surface. A very slight amount of vibration is not a malfunction.

Scheme 200

1. STEP 1. Check the fluid level. Park the vehicle on a flat, level surface, and then start the engine. Turn the steering wheel several times to raise the temperature of the fluid to approximately 50 - 60°C (122 - 140°F). With the engine running, turn the wheel all the way to the left and right several times. Check the fluid in the oil reservoir for foaming or milkiness. Check the difference of the fluid level when the engine is stopped, and while it is running. Q: Is the check result OK? YES: Go to Step 2. NO: Bleed the air (Refer to «POWER STEERING SYSTEM AIR BLEEDING»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/manual-power-steering/#power-steering-evolution__power-steering-system-air-bleeding) ). Then go to Step 3 .
2. STEP 2. Check the steering gear for damage. Q: Is there damage? YES: Repair or replace the part. Then go to Step 3. NO: Go to Step 3.
3. STEP 3. Retest the system. Confirm that no vibration is generated. Q: Is there vibration? YES: Repeat from Step 1 . NO: The procedure is complete.

1. STEP 1. Check for loosening of the pressure and return tube flare nut. Refer to «POWER STEERING HOSES»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/manual-power-steering/#power-steering-evolution) . Q: Is the flare nut loose? YES: Tighten it to 15 +/- 3 N.m (11 +/- 2 ft-lb). Then go to Step 3 . NO: Go to Step 2.
2. STEP 2. Check the hose connection and the clamp installation. Refer to «POWER STEERING HOSES»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/manual-power-steering/#power-steering-evolution) . Q: Are they correct? YES: Go to Step 3. NO: Repair or replace the part. Then go to Step 3.
3. STEP 3. Retest the system. Check that no oil is leaking. Q: Is there oil leakage? YES: Repeat from Step 1 . NO: The procedure is complete.

1. STEP 1. Check the hose for damage or clogging. Refer to «POWER STEERING HOSES»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/manual-power-steering/#power-steering-evolution) . Q: Is the hose damaged or clogged? YES: Repair or replace it. Then go to Step 2. NO: Go to Step 2.
2. STEP 2. Retest the system. Check that no oil is leaking. Q: Is there oil leakage? YES: Repeat from Step 1 . NO: The procedure is complete.

1. STEP 1. Check the oil reservoir for damage. Q: Is there damage? YES: Repair or replace it. Then go to Step 3 . NO: Go to Step 2.
2. STEP 2. Check for overflowing. Q: Is there oil overflowing from the reservoir? YES: Adjust fluid level. Then go to Step 3. NO: Go to Step 3.
3. STEP 3. Retest the system. Q: Is there oil leakage? YES: Repeat from Step 1 . NO: The procedure is complete.

1. STEP 1. Check the oil pump body for damage. Q: Is there damage? YES: Replace the part. Then go to Step 3 . NO: Go to Step 2.
2. STEP 2. Check the O-ring or oil seal for damage. Q: Is there damage? YES: Replace the part. Then go to Step 3. NO: Go to Step 3.
3. STEP 3. Retest the system. Check that no oil is leaking. Q: Is there oil leakage? YES: Repeat from Step 1 . NO: The procedure is complete.

1. STEP 1. Check the steering gear housing for damage. Q: Is there damage? YES: Replace the part. Then go to Step 3 . NO: Go to Step 2.
2. STEP 2. Check the oil-ring or oil seal for damage. Q: Is there damage? YES: Replace the part. Then go to Step 3. NO: Go to Step 3.
3. STEP 3. Retest the system. Check that no oil is leaking. Q: Is there oil leakage? YES: Repeat from Step 1 . NO: The procedure is complete.

Scheme 201

Scheme 202

Scheme 203

Scheme 204

1. With the engine running (hydraulic operation), set the front wheels straight ahead.
2. Measure the play on the steering wheel circumference before the wheels start to move when slightly moving the steering wheel in both directions. Limit: 30 mm (1.2 inch)
3. When the play exceeds the limit, check for the play on the steering shaft and steering linkage connection. Correct or replace.
4. If the free play still exceeds the limit value, set the steering wheel straight ahead with the engine stopped. Apply 5 N (1.1 pound) in one direction and check the play. Standard value (steering wheel play with the engine stopped): 10 mm (0.4 inch) or less
5. If the play exceeds the standard value, remove the steering gear (Refer to «REMOVAL AND INSTALLATION»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/manual-power-steering/#power-steering-evolution) .) and check the total pinion torque (Refer to «REMOVAL AND INSTALLATION»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/manual-power-steering/#power-steering-evolution) ).

Scheme 205

Scheme 206

Scheme 207

1. Place the front wheel on a turning radius gauge and measure the steering angle. Standard value
2. If the steering angle is not within the standard value, adjust the toe-in as follows. Standard value: 0 +/- 2 mm (0 +/- 0.08 inch) Loosen the jam nut, and unclip the bellows. Adjust the toe-in by 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. Tighten the jam nut to the specified torque, and tighten the bellows by the clip. Tightening torque: 52 +/- 2 N.m (38 +/- 2 ft-lb)
3. Recheck the steering angle.

TIE ROD END BALL JOINT BREAKAWAY TORQUE CHECK

Required Special Tools

1. MB990326: Preload Socket
2. MB991897: Ball Joint Remover

Scheme 208

Scheme 209

Scheme 210

1. Install special tool MB991897 (Scheme 208)
2. Turn the bolt and knob as necessary to make the jaws of special tool MB991897 parallel, tighten the bolt by hand and confirm that the jaws are still parallel. NOTE: When adjusting the jaws in parallel, make sure the knob is in the position shown in the figure.
3. Tighten the bolt with a wrench to disconnect the tie rod end.
4. Move the ball joint stud several times and install the nut on the stud. Using special tool MB990326, measure the ball joint breakaway torque. Standard value: 1.0 - 3.0 N.m (8.9 - 26.6 in-lb)
5. If the breakaway torque exceeds the standard value, replace the tie rod end.
6. If the breakaway torque is under the standard value, check the ball joint for end play or ratcheting. If no end play or ratcheting, the ball joint can be re-used. CAUTION: Always use a new ball joint nut as it is a self-locking nut.
7. Install the tie rod end to the knuckle, then tighten a new self-locking nut to the specified torque. Tightening torque: 25 +/- 5 N.m (19 +/- 3 ft-lb)

Scheme 211

1. With the vehicle stopped on a flat and paved surface, turn the steering wheel to the straight ahead position.
2. Start the engine and set the engine idle speed. Standard value: 850 +/- 100 r/min
3. Attach a spring scale to the outer circumference of the steering wheel and measure the steering force required to turn the steering wheel from the straight ahead position to the left and right (within a range of 1.5 turns). Also check to be sure that there is no significant change in the required steering effort. Standard value: Steering effort: 32 N (7.2 lb) or less Fluctuation allowance: 6.0 N (1.35 lb) or less
4. If the measured value exceeds the standard value, refer to «INSPECTION PROCEDURE 2: DIFFICULT STEERING WHEEL OPERATION (INSUFFICIENT POWER ASSIST)»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/manual-power-steering/#power-steering-evolution) .

STEERING WHEEL RETURN TO CENTER CHECK

Conduct a road test

1. Make both gradual and sudden turns and check the steering wheel return.
2. At a vehicle speed of approximately 35 km/h (22 mph), turn the steering wheel 90 degrees, hold a few seconds, then release. If the steering wheel then returns 70 degrees or more, the return can be judged satisfactory. NOTE: There will be a momentary feeling or "heaviness" when the wheel is turned quickly, but this is not abnormal. (Oil pump discharge amount is especially apt to be insufficient during idling.)

Scheme 212

DRIVE BELT TENSION CHECK

Refer to 8. DRIVE BELT (FOR GENERATOR, WATER PUMP AND POWER STEERING OIL PUMP (CHECK CONDITION) .

Scheme 213

1. Park the vehicle on a flat, level surface.
2. Start the engine, and then turn the steering wheel several times to raise the temperature of the fluid to approximately 50 - 60°C (122 - 140°F).
3. With the engine running, turn the wheel all the way to the left and right several times.
4. Check the fluid in the oil reservoir for foaming or milkiness. Check the difference of the fluid level when the engine is stopped, and while it is running. If the fluid contains air or has milky appearance, or the fluid level fluctuate by 5 mm (0.2 inch) or more, power steering system air bleeding should be done.

Scheme 214

1. Raise and support the front wheels.
2. Disconnect the return hose connection, and then connect a vinyl hose to the return hose, and drain the fluid into a container.
3. Disconnect the ignition coil connectors (Refer to «IGNITION COIL»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/ignition-system/#ignition-system-evolution) ).
4. While operating the starter motor intermittently, turn the steering wheel all the way to the left and right several times to drain all of the fluid.
5. Connect the return hose securely, and then secure with the clip.
6. Fill the oil reservoir with GENUINE MITSUBISHI POWER STEERING FLUID or it's equivalent up to the lower position of the filler, and then bleed the air.

POWER STEERING SYSTEM AIR BLEEDING

Perform air bleeding procedure as necessary after replacing the steering gear, oil pump or the steering fluid lines.

1. Raise and support the front wheels.
2. Disconnect the ignition coil connectors (Refer to «IGNITION COIL»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/ignition-system/#ignition-system-evolution) ). CAUTION: Perform air bleeding only while cranking the engine. Do not perform air bleeding while the engine is running. If you do so, air in the fluid will be grained and air bleeding will become more difficult. During air bleeding, refill the steering fluid so that the level never falls below the lower mark on the dipstick.
3. Turn the steering wheel all the way to the left and right five or six times while using the starter motor to crank the engine intermittently several times (for 15 to 20 seconds).
4. Connect the ignition coil connectors (Refer to «IGNITION COIL»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/ignition-system/#ignition-system-evolution) ).
5. Start the engine (idling).
6. Turn the steering wheel to the left and right until there are no air bubbles in the oil reservoir.
7. Confirm that the fluid is not milky, and that the level is between the high and low dipstick marks.
8. Confirm that there is very little change in the fluid level when the steering wheel is turned left and right. CAUTION: If the fluid level rises suddenly after the engine is stopped, the air has not been completely bled. If air bleeding is not complete, there will be abnormal noises from the pump and the flow-control valve, and this condition could cause reduce the life of the power steering components.
9. Confirm that the change in the fluid level is no more than 5 mm (0.2 inch) when the engine is stopped and when it is running.
10. If the change of the fluid level is 5 mm (0.2 inch) or more, the air has not been completely bled from the system. The air bleeding procedure must be repeated.

Scheme 215

OIL PUMP PRESSURE TEST

Required Special Tools

1. MB990662: Power Steering Oil Pressure Gauge
2. MB991548: Power Steering Oil Pressure Gauge Adapter (Pump Side)
3. MB991549: Power Steering Oil Pressure Gauge Adapter (Hose Side)

Scheme 216

1. Disconnect the pressure hose from the oil pump, and then connect special tools MB991548, MB990662 and MB991549.
2. Bleed air, then turn the steering wheel several times while the vehicle is not moving so that the temperature of the fluid rises to approximately 50 - 60°C (122 - 140°F).
3. Start the engine and idle it at 1,000 +/- 100 r/min. CAUTION: The pressure gauge shut-off valve must not remain closed for more than 10 seconds.
4. Fully close the shut-off valve of the pressure gauge and measure the oil pump relief pressure to confirm that it is within the standard value range. Open it again immediately after checking the pressure. Standard value: 8.4 - 9.0 MPa (1,219 - 1,306 psi)
5. If it is not within the standard value, replace the oil pump.
6. Check whether or not the hydraulic pressure is the standard value when no-load conditions are created by fully opening the shut-off valve of the pressure gauge. Standard value: 0.2 - 0.8 MPa (29 - 116 psi)
7. If it is not within the standard value, the probable cause is a malfunction of the oil line or steering gear, so check these parts and repair as necessary.
8. Turn the steering wheel all the way to the left or right; then check whether or not the retention hydraulic pressure is the standard value. Standard value: 8.4 - 9.0 MPa (1,219 - 1,306 psi)
9. If not the standard value, overhaul the steering gear. Remeasure fluid pressure.
10. Remove special tools MB991548, MB990662 and MB991549, and then tighten the pressure tube flare nut to the specified torque. Tightening torque: 18 +/- 3 N.m (13 +/- 2 ft-lb)
11. Bleed the system (Refer to «POWER STEERING SYSTEM AIR BLEEDING»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/manual-power-steering/#power-steering-evolution__power-steering-system-air-bleeding) ).

POWER STEERING PRESSURE SWITCH CHECK

Required Special Tools

1. MB990662: Power Steering Oil Pressure Gauge
2. MB991548: Power Steering Oil Pressure Gauge Adapter (Pump Side)
3. MB991549: Power Steering Oil Pressure Gauge Adapter (Hose Side)

Scheme 217

1. Disconnect the pressure hose from the oil pump, and then connect the special tools MB991548, MB990662 and MB991549.
2. Bleed air, and then turn the steering wheel several times while the vehicle is not moving so that the temperature of the fluid rises to approximately 50 - 60°C (122 - 140°F).
3. The engine should be idling.
4. Disconnect the connector for the oil pressure switch, and place an ohmmeter at the switch.
5. Gradually close the shut-off valve of the pressure gauge and increase the hydraulic pressure, then check whether or not the hydraulic pressure then check whether or not the hydraulic pressure that activates the switch is the standard value. Standard value: 1.8 - 2.4 MPa (261 - 348 psi)
6. Gradually open the shut-off valve and reduce the hydraulic pressure; then check whether or not the hydraulic pressure that deactivates the switch is the standard value. Standard value: 1.0 - 2.4 MPa (145 - 348 psi)
7. Remove the special tools MB991548, MB990662 and MB991549, and then tighten the pressure tube flare nut to the specified torque. Tightening torque: 18 +/- 3 N.m (13 +/- 2 ft-lb)
8. Bleed the system (Refer to «POWER STEERING SYSTEM AIR BLEEDING»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/manual-power-steering/#power-steering-evolution__power-steering-system-air-bleeding) ).

TIE ROD END BALL JOINT DUST COVER CHECK

1. Press the dust cover with your finger to check whether the dust cover is cracked or damaged.
2. If the dust cover is cracked or damaged, replace the tie rod end.

Note. If the dust cover is cracked or damaged, the ball joint could be damaged.

STEERING COLUMN SHAFT ASSEMBLY SHOCK ABSORBING MECHANISM CHECK

1. If a collision accident occurs or severe impact is applied on the steering wheel, the collision energy absorbing mechanism may have operated. Once the mechanism has operated, it will be inoperative even if there is no apparent damage. Determine if the steering column shaft can be reused by the following procedure. If the collision energy absorbing mechanism has already operated, replace the steering column shaft assembly.
2. If any excessive radial free play on the steering wheel is found with the tilt lever in the lock position, always check the steering shaft assembly.

Scheme 218

1. Remove the lower and upper column covers. CAUTION: On completion, do not release the tilt lever until the steering column has been installed.
2. Ensure that the tilt lever is in the lock position. NOTE: If not, place the tilt lever in the lock position.
3. Loosen the two upper steering column mounting bolts by two turns.
4. Hold the mounting base (Scheme 218), and then try to lock them. If there is a slack in either of the capsules, replace the steering column shaft assembly. NOTE: If not, place the tilt lever in the lock position. CAUTION: Be careful that nothing is pinched between the mounting base and the body. On completion, do not release the tilt lever until the steering column has been installed.
5. If no problem is found during the inspection, tighten the steering column mounting bolts to the specified torque. Tightening torque: 12 +/- 2 N.m (102 +/- 22 in-lb)

REMOVAL AND INSTALLATION

Scheme 219

<< A >> STEERING WHEEL REMOVAL

Insert special tool MB990784 at the indicated position to remove the cover.

Scheme 220

Note. Special tool MB990784 can be inserted through the notch behind the area shown.

Scheme 221

Scheme 222

1. By sliding section A of the clock spring connector (Scheme 221)in the arrow direction, disconnect the connector.
2. Loosen the bolt completely. Then, remove the steering wheel and airbag module assembly. NOTE: Use a hexagonal bit socket or a hexagonal wrench having an effective length of 75 mm (3.0 inches) or more in the hexagonal section and the diameter of 8 mm (0.31 inches) or more.

Scheme 223

<< A >>STEERING COLUMN SHAFT ASSEMBLY REMOVAL

Scheme 224

1. Ensure that the tilt lever is in the lock position, and remove the steering column mounting bolts.
2. Pinch the steering column shaft clip with pliers, and pull up the shaft towards the direction shown to disengage the steering column shaft assembly.

>> A << STEERING COLUMN SHAFT ASSEMBLY INSTALLATION

Ensure that the tilt lever is in the lock position, and install the steering column. Tighten the four bolts in the order shown by hand, and then tighten them to the specified torque in the order shown.

Scheme 225

1. Tightening torque: 12 +/- 2 N.m (102 +/- 22 in-lb)

DISASSEMBLY AND ASSEMBLY

Scheme 226

<< A >> SPECIAL BOLT REMOVAL

1. Drill in the special bolt a hole deep enough for the tap to stand.
2. Remove the special bolt with a left-hand tap.

Scheme 227

>> A << STEERING LOCK CYLINDER ASSEMBLY/STEERING LOCK BRACKET/SPECIAL BOLT INSTALLATION

Scheme 228

1. When installing the steering lock cylinder and steering lock bracket to the steering column assembly, temporarily install the steering lock in alignment with the column boss.
2. After checking that the lock works properly, tighten the special bolts until the head is twisted off.

Scheme 229

Scheme 230

<< A >> LOWER ARM ASSEMBLY REMOVAL

Lift the transaxle with a transmission jack, and then withdraw the front mounting bolt on the left lower arm assembly.

Scheme 231

<< B >> SELF LOCKING NUT (TIE ROD END AND KNUCKLE CONNECTION) DISCONNECTION

Scheme 232

Scheme 233

1. Install special tool MB991897 (Scheme 232)
2. Turn the bolt and knob as necessary to make the jaws of special tool MB991897 parallel, tighten the bolt by hand and confirm that the jaws are still parallel. NOTE: When adjusting the jaws in parallel, make sure the knob is in the position shown in the figure.
3. Tighten the bolt with a wrench to disconnect the tie rod end.

<< C >> FRONT AXLE NO. 1 CROSSMEMBER ASSEMBLY REMOVAL

Retain the crossmember with a transmission jack, and then remove the crossmember mounting bolt.

Scheme 234

JOINT COVER GROMMET INSTALLATION

Align the joint cover grommet notch (arrow A) with the steering gear lug (arrow B), and then install the steering joint cover to the steering gear.

Scheme 235

STEERING GEAR TOTAL PINION TORQUE CHECK

Required Special Tool

1. MB991006: Preload Socket

Scheme 236

1. Using special tool MB991006, rotate the pinion gear at the rate of one rotation in approximately 4 to 6 seconds to check the total pinion torque. Standard value: 0.8 - 1.8 N.m (7.1 - 15.9 in-lb) [Change in torque: 0.49 N.m (4.3 in-lb) or less] NOTE: When measuring, remove the bellows from the rack housing. Measure the pinion torque through the whole stroke of the rack. If the measured value is not within the standard range, first adjust the rack support cover, and then check the total pinion torque again.
2. If the total pinion torque cannot be adjusted to within the standard range by adjusting the rack support cover, rack support spring, or rack support, replace any parts if necessary.

Scheme 237

1. Give 10 hard swings to the tie rod.
2. Measure the tie rod swing resistance with a spring scale. Standard value: 8 - 27 N (1.8 - 6.1 lb) [1.5 - 4.9 N.m (13.2 - 43.4 in-lb)]
3. If the measured value exceeds the standard value, the tie rod can be re-used if it swings smoothly without excessive play.

1. Check the dust cover for cracks or damage by pushing it with your finger.
2. If the dust cover is cracked or damaged, replace the tie rod end. (Refer to «DISASSEMBLY AND ASSEMBLY»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/manual-power-steering/#power-steering-evolution) ).

Note. Cracks or damage of the dust cover may damage the ball joint. If it is damaged during service work, replace the dust cover. (Refer to TIE ROD END BALL JOINT DUST COVER REPLACEMENT .)

Scheme 238

Required Special Tools

1. MB990776: Front Axle Base
2. MB990927: Installer Adapter
3. MB990938: Bar (Snap-in type)
4. MB990939: Brass Bar
5. MB990941: Torque Tube Bearing Installer
6. MB991006: Preload Socket
7. MB991120: Needle Bearing Puller
8. MB991152: Dust Cover Installer
9. MB991197: Bar (Long type)
10. MB991199: Oil Seal and Bearing Installer
11. MB991203: Oil Seal and Bearing Installer
12. MB991214: Rack Installer
13. MB991317: Seal Ring Installer
14. MB991561: Boot Band Crimping Tool
15. MB991621: Rack Support Cover Wrench

Scheme 239

<< A >> RACK SUPPORT COVER REMOVAL

Using special tool MB991621, remove the rack support cover from the gear box.

Scheme 240

<< B >> LOWER OIL SEAL/PINION AND VALVE ASSEMBLY REMOVAL

Using a plastic hammer, gently tap the pinion to remove it.

Scheme 241

<< C >> SEAL RING REMOVAL

Cut the seal ring and remove it from the pinion and valve assembly and the rack.

Scheme 242

<< D >> UPPER BEARING/UPPER OIL SEAL REMOVAL

Using a socket, remove the oil seal and the ball bearing from the valve housing simultaneously.

Scheme 243

<< E >> CIRCLIP REMOVAL

Scheme 244

1. Turn the rack stopper clockwise until the end of the circlip comes out of the slot in the rack housing.
2. Turn the rack stopper counterclockwise to remove the circlip.

Scheme 245

Scheme 246

1. Pull out the rack slowly. Take out the rack stopper and the rack bushing at the same time. CAUTION: Do not damage the oil seal press fitting surface.
2. Partially bend the oil seal and remove it from the rack bushing.

<< G >> LOWER BEARING REMOVAL

Use a brass bar or special tool MB990939 to remove the ball bearing from the gear housing.

Scheme 247

<< H >> NEEDLE BEARING REMOVAL

Scheme 248

Use special tool MB991120 to remove the needle roller bearing from the rack housing.

<< I >> OIL SEAL REMOVAL

Use a piece of pipe or similar tool to remove the oil seal from the gear housing.

Scheme 249

>> A << OIL SEAL INSTALLATION

1. Apply a coating of GENUINE MITSUBISHI POWER STEERING FLUID to the both sides of the oil seal.
2. Using special tools MB991199 and MB991197, press the oil seal into the rack housing.

Scheme 250

Scheme 251

1. Apply GENUINE MITSUBISHI POWER STEERING FLUID to housing, bearing and oil seal press fitting surface. CAUTION: Press-fit straight. The valve housing is aluminum, and may become deformed if press-fit on an angle.
2. Press fit needle roller bearing with special tools MB990938 and MB991202.

>> C << RACK ASSEMBLY INSTALLATION

Scheme 252

1. Apply a coating of multipurpose grease to the rack teeth face.
2. Cover rack serrations with special tool MB991214.
3. Apply GENUINE MITSUBISHI POWER STEERING FLUID to special tool MB991214.
4. Align the center of the oil seal with the rack to prevent the retainer spring from slipping. Slowly insert the rack from power cylinder side.

Scheme 253

Scheme 254

Scheme 255

1. Apply GENUINE MITSUBISHI POWER STEERING FLUID to the outer surface of the oil seal. Using special tool MB990927, press in the oil seal until it is flush with the bushing end face.
2. Apply GENUINE MITSUBISHI POWER STEERING FLUID to the oil seal inner surface and the O-ring.
3. Wrap the rack end with plastic tape, and push the rack bushing onto the rack.

>> E << CIRCLIP INSTALLATION

Insert the circlip to the rack stopper hole through cylinder hole. Turn the rack stopper clockwise and insert the circlip firmly.

Scheme 256

>> F << UPPER OIL SEAL/UPPER BEARING INSTALLATION

Apply a coating of GENUINE MITSUBISHI POWER STEERING FLUID to the outside of the upper oil seal/upper bearing. Using special tools MB990938 and MB991203, press the upper oil seal/upper bearing into the valve housing.

Scheme 257

>> G << SEAL RING INSTALLATION

Because the seal rings expand after installation, tighten after installing by using special tool MB991317 to compress the rings, or press down by hand.

Scheme 258

>> H << LOWER OIL SEAL INSTALLATION

Scheme 259

Using special tool MB990941, press the oil seal into the valve housing.

Scheme 260

1. Apply 3M™ AAD Part number 8661, 8663, 8672, 8678, 8679 or equivalent to the threaded part of the end plug.
2. Secure the threaded portion of the end plug at two places by using a punch.

Scheme 261

1. Position the rack at its center.
2. Apply 3M™ AAD Part number 8661, 8663, 8672, 8678, 8679 or equivalent to the threaded part of the rack support cover.
3. Use special tool MB991621 to tighten the rack support cover to 23 +/- 2 N.m (17 +/- 1 ft-lb).
4. Turn the rack support cover 30 degrees counterclockwise.
5. Use special tool MB991204 to hold the rack support cover, and then tighten the jam nut to 59 +/- 10 N.m (44 +/- 7 ft-lb).

>> K << TOTAL PINION TORQUE ADJUSTMENT

Scheme 262

1. Using special tool MB991006, rotate the pinion shaft at the rate of one rotation in four to six seconds to check the total pinion torque and the change in torque. Standard value: Total pinion torque: 0.8 - 1.8 N.m (7.1 - 15.9 in-lb) [Change in torque: 0.49 N.m (4.3 in-lb) or less] CAUTION: When adjusting, set at the highest value of the standard value range.
2. If the total pinion torque or the change in torque is outside the standard value, move the rack support cover 0 - 30 degrees, and adjust the pinion torque again. NOTE: If the total pinion toque cannot be adjusted to the standard value within the specified return angle, check the rack support cover components and replace any parts if necessary.

>> L << GEAR MOUNTING RUBBER INSTALLATION

Install the gear mounting rubber to the rack housing so that the distance is (Scheme 263)

Scheme 263

>> M << TAB WASHER/TIE ROD INSTALLATION

After installing the tie rod to the rack, fold the tab washer end (two locations) to tie rod notch.

Scheme 264

Scheme 265

Scheme 266

1. Turn the adjusting bolt of special tool MB991561 to adjust the opening dimension (W) to the standard value. NOTE: The dimension (W) is adjusted by approximately 0.7 mm (0.03 inch) per one turn. NOTE: Do not turn the adjusting bolt more than one turn. Standard value (W): 2.9 mm (0.11 inch) < When more than 2.9 mm (0.11 inch) >: Screw in the adjusting bolt. < When less than 2.9 mm (0.11 inch) >: Loosen the adjusting bolt. CAUTION: Hold the rack housing, and use special tool MB991561 to crimp the bellows band securely. Crimp the bellows band until special tool MB991561 touches the stopper.
2. Use special tool MB991561 to crimp the bellows band.
3. Check that crimped width (A) is within the standard value. Standard value (A): 2.4 - 2.8 mm (0.09 - 0.11 inch) < When more than 2.8 mm (0.11 inch) >: Readjust the dimension (W) of step (1) to the value calculated by the following equation, and repeat step (2). W = 5.5 mm (0.22 inch) - A [Example: if (A) is 2.9 mm (0.11 inch), (W) is 2.6 mm (0.10 inch).] < When less than 2.4 mm (0.09 inch) >: Remove the bellows band, readjust the dimension (W) of step (1) to the value calculated by the following equation, and use a new bellows band to repeat steps (2) to (3). W = 5.5 mm (0.22 inch) - A [Example: if (A) is 2.3 mm (0.09 inch), (W) is 3.2 mm (0.13 inch).]

Scheme 267

>> O << TIE ROD END/JAM NUT INSTALLATION

Screw in the tie rod end to achieve the right and left length. (Scheme 268) Lock with the jam nut.

Scheme 268

Note. The locking nut must be tightened securely only after the power steering gear box and linkage are installed to the vehicle and toe-in is adjusted.

TIE ROD END BALL JOINT DUST COVER REPLACEMENT

If the dust cover is damaged accidentally during service work, replace the dust cover as follows

Scheme 269

1. Apply grease to the lip and inside of the dust cover.
2. Drive in the dust cover with special tool MB990776 until it is fully seated.
3. Check the dust cover for cracks or damage by pushing it with your finger.

Scheme 270

Scheme 271

Scheme 272

Scheme 273

1. Install the pressure hose so that the notch is fixed with bracket (Scheme 273)
2. Install the suction hose so that the marking is positioned (Scheme 273)

Scheme 274

INSPECTION

1. Check the drive belt for cracks.
2. Check the pulley for uneven rotation.

Scheme 275

<< A >> EYE BOLT/RETURN TUBE REMOVAL

1. Loosen the crossmember mounting bolts and nuts, and lower the crossmember to a position so that the eye bolts or return tube at the steering gear side can be removed. NOTE: In this case, do not remove the crossmember mounting bolts and nuts.
2. Remove the eye bolts or return tube.

Scheme 276

Scheme 277

1. Install the return hose so that the marking is positioned (Scheme 276)
2. Install the clip (Scheme 277)

Scheme 278

Scheme 279

1. Install the pressure hose on pump side so that the notch is fixed with bracket (Scheme 278)
2. Install the suction hose so that the marking is positioned (Scheme 278)
3. Install the pressure hose on gear box side so that its plate part is positioned (Scheme 279)

>> C << RETURN HOSE INSTALLATION

Install the return hose so that the marking is positioned (Scheme 280)

Scheme 280

Scheme 281

Scheme 282

GENERAL SPECIFICATIONS

Identifying General Specifications

Scheme 283

Scheme 284

Scheme 285

See also:
• 8. DRIVE BELT (FOR GENERATOR, WATER PUMP AND POWER STEERING OIL PUMP (CHECK CONDITION)
• FRONT WHEEL ALIGNMENT CHECK AND ADJUSTMENT
• IGNITION COIL
• AIR BAG SAFETY PRECAUTIONS
• DRIVER-SIDE AIR BAG MODULE & CLOCKSPRING
• SYMPTOM CHART
• POWER STEERING SYSTEM AIR BLEEDING
• TIE ROD END BALL JOINT BREAKAWAY TORQUE CHECK
• TIE ROD END BALL JOINT DUST COVER REPLACEMENT