Lamp MITSUBISHI LANCER 2005 Owner's Manual

STARTING SYSTEM
ENGINE ELECTRICAL16-22
REMOVAL AND INSTALLATION <4G6>M1162001000617
REMOVAL SERVICE POINT
<<A>> STARTER ASSEMBLY REMOVAL
Remove the starter assembly from above the
vehicle.
Pre-removal and Post-installation Operation
•Air Cleaner Assembly Removal and Installation (Refer to
GROUP 15 P.15-3).
•Under Cover Removal and Installation
AC304005
521
6
49 ± 9 N·m 18 ± 3 N·m9.0 ± 2.0 N·m
30 ± 3 N·m
AB
4
3
Removal steps
1. Starter cover
2. Starter connector and terminal
3. Clutch release cylinder connecting
bolts4. Clutch hose clamp
<<A>>5. Starter assembly
6. Starter cover bracketRemoval steps (Continued)

STARTING SYSTEM
ENGINE ELECTRICAL16-27
DISASSEMBLY SERVICE POINTS
<<A>> MAGNETIC SWITCH REMOVAL
CAUTION
Do not clamp the yoke assembly with a vise.
Disconnect the lead from the M terminal of the
magnetic switch.
<<B>> SNAP RING/STOP RING REMOVAL
1. Apply a long socket wrench of an appropriate size
to the stop ring and strike the wrench to drive out
the stop ring toward the pinion gear side.
2. Remove the snap ring with snap ring pliers, then
remove the stop ring and overrunning clutch.
STARTER MOTOR PARTS CLEANING
Never clean in a solvent such starter motor parts
as the magnetic switch, brush holder, and
armature. If they are soaked in a solvent, their
insulation could be impaired. When these parts
require cleaning, wipe off contamination with
cloth.
1. Never soak the drive unit in a solvent. If it is
washed in a solvent, the grease having been
packed in the overrunning clutch at the factory will
be washed out. Wipe the drive unit with cloth if it
requires cleaning.
REASSEMBLY SERVICE POINTS
>>A<< STOP RING/SNAP RING
INSTALLATION
Use a suitable puller to pull the stop ring until it gets
over the snap ring.
INSPECTION M1162001300157
COMMUTATOR
1. Support the armature with a pair of V block and
turn it to measure the runout of the surface not
rubbed by the brushes using a dial gauge.
Standard value: 0.05 mm or less
Limit: 0.1 mm
AK201882
B terminal
M terminal S terminal
AC
AK100883AC
Socket wrench
Stop ring
Pinion Gear
Overrunning
clutch
AK202791
Snap ring
pliersSnap ring
Pinion gear
Overrunning
clutch
AB
AK202911
Overrunning
clutchStop ring
Snap ring Stop ring
AB
AK202712

IGNITION SYSTEM
ENGINE ELECTRICAL16-33
SPARK PLUG CHECK AND CLEANING
<4G6>
M1163004300353
CAUTION
When pulling off the spark plug cable from the
plug always hold the cable cap, not the cable.
1. Remove the spark plug cables.
2. Remove the spark plugs.
CAUTION
•Do not attempt to adjust the gap of the iridium
plug.
•Always use a plug cleaner and finish cleaning
within 20 seconds. Do not use wire brushes.
Otherwise, the iridium and platinum tip may
be damaged.
3. Check the plug gap and replace if the limit is
exceeded.
Standard value: 1.0 − 1.1 mm
Limit: 1.3 mm
CAUTION
Be careful not to allow foreign matter in
cylinders.
4. Clean the engine plug holes.
5. Install the spark plugs.
CAMSHAFT POSITION SENSOR CHECKM1163004400219
Check the camshaft position sensor circuit if
self-diagnosis code No. P0340 is shown.
(Refer to GROUP 13A − Troubleshooting −
Inspection chart for diagnosis code <4G1> P.13A-15
or GROUP 13B − Troubleshooting − Inspection chart
for diagnosis code <4G6> P.13B-15 ).
CRANK ANGLE SENSOR CHECKM1163004500272
Check the crank angle sensor circuit if self-diagnosis
code No. P0335 is shown.
(Refer to GROUP 13A − Troubleshooting −
Inspection chart for diagnosis code <4G1> P.13A-15
or GROUP 13B − Troubleshooting − Inspection chart
for diagnosis code <4G6> P.13B-15 ).
DETONATION SENSOR CHECKM1163002900047
Check the detonation sensor circuit if self-diagnosis
code No. P0325 is shown.
(Refer to GROUP 13A − Troubleshooting −
Inspection chart for diagnosis code <4G1> P.13A-15
or GROUP 13B − Troubleshooting − Inspection chart
for diagnosis code <4G6> P.13B-15).
IGNITION SECONDARY VOLTAGE
WAVEFORM CHECK USING AN
OSCILLOSCOPE
M1163001700170
MEASUREMENT METHOD
1. Clamp the secondary pickup around the spark
plug cable.
NOTE: .
•The peak ignition voltage will be reversed
when the spark plug cables No. 2 and No. 4,
or No. 1 and No. 3 cylinders are clamped.
•Because of the two-cylinder simultaneous
ignition system, the waveforms for two
cylinders in each group appear during
waveform observation (No. 1 cylinder - No. 4
cylinder, No. 2 cylinder - No. 3 cylinder).
However, waveform observation is only
applicable for the cylinder with the spark plug
cable clamped by the secondary pickup.
•Identifying which cylinder waveform is
displayed can be difficult. For reference,
remember that the waveform of the cylinder
attached to the secondary pickup will be
displayed as stable.
2. Clamp the spark plug cable with the trigger
pickup.
NOTE: Clamp the trigger pickup to the same
spark plug cable clamped by the secondary
pickup.
AKX00383
AL
Platinum
tipIridium
tip

IGNITION SYSTEM
ENGINE ELECTRICAL16-38
IGNITION COIL
REMOVAL AND INSTALLATION <4G1>M1163004000404
AC303965AB
11
5 2
2
10 ± 2 N·m
10 ± 2 N·m
25 ± 5 N·m
3
4
4
Removal steps
1. Ignition coil connector
2. Spark plug cable
3. Accelerator cable support clamp
<RHD>4. Ignition coil
5. Spark plugRemoval steps (Continued)

IGNITION SYSTEM
ENGINE ELECTRICAL16-42
REMOVAL AND INSTALLATION <4G6>M1163003500440
REMOVAL SERVICE POINT
<<A>> POWER STEERING OIL PUMP
ASSEMBLY REMOVAL
Remove the power steering oil pump assembly from
the bracket with the hose attached.
NOTE: Place the removed power steering oil pump
assembly in a place where it will not be a hindrance
when removing and installing and secure it with a
cord or wire.
Pre-removal and Post-installation Operation
•Valve Timing Belt Removal and Installation (Refer to
GROUP 11C P.11C-35).
AC301612
8.8 ± 1.0 N·m
8
8.8 ± 1.0 N·m
9
1
22 ± 4 N·m
4
2
3
49 ± 9 N·m49 ± 9 N·m5
22 ± 4 N·m
3.0 ± 0.5 N·m
6
7
AC
Removal steps
1. Power steering pressure switch
connector
2. A/C compressor connector
3. A/C compressor connector clamp
<<A>>4. Power steering oil pump assembly
5. Power steering oil pump bracket6. Rocker cover centre cover
7. Engine crankshaft position sensor
connector
8. Engine crankshaft position sensor
9. Crankshaft position sensor
connector bracket Removal steps (Continued)

EMISSION CONTROL <MPI>
ENGINE AND EMISSION CONTROL17-12
4. Check airtightness by applying a vacuum with
voltage applied directly from the battery to the
purge control solenoid valve and without applying
voltage.
5. Measure the resistance between the terminals of
the solenoid valve.
Standard value: 30 − 34 Ω (at 20°C)
FUEL VAPOUR CANISTER REMOVAL
AND INSTALLATION
M1173004200153
Battery voltage Normal condition
Applied Vacuum leaks
Not applied Vacuum maintained
Pre-removal and Post-installation Operation
Air Cleaner Assembly Removal and Installation (Refer to
GROUP 15 P.15-3).
AC208253
1 2 3
4
56
78
AD
Removal steps
1. Emission vacuum hose connection
2. Fuel vapour control line hose
3. Fuel vapour control check valve
4. Fuel vapour control line hose5. Fuel vapour control line clamp
6. Fuel vapour canister
7. Fuel high-pressure hose clamp
8. Fuel vapour canister bracketRemoval steps (Continued)

DRIVE SHAFT ASSEMBLY
FRONT AXLE26-22
CAUTION
•Secure the drive shaft in an upright position
and clamp part of the boot band to be crimped
securely in the jaws of special tool.
•Crimp the boot band until special tool
touches the stopper.
7. Use the special tool to crimp the boot band
(small).
8. Check that the crimping amount (C) of the boot
band is at the standard value.
Standard value (C): 2.4 − 2.8 mm
<If the crimping amount is larger than 2.8 mm >
Readjust the value of (W) in step 5 according
to the following formula, and then repeat the
operation in step 7.
W = 5.5 mm − C
Example: If C = 2.9 mm, then W = 2.6 mm.
<If the crimping amount is smaller than 2.4
mm >
Remove the BJ boot band, readjust the value
of (W) in step 5 according to the following
formula, and then repeat the operations in
steps 6 and 7 using a new BJ boot band.
W = 5.5 mm − C
Example: If C = 2.3 mm, then W = 3.2 mm.
9. Check that the boot band is not sticking out past
the place where it has been installed. If the boot
band is sticking out, remove it and then repeat
steps 6 to 8, using a new boot band.
CAUTION
The drive shaft joint uses special grease. Do not
mix old and new or different types of grease.
10.Fill the inside of the boot with the specified
amount of the specified grease.
Specified grease: Repair kit grease
Amount to use: 95 ± 10 g
11.Align the centre groove on the BJ boot big end
with the BJ case groove.
12.Follow the same procedure as in step 5 to adjust
the size of the opening (W) on the special tool so
that it is at the standard value.
Standard value (W): 2.9 mm
13.Position the BJ boot band (large) so that there is
even clearance at either end (D and E).
14.Use the special tool to crimp the BJ boot band
(large) in the same way as in step 7.
15.Check that the crimping amount (F) of the boot
band is at the standard value.
AC102663 ACMB991561
AC102662
C
AD
AC102664AC
AC102665
AC
BootProjection
Boot band
(large) D
E
AC102666FAD

TROUBLESHOOTING
WHEEL AND TYRE31-5
<Confirming Proper Balance>
1. After balancing the wheel, loosen the wing nut
and turn the wheel 180° against the balancer's
hub. Then re-tighten the wing nut and check the
balance again. Repeat wheel balance if
necessary.
2. Turn the wheel again 180° against the balancer's
hub. If the wheel becomes out-of-balance each
time it is turned against the balancer's hub, the
wheel balancer may require calibration.
<Wheel Balancer Calibration Checks>
1. Mount an undamaged original-equipment alloy
rim and tyre assembly (wheel) onto your
off-the-car wheel balancer. Balance the wheel.
2. <<Zero Calibration Check>>
Loosen the balancer wing nut, rotate the wheel a
half-turn (180°), and retighten the nut. Recheck
the balance.
•If the imbalance is 5g or less, the zero calibration
is OK. Rebalance the wheel, then go to Step 4 to
check static balance.
•If the imbalance is more than 5g, go to Step 3.
3. Loosen the balancer wing nut, rotate the wheel
1/4 turn (90°), and retighten the nut. Recheck the
wheel balance.
•If the imbalance is 5g or less, the wheel may not
be centred on the balancer, or the balancing
cones, the cup, and/or wing nut are damaged,
dirty, or inappropriate for the wheel. You may
need to refer to the balancer manufacturer's
instructions to verify the correct attachments.
After making the necessary corrections, recheck
the wheel balance. If OK, then go to Step 4.•If the imbalance is more than 5g, the balancer
requires calibration. Contact the balancer
manufacturer for calibration by their repair
representative.
4. <<Static Balance Check>>
Attach a 5g weight to the outer rim. Recheck the
balancer. The balancer should detect 5 ± 2g of
imbalance 170 to 190° away from the 5g weight.
•If the imbalance is within specification, the static
balance calibration is correct. Go to Step 5 to
check the dynamic balance.
•If the imbalance is out of specification, the
balancer requires calibration. Contact the
balancer manufacturer for calibration by their
repair representative.
5. <<Dynamic Balance Check>>
Attach a 5g weight to the inner rim at 180°
opposite the 5g weight that was added in Step 4.
Recheck the balance. The balancer should detect
5 ± 2g of imbalance 170 to 190° away from both
the inner and outer 5g weights.
•If the imbalance is within specification, the
dynamic balance calibration is correct. The
balancer calibration checks are complete.
•If the imbalance is out of specification, the
balancer requires calibration. Contact the
balancer manufacturer for calibration by their
repair representative.
AC305700AB
Hub/shaft assemblyClamping cup
Wing nut
Standard passenger car wheel Wheel mounting cone Spring plate

ENGINE MOUNTING
POWER PLANT MOUNT32-4
ENGINE MOUNTING
REMOVAL AND INSTALLATIONM1321001100440
CAUTION
*: Indicates parts which should be initially tightened, and then fully tightened after placing the vehicle
horizontally and loading the full weight of the engine on the vehicle body.
Pre-removal Operation
Raise the engine and transmission assembly until its weight
is not applied to the insulator, and support it securely.
AC303999AC303968AC304304
AB
<4G1> <4G6>
44 ± 10 N·m*
67 ± 7 N·m*
2N
3
44 ± 10 N·m*
67 ± 7 N·m*
2N
3
12 ± 2 N·m
1
Removal steps
1. Pressure hose clamp <4G6>2. Self-locking nuts
3. Engine front mounting bracketRemoval steps (Continued)

CROSSMEMBER
POWER PLANT MOUNT32-9
<L.H. drive vehicles>
AC304000
108 ± 10 N·m 25 ± 4 N·m 18 ± 2 N·m
70 ± 10 N·m
21 ± 4 N·m 21 ± 4 N·m
186 ± 10 N·m*
167 ± 9 N·m
49 ± 10 N·m 52 ± 7 N·m*45 ± 5 N·m*
70 ± 10 N·m57 ± 7 N·m 12 ± 2 N·m
5
4 10
9 11
8
12
1413 6
716
15
172
3
1
N
N
N
2 11
AB
Removal steps
1. Lower arm and knuckle connection
>>B<<2. Self-locking nut
3. Lower arm assembly
4. Shaft cover
5. Steering shaft assembly and gear
box connecting bolt
6. Engine rear roll stopper bracket
connection bolt
7. Engine rear roll stopper bracket
8. Return hose connection9. Eye bolt
10. Pressure hose connection
11. Gasket
12. Clamp
13. Self-locking nut
<<A>>14. Tie rod end and knuckle connection
<<B>>•Crossmember assembly
>>A<<15. Stabilizer bar
16. Steering gear and linkage
17. CrossmemberRemoval steps (Continued)