brake MITSUBISHI LANCER 2006 Workshop Manual

INLET MANIFOLD
INTAKE AND EXHAUST15-5
INLET MANIFOLD
REMOVAL AND INSTALLATION <4G1>M1151003000749
Pre-removal Operation
•Fuel Line Pressure Reduction (Refer to GROUP 13A -
On-vehicle Service
P.13A-372).
•Engine Coolant Draining (Refer to GROUP 14 - On-vehi-
cle Service P.14-21).
•Strut Tower Bar Removal (Refer to GROUP 42 P.42-9).
•Throttle Body Assembly Re moval (Refer to GROUP 13A
P.13A-383).
•Fuel Delivery Pipe and Fuel Injector Assembly Removal
(Refer to GROUP 13A
P.13A-381).
Post-installation Operation
•Fuel Delivery Pipe and Fuel Injector Assembly Installation
(Refer to GROUP 13A
P.13A-381).
•Throttle Body Assembly Inst allation (Refer to GROUP
13A
P.13A-383).
•Strut Tower Bar Installati on (Refer to GROUP 42 P.42-9).
•Engine Coolant Supplying (Refer to GROUP 14 - On-vehi-
cle Service P.14-21).
•Accelerator Cable Adjustment (Refer to GROUP 17 -
On-vehicle Service
P.17-2).
•Fuel Leak Check
AC303642AB
15
36
5
4 12
10
7
1
2
11
9 13
14
21 ± 4 N·m
9.0 ± 1.0 N·m
9.0 ± 1.0 N·m
18 ± 2 N·m
18 ± 2 N·m 18 ± 2 N·m
5.0 ± 1.0 N·m
31 ± 3 N·m
49 ± 9 N·m
N
N
N
8
Removal steps
1.Inlet manifold absolute pressure sensor
2.Engine control pressure sensor O-ring
3.Engine control detonation sensor
connector
4.T/M housing front lower cover stay (L.H.)
5.Battery wiring harness clamp connection
6.Inlet manifold stay
7.Brake booster vacuum hose connection
8.Emission control equip hose connection
9.Fuel vapour control hose connection
10.Inlet manifold stay
11 .Inlet manifold
12.Inlet manifold gasket
13.EGR valve
14.EGR valve gasket
15.Emission vacuum hose & pipe and
emission solenoid valve assembly
Removal steps (Continued)

INLET MANIFOLD
INTAKE AND EXHAUST15-6
REMOVAL AND INSTALLATION <4G6>
M1151003001236
Pre-removal Operation
•Fuel Line Pressure Reduction (Refer to GROUP 13A -
On-vehicle Service P.13B-325).
•Engine Coolant Draining (Refer to GROUP 14 - On-vehi-cle Service P.14-21).
•Strut Tower Bar Removal (Refer to GROUP 42 P.42-9).
•Throttle Body Assembly Re moval (Refer to GROUP 13B
P.13B-335).
•Fuel Delivery Pipe and Fuel Injector Assembly Removal
(Refer to GROUP 13B
P.13B-333).
Post-installation Operation
•Fuel Delivery Pipe and Fuel Injector Assembly Installation
(Refer to GROUP 13B P.13B-333).
•Throttle Body Assembly Inst allation (Refer to GROUP
13B P.13B-335).
•Strut Tower Bar Installati on (Refer to GROUP 42 P.42-9).
•Engine Coolant Supplying (Refer to GROUP 14 - On-vehi-
cle Service P.14-21).
•Accelerator Cable Adjustment (Refer to GROUP 17 -
On-vehicle Service
P.17-2).
•Fuel Leak Check
AC303657
9.0 ± 1.0 N·m11 ± 1 N·m
20 ± 2 N·m 31 ± 3 N·m
36 ± 6 N·m
20 ± 2 N·m
20 ± 2 N·m
36 ± 6 N·m
20 ± 2 N·m
11
9
10
2
12
N14
13N
AB
5.0 ± 1.0 N·m
3
1
11 ± 1 N·m
4
N
13 ± 1 N·m
5
6
(Engine oil)
7
8
Removal steps
1.Emission control equip hose
connector
2.Brake booster vacuum hose
connection
3.Earth cable connection
4.Engine control detonation sensor
connector
5.Engine oil level gauge and guide
assembly
6.Engine oil filler O-ring
7.Emission vacuum hose connection
Removal steps (Continued)

CHARGING SYSTEM
ENGINE ELECTRICAL16-5
OUTPUT CURRENT TEST
M1161001000368
AK203362
Alternator
Ammeter
(clamp-type)
Voltmeter
Battery
Inition switch
Engine-ECU
<M/T> or
Engine-A/T-ECU
<A/T> Load
B FR
L
S
G
+
AH
–
Charging indicator
Brake warning light
This test determine s whethe r the a l terna t or outp u t
curren
t is normal.
1.Befo re the t e st, always be sure t o che c k the
fo llowi ng.
•Alternator inst allatio n
•Battery (Refer to GROUP 54 A − Battery − On-vehi-
cle Serv ice P.54A-5).
NOTE: The battery sh ould be sligh t ly discharg ed.
The
load neede d by a fully-charge d batte ry is
in
sufficient for an accurat e test.
•Drive belt tension
(Ref er to GROUP 1 1 A − On-vehicle Service <4G1>
P.11A-7 or GROUP 1 1 C − On-vehicle Se rvice
<4G6> P.11C-7.)
•Fusible link
• Abnormal noise from the altern ator while the
eng
ine is ru nning .
2.T u rn the ignition switch to the "LOCK" (OFF)
po sit i on.
3.Disco nnect the ne gative ba ttery cable.
CAUTION
Never use clips but tighten bolts and nuts to con-
nect the line. Otherwise loose connections (e.g.
using clips) will lead to a serious accident
because of high current.
4. Connect a clamp-type DC test ammeter with a
range of 0
− 120 A to the alternator "B" terminal
output wire.
NOTE: The way of disconnecting the alternator
output wire and of connecting the ammeter is pos
-
sibly not found the problem that the output current
is dropping due to the insufficient connection
between terminal "B" and the output wire.
5. Connect a voltmeter with a range of 0 − 20 V
between the alternator "B" terminal and the earth
[Connect the (+) lead of the voltmeter to the "B"
terminal, and then con nect the (-) lead of the
voltmeter to the earth].
6. Connect the negative battery cable.
7. Connect a tachometer or the M.U.T.-II/III (Refer to GROUP 11A
− On-vehicle Service − Idle speed
check <4G1>
P.11A-11 or GROUP 11C −
On-vehicle Service − Idle speed check <4G6>
P.11C-11).
8. Leave the hood open.

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)

FRONT AXLE HUB ASSEMBLY
FRONT AXLE26-9
REMOVAL SERVICE POINTS
<<A>> CALIPER ASSEMBLY REMOVAL
Secure the removed caliper assembly with wire, etc.
<<B>> BRAKE DISC REMOVAL
AC209507AC
BOLT
(M8×1.25)
If the b
r ake d i sc is se ize d , inst all M8x1.25-mm b o lt s
as shown, an
d remove t he disc by tighten ing t he
bolt
s e v enly a nd grad ually .
<<C> > DRIVESHAFT NUT REMOV A L
CAUTION
Do not apply pressure to wheel bearing by the
vehicle weight to avoid possible damage when
driveshaft nut is loosened.
AC102462AC
MB990767
Use special tool front hub and end yoke holder
(MB990767) to fix the hub and remove the driveshaft
nut.
<<D>> SELF-LOCKING NUT (TIE ROD
END CONNECTION) REMOVAL
CAUTION
•Do not remove the nut from ball joint. Loosen
it and use the special tool to avoid possible
damage to ball joint threads.
•
AC208247AJ
Cord
BoltMB991897
or
MB992011
Nut
Ball joint
Hang the special tool with cord to prevent it
from falling.
1. Install special tool ball joint remover (MB991897 or MB992011) as shown in the figure.
AC106821
Knob
Parallel
Bolt
Correct Wrong
AB
2. Turn the bolt and knob as necessary to make the jaws of 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 fig
-
ure.
3. Tighten the bolt with a wrench to disconnect the tie rod end.

AC100136
MB990685MB990326
AB
FRONT AXLE HUB ASSEMBL Y
FRONT AXLE26-13
3.Measure the hub st a r ting torque b y using the
fo llowing special to ols.
•To rque wren ch (MB99068 5)
•Preload socket (MB9 90326 )
Limit: 1.8 N⋅m
4.Th e st arting torq ue must b e within the limit an d
th e hub rot a tion must be smoo th.
>>C<< WH EEL BEARING AXIAL PLA Y
CHECK
AC100137
MB991000
MB991017
245 ± 29 N·m AB
Tighten the nut
with the bolt
secured
1.
Measure to d e termine whe t her th e wheel bearing
a x ial pla y is with in the limit o r not by using t he
fo llowing special to ols.
•Front hub re mover and inst a ller (MB9910 17)
•Sp a c er (MB9910 00)
Limit: 0.05 mm
2. If the play is not wit h in the limit rang e while the nut
is tighten ed to 2 45
± 29 N⋅m, the bearing, hu b
a
nd/or knuckle
have
proba
bly not be en in st alled
correctly
. Replace
the be
aring and re -inst a ll.
INSPECTION
M12610020 0007 8
•Check the fro n t hu b and brake disc mo untin g sur-
faces for gallin g and cont amination.
•Check the knu c kle in ner surface for ga lling an d
crac
ks .

DRIVESHAFT ASSEMBLY
FRONT AXLE26-14
DRIVESHAFT ASSEMBLY
REMOVAL AND INSTALLATIONM1261003500849
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.
•
Pre-installation Operation
•Transmission Fluid Draining (Refer to GROUP
22A, On-vehicle Service
− Transmission Oil
Replacement
P.22A-8).
•Front Exhaust Pipe Removal (Refer to GROUP
15, Exhaust Pipe and Muffler
P.15-10).
Post-installation Operation
•Front Exhaust Pipe Installation (Refer to
GROUP 15, Exhaust Pipe and Muffler
P.15-10).
•Check the Ball Joint Dust Cover for cracks or
damage by pushing it with your finger.
•Transmission Fluid Filling (Refer to GROUP
22A, On-vehicle Service
− Transmission Oil
Replacement
P.22A-8).
AC303689AB
9
N
N
NN
10
7
4
3
2 1
25 ± 5 N·m
245 ± 29 N·m
108 ± 10 N·m
8
5
6
11 12
77
Removal steps
<<A>>>>C<<1.Driveshaft nut
>>C<<2.Washer
3.Front ABS sensor
4.Front ABS sensor bracket
5.Brake hose bracket
>>B<<6.Self-locking nut (stabilizer bar
connection)
>>B<<7.Stabilizer rubber
8.Collar
9.Lower arm connecting bolt
<<B>>10.Self-locking nut (tie rod end
connection)
<<C>>>>A<<11 .Driveshaft
12.Circlip
Be careful not to strike the pole piece at the tip of the front ABS sensor with tools during servicing
work.
Removal steps (Continued)

AC102551AC
Drive shaft
DRIVESHAFT ASSEMBL Y
FRONT AXLE26-16
2.Remove th e dr ivesh a f t from th e h ub b y p u lling the
bo ttom of the brake disc toward s you.
CAUTION
•Do not pull on the driveshaft; doing so will
damage the TJ; be sure to use the pry bar.
•
AC100141
Transmission
TJ assembly Pry bar
AG
When pulling the driveshaft out from the
transmission, be careful that the spline part of
the driveshaft does not damage the oil seal.
3. Insert a pry bar between the transmission case and the driveshaft, and then pry and remove the
driveshaft from the transmission.
AC102554
MB991460
AC
4. Use special tool plug (MB991460) to prevent the
entry of foreign material into the transmission
case.
AC102555 AC
MB991017
MB991000
CAUTION
Do not apply pressure to the wheel bearing by
the vehicle weight to avoid possible damage
when the driveshaft is removed. If, however, vehi
-
cle weight must be applied to the bearing in mov-
ing the vehicle, temporarily secure the wheel
bearing by using the following special tools.
•Spacer (MB991000)
•Front hub remover and installer (MB991017)
INSTALLATION SERVICE POINTS
>>A<< DRIVESHAFT INSTALLATION
CAUTION
When installing the driveshaft, be careful that the
spline part of the driveshaft does not damage the
oil seal.
>>B<< STABILIZER
RUBBER/SELF-LOCKING NUT
(STABILIZER BAR CONNECTION)
INSTALLATION
AC210393
AC
A
Install the stabilizer rubber and collar as shown in the
figure, and tighten the self-locking nut so that the
protruding length of the stabilizer bar mounting bolt
protruding part meets its standard value (A).
Standard value (A): 22 ± 1.5 mm

ON-VEHICLE SERVICE
REAR AXLE27-4
ON-VEHICLE SERVICE
WHEEL BEARING AXIAL PLAY CHECKM1271000900452
1. Remove the caliper assembly, and suspend the caliper assembly with a wire and remove the
brake disc.
AC303736AB
2.Check the be aring ' s axial play . Place a dial gau ge
ag ainst th e hub su rface; then mo ve t he hu b in the
axial dire ction and check whe t her or not the r e is
axial pla y .
Limit: 0.05 mm
3.If the play e xce eds the limit, the self -lockin g nut
should be tighte ned to the specified torque and
check the axial play again .
Ti ghte n ing torque: 175 ± 25 N⋅m
4.Replace the re ar hub a s sembly if an ad justmen t
cannot be made to within the limit.
REAR HUB ROTA R Y -SLIDING
RESIST
ANCE CHECK
M127100 1 1 0024 4
1.Remove the caliper assembly , a nd suspe nd the
caliper assembly with a wire an d remove t he
bra k e d i sc.
2.T u rn the hu b a few times to seat th e bea ring.
AC303737
3.Wind a rope a r ound the hu b bolt and turn t he hub
b y pullin g at a 90
° angle with a spring balance.
Measure to d
e
termine whe t her or not the
ro
t
a
ry-sliding resist an ce of the rea r hub is at the
limit va
lue.
Limit: 19 N
4.If limit value is exceeded , loo s en the self-locking
n u t and then tighten it to the specified torque and
check the rear hu b rot a ry sliding resist ance again.
Ti ghte n ing torque: 175 ± 25 N⋅m
5.Replace the re ar hub assembly if an a d justmen t
canno t be made to within the limit.
HUB BOLT REPLACEMENTM12710010 0025 8
1.Remove the calip er assembly and suspe nd it with
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 60
± 5 N⋅m.