ect MITSUBISHI LANCER 2005 Workshop Manual

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)

POWER STEERING OIL PUMP ASSEMBLY
POWER STEERING37-40
<2000>
>>A<<15. O-ring
16. Flow control springDisassembly steps (Continued)
17. Suction connector
>>A<<18. O-ringDisassembly steps (Continued)
AC100143AF
411
12
13
28 ± 2 N·m
102
9
8
6
5
7
3
1
28 ± 1 N·m
15
16
14
59 ± 9 N·m 9.9 ± 2.1 N·m
<Sedan, Wagon (Comfort)>
12 ± 1 N·m
<Wagon (Sport)>
18
17
5
7
3
98
6 3 13
10
2 13
10 15 18 114
3
Oil pump seal kit Oil pump cartridge kit Oil pump pulley and shaft kit
: ATF DEXRON III or DEXRON II
Disassembly steps
1. Pump cover
2. O-ring
3. Snap ring
4. Pulley and shaft
5. Vanes
>>C<<6. Cam ring
7. Rotor
8. Pin
9. Side plate
>>A<<10. O-ring
>>B<<11 . O i l s e a l
12. Terminal assembly
>>A<<13. O-ring
14. Plug assembly
>>A<<15. O-ring
16. Flow control spring
17. Suction connector
>>A<<18. O-ringDisassembly steps (Continued)

POWER STEERING OIL PUMP ASSEMBLY
POWER STEERING37-41
REASSEMBLY SERVICE POINTS
>>A<< O-RING INSTALLATION>>B<< OIL SEAL INSTALLATION
Use following special tool to install the oil seal.
•MB990938: Bar (Snap-in type)
•MB991203: Oil Seal and Bearing Installer
>>C<< CAM RING INSTALLATION
CAUTION
Be sure to install the cam ring in the correct
direction as shown.
Install the cam ring as shown in the illustration.
INSPECTIONM1372005500200
•Check the flow control valve of the pump body for
clogging.
•Check the pulley and shaft for wear or damage.
•Check the rotor and vane groove for "stepped"
wear.
•Check the contact surface of cam ring and vanes
for "stepped" wear.
•Check the vanes for damage. No. ID × Width mm
1 15.8 × 2.4
2 21.0 × 1.9
3 14.8 × 2.4
43.8 × 1.9
5 14.8 × 1.9
AC100170
AB
Suction connectorPlug assembly
Terminal assembly Side plate
1
2
3
4
5
AC000752
MB990938
AB
MB991203
AC100171AB
Side plate side
Pump cover side

POWER STEERING HOSES
POWER STEERING37-43
<RH drive vehicles>
•Centermember (Refer to GROUP 32,
Engine Roll Stopper Centermember
P.32-7).
•Front exhaust pipe (Refer to GROUP
15, Exhaust Pipe and Main Muffler
P.15-11).
4. Steering gear and joint connecting
bolt
5. Rear roll stopper connecting bolt
6. Rear roll stopper (Refer to GROUP
32, Engine Roll Stopper
Centermember P.32-7).
<<A>>7. Eye boltRemoval steps (Continued)
8. Gasket
9. Pressure hose assembly
10. Return tube
>>A<<11. Return hose
<<A>>12. Return tube
13. O-ringRemoval steps (Continued)
AC304698AB
15 ± 3 N·m
18 ± 2 N·m
167 ± 9 N·m 12 ± 2 N·m
49 ± 10 N·m 12 ± 2 N·m
57 ± 7 N·m*
3 1
2
9
10
7
5 6
24
8857 ± 7 N·m
167 ± 9 N·m
Crossmember12 ± 2 N·m <1300, 1600>
<2000>
7
6
57 ± 7 N·m
7 6
57 ± 7 N·m
7
6
57 ± 7 N·m
12 ± 2 N·m
Removal steps
1. Oil reservoir
>>C<<2. Suction hose
>>B<<3. Return hose•Clock spring (Refer to GROUP 52B,
Air Bag Modules and Clock Spring
P.52B-210). Removal steps (Continued)

POWER STEERING HOSES
POWER STEERING37-44
REMOVAL SERVICE POINT
<<A>> EYE BOLT/RETURN TUBE
REMOVAL
CAUTION
If the joint cover grommet has been removed,
install it properly as follows.
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.
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.
INSTALLATION SERVICE POINTS
>>A<< RETURN HOSE INSTALLATION
<LH DRIVE VEHICLES>
Install the return hose so that the marking is
positioned as shown in the illustration.
>>B<< RETURN HOSE INSTALLATION
Install the return hose so that the markings are
positioned as shown in the illustration.
>>C<< SUCTION HOSE INSTALLATION
Install the suction hose (oil pump side) so that the
marking is positioned forward.
•Centermember (Refer to GROUP 32,
Engine Roll Stopper Centermember
P.32-7).
•Front exhaust pipe (Refer to GROUP
15, Exhaust Pipe and Main Muffler
P.15-11).
4. Steering gear and joint connecting
bolt
5. Rear roll stopper connecting bolt
<<A>>6. Eye bolt
7. Gasket
8. Pressure hose assembly
<<A>>9. Return tube
10. O-ringRemoval steps (Continued)
AC304922AB
A
B Joint cover
grommet
Steering gear
AC100277
ABReturn hose
AC305132AB
Return hose
Return tubeReturn hose <L.H. drive vehicles> <R.H. drive vehicles>

42-2
TROUBLESHOOTING . . . . . . . . . .42-26
ON-VEHICLE SERVICE. . . . . . . . .42-27
DOOR FIT ADJUSTMENT. . . . . . . . . . . 42-27
DOOR WINDOW GLASS ADJUSTMENT42-28
GLASS SLIDING MECHANISM CHECK
AND ADJUSTMENT . . . . . . . . . . . . . . . 42-28
POWER WINDOW OPERATING
CURRENT CHECK . . . . . . . . . . . . . . . . 42-28
POWER WINDOW RELAY CHECK . . . 42-29
CIRCUIT BREAKER (INCORPORATED
IN THE POWER WINDOW MOTOR)
INSPECTION . . . . . . . . . . . . . . . . . . . . . 42-29
POWER WINDOW CHECK . . . . . . . . . . 42-29
CENTRAL DOOR LOCKING SYSTEM
INSPECTION . . . . . . . . . . . . . . . . . . . . . 42-29
DOOR OUTSIDE HANDLE PLAY
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . 42-29
DOOR INSIDE HANDLE PLAY
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . 42-30
DOOR ASSEMBLY . . . . . . . . . . . .42-31
REMOVAL AND INSTALLATION . . . . . 42-31
INSPECTION . . . . . . . . . . . . . . . . . . . . . 42-32
DOOR GLASS AND
REGULATOR . . . . . . . . . . . . . . . . .
42-32
REMOVAL AND INSTALLATION . . . . . 42-32
INSPECTION . . . . . . . . . . . . . . . . . . . . . 42-34
DOOR HANDLE AND LATCH . . . .42-36
REMOVAL AND INSTALLATION . . . . . 42-36
INSPECTION . . . . . . . . . . . . . . . . . . . . . 42-37
WINDOW GLASS RUNCHANNEL AND
DOOR OPENING
WEATHERSTRIP . . . . . . . . . . . . . .
42-39
REMOVAL AND INSTALLATION . . . . . 42-39
TRUNK LID . . . . . . . . . . . . . . . .42-41
SPECIAL TOOL . . . . . . . . . . . . . . .
42-41
ON-VEHICLE SERVICE. . . . . . . . .42-41
TRUNK LID ADJUSTMENT . . . . . . . . . . 42-41
ADJUSTMENT OF CLEARANCE
AROUND TRUNK LID . . . . . . . . . . . . . . 42-42
TRUNK LID STRIKER ADJUSTMENT . 42-42
TRUNK LID HEIGHT ADJUSTMENT . . 42-42
TRUNK LID . . . . . . . . . . . . . . . . . . .42-43
REMOVAL AND INSTALLATION . . . . . . 42-43
INSPECTION . . . . . . . . . . . . . . . . . . . . . 42-45
TAILGATE . . . . . . . . . . . . . . . . 42-46
SERVICE SPECIFICATIONS . . . . .
42-46
SEALANTS . . . . . . . . . . . . . . . . . . .42-46
SPECIAL TOOL . . . . . . . . . . . . . . .42-46
TROUBLESHOOTING . . . . . . . . . .42-46
ON-VEHICLE SERVICE . . . . . . . . .42-46
TAILGATE FIT ADJUSTMENT. . . . . . . . 42-46
TAILGATE HANDLE PLAY CHECK . . . . 42-47
TAILGATE . . . . . . . . . . . . . . . . . . .42-48
REMOVAL AND INSTALLATION . . . . . . 42-48
TAILGATE HANDLE AND
LATCH . . . . . . . . . . . . . . . . . . . . . .
42-50
REMOVAL AND INSTALLATION . . . . . . 42-50
INSPECTION . . . . . . . . . . . . . . . . . . . . . 42-51
KEYLESS ENTRY SYSTEM . . 42-51
SERVICE SPECIFICATIONS . . . . .
42-51
SPECIAL TOOLS . . . . . . . . . . . . . .42-52
TROUBLESHOOTING . . . . . . . . . .42-53
ON-VEHICLE SERVICE . . . . . . . . .42-53
KEYLESS ENTRY SYSTEM CHECK. . . 42-53
KEYLESS ENTRY SYSTEM TIMER
LOCK FUNCTION INSPECTION . . . . . . 42-53
ENABLING/DISABLING
THE ANSWERBACK FUNCTION . . . . . 42-53
HOW TO REGISTER SECRET CODE . 42-55
TRANSMITTER. . . . . . . . . . . . . . . .42-58
DISASSEMBLY AND REASSEMBLY . . 42-58
INSPECTION . . . . . . . . . . . . . . . . . . . . . 42-59

HOOD
BODY42-3
HOOD
ON-VEHICLE SERVICE
ADJUSTMENT OF CLEARANCE AROUND
HOOD
M1421007200129
ADJUSTMENT OF ALIGNMENT OF HOOD
STEPPED PORTION AND HOOD
STRIKER
M1421007300126
ADJUSTMENT OF HOOD HEIGHTM1421007400123
Rotate the hood bumper by using arrow mark on the
hood bumper as a guide to adjust the hood height. If
the hood bumper is rotated just one turn, the hood
height changes by approximately 3 mm.
AC005945
AC005947
Y0215AU
X0424CA
AC005948
AB
Section A – AA
A
Hood
Hood bumper 17 mm

FENDER
BODY42-5
FENDER
SPECIAL TOOLM1421000600256
AC300865
Note
: Clip positions
Section A – A
AC
Clip
A
A
6 8
6 8
Clip positions
Tool Number Name Use
MB990784 Ornament remover Side turn-signal lamp removal
MB990784

FENDER
BODY42-6
FENDER
REMOVAL AND INSTALLATIONM1421001900302
Pre-removal and Post-installation Operation
•Front Bumper Removal and Installation (Refer to GROUP
51, Front Bumper P.51-2.)
•Front Deck Garnish Removal and Installation (Refer to
GROUP 51, Windshield Wiper and Washer P.51-23.)
•Side Air Dam Removal and Installation <Vehicles with
side air dam> (Refer to GROUP 51, Side Air Dam
P.51-15.)
AC300491
AC304753
AC303863
Clip Section A – A
AB
A A
123
3 4
Note
: Clip positions
Removal steps
1. Splash shield
<<A>> >>A<<2. Side turn-signal lamp3. Delta outer garnish
4. FenderRemoval steps (Continued)

WINDOW GLASS
BODY42-10
WINDOW REPAIRM1422005600027
The windshield, rear window glass, quarter window
glass and tailgate window glass are attached by an
urethane-base adhesive to the window frame. This
adhesive provides improved glass holding and
sealing, and also gives body openings a greater
structural strength.
ITEMS
HANDLING OF AUTO WINDOW SEALER
Keep the sealant in a cool place, not exposed to the
direct rays of the sun. Do not place any heavy article
on the sealant nor press it, otherwise it will become
deformed. Avoid storing the sealant for more than 6
months, because it will lose its sealing effect.
BODY PINCH-WELD FLANGE SERVICING
Before servicing the body pinch-weld flange, remove
old adhesive completely. If the flange requires
painting, bake it after painting is completed. Name Remark
Adhesive 3M ATD Part No.8609 Super Fast Urethane Auto Glass Sealant or
equivalent
Primer 3M ATD Part No.8608 Super Fast Urethane Primer or equivalent
Spacers Available as service part
Dam Available as service part
Anti-rust solvent (or Tectyl
506T.Valvoline Oil Company)For rust prevention
Isopropyl alcohol For grease removal from bonded surface
Steel piano wire Dia. × length... 0.6mm × 1m For cutting adhesive
Glass adhesive knife For cutting adhesive
Adhesive gun For pressing-out adhesive