service MITSUBISHI LANCER 2006 Owners Manual

STEERING COLUMN SHAFT ASSEMBLY
POWER STEERING37-20
STEERING COLUMN SHAFT ASSEMBLY
REMOVAL AND INSTALLATIONM1372003100080
WARNING
Before removing the steering wheel and air bag module assembly, refer to GROUP 52B, Serv-
ice Precautions (P.52B-5) and Air Bag Module and Clock Spring (P.52B-194).
Pre-removal Operation
•Steering Wheel and Air bag Module Assembly Removal
(INVITE: refer to
P.37-17/INTENSE: refer to P.37-18).
•Under Cover Removal (Refer to GROUP 52A, Instrument
Panel
P.52A-3).
Post-installation Operation
•Under Cover Installation (Refer to GROUP 52A, Instru-
ment Panel P.52A-3).
•Steering Wheel and Air bag Module Assembly Installation
(INVITE: refer to
P.37-17/INTENSE: refer to P.37-18).
AC304919AB
12 ± 2 N·m
18 ± 2 N·m 5.0 ± 1.0 N·m
1
2
73
2
1
8
8 6
A
A
Ta b Section 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-147).
6.Shaft cover
<<A>>>>A<<7.Steering column shaft assembly
8.Cover assembly
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 absorb
-
ing mechanism may be damaged.
1. Ensure that the tilt lever is in the lock position, and remove the steering column mounting bolts.

POWER STEERING GEAR BOX AND LINKAGE
POWER STEERING37-23
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-194). 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.37-14.)
•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.33-6.)
AC304920 AB
57 ± 7 N·m
15 ± 3 N·m
70 ± 10 N·m
7
3
8
5
6
9
10 24
1
12 ± 2 N·m
12 ± 2 N·m
<LH 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 hose
4.Return tube
5.O-ring
6.Return tube
7.Eye bolt
8.Pressure hose assembly
9.Clamp
10.Steering gear and linkage
Removal steps (Continued)

POWER STEERING GEAR BOX AND LINKAGE
POWER STEERING37-29
DISASSEMBLY SERVICE POINTS
<<A>> RACK SUPPORT COVER
REMOVAL
AC209838
MB990607
AK
<Invite>
AC103692AI
MB991621
<Intense>
Using
the followin g sp ecial too l , remove the ra ck
supp
ort co ver fro m the stee ring gear .
•To rque wren ch socket (MB990607 ) <Invite>
•Piston driver (MB9916 21) <In t ense >
<<B>> LOWER OIL SEAL/PINION AND
V
A L V E ASSEMBL Y REMOV A L
ACX01143AB
Using a pla s tic hamme r , gently t ap t he pinion to
remove it.
<<C>> SEAL RING REMOVA L
CAUTION
When cutting the seal ring, be careful not to dam-
age the pinion and valve assembly or the rack.
ACX01144
AB
Cut the seal ring and remove it from the pinion and
valve assembly or the rack.
<<D>> UPPER BE ARING/UPPER OIL
SEAL REMOVAL
ACX01145 AC
Socket
Using a socket, remove the oil seal and the ball bear-
ing from the valve housing simultaneously.
<<E>> CIRCLIP REMOVAL
CAUTION
If the rack stopper is first turned anticlockwise,
the circlip will get caught in the slot in the hous
-
ing and the rack stopper will not turn.
ACX01146
AB
Circlip
Rack stopper
1. Turn the rack stopper clockwise until the end of
the circlip comes out of the slot in the rack
housing.

POWER STEERING GEAR BOX AND LINKAGE
POWER STEERING37-30
2. Turn the rack stopper anticlockwise to remove the circlip.
<<F>> RACK STOPPER/RACK
BUSHING/OIL SEAL/O-RING/RACK
ASSEMBLY REMOVAL
ACX01147 AB
1.
Pull out th e rack slo w ly . T a ke out th e rack stop per
an d the rack bushing at the same time.
CAUTION
Do not damage the oil seal press fitting surface.
ACX01148AB
Rack bushing
2. Partially bend the oil seal and remove it from the
rack bushing.
<<G>> LOWER BEARING REMOVAL
ACX01149
MB990939
Lower bearing
AC
Valve housing
Use a brass bar or special tool brass bar
(MB990939) to remove the lower bearing from the
valve housing.
<<H>> NEEDLE BEARING REMOVAL
CAUTION
Do not open special tool excessively to prevent
damaging housing interior.
ACX01150 AB
Valve housing MB991120Needle
bearing
Use special tool needle bearing puller (MB991120) to
remove the needle bearing from the valve housing.
<<I>> OIL SEAL REMOVAL
CAUTION
Be careful not to damage the inner surface of the
rack cylinder of the gear housing.
AC100259
Oil seal
Pipe or similar tool
Gear housing
AB
Use a piece of pipe or simila
r tool to remove the oil
seal from the gear housing.
REASSEMBLY SERVICE POINTS
>>A<< OIL SEAL INSTALLATION
1. Apply a coating of ATF DEXRON III or DEXRON II to the both sides of the oil seal.
AC100260AI
Oil seal
MB991202 <Invite>
MB991199 <Intense>
Gear housing
MB991197
2. Using the following special tools, press the oil seal
into the rack housing.

POWER STEERING OIL PUMP ASSEMBLY
POWER STEERING37-35
TIE ROD END BALL JOINT DUST COVER
REPLACEMENT
M1372008200327
If the dust cover is damaged accidentally during
service work, replace the dust cover as follows:
AC001012AB
MB990776
1.App l y specified grea se to the lip an d inside of the
d u st c o ve r .
Specified grease:
Mu l t i p u r po se g r ea se SAE J3 10 , NL GI No .2 or
equival
ent
2.Drive in the d u st cover with special tool f r ont axle
b a se (MB9907 76) unt il it is fully seated .
3.Check t he dust co ver f o r cracks or da mage by
p u shing it with your finger .
POWER STEERING OIL PUMP ASSEMBL Y
REMOVA L AND INST ALLA TIONM13720052 0029 8
Pre-removal Operation
•Power Steering Fluid Draining (Refer to P.37-13).
Post-installation Operation
•Power Steering Fluid Supplying and Bleeding (Refer to
P.37-14).
•Drive Belt Tension Check (1300, 1600: refer to GROUP
11A, On-vehicle Service
− Drive Belt Tension Check
P.11A-7/2000: refer to GROUP 11C, On-vehicle Service − Drive Belt Tension Check P.11C-7).
<1300, 1600>
AC209708
87
1 2
3 4
5
6
57 ± 7 N·m
40 ± 4 N·m
22 ± 4 N·m
N
9
40 ± 5 N·m
AC

POWER STEERING OIL PUMP ASSEMBLY
POWER STEERING37-39
REASSEMBLY SERVICE POINTS
>>A<< O-RING INSTALLATION
AC100170AB
Suction connector Plug assembly
Terminal assembly Side plate
1 2
3
4 5
No.ID × Width mm
115.8 × 2.4
221.0 × 1.9
314.8 × 2.4
43.8 × 1.9
514.8 × 1.9
>>B<< OIL SEAL INST ALLA TION
AC000752
MB990938
AB
MB991203
Use following spe c ia l too l to inst all the oil seal.
•Bar (Snap-in type) (MB9909 38)
•Oil Seal and Bearin g Inst aller (MB9912 03)
>>C<< CAM RING INSTALLA TION
CAUTION
Be sure to install the cam ring in the correct
direction as shown.
AC100171AB
Side plate side
Pump cover side
Install the cam ring as shown in the illustration.
INSPECTION
M1372005500200
•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.

POWER STEERING HOSES
POWER STEERING37-40
POWER STEERING HOSES
REMOVAL AND INSTALLATIONM1372005700679
CAUTION
•Before removing the clock spring, refer to GROUP 52B, Service Precautions (P.52B-5) and Air Bag
Module and Clock Spring (P.52B-194). Also, put the front wheels in straight-ahead position. Fail-
ure to do so may damage the SRS clock spring and render the SRS air bag inoperative, which
results serious driver injury.
•
Pre-removal and Post-installation Operation
•Power Steering Fluid Draining and Refilling (Refer to P.37-13). and Bleeding (Refer to P.37-14).
*: 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.
<LH drive vehicles>
AC304699AB
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*57 ± 7 N·m
3
1
2
9
1310
7 11
12
5 68
12 ± 2 N·m
12 ± 2 N·m
2
9
4
7
8
7
8
7
8
57 ± 7 N·m57 ± 7 N·m
57 ± 7 N·m
12 ± 2 N·m
167 ± 9 N·mCrossmember
12 ± 2 N·m
<1300, 1600>
<2000>
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-194).
Removal steps (Continued)

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-194).
•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.15-10).
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-ring
POWE R STEERING HOSES
POWER S T E E RING37-42
REMOVA L SER V ICE POINT
<<A>> EYE BOLT /RETURN TUBE
REMOV
A L
CAUTION
If the joint cover grommet has been removed,
install it properly as follows.
AC304922AB
A
B
Joint cover
grommet
Steering gear
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 crossmem-
ber mounting bolts and nuts.
2. Remove the eye bolts or return tube.
INSTALLATION SERVICE POINTS
>>A<< RETURN HOSE INSTALLATION
<LH DRIVE VEHICLES>
AC100277 ABReturn hose
Install the return hose so that the marking is posi-
tioned as shown in the illustration.
>>B<< RETURN HOSE INSTALLATION
AC305132AB
Return hose
Return tubeReturn hose
<LH drive vehicles> <RH drive vehicles>
Install the return hose so that the markings are posi-
tioned as shown in the illustration.
>>C<< SUCTION HOSE INSTALLATION
Install the suction hose (oil pump side) so that the
marking is positioned forward.

42-1
GROUP 42
BODY
CONTENTS
HOOD . . . . . . . . . . . . . . . . . . . . .42-3
ON-VEHICLE SERVICE. . . . . . . . .42-3
ADJUSTMENT OF CLEARANCE
AROUND HOOD . . . . . . . . . . . . . . . . . . 42-3
ADJUSTMENT OF ALIGNMENT OF
HOOD STEPPED PORTION AND
HOOD STRIKER . . . . . . . . . . . . . . . . . . 42-3
ADJUSTMENT OF HOOD HEIGHT . . . 42-3
HOOD . . . . . . . . . . . . . . . . . . . . . . .42-4
REMOVAL AND INSTALLATION . . . . . 42-4
FENDER . . . . . . . . . . . . . . . . . . .42-5
SPECIAL TOOL . . . . . . . . . . . . . . .42-5
FENDER . . . . . . . . . . . . . . . . . . . . .42-6
REMOVAL AND INSTALLATION . . . . . 42-6
FUEL FILLER LID . . . . . . . . . . .42-8
REMOVAL AND INSTALLATION .42-8
STRUT TOWER BAR . . . . . . . .42-9
REMOVAL AND INSTALLATION .42-9
WINDOW GLASS . . . . . . . . . . . 42-10
ADHESIVE . . . . . . . . . . . . . . . . . . .42-10
SPECIAL TOOLS . . . . . . . . . . . . . .42-10
WINDOW REPAIR . . . . . . . . . . . . .42-10
WINDSHIELD . . . . . . . . . . . . . . . . .42-12
REMOVAL AND INSTALLATION . . . . . . 42-12
REAR WINDOW GLASS
<SEDAN> . . . . . . . . . . . . . . . . . . . .42-17
REMOVAL AND INSTALLATION . . . . . . 42-17
QUARTER WINDOW GLASS
<WAGON> . . . . . . . . . . . . . . . . . . .42-20
REMOVAL AND INSTALLATION . . . . . . 42-20
TAILGATE WINDOW GLASS
<WAGON> . . . . . . . . . . . . . . . . . . .42-23
REMOVAL AND INSTALLATION . . . . . . 42-23
DOOR . . . . . . . . . . . . . . . . . . . . 42-25
SERVICE SPECIFICA TIONS . . . . .42-25
SEALANT . . . . . . . . . . . . . . . . . . . .42-25
SPECIAL TOOLS . . . . . . . . . . . . . .42-26
Continued on next page

42-2
TROUBLESHOOTING . . . . . . . . . .42-26
ON-VEHICLE SERVICE. . . . . . . . .42-27
DOOR FIT ADJUSTMENT. . . . . . . . . . . 42-27
DOOR WINDOW GLASS
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . 42-28
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 REGULATOR42-32
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 . . . . . . . . . .42-47
ON-VEHICLE SERVICE . . . . . . . . .42-47
TAILGATE FIT ADJUSTMENT. . . . . . . . 42-47
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