Group 80 MITSUBISHI LANCER 2005 Repair Manual

PARKING BRAKE CABLE
PARKING BRAKES36-6
PARKING BRAKE CABLE
REMOVAL AND INSTALLATIONM1361001900785
Pre-removal Operation
•Rear Console Assembly and Rear Console Bracket
Removal (Refer to GROUP 52A, Rear Floor Console
P.52A-8).
•Rear Seat Cushion Assembly Removal (Refer to GROUP
52A, Rear Seat P.52A-28).Post-installation Operation
•Parking Brake Lever Stroke Adjustment (Refer to P.36-3).
•Rear Seat Cushion Assembly Installation (Refer to
GROUP 52A, Rear Seat P.52A-28).
•Rear Console Bracket and Rear Console Assembly
Installation (Refer to GROUP 52A, Rear Floor Console
P.52A-8).
AC301226
1
AB
2
3
Removal steps
•Rear brake shoe assembly (Refer to
P.36-7).
•Loosen the parking brake lever stroke
adjusting nut.1. Parking brake cable connection
2. Parking brake cable connection
3. Parking brake cableRemoval steps (Continued)

PARKING BRAKE LINING AND DRUM
PARKING BRAKES36-7
PARKING BRAKE LINING AND DRUM
REMOVAL AND INSTALLATIONM1361002500296
Post-installation Operation
•Parking Brake Lever Stroke Check and Adjustment (Refer
to P.36-3).
•Lining Running-in (Refer to P.36-3).
AC304238
19
60 ± 5 N·m
63 ± 7 N·m
AB
13
4
155
3
89
72 1
6
10
11 121718
14 16 20
N
15
14
208
Specified grease: Brake grease SAE J310, NLGI No.1
Removal steps
<<A>>
1. Rear brake assembly
2. Rear brake disc
3. Rear hub assembly (Refer to
GROUP 27, Rear Hub Assembly
P.27-5).
>>D<<4. Shoe return spring
>>D<<5. Shoe return spring
6. Shoe guide plate
7. Shoe auto adjuster spring
>>C<<8. Shoe slack adjuster
9. Parking brake operating lever strut
10. Shoe to strut spring
11. Shoe spring cup
12. Shoe hold-down spring
13. Rear brake pin
14. Rear brake primary shoe assembly
15. Rear brake secondary shoe
assembly
<<B>> >>B<<16. Rear brake chamber retainer
>>A<<17. Rear brake washer
18. Parking brake operating lever
19. Parking brake cable clip
20. Rear brake backing plate
Removal steps (Continued)

37-1
GROUP 37
POWER STEERING
CONTENTS
GENERAL INFORMATION . . . . . . . .37-3
SERVICE SPECIFICATIONS . . . . . . .37-6
LUBRICANTS . . . . . . . . . . . . . . . . . .37-7
SEALANTS . . . . . . . . . . . . . . . . . . . .37-7
SPECIAL TOOLS . . . . . . . . . . . . . . . .37-8
ON-VEHICLE SERVICE . . . . . . . . . . .37-11
STEERING WHEEL FREE PLAY
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37-11
STEERING ANGLE CHECK . . . . . . . . . . . . 37-11
TIE ROD END BALL JOINT TURNING
TORQUE CHECK . . . . . . . . . . . . . . . . . . . . 37-12
STATIONARY STEERING EFFORT
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37-12
STEERING WHEEL RETURN TO
CENTRE CHECK . . . . . . . . . . . . . . . . . . . . 37-13DRIVE BELT TENSION CHECK . . . . . . . . . 37-13
FLUID LEVEL CHECK . . . . . . . . . . . . . . . . 37-13
FLUID REPLACEMENT . . . . . . . . . . . . . . . 37-13
POWER STEERING SYSTEM AIR
BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . 37-13
OIL PUMP PRESSURE TEST . . . . . . . . . . 37-14
POWER STEERING PRESSURE
SWITCH CHECK . . . . . . . . . . . . . . . . . . . . . 37-15
TIE ROD END BALL JOINT DUST COVER
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37-15
STEERING COLUMN SHAFT
ASSEMBLY SHOCK ABSORBING
MECHANISM CHECK . . . . . . . . . . . . . . . . . 37-15
STEERING WHEEL* . . . . . . . . . . . . . .37-17
REMOVAL AND INSTALLATION
<COMFORT> . . . . . . . . . . . . . . . . . . . . . . . 37-17
REMOVAL AND INSTALLATION
<SPORT> . . . . . . . . . . . . . . . . . . . . . . . . . . 37-19
Continued on next page
WARNINGS REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM (SRS) EQUIPPED VEHICLES
WARNING
•Improper service or maintenance of any component of the SRS, or any SRS-related component, can lead to
personal injury or death to service personnel (from inadvertent firing of the air bag) or to the driver and
paassenger (from rendering the SRS inoperative).
•Service or maintenance of any SRS component or SRS-related component must be performed only at an
authorized MITSUBISHI dealer.
•MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B - Supplemental
Restraint System (SRS) before beginning any service or maintenance of any component of the SRS or any
SRS-related component.
NOTE
The SRS includes the following components: SRS air bag control unit, SRS warning light, front impact sensors, air bag module,
clock spring, and interconnecting wiring. Other SRS-related components (that may have to be removed/installed in connection
with SRS service or maintenance) are indicated in the table of contents by an asterisk (*).

SPECIAL TOOLS
POWER STEERING37-9
MB990607 Torque wrench
socket•Rack support cover removal
<Comfort>
•Rack support adjustment
<Comfort>
MB991621 Piston driver•Rack support cover removal
<Sport>
•Rack support adjustment <Sport>
MB990925 Bearing and oil
seal installer set•Lower bearing removal
•Oil seal and bearing installation
•MB990927, MB990938, MB990939
(For details, refer to GROUP 26,
Special Tools P.26-4).
MB991120 Needle bearing
pullerNeedle bearing removal
MB991202 Oil seal and
bearing installer•Oil seal installation <Comfort>
•Needle bearing installation
•Lower bearing installation
MB991199 Oil seal and
bearing installerOil seal installation <Sport>
MB991197 Bar (long type) Oil seal installation
MB991212
MB991213Oil seal protector Rack installation Tool Number Name Use
MB991621
MB990925
MB991120
MB991202
MB991199
AB
MB991197
MB991212

ON-VEHICLE SERVICE
POWER STEERING37-13
STEERING WHEEL RETURN TO CENTRE
CHECK
M1372001800317
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, turn
the steering wheel 90°, hold a few seconds, then
release. If the steering wheel then returns 70° 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).
DRIVE BELT TENSION CHECKM1372001900392
For vehicles with 1300 and 1600 engine, refer to
GROUP 11A, On-vehicle Service − Drive Belt
Tension Check P.11A-7.
For vehicles with 2000 engine, refer to GROUP 11C,
On-vehicle Service − Drive Belt Tension Check
P.11C-7.
FLUID LEVEL CHECKM1372002000284
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.
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 change of the fluid level is 5 mm or
more, air bleeding should be done.
FLUID REPLACEMENTM1372002100333
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
GROUP 16, Ignition Coil P.16-38or P.16-39).
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 specified fluid up to
between "MAX" and "MIN" marks, and then bleed
the air.
Specified fluid: ATF DEXRON III or DEXRON
II
POWER STEERING SYSTEM AIR
BLEEDING
M1372002200330
Perform air bleeding procedure as necessary after
replacing the steering gear or the steering fluid lines.
1. Raise and support the front wheels.
2. Disconnect the ignition coil connectors (Refer to
GROUP 16, Ignition Coil P.16-38 or P.16-39).
ACX01130
AB
70˚70˚
ACX01131While engine running While engine stoppedAC
Fluid level change: Within 5 mm
AC100369AB
Return hoseReturn hose
Vinyl hose

ON-VEHICLE SERVICE
POWER STEERING37-14
CAUTION
Perform air bleeding only while cranking the
engine. If air bleeding is performed while the
engine is running, air could enter the fluid.
During air bleeding, refill the steering fluid
supply so that the level never falls below the
"MIN" mark on the oil reservoir.
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
GROUP 16, Ignition Coil P.16-38 or P.16-39).
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 "MAX" and "MIN" 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 when the engine is stopped and
when it is running.
10.If the change of the fluid level is 5 mm or more,
the air has not been completely bled from the
system. The air bleeding procedure must be
repeated.
OIL PUMP PRESSURE TESTM1372002300315
1. Disconnect the pressure hose from the oil pump,
and then connect the following special tools.
•MB990662: Power Steering Oil Pressure Gauge
•MB991548: Power Steering Oil Pressure Gauge
Adapter (pump side)
•MB991549: Power Steering Oil Pressure Gauge
Adapter (hose side)
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.
3. Start the engine and idle it at 1000 ± 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: 8.8 − 9.5 MPa
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 − 0.7 MPa
ACX01131While engine running While engine stoppedAC
Fluid level change: Within 5 mm
ACX01133
Temperature
gauge
Oil reservoir
Adapter
(MB991548)
Oil
pump
Adapter
(MB991549)
AB
Shut-off valve
(fully closed) Pressure
gauge
(MB990662)

STEERING WHEEL
POWER STEERING37-17
STEERING WHEEL
REMOVAL AND INSTALLATION
<COMFORT>
M1372011400183
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).
•When removing and installing the steering wheel, do not let it bump against the air bag
module.
NOTE: For air bag module removal, refer to GROUP
52B, Air Bag Module and Clock Spring P.52B-210.
Post-installation Operation
•Checking Steering Wheel Position with Wheels Straight
Ahead
AC107402AB
50 ± 5 N·m
1 2
2
1
12
A
AB
BTa b
Ta b Section A - A
Section B - B
Removal steps
<<A>>1. Cover
<<B>>2. Steering wheel and air bag module
assembly

STEERING WHEEL
POWER STEERING37-19
REMOVAL AND INSTALLATION <SPORT>M1372011400194
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).
•When removing and installing the steering wheel, do not let it bump against the air bag
module.
NOTE: For air bag module removal, refer to GROUP
52B, Air Bag Module and Clock Spring P.52B-210.
REMOVAL SERVICE POINTS
<<A>> COVER REMOVAL
Insert special tool ornament remover (MB990784) at
the indicated position to remove the cover.
NOTE: The special tool can be inserted through the
notch behind the area shown.
Post-installation Operation
•Checking Steering Wheel Position with Wheels Straight
Ahead
AC211760
AD
50 ± 5 N·m2
1 2
Removal steps
<<A>>1. Cover
<<B>>2. Steering wheel and air bag module
assembly
AC211761AB
MB990784

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)

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)