service MITSUBISHI LANCER 2005 Workshop Manual

STEERING SHAFT
POWER STEERING37-21
STEERING SHAFT
REMOVAL AND INSTALLATIONM1372011500113
WARNING
Before removing the steering wheel and air bag module assembly, refer to GROUP 52B,
Service Precautions (P.52B-5) and Air Bag Module and Clock Spring (P.52B-210).
REMOVAL SERVICE POINT
<<A>> STEERING COLUMN SHAFT
ASSEMBLY REMOVAL
CAUTION
The tilt lever should be held in the lock position
until the steering column shaft is installed to the
vehicle. If the steering column is removed with
the tilt lever released, or the tilt lever is released
after the steering column shaft was removed from the vehicle, the steering column can not be
reinstalled correctly. If the steering column is
installed incorrectly, the collision energy
absorbing mechanism may be damaged.
1. Ensure that the tilt lever is in the lock position, and
remove the steering column mounting bolts.
Pre-removal Operation
•Steering Wheel and Air bag Module Assembly Removal
(Comfort: refer to P.37-17/Sport: refer to P.37-19).
•Under Cover Removal (Refer to GROUP 52A, Instrument
Panel P.52A-2).Post-installation Operation
•Under Cover Installation (Refer to GROUP 52A,
Instrument Panel P.52A-2).
•Steering Wheel and Air bag Module Assembly Installation
(Comfort: refer to P.37-17/Sport: refer to P.37-19).
AC304919AB
12 ± 2 N·m
18 ± 2 N·m
5.0 ± 1.0 N·m
1 2
73 2
1
8
86
A
A
Ta bSection A - A
Section B - B
BB
Toe board
Specified sealant:
3M ATD Part No.8513 or equivalent
BB
4
5
(mounting screw)2.5 ± 0.5 N·m
Removal steps
1. Lower column cover
2. Upper column cover
3. Clock spring and column switch
assembly
4. Cover <A/T>5. Key interlock cable <A/T> (Refer to
GROUP 23A, A/T Key Interlock and
Shift Lock Mechanism P.23A-151).
6. Shaft cover
<<A>> >>A<<7. Steering column shaft assembly
8. Cover assemblyRemoval steps (Continued)

STEERING SHAFT
POWER STEERING37-22
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.
INSTALLATION SERVICE POINT
>>A<< STEERING COLUMN SHAFT
ASSEMBLY INSTALLATION
CAUTION
•When reusing the steering column, do not
release the tilt lever until the steering column
shaft has been installed.•When the steering column is replaced, do not
release the tilt lever until it has been installed.
Do not remove the tilt lever fixing band until
the installation has completed.
•When installing the steering column, do not
leave it fixed temporarily at only one point
and make sure the column shaft is not shaken
strongly. If you fail to do, the collision
absorbing mechanism at the column shaft
mounting location may be damaged.
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.
Tightening torque: 12 ± 2 N⋅m
DISASSEMBLY AND REASSEMBLYM1372011700106
AC210969AD
Clip
Steering column
shaft
AC209383
AD
14
32
Tilt lever
AC210967AD
3 2 14
Disassembly steps
<<A>> >>A<<1. Special bolt
>>A<<2. Steering lock bracket
>>A<<3. Steering lock cylinder assembly
4. Steering column shaft assemblyDisassembly steps (Continued)

STEERING SHAFT
POWER STEERING37-23
DISASSEMBLY SERVICE POINT
<<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.
REASSEMBLY SERVICE POINT
>>A<< STEERING LOCK CYLINDER
ASSEMBLY/STEERING LOCK
BRACKET/SPECIAL BOLT
INSTALLATION
CAUTION
The steering lock bracket and bolts must be
replaced with new ones when the steering lock is
installed.
1. When installing the steering lock cylinder
assembly and steering lock bracket to the column
tube, 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 twists off.
ACX01138
AB
Steering lock
bracket
Reverse screw tap
Special bolt
Steering lock
cylinder
ACX01139AB

POWER STEERING GEAR BOX AND LINKAGE
POWER STEERING37-24
POWER STEERING GEAR BOX AND LINKAGE
REMOVAL AND INSTALLATIONM1372010900237
WARNING
Before removing the steering gear, refer to GROUP 52B, Service Precautions (P.52B-5) and
Air Bag Module and Clock Spring (P.52B-210). Centre the front wheels. Failure to do so may
damage the SRS clock spring and render the SRS system inoperative, risking serious injury.
Pre-removal Operation
•Power Steering Fluid Draining (Refer to P.37-13.)Post-installation Operation
•Check the dust cover for cracks or damage by pushing it
with your finger.
•Power Steering Fluid Supplying (Refer to P.37-13.)
•Power Steering Fluid Line Bleeding (Refer to P.37-13.)
•Checking Steering Wheel Position with Wheels Straight
Ahead.
•Front Wheel Alignment Adjustment (Refer to GROUP 33,
On-vehicle Service − Front Wheel Alignment Check and
Adjustment P.33-5.)
AC304920
AB
57 ± 7 N·m
15 ± 3 N·m 70 ± 10 N·m
7
3 8
5
6
9
1024
1
12 ± 2 N·m
12 ± 2 N·m
<L.H. drive vehicles>
Removal steps
1. Crossmember (Refer to GROUP 32,
Crossmember P.32-8).
•Engine rear roll stopper bracket (Refer
to GROUP 32, Engine Roll Stopper
and Centermember P.32-7).
>>A<<2. Joint cover grommet
3. Return hose4. Return tube
5. O-ring
6. Return tube
7. Eye bolt
8. Pressure hose assembly
9. Clamp
10. Steering gear and linkageRemoval steps (Continued)

POWER STEERING GEAR BOX AND LINKAGE
POWER STEERING37-26
INSTALLATION SERVICE POINT
>>A<< 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.
INSPECTIONM1372011000237
STEERING GEAR TOTAL PINION
TORQUE CHECK
CAUTION
When holding the steering gear in a vice, secure
its mounting positions. If it is secured in any
other place, the gear housing may become
deformed or damaged.
Using special tool preload socket (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: 0.7 − 1.6 N⋅m
1300, 1600(Comfort): 0.8 − 2.1
1600(Sport), 2000: 0.7 − 2.1
[Change in torque: 0.6 N⋅m 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.
If the total pinion torque cannot be adjusted to within
the standard range by adjusting the rack support
cover, check the rack support cover, rack support
spring, rack support and replace any parts if
necessary.
TIE ROD SWING RESISTANCE CHECK
1. Give 10 hard swings to the tie rod.
2. Measure the tie rod swing resistance [tie rod
swing torque] with a spring balance.
Standard value: 8 − 27 N [1.5 − 4.9 N⋅m]
3. If the measured value exceeds the standard
value, replace the tie rod.
4. If the measured value is below the standard value,
the tie rod can be re-used if it swings smoothly
without excessive play.
TIE ROD END BALL JOINT DUST COVER
CHECK
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 P.37-27).
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
P.37-36).
AC304922AB
A
B Joint cover
grommet
Steering gear
AC000996 AC
MB991006
AC000997

POWER STEERING GEAR BOX AND LINKAGE
POWER STEERING37-30
DISASSEMBLY SERVICE POINTS
<<A>> RACK SUPPORT COVER
REMOVAL
Using the following special tool, remove the rack
support cover from the steering gear.
•MB990607: Torque Wrench Socket <Comfort>
•MB991621: Piston Driver <Sport>
<<B>> LOWER OIL SEAL/PINION AND
VALVE ASSEMBLY REMOVAL
Using a plastic hammer, gently tap the pinion to
remove it.
<<C>> SEAL RING REMOVAL
CAUTION
When cutting the seal ring, be careful not to
damage the pinion and valve assembly or the
rack.
Cut the seal ring and remove it from the pinion and
valve assembly or the rack.
<<D>> UPPER BEARING/UPPER OIL
SEAL REMOVAL
Using a socket, remove the oil seal and the ball
bearing from the valve housing simultaneously.
AC209838
MB990607
AC
<Comfort>
AC103692AD
MB991621 <Sport>
ACX01143
AB
ACX01144
AB
ACX01145
AC
Socket

POWER STEERING GEAR BOX AND LINKAGE
POWER STEERING37-32
REASSEMBLY SERVICE POINTS
>>A<< OIL SEAL INSTALLATION
1. Apply a coating of ATF DEXRON III or DEXRON II
to the both sides of the oil seal.
2. Using the following special tools, press the oil seal
into the rack housing.
•MB991197: Bar (long type)
•MB991199: Oil Seal Installer <Sport>
•MB991202: Oil Seal and Bearing Installer
<Comfort>
>>B<< NEEDLE BEARING/LOWER
BEARING INSTALLATION
1. Apply ATF DEXRON III or DEXRON II to housing
and bearing press fitting surface.
CAUTION
Press-fit straight. The valve housing is
aluminium, and may become deformed if
press-fit on an angle.
2. Press fit needle bearing/lower bearing with the
following special tools.
•MB990938: Bar (snap-in type)
•MB991202: Oil Seal and Bearing Installer
>>C<< RACK ASSEMBLY INSTALLATION
CAUTION
Do not close the vent hole in the rack with
grease.
1. Apply a coating of repair kit grease to the rack
teeth face.
2. Cover rack serrations with the following special
tool.
•MB991212: Oil Seal Protector <Comfort>
•MB991213: Oil Seal Protector <Sport>
3. Apply ATF DEXRON III or DEXRON II to special
tool, and to the outer surface of the seal ring and
the O-ring.
4. Align the centre of the oil seal with the rack to
prevent the retainer spring from slipping. Slowly
insert the rack from power cylinder side.
AC100260AD
MB991197
Oil seal MB991202 <Comfort>
MB991199 <Sport>
Gear housing
ACX01153
Needle bearing
MB990938
MB991202MB991202
Lower
bearing
AE MB990938
ACX01154
AB
Seal ring and O-ringVent hole
ACX01155
MB991212 <Comfort>
MB991213 <Sport>
AG
Oil seal

POWER STEERING GEAR BOX AND LINKAGE
POWER STEERING37-36
>>N<< TIE ROD END/LOCK NUT
INSTALLATION
Screw in the tie rod end to achieve the right and left
length as illustrated. Lock with the lock nut.
NOTE: The lock nuts must be tightened securely
only after the steering gear is installed to the vehicle
and toe-in is adjusted.
>>O<< GEAR MOUNTING RUBBER
INSTALLATION
Install the gear mounting rubber to the rack housing
so that the distance is as shown in the illustration.
TIE ROD END BALL JOINT DUST COVER
REPLACEMENT
M1372008200327
If the dust cover is damaged accidentally during
service work, replace the dust cover as follows:
1. Apply specified grease to the lip and inside of the
dust cover.
Specified grease:
Multipurpose grease SAE J310, NLGI No.2 or
equivalent
2. Drive in the dust cover with special tool front axle
base (MB990776) until it is fully seated.
3. Check the dust cover for cracks or damage by
pushing it with your finger.
AC001011
AM
Lock nut Edge of bellows
assembly groove
180 mm
AC100275
AB
220 mm
AC001012
AB
MB990776

POWER STEERING OIL PUMP ASSEMBLY
POWER STEERING37-37
POWER STEERING OIL PUMP ASSEMBLY
REMOVAL AND INSTALLATIONM1372005200298
<1300, 1600>
Pre-removal Operation
•Power Steering Fluid Draining (Refer to P.37-13).Post-installation Operation
•Power Steering Fluid Supplying and Bleeding (Refer to
P.37-13).
•Drive Belt Tension Check (1300, 1600: refer to GROUP
11A, On-vehicle Service − Drive Belt Tension Check
P.11A-7/2000: refer to GROUP 11C, On-vehicle Service −
Drive Belt Tension Check P.11C-7).
AC209708
87
12 34
5
6
57 ± 7 N·m
40 ± 4 N·m 22 ± 4 N·m
N
9
40 ± 5 N·m
AC
Removal steps
1. Pressure switch connector
2. A/C compressor harness connector
bracket <Vehicles with A/C>
3. Drive belt
4. Suction hose5. Eye bolt
6. O-ring
7. Pressure hose
8. Oil pump assembly
9. Oil pump braceRemoval steps (Continued)

POWER STEERING OIL PUMP ASSEMBLY
POWER STEERING37-38
<2000>
REMOVAL SERVICE POINT
<<A>> OIL PUMP ASSEMBLY REMOVAL
<2000>
With the engine lifted by the jack, remove the oil
pump assembly mounting bolt (lower side) at the
pulley side.
INSPECTIONM1372005300187
•Check the drive belt for cracks.
•Check the pulley for uneven rotation.
AC200116
AB
22 ± 4 N·m 12 ± 2 N·m
22 ± 4 N·m 49 ± 9 N·m57 ± 7 N·m
1
5 4 3
6 2
7
49 ± 9 N·m
Removal steps
1. Pressure switch connector
2. Drive belt
3. Suction hose
4. Pressure hose<<A>>5. Oil pump assembly
6. A/C compressor harness
7. Power steering pump bracketRemoval steps (Continued)