ISC MITSUBISHI LANCER 2006 Owner's Manual

STARTING SYSTEM
ENGINE ELECTRICAL16-25
MAGNETIC SWITCH RETURN TEST
AK300652AB
<4G1>S
B MWire
Battery
Starter
motor
AKX01248
<4G6>
SB
M
Battery
Starter
motorWire
AF
1.
Disco nnect the field coil wire f r om th e M-te rmin al
o f the magnet ic switch.
CAUTION
This test must be performed quickly (in less than
10 seconds) to prevent the coil from burning.
2. Connect a 12-volt battery between the M-terminal and body.
WARNING
Be careful not to ge t your fingers caught
when pulling out the pinion.
3. Pull the pinion out and release. If the pinion
quickly returns to its original position, everything is
operating properly. If it doesn't, replace the
magnetic switch.

STARTING SYSTEM
ENGINE ELECTRICAL16-26
DISASSEMBLY AND REASSEMBLY
M1162001200202
AK201881
141211
20
1
1516
17 18 19
13 10
2
43
5
7
6
8
9
AG
Disassembly steps
1.Screw
<<A>>2.Magnetic switch
3.Screw
4.Bolt
5.Rear bracket
6.Brush holder
7.Rear bearing
8.Armature
9.Yoke assembly
10.Packing A
11 .Packing B
12.Plate
13.Planetary gear
14.Lever
<<B>>>>A<<15.Snap ring
<<B>>>>A<<16.Stop ring
17.Overrunning clutch
18.Internal gear
19.Planetary gear shaft
20.Front bracket
DISASSEMBL Y SER V ICE POINTS
<<A>> MA GNETIC SW ITCH REM O V A L
AK201882
B terminal
M terminal
S terminal
AC
CAUTION
Do not clamp the yoke assembly with a vise.
Disconnect the lead from the M terminal of the mag-
netic switch.

EMISSION CONTROL <MPI>
ENGINE AND EMISSION CONTROL17-10
SYSTEM DIAGRAM
AK204367AC
Throttle body
Canister
From
fuel
tank
OFF
ON Purge
control
solenoid
valve
Control
relay
Battery Engine-ECU <4G1-M/T, 4G6>,
Engine-A/T-ECU <4G1-A/T>
Air flow sensor <4G6>Engine coolant
temperature sensor
Intake air
temperature sensor
Barometric pressure
sensor <4G6>
Manifold absolute pressure
(MAP) sensor <4G1>
COMPONENT LOCA
TION (EV A PORA TIVE
EMISSION CONTROL SYSTEM)
M1173 0075 0021 6
AK300769
<4G1>
AB
Purge control
solenoid valve
AK300770
<4G6>
AB
Purge control
solenoid valve
PURGE CONTROL SYSTEM CHECK
M1173 0014 0029 9
AK300771
<4G1>
AB
Plug
Vacuum hose
AK300772
<4G6>
AB
Plug
Vacuum hose
1.Disco nnect the vacu um h o se (re d str i pe) fro m
th rottle body and conne ct it to a h and vacu um
pu m p .

EMISSION CONTROL <MPI>
ENGINE AND EMISSION CONTROL17-11
2. Plug the nipple from which the vacuum hose was removed.
3. When the engine is cold or hot, apply a vacuum of 53 kPa, and check the condition of the vacuum.
When engine is cold
(Engine coolant temperature: 40°C or less)
Engine conditionNormal condition
At idleVacuum is maintained.
3,000 r/min
When engine is hot
(Engine coolant temperature: 80°C or higher)
Engine conditionNormal condition
At idleVacuum is maintained.
3,000 r/min (within 3
minutes after engine
starts)Vacuum will leak.
PURGE PORT VACUUM CHECKM1173001500177
AK300773
<4G1>
AB
Plug
Vacuum hose
AK300774
<4G6>
AB
Plug
Vacuum hose
1.Disco nnect th e vacuum ho se (red st ripe) from the
throttle body and connect a hand vacuum pump to
th e nip p le.
2.Plu g the vacuum hose (red stripe).
AK100011AC
Vac-
uum
Engine speed (r/min)
3.S t art the engine.
4.Check t hat a f a irly co nst ant n egative p r essure is
g enerate d regard l ess of the en gine spee d.
5.If no neg ative pressur e is genera t ed, th e port is
p r obably blocked an d sh ould be cleane d.
PURGE CONTROL SOLENOID VA L V E
CHECK
M1173 0017 0019 3
NOTE: Whe n discon nect i ng th e va cuum hose,
always make a mark so th at it can be reconnected at
original p o sition.
AK100012AC
Battery
A
AK100013
1.
Disco nnect the vacu um h o se f r om th e solenoid
valve.
2.Disco nnect the ha rness connector .
3.Con nect a ha nd vacu um pump to nipp le (A) of the
solen o id valve (ref e r to th e ill ust r ation at le f t ).
4.Check a i rtig htness b y app lying a vacuum with
volt age applied d i rectly from t he batt e ry to the
p u rge con t rol so leno id valve an d without app lying
volt age .

EMISSION CONTROL <MPI>
ENGINE AND EMISSION CONTROL17-15
EGR SYSTEM CHECK
M1173002600348
AK300780AB
<4G1>
EGR valve
Green stripe
Three-way
terminal
AK300781AB
<4G6>
EGR valve
Green stripe
Three-way
terminal
1.Disco nnect the vacu um ho se (Green stripe) from
th e EGR valve, a nd th en connect a hand vacuum
pu mp via t he thre e-way te rmin al.
2.Wh en the engine is hot o r cold, check the
condition of va cuum by racing the engine.
When engine is c o ld
(Eng ine coo lant tem perature: 20°C or less)
Throttle valveNormal vacuum co ndition
Open quicklyNo va cuum will gene rate (th e
same as baro
m etric pre s sure.)
When engine is h o t
(Eng ine coo lant tem perature: 80°C or higher)
Throttle valveNormal vacuum c ondition
Open quicklyIt will mo me nt a r i l y rise o v er 13
kPa
3.Disco nnect the th ree-way t e rminal.
AK300782AB
<4G1>
EGR valve
Green stripe
AK300783AB
<4G6>
EGR valve
Green stripe
4.Conn ect the han d va cuum pump to t he EGR
valve nipple.
5.Check whe t her th e engine st alls or the idling is
u n st able when a vacuum of 30 kPa or h i gher is
a pplied during idling.
EGR V A L V E CHECKM1173 0028 0022 3
1.Remove the EGR valve an d inspect for stickin g ,
carbon deposit s, e t c. If found , clean with a
suit able so lve n t so that th e va lve seat s corre ctly .
2.Conn ect a hand vacuum pump to the EGR va lve .
3.App l y 6 7 kPa of va cuum, and check t hat the
vacu um is maint a ined.
AKX00348
4.App l y a vacuum and chec k th e p a ssage of air by
b l owing throug h one side of the EGR p a ssage.
VacuumPassage of air
5.3 kPa or lessAir is not blown out
27 kPa or moreAir is blown out

EMISSION CONTROL <MPI>
ENGINE AND EMISSION CONTROL17-16
5. Replace the gasket, and tighten to the specified torque.
Tightening torque:
<4G1> 21 ± 4 N⋅m
<4G6> 20 ± 2 N⋅m
EGR PORT VACUUM CHECK <4G1>M1173002900167
AK300784AB
Green strip
1.Disco nnect the vacu um ho se (Green stripe) from
th e t h ro tt le b o d y EGR va cuu m ni pp le an d co nn ec t
a hand vacu um p u mp to the nipple.
2.Plu g the vacuum hose (Gree n stripe).
AK201224AB
Vac-
uum
Engine speed (r/min)
3.S t art the engin e and check t hat, af ter ra ising th e
engine spe ed by ra cin g the e ngine, p u rge vacuu m
raises according to engine speed.
NOTE: If ther e is a prob lem with change in vac-
uum, the t h rottle bod y p u rge port may be clo gged
an
d requ ire clean ing.
EGR PORT VA CUUM CHECK <4G6>M1173 0029 0015 6
AK300786AB
White stripe
1.Disco nnect the vacu um h o se (W hite strip e ) from
th e t h ro tt le b o d y EGR va cuu m ni pp le an d co nn ec t
a hand vacuum p u mp to the nipple.
2.Plug the vacuum hose (White stripe).
AK100011AC
Vac-
uum
Engine speed (r/min)
3.S t art the engine.
4.Check that a fairly const a nt n egative is gene rated
re gardle s s of the engine sp eed.
5.If no neg ative pressur e is genera t ed, th e port is
p r obably blocked an d sh ould be cleane d.
EGR CONTROL SOLENOID VA L V E
CHECK <
4 G1 >
M1173 0031 0023 8
NOTE: Whe n discon nect i ng th e va cuum hose,
always make a mark so th at it can be reconnected at
original p o sition.
AKX00351
A
B
AE
Battery
1. Disco nnect the vacu um h o se f r om th e solenoid
valve.
2.Disco nnect the ha rness connector .
3.Con nect a ha nd vacu um pump to nipp le (A) of the
solen o id valve (ref e r to th e ill ust r ation at le f t ).
4.Check a i r tightness b y ap plying a vacuum with
volt age applied d i rectly from t he batt e ry to the
EGR cont rol solen o id valve and withou t applyin g
volt age .
Battery voltageNormal condition
AppliedVa c u u m l e a k s
Not appliedVacuum maintained

AKX00352
EMISSI ON CONTROL <MPI>
ENGINE AND E M ISSION CON T R O L17-17
5.Measure the resist ance between the te rmin als of
th e solenoid va lve .
St andard va lue: 29 − 35 Ω (at 20°C)
EGR CONTROL SOLENOID V A L V E
CHECK <
4 G6>
M1173 0031 0024 9
NOTE: Whe n discon nect i ng th e va cuum hose,
always
make a mark so th at it can be reconnected at
original p o sition.
AK201251AB
A
B
C
Battery
1.Disco nnect the vacu um h o se f r om th e solenoid
valve.
2.Disco nnect the ha rness connector .
3.Con nect a ha nd vacu um pump to nipp le (A) of the
solen o id valve (ref e r to th e ill ust r ation at le f t ).
4.Check a i r tightness b y ap plying a vacuum with
volt age applied d i rectly from t he batt e ry to the
EGR cont rol solen o id valve and withou t applyin g
volt age .
Battery
voltageB nipple
conditionNormal condition
Not appliedOpenVacuum
maintained
AppliedOpenVacuum leaks
ClosedVacuum
maintained
AK100016
5.Measure the resist ance betwee n the te rminals of
th e so lenoid valve .
St andard va lue: 29 − 35 Ω (at 20°C)

SPECIAL TOOLS
FRONT AXLE26-4
SPECIAL TOOLS
M1261000600773
ToolNumberNameUse
B990767
MB990767Fr o n t hu b a n d en d
yoke holderFixing of the h u b
MB991618
MB991618Hub bolt remo verRemoval of the h ub bolt
AC106827
MB991897 or
MB992
01 1Ball j o int remo verKnuckle and tie rod e nd ball joint
discon
nection
NOTE: St eering linkage pu lle r
(MB990 635 or MB991 1 13)is also u s ed
to disconnect kn uckle an d tie rod en d
bal
l j
o
int.
MB990241AB
A BMB990241
A: MB9902 42
B: MB990244
Axle shaft pu ller
A: Puller shaf t
B: Puller bar
Rem o va l of t h e dri v es h a f t
MB991354
MB991354Pulle r body
MB991 056 or
MB991
355Knuckle a r m
bridg
e•Removal of the hu b
•Removal of the whee l bea ring
AC100320 ABA
B
C
A: MB9910 17
B: MB990998
C: MB99100 0
A, B: Fr ont hu b
remover and
ins t all e r
C: Sp acer
•Removal of the hu b
•Prov ision a l ho ldin g of th e wheel
b
earin g
•Measurement of hub st a r ting t o rque
•Measurement of wh eel b earin g axial
pl
a y
NOTE: MB9 91000, which b e lon g s to
MB9909 98, should be used a s a
sp
acer
.

ON-VEHICLE SERVICE
FRONT AXLE26-7
ON-VEHICLE SERVICE
WHEEL BEARING AXIAL PLAY CHECKM1261000900224
1. Remove the caliper assembly and suspend it with a wire.
2. Remove the brake disc from the front hub.
AC209503 AC
3.
Att a ch a dial ga uge a s sh own in the illustration,
an d th en measure the axial play while moving the
hu b in the axial dire ctio n.
Limit: 0.05 mm
4.If axial play e x ceeds t he limit, disassemble the
fro n t hub assemb ly a nd check the p a rt s.
5.In st all the bra k e d i sc, ca lipe r assembly and
tighten th e caliper assemb ly mount ing bolt s to the
specifie d torqu e 100
± 10 N⋅m.
HUB BOL T REPLACEMENTM12610010 0029 1
1.Remove the ca lip er assembly a nd suspe nd it wit h
wire so t hat it does not fa ll.
2.Remove the bra k e d i sc.
AC302114
MB991618
AD
Hub bolt
3.Use spe c ia l too l hub bolt remover (MB99161 8) to
re move the h ub bo lt s.
AC104588
MB990767
Plain
washer
AC
4. In st all the plain wa sher to the n e w hub b o lt, a nd
inst all the bolt with a nu t while hold i ng the hub
wit h spe c ia l too l fron t hub a nd end yoke holder
(MB99076 7).
5.In st all the bra k e d i sc, ca lip er assembly and
tighten th e caliper assembly mount ing bolt s to the
specifie d torqu e 100
± 10 N⋅m.

FRONT AXLE HUB ASSEMBLY
FRONT AXLE26-8
FRONT AXLE HUB ASSEMBLY
REMOVAL AND INSTALLATIONM1261001700739
CAUTION
•Do not strike the ABS rotors installed to the BJ outer race of driveshaft against other parts when
removing or installing the driveshaft. Otherwise the ABS rotors will be damaged.
•
Post-installation Operation
•Check the dust cover for cracks or damage by pushing it
with your finger.
AC209505
N
N
N
5
4
3
1
8
10
9
2
7
6
167 ± 9 N·m 25 ± 5 N·m
108 ± 10 N·m 245 ± 29 N·m
100 ± 10 N·m
AC
7 7
11 12
13
Removal steps
1. Front ABS sensor
<<A>> 2. Caliper assembly
<<B>> 3. Brake disc
<<C>>>>B<<4. Driveshaft nut
>>B<<5. Washer
>>A<<6.Self-locking nut (stabilizer bar
connection)
>>A<<7.Stabilizer rubber
8.Collar
9. Lower arm connecting bolt
<<D>> 10. Self-locking nut (tie rod end
connection)
<<E>> 11 . Driveshaft
12.Nut (hub and knuckle to strut
connection)
13.Hub and knuckle
Be careful not to strike the pole piece at the tip of the front ABS sensor with tools during servicing
work.
Removal steps (Continued)