Head assembly MITSUBISHI LANCER 2005 User Guide

54A-2
COMBINATION METER
ASSEMBLY . . . . . . . . . . . . . . . .
54A-29
SERVICE SPECIFICATIONS. . . . .
54A-29
SEALANT. . . . . . . . . . . . . . . . . . . .54A-29
SPECIAL TOOLS. . . . . . . . . . . . . .54A-29
TROUBLESHOOTING . . . . . . . . . .54A-31
SYMPTOM CHART . . . . . . . . . . . . . . . . 54A-31
SYMPTOM PROCEDURES . . . . . .54A-32
ON-VEHICLE SERVICE. . . . . . . . .54A-60
SPEEDOMETER CHECK . . . . . . . . . . . 54A-60
TACHOMETER CHECK . . . . . . . . . . . . 54A-60
FUEL TANK GAUGE UNIT CHECK . . . 54A-61
ENGINE COOLANT TEMPERATURE GAUGE
UNIT CHECK . . . . . . . . . . . . . . . . . . . . . 54A-61
COMBINATION METER ASSEMBLY54A-63
REMOVAL AND INSTALLATION . . . . . 54A-63
INSPECTION . . . . . . . . . . . . . . . . . . . . . 54A-64
DISASSEMBLY AND REASSEMBLY . . 54A-65
HEADLAMP . . . . . . . . . . . . . . . .54A-66
SERVICE SPECIFICATIONS. . . . .
54A-66
TROUBLESHOOTING . . . . . . . . . .54A-66
ON-VEHICLE SERVICE. . . . . . . . .54A-66
HEADLAMP AIMING . . . . . . . . . . . . . . . 54A-66
LUMINOUS INTENSITY
MEASUREMENT . . . . . . . . . . . . . . . . . . 54A-67
BULB REPLACEMENT . . . . . . . . . . . . . 54A-68
HEADLAMP . . . . . . . . . . . . . . . . . .54A-69
REMOVAL AND INSTALLATION . . . . . 54A-69
HEADLAMP LEVELING SWITCH .54A-70
REMOVAL AND INSTALLATION . . . . . 54A-70
INSPECTION . . . . . . . . . . . . . . . . . . . . . 54A-70
FOG LAMP . . . . . . . . . . . . . . . . 54A-71
SERVICE SPECIFICATION . . . . . .
54A-71
SPECIAL TOOL . . . . . . . . . . . . . . .54A-71
TROUBLESHOOTING . . . . . . . . . .54A-71
ON-VEHICLE SERVICE . . . . . . . . .54A-71
FRONT FOG LAMP AIMING CHECK . . 54A-71
FOG LAMP . . . . . . . . . . . . . . . . . . .54A-73
REMOVAL AND INSTALLATION . . . . . . 54A-73
FOG LAMP SWITCH . . . . . . . . . . .54A-74
REMOVAL AND INSTALLATION . . . . . . 54A-74
INSPECTION . . . . . . . . . . . . . . . . . . . . . 54A-74
REAR FOG LAMP . . . . . . . . . . 54A-75
TROUBLESHOOTING . . . . . . . . . .
54A-75
SPECIAL TOOL . . . . . . . . . . . . . . .54A-75
REAR FOG LAMP . . . . . . . . . . . . .54A-76
REMOVAL AND INSTALLATION . . . . . . 54A-76
REAR FOG LAMP SWITCH . . . . . .54A-76
REMOVAL AND INSTALATION . . . . . . . 54A-76
INSPECTION . . . . . . . . . . . . . . . . . . . . . 54A-76
SIDE TURN-SIGNAL LAMP. . . 54A-77
SPECIAL TOOL . . . . . . . . . . . . . . .
54A-77
SIDE TURN-SIGNAL LAMP . . . . . .54A-77
REMOVAL AND INSTALLATION . . . . . . 54A-77
ROOM LAMP . . . . . . . . . . . . . . 54A-78
TROUBLESHOOTING . . . . . . . . . . . . . . 54A-78
Continued on next page

HEADLAMP
CHASSIS ELECTRICAL54A-69
HEADLAMP
REMOVAL AND INSTALLATIONM1542001800244
REMOVAL SERVICE POINT
<<A>> HEADLAMP ASSEMBLY
REMOVAL1. Remove the splash shield, the radiator grill, the
front bumper assembly installation clips, the
screws and the bolts as shown.
2. Slide the front bumper assembly and remove the
headlamp assembly.
Post-installation Operation
Headlamp Aiming Adjustment (Refer to P.54A-66.)
AC304719
1
AB
Removal steps
<<A>>1. Headlamp assembly
AC300690
AC300678

REAR COMBINATION LAMP
CHASSIS ELECTRICAL54A-79
REAR COMBINATION LAMP
TROUBLESHOOTINGM1542000701322
The lamps setup on the rear combination lamp is
controlled in the same manner as the lamps of the
headlamp assembly. For details go to the reference.
For troubleshooting, refer to respective Groups
below.•Not using SWS monitor: GROUP 54B, SWS
Troubleshooting P.54B-38.
•Using SWS monitor: GROUP 54C, SWS
Troubleshooting P.54C-22.
SPECIAL TOOLM1542000600924
REAR COMBINATION LAMP
REMOVAL AND INSTALLATIONM1542003900441
<Sedan>
Tool Number Name Use
MB990784 Ornament remover Removal of rear combination
lamp assembly
MB990784
AC304667
4.9 ± 0.7 N·m
AB
3
4
2
1
Removal steps
1. Rear combination lamp assembly
2. Rear combination lamp body3. Socket assembly
4. BulbRemoval steps (Continued)

ANTENNA
CHASSIS ELECTRICAL54A-94
ANTENNA
REMOVAL AND INSTALLATIONM1544002900529
<Sedan>
Pre-removal and Post-installation Operation
•Front pillar trim, Rear pillar trim, Centre pillar trim lower,
Centre pillar trim upper (Refer to GROUP 52A − Trims
P.52A-11.)
•Headlining Removal and Installation (Refer to GROUP
52A, Headlining P.52A-21.)
AC305315AB
1
23
1. Roof antenna poleRemoval steps
2. Roof antenna base
•Instrument panel assembly (Refer to
GROUP 52A, Instrument panel assembly
P.52A-2.)
3. Antenna feeder cable

REAR WINDOW DEFOGGER
CHASSIS ELECTRICAL54A-95
<Wagon>
REAR WINDOW DEFOGGER
GENERAL INFORMATIONM1543000100319
Rear Defogger operation
The defogger relay turns ON if the defogger switch
built-in the A/C-ECU is turned ON when the ignition
switch is in the "ON" position. When the defogger
relay turns ON, power is supplied to the defogger
and the defogger is activated. The defogger comes
with a timer function that causes the defogger switch
to automatically turn OFF in about 11 minutes after
the defogger switch is turned ON.
TROUBLESHOOTINGM1543000701013
The rear window defogger is controlled by the
A/C-ECU. For troubleshooting, refer to GROUP 55-
Troubleshooting P.55-5.
Pre-removal and Post-installation Operation
•Front pillar trim, Centre pillar trim lower, Centre pillar trim
upper, Quarter trim lower, Quarter trim upper (Refer to
GROUP 52A − Trims P.52A-11.)
•Headlining Removal and Installation (Refer to GROUP
52A, Headlining P.52A-21.)
AC305316
AB
1
23
1. Roof antenna poleRemoval steps
2. Roof antenna base
•Instrument panel assembly (Refer to
GROUP 52A, Instrument panel assembly
P.52A-2.)
3. Antenna feeder cable

ON-VEHICLE SERVICE
HEATER, AIR CONDITIONER AND VENTILATION55-74
REFRIGERANT LEAK REPAIR
PROCEDURE
M1552001500277
LOST CHARGE
If the system has lost all charge due to a leak:
1. Evacuate the system (Refer to P.55-72).
2. Charge the system with approximately 480 − 520
g of refrigerant.
3. Check for leaks.
4. Discharge the system.
5. Repair leaks.
CAUTION
Replacement filter-drier units must be sealed
while in storage. The drier used in these units will
saturate water quickly upon exposure to the
atmosphere. When installing a drier, have all
tools and supplies ready for quick assembly to
avoid keeping the system open any longer than
necessary.
6. Replace receiver drier.
7. Evacuate and charge system.
LOW CHARGE
If the system has not lost all of its refrigerant charge;
locate and repair all leaks. If it is necessary to
increase the system pressure to find the leak
(because of an especially low charge) add
refrigerant. If it is possible to repair the leak without
discharging the refrigerant system, use the
procedure for correcting low refrigerant level.
HANDLING TUBING AND FITTINGS
Kinks in the refrigerant tubing or sharp bends in the
refrigerant hose lines will greatly reduce the capacity
of the entire system. High pressures are produced in
the system when it is operating. Extreme care must
be exercised to make sure that all connections are
pressure tight. Dirt and moisture can enter the
system when it is opened for repair or replacement of
lines or components. The following precautions must
be observed. The system must be completely
discharged before opening any fitting of connection
in the refrigeration system. Open fittings with caution
even after the system has been discharged. If any
pressure is noticed as a fitting is loosened, allow
trapped pressure to bleed off very slowly.
Never attempt to rebend formed lines to fit. Use the
correct line for the installation you are servicing. A
good rule for the flexible hose lines is keep the radius
of all bends at least 10 times the diameter of the
hose.Sharper bends will reduce the flow of refrigerant. The
flexible hose lines should be routed so that they are
at least 80 mm from the exhaust manifold. It is good
practice to inspect all flexible hose lines at least once
a year to make sure they are in good condition and
properly routed.
On standard plumbing fittings with O-rings, these
O-rings are not reusable.
COMPRESSOR NOISE CHECKM1552008700272
You must first know the conditions when the noise
occurs. These conditions are: weather, vehicle
speed, in gear or neutral, engine temperature or any
other special conditions.
Noises that develop during A/C operation can often
be misleading. For example: what sounds like a
failed front bearing or connecting rod, may be
caused by loose bolts, nuts, mounting brackets, or a
loose clutch assembly. Verify accessory drive belt
tension (power steering or alternator).
Improper accessory drive belt tension can cause a
misleading noise when the compressor is engaged
and little or no noise when the compressor is
disengaged.
Drive belts are speed-sensitive. That is, at different
engine speeds, and depending upon belt tension,
belts can develop unusual noises that are often
mistaken for mechanical problems within the
compressor.
ADJUSTMENT
1. Select a quiet area for testing. Duplicate
conditions as much as possible. Switch the
compressor on and off several times to clearly
identify compressor noise. To duplicate high
ambient conditions (high head pressure), restrict
air flow through the condenser. Install a manifold
gauge set to make sure discharge pressure
doesn't exceed 2,070 kPa.
2. Tighten all compressor mounting bolts, clutch
mounting bolt, and compressor drive belt. Check
to assure clutch coil is tight (no rotation or
wobble).
3. Check refrigerant hoses for rubbing or
interference that can cause unusual noises.
4. Check refrigerant charge (Refer to P.55-69).
5. Recheck compressor noise as in Step 1.
6. If noise still exists, loosen compressor mounting
bolts and retighten. Repeat Step 1.
7. If noise continues, replace compressor and repeat
Step 1.

CENTRALIZED JUNCTION
CIRCUIT DIAGRAMS90-10
CENTRALIZED JUNCTION
M1901000300991
FUSIBLE LINK AND FUSE
ENGINE COMPARTMENT
No. Power supply circuit Name Rated
capacity (A)Housing
colourLoad circuit
1 Battery/ Alternator
(Fusible link No.26)Fusible
link60 Yellow Fuse No.15, 16, 19, 20 (in junction
block) circuit
2 50 Red Fan controller
3 60 Yellow ABS-ECU
4 40 Green Ignition switch circuit
5 30 Pink Power window main switch and power
window sub switch
6 Fuse 15 Blue Front fog lamp, front fog lamp
indicator lamp, front fog lamp relay
and spare connector (for front fog
lamp)
7 10 Red Horn relay and horn
8 20 Yellow Air cleaner air flow sensor, camshaft
position sensor, emission solenoid
valve (EGR system), emission
solenoid valve (purge control system),
engine-A/T-ECU, engine-ECU, engine
control oxygen sensor, engine control
relay, engine crank angle sensor, fan
control relay, fuel injector, ignition coil
relay, immobilizer-ECU and throttle
body idle speed control servo
9 10 Red A/C compressor
10 15 Blue ABS-ECU, engine-A/T-ECU, high
mount stop lamp and rear combination
lamp
11 15 Blue Accessory socket
12 7.5 Brown Alternator
13 10 Red ETACS-ECU, front turn signal lamp,
rear combination lamp, side turn
signal lamp and turn signal indicator
lamp
14 20 Yellow A/T control solenoid valve assembly
and engine-A/T-ECU
15 15 Blue Fuel pump
16 Front-ECU
(Headlamp relay: HI)10 Red Headlamp (RH)
17 10 Red Headlamp (LH) and high beam
indicator lamp
18 Front-ECU
(Headlamp relay: LO)10 Red Headlamp (RH)
19 10 Red Headlamp (LH), headlamp assembly
and headlamp levelling switch

CENTRALIZED JUNCTION
CIRCUIT DIAGRAMS90-11
20 Front-ECU (Tail lamp
relay)Fuse 7.5 Brown A/C-ECU, ashtray illumination lamp,
cigarette lighter illumination lamp,
combination meter, fog lamp switch,
front turn signal lamp, hazard warning
switch, headlamp assembly (RH),
headlamp levelling switch, heated
seat switch, heater control unit,
licence plate lamp, rear combination
lamp, rheostat, side turn signal lamp
and spare connector (for audio)
21 7.5 Brown Combination meter, headlamp
assembly (LH), licence plate lamp,
position lamp (LH) and rear
combination lamp (LH)
22 Battery/ Alternator
(Fusible link No.26)10 Red Combination meter, column switch,
ETACS-ECU and front-ECU
23 Ignition switch (ACC) 10 Red Clock, ETACS-ECU and spare
connector (for audio)
24
−−−−
25 Battery/ Alternator
(Fusible link No.26)20 Yellow Heated seat assembly and heated
seat switch
26 Alternator Fusible
link100 <4G1>
120 <4G6>−Battery, fusible link No.1, 2, 3, 4, 5,
fuse No.6, 7, 8, 9, 10, 11, 12, 13, 14,
15, 22 (relay box) and front-ECU No. Power supply circuit Name Rated
capacity (A)Housing
colourLoad circuit
AC208462
Front of vehicle
(Relay box in engine compartment)
1
6
7 8 9 10 1112 13141524
4 25
2316
1718
1920
2123 225
AO