service MITSUBISHI LANCER 2005 Manual PDF

SERVICE SPECIFICATION
POWER PLANT MOUNT32-3
SERVICE SPECIFICATION
M1321000300333
SPECIAL TOOL
M1321000600378
ItemStandard value
Protruding length of stabilizer link thread part mm 22 ± 1.5
Tool Number Name Use
MB991897 Ball joint remover Knuckle and tie rod end ball joint
disconnection
NOTE: Steering linkage puller
(MB990635 or MB991113) is also
available to disconnect knuckle and
tie rod end ball joint.
AC106827

TRANSMISSION MOUNTING
POWER PLANT MOUNT32-6
INSTALLATION SERVICE POINT
>>A<< TRANSMISSION MOUNTING
STOPPER INSTALLATIONInstall the transmission mounting stopper so that its
arrow points upward.
AC200645
Engine side
Transmission
mounting body
side bracket
Transmission
mounting
stopper
AB

CROSSMEMBER
POWER PLANT MOUNT32-8
INSTALLATION SERVICE POINTS
>>A<< ENGINE FRONT ROLL STOPPER
BRACKET INSTALLATION
Install the engine front roll stopper bracket so that its
hole points towards the front side of the vehicle.
>>B<< ENGINE MOUNTING CUSHION
STOPPER INSTALLATION <4G6>
Install the engine mounting cushion stopper as
shown.
CROSSMEMBER
REMOVAL AND INSTALLATIONM1321003200368
CAUTION
•Before removing the steering wheel and air bag module assembly, always refer to GROUP 52B -
Service Precautions P.52B-5, Air bag Module and Clock Spring P.52B-210. Also, set the front
wheels so that they are facing straight forward, and remove the ignition key. If you fail to do this,
the SRS clock spring will be damaged, causing the SRS air bag to be inoperative and serious
injury.
•*
1: 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.
•*
2: Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle
on the earth in the unladen condition.
AC005918Front of vehicleHoleACAC304315ABFront of vehicle
HoleEngine mounting
cushion stopper
Pre-removal Operation
•Centermember Removal (Refer to P.32-7).
•Front Exhaust Pipe Removal (Refer to GROUP 15,
Exhaust Pipe and Main Muffler P.15-11).
•Steering Wheel Air Bag Module Assembly Removal
(Refer to GROUP 37, Steering Wheel P.37-17).
•Power Steering Fluid Draining (Refer to GROUP 37,
On-vehicle Service P.37-13).Post-installation Operation
•Front Exhaust Pipe Installation (Refer to GROUP 15,
Exhaust Pipe and Main Muffler P.15-11).
•Centermember Installation (Refer to P.32-7).
•Clock Spring Centring (Refer to GROUP 52B, Air Bag
Modules and Clock Spring P.52B-210).
•Steering Wheel Air Bag Module Assembly Installation
(Refer to GROUP 37, Steering Wheel P.37-17).
•Power Steering Fluid Supplying (Refer to GROUP 37,
On-vehicle Service P.37-13).
•Power Steering Fluid Line Bleeding (Refer to GROUP 37,
On-vehicle Service P.37-13).
•Press the dust cover with a finger to check whether the
dust cover cracked or damaged.
•Checking Steering Wheel Position with Wheels Straight
Ahead.
•Front Wheel Alignment Check and Adjustment (Refer to
GROUP 33, On-vehicle Service P.33-5).

CROSSMEMBER
POWER PLANT MOUNT32-11
REMOVAL SERVICE POINTS
<<A>> TIE ROD END AND KNUCKLE
DISCONNECTION
CAUTION
•Do not remove the nut from ball joint. Loosen
it and use special tool to avoid possible
damage to ball joint threads.
•Hang special tool with a cord to prevent it
from falling.
1. Install the special tool ball joint remover
(MB991897) as shown in the figure.
2. Turn the bolt and knob as necessary to make the
jaws of the special tool parallel, tighten the bolt by
hand and confirm that the jaws are still parallel.
NOTE: When adjusting the jaws in parallel, make
sure the knob is in the position shown in the
figure.
3. Tighten the bolt with a wrench to disconnect the
tie rod end.
<<B>> CROSSMEMBER ASSEMBLY
REMOVAL
1. Use a transmission jack to hold the crossmember,
and then remove the crossmember mounting nuts
and bolts.
2. Lower the crossmember with the engine rear roll
stopper bracket, the stabilizer bar, the return tube,
and the steering gear.
INSTALLATION SERVICE POINTS
>>A<< STABILIZER
BAR/BUSHING/FIXTURE INSTALLATION
Align the stabilizer bar identification mark with the
right end of the bushing (LH).
>>B<< SELF-LOCKING NUT
INSTALLATION
Tighten the self-locking nut until the stabilizer link
thread part protruding length meets the standard
value.
Standard value (A): 22 ± 1.5 mm
AC208247AD
Cord
BoltMB991897
Nut
Ball joint
AC106821
Knob ParallelBolt
Good
Bad
AB
AC102600
AD
Piece of wood
Transmission
jack
AC006141
AD
Fixture (LH) Outside of
vehicle
Bushing (LH)Approximately
10 mm
Identification
mark
AC101741AC
A

33-1
GROUP 33
FRONT
SUSPENSION
CONTENTS
GENERAL INFORMATION . . . . . . . .33-2
SERVICE SPECIFICATIONS . . . . . . .33-3
LUBRICANT . . . . . . . . . . . . . . . . . . . .33-3
SPECIAL TOOLS . . . . . . . . . . . . . . . .33-4
ON-VEHICLE SERVICE . . . . . . . . . . .33-5
FRONT WHEEL ALIGNMENT CHECK
AND ADJUSTMENT . . . . . . . . . . . . . . . . . . 33-5
LOWER ARM BALL JOINT AXIAL PLAY
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-6
LOWER ARM BALL JOINT COVER
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-6
STRUT ASSEMBLY . . . . . . . . . . . . . .33-7
REMOVAL AND INSTALLATION . . . . . . . . 33-7
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 33-7
DISASSEMBLY AND REASSEMBLY . . . . . 33-8
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 33-10
LOWER ARM . . . . . . . . . . . . . . . . . . .33-11
REMOVAL AND INSTALLATION . . . . . . . . 33-11
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 33-12
LOWER ARM BALL JOINT COVER
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . 33-12
LOWER ARM BUSHING (REAR)
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . 33-13
STABILIZER BAR* . . . . . . . . . . . . . . .33-14
REMOVAL AND INSTALLATION . . . . . . . . 33-14
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 33-17
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 (*).

SERVICE SPECIFICATIONS
FRONT SUSPENSION33-3
SERVICE SPECIFICATIONS
M1332000300586
NOTE: *: difference between right and left wheels must be less than 30'
LUBRICANT
M1332000400152
ItemStandard value
Toe-in At the centre of tyre tread mm 1 ± 2
Toe-angle (per wheel) 0°03' ± 06'
Toe-out angle on turns (inner wheel when outer wheel at 20°)21°42' ± 1°30'
Steering angle Inner wheel Comfort 39°30' ± 1°30'
Sport (LH drive vehicles) 33°40' +1°00'/-2°00'
Sport (RH drive vehicles) 37°00' +1°00'/-2°00'
Outer wheel (reference) Comfort 32°30'
Sport (LH drive vehicles) 28°46'
Sport (RH drive vehicles) 30°00'
Camber Comfort 0°05' ± 30'*
Sport -0°05' ± 30'*
Caster Comfort 2°45' ± 30'*
Sport 2°55' ± 30'*
Kingpin inclination Comfort 12°30' ± 1°30'
Sport 12°40' ± 1°30'
Lower arm ball joint rotation starting torque N⋅m0 − 3.9
Protruding length of stabilizer link thread part mm 22 ± 1.5
Item Specified lubricant Quantity
Lower arm ball joint Lip portion of ball joint cover Multipurpose grease SAE J310,
NLGI No.2 or equivalentAs required
Inside of ball joint cover

ON-VEHICLE SERVICE
FRONT SUSPENSION33-5
ON-VEHICLE SERVICE
FRONT WHEEL ALIGNMENT CHECK AND
ADJUSTMENT
M1331000900682
Measure wheel alignment with alignment equipment
on a level surface. The front suspension, steering
system, wheels, and tyres should be serviced to
normal condition before measuring wheel alignment.
TOE-IN
Standard value:
at the centre of tyre tread: 1 ± 2 mm
Toe angle (per wheel): 0°03' ± 06'
1. Adjust the toe-in by undoing the clip and lock nut,
and turning the left and right tie rod turnbuckles by
the same amount (in opposite directions). MB990883 Rear suspension bushing
arborLower arm bushing (rear)
removal and press-fitting
MB990972 Torsion bar bushing
remover base
MB990887 Ring
MB990890 Rear suspension bushing
base
MB991897 Ball joint remover Knuckle and tie rod end
ball joint disconnection
NOTE: Steering linkage
puller (MB990635 or
MB991113) is also
available to disconnect
knuckle and tie rod end
ball joint. Tool Number Name Use
MB990883
MB990971
MB990890
AC106827
AC006074AD
Lock nut
Clip

ON-VEHICLE SERVICE
FRONT SUSPENSION33-6
NOTE: The toe will move out as the left
turnbuckle is turned toward the front of the vehicle
and the right turnbuckle is turned toward the rear
of the vehicle.
2. Install the clip and tighten the lock nut to the
specified torque.
Tightening torque: 40 ± 5 N⋅m
3. Confirm that the toe-in is at the standard value.
4. Use a turning radius gauge to check that the
steering angle is at the standard value.
STEERING ANGLE
Standard value:
TOE-OUT ANGLE ON TURNS
To check the steering linkage, especially after the
vehicle has been involved in an accident or if an
accident is presumed, it is advisable to check the
toe-out angle on turns in addition to the wheel
alignment.
Conduct this test on the left turn as well as on the
right turn.
Standard value:
CAMBER, CASTER AND KINGPIN
INCLINATION
Standard value:NOTE: *: difference between right and left wheels
must be less than 30'
NOTE: Camber and caster are preset at the factory
and cannot be adjusted.
CAUTION
Never subject the wheel bearings to the vehicle
load when the driveshaft nuts are loosened.
NOTE:
For vehicles with aluminium wheels, attach the
camber/caster/kingpin gauge to the driveshaft by
using special tool wheel alignment gauge attachment
(MB991004). Tighten the special tool to the same
torque 245
± 29 N⋅m as the driveshaft nut.
LOWER ARM BALL JOINT AXIAL PLAY
CHECK
M1332011300074
1. Raise the vehicle.
2. Remove the stabilizer link from the lower arm.
3. Move the lower arm up and down with your hands
to check for an excessive play in the axial
direction of the ball joint. If there is an excessive
play, replace the lower arm assembly.
LOWER ARM BALL JOINT COVER
CHECK
M1332008600321
1. Press the lower arm ball joint cover with your
finger to check that there are no cracks or
damage in the lower arm ball joint cover.
2. If the lower arm ball joint cover is cracked or
damaged, replace the lower arm assembly.
NOTE: If the lower arm ball joint cover is cracked
or damaged, it is possible that there may also be
damage to the ball joint. Inner
wheelsComfort 39°30' ± 1°30'
Sport (LH drive
vehicles)33°40' +1°00'/-2°00'
Sport (RH drive
vehicles)37°00' +1°00'/-2°00'
Outer
wheels
(reference)Comfort 32°30'
Sport (LH drive
vehicles)28°46'
Sport (RH drive
vehicles)30°00'
Item Specification
Toe-out angle on turns (inner
wheel when outer wheel at 20°)21°42' ± 1°30'
Item Comfort Sport
Camber 0°05' ± 30'* -0°05' ± 30'*
Caster 2°45' ± 30'* 2°55' ± 30'*
Kingpin
inclination12°30' ± 1°30' 12°40' ± 1°30'
AC001079
MB991004
AB

STRUT ASSEMBLY
FRONT SUSPENSION33-9
DISASSEMBLY SERVICE POINTS
<<A>> STRUT NUT (SELF-LOCKING NUT)
REMOVAL
CAUTION
•Install special tool arm set (MB991238) evenly,
and so that the maximum length will be
attained within the installation range.
•Do not use an impact wrench to tighten the
bolt of special tool spring compressor body
(MB991237), otherwise the special tool will
break.
1. Use following special tools to compress the coil
spring.
•MB991237: Spring Compressor Body
•MB991238: Arm Set
WARNING
Do not use an impact wrench to remove the
strut nut (self-locking nut). Vibration of the
impact wrench will cause special tools
(MB991237 and MB991238) to slip and cause
personal injury.
2. Use following special tools to secure the strut, and
then remove the strut nut (self-locking nut).
•MB991681: Wrench
•MB991682: Socket
<<B>> STRUT DISPOSAL
WARNING
Wear goggles when drilling to protect your
eyes from flying metal debris.
The gas must be discharged from the strut before
discarding it. Place the strut horizontally with its
piston rod extended. Then drill a hole of
approximately 3 mm in diameter at the location
shown in the illustration and discharge the gas.
REASSEMBLY SERVICE POINTS
>>A<< SPRING UPPER SEAT
INSTALLATION
If the spring upper seat peeled off the pad, adhere
the seat and the pad with a double-sided tape.
AC001085 AB
MB991238
MB991237
AC006091 AB
MB991681 MB991682
AC001087
AC304396AB
Seat
Pad

LOWER ARM
FRONT SUSPENSION33-12
REMOVAL SERVICE POINT
<<A>> LOWER ARM BOLT REMOVAL
Lift the transmission with a transmission jack, and
then withdraw the lower arm bolt (front) on the lower
arm assembly (L.H.).
INSTALLATION SERVICE POINT
>>A<< SELF-LOCKING NUT
INSTALLATION
Tighten the self-locking nut until the stabilizer link
thread part protruding length meets the standard
value.
Standard value (A): 22 ± 1.5 mm
INSPECTIONM1332001700286
•Check the lower arm bushings for wear and
deterioration.
•Check the lower arm assembly for bend or
breakage.
•Check all bolts for condition and straightness.
LOWER ARM BALL JOINT ROTATION
STARTING TORQUE CHECK
1. After shaking the ball joint stud several times, use
special tool preload socket (MB991006) to
measure the rotation starting torque of the ball
joint.
Standard value: 0 − 3.9 N⋅m
2. If the measured value is not within the standard
value, or if the ball joint is difficult to turn or does
not turn smoothly, replace the lower arm
assembly.
LOWER ARM BALL JOINT COVER
CHECK
1. Check the lower arm ball joint cover for cracks or
damage by pushing it with your finger.
2. If the lower arm ball joint cover is cracked or
damaged, replace the lower arm assembly.
NOTE: Cracks or damage to the dust cover may
cause damage to the ball joint. When it is
damaged during service work, replace the lower
arm ball joint cover.
LOWER ARM BALL JOINT COVER
REPLACEMENT
M1332008200260
If the lower arm ball joint cover is damaged
accidentally during service work, replace the lower
arm ball joint cover as follows:
1. Remove the lower arm ball joint cover.
2. Apply specified grease to the lip and the inside of
a new lower arm ball joint cover.
Specified grease: Multipurpose grease SAE
J310, NLGI No.2 or equivalent
Grease amount for the inside the dust cover
(reference): 8 − 10g
AC006133ADLower arm bolt (front)Transmission jackPiece of wood
AC101741AC
A
AC001091 AB
MB991006