warning MITSUBISHI LANCER IX 2006 Service Manual

GENERAL INFORMATION
ENGINE LUBRICATION12-2
GENERAL INFORMATION
M1121000100357
The lubrication method is a fully force-fed, full-flow fil-
tration type. The engine oil pump is a trochoid type
which is driven by the crankshaft <4G1>.The engine
oil pump is a gear type which is driven by the crank
-
shaft via the balancer timing belt <4G6>.
ENGINE OILS
Health Warning
Prolonged and repeated contact with mineral oil will
result in the removal of natural fats from the skin,
leading to dryness, irritation and dermatitis. In addi
-
tion, used engine oil contains potentially harmful con-
taminants which may cause skin cancer. Adequate
means of skin protection and washing facilities must
be provided.
Recommended Precautions
The most effective precaution is to adapt working
practices which prevent, as far as practicable, the
risk of skin contact with mineral oils, for example by
using enclosed systems for handling used engine oil
and by degreasing components, where practicable,
before handling them. Other precautions:
•Avoid prolonged and repeated contact with oils,
particularly used engine oils.
•Wear protective clothing, including impervious
gloves where practicable.
•Avoid contaminating clothes, particularly under-
pants, with oil.
•Do not put oily rags in pockets, the use of overalls
without pockets will avoid this.
•Do not wear heavily soiled clothing and
oil-impregnated foot-wear. Overalls must be
cleaned regularly and kept separate from per
-
sonal clothing.
•Where there is a risk of eye contact, eye protec-
tion should be worn, for example, chemical gog-
gles or face shields; in addition an eye wash
facility should be provided.
•Obtain first aid treatment immediately for open
cuts and wounds.
•Wash regularly with soap and water to ensure all
oil is removed, especially before meals (skin
cleansers and nail brushes will help). After clean
-
ing, the application of preparations containing
lanolin to replace the natur al skin oils is advised.
•Do not use petrol, kerosine, diesel fuel, gas oil,
thinners or solvents for cleaning skin.
•Use barrier creams, applying them before each
work period, to help the removal of oil from the
skin after work.
•If skin disorders develop, obtain medical advice
without delay.
SERVICE SPECIFICATION
M1121000300232
ItemStandard value
Oil pressure kPaat idle29 or more
at 3,500 r/min294 − 686
LUBRICANT
M1121000400433
ItemSpecification
Engine oil ACEA classificationA1, A2 or A3
Engine oil API classificationSG or higher
Engine oil quantity L4G1Oil filter0.3
To t a l3.3
4G6Oil filter0.3
To t a l4.3

ON-VEHICLE SERVICE
ENGINE COOLING14-21
ON-VEHICLE SERVICE
ENGINE COOLANT LEAK CHECKM1141001000300
WARNING
When pressure testing the cooling system,
slowly release cooling system pressure to
avoid getting burned by hot coolant.
CAUTION
•Be sure to completely clean away any mois-
ture from the places checked.
•When the tester is taken out, be careful not to
spill any coolant.
•
ACX01844
Cap adapter
Adapter
AC
Be careful when installing and removing the
tester and when testing not to deform the
filler neck of the radiator.
1. Check that the coolant leve l is up to the filler neck.
Install a radiator tester and apply 160 kPa
pressure, and then check for leakage from the
radiator hose or connections.
2. If there is leakage, repair or replace the
appropriate part.
RADIATOR CAP VALVE OPENING
PRESSURE CHECK
M1141001300389
NOTE: Be sure that the cap is clean before test-
ing. Rust or other foreign material on the cap seal
will cause an improper reading.
AC211643AB
Cap adapter
1. Use a cap adapter to attach the cap to the tester.
2. Increase the pressure until the indicator of the gauge stops moving.
Minimum limit: 83 kPa
Standard value: 93 − 123 kPa
3. Replace the radiator cap if the reading does not remain at or above the limit.
ENGINE COOLANT REPLACEMENT
M1141001200434
WARNING
When removing the radiator cap, use care to
avoid contact with hot coolant or steam.
Place a shop towel over the cap and turn the
cap counterclockwise a little to let the pres
-
sure escape through the vinyl tube. After
relieving the steam pres sure, remove the cap
by slowly turning it counterclockwise.
1. Drain the water from the radiator, heater core and
engine after unplugging the radiator drain plug
and removing the radiator cap.
AC208283AC
Cylinder block
drain plug
<4G1>
Inlet side
AC303355
<4G6>
Inlet side
Cylinder block
drain plug
AB
2. Drain the water in the water jacket by unplugging the drain plug of the cylinder block.
3. Remove the radiator condenser tank and drain
the coolant.
4. Drain the coolant then clean the path of the coolant by injecting water into the radiator from
the radiator cap area.

ON-VEHICLE SERVICE
ENGINE COOLING14-23
3. Connect the cooling fan motor drive control unit connector, and disconnect the cooling fan motor
(L.H.) connector.
4. Ensure that the A/C switch is off, and start the engine and run it at idle.
AC303496AB
Cooling fan motor
drive control unit
5.Measure the volt ag e betwee n the cooling f an
motor d r ive cont rol un it side conne ctor t e rminal 1
an d 2.
St andard va lue: 1V or le ss
WARNING
Stay clear of the fan when the fan starts run-
ning.
6. Turn the A/C switch to the "ON" position.
7. Measure the voltage between the cooling fan
motor drive control unit side connector terminal 1
and 2 while the fan is running. The voltage should
repeat the values below.
Standard value:
1. 1 V or less
2. 8.2 ± 0.7 V
3. System voltage ± 2.6 V
8. If the voltage does not repeatedly change as indicated, replace the cooling fan motor drive
control unit. (Refer to
P.14-33) <4G1> (Refer to
P.14-35) <4G6>.
FAN CONTROL RELAY CONTINUITY CHECK
M1141006200280
AC211776
13
4 2
3 4
1
2
AC301712
Fan control relay
AB
Battery
voltageTerminal No.to
be connected
to testerContinuity test
results
Not applied4 − 2Open circuit
Connect
terminal No.1
and battery (
−)
terminal.
Connect
terminal No.3
and battery (+)
terminal.
4 − 2Less than 2
ohms

CHARGING SYSTEM
ENGINE ELECTRICAL16-2
CHARGING SYSTEM
GENERAL INFORMATIONM1161000100522
The charging system uses the alternator output to
keep the battery charged at a constant level under
various electrical loads.
OPERATION
AKX00183
VoltageTime
Approximately
14.4 V
AC
Rota tion of the excited fi eld coil gene rates AC volt-
age in the sta t or .
This alternatin g cur r ent is rectified throu gh diodes to
DC volt
age h a ving a waveform sh own in t he illustra
-
tion.
The average outpu t volt a ge flu c tua t es slightly with
the alternato
r load con d ition.
When the ign i tion switch is t u rned on, current flows in
the field coil and initial e
x cit a tion of the field coil
occurs.
When the st ator coil beg ins to gen erate p o wer af ter
the eng
ine is st a r ted, th e fie l d coil is excited by th e
output
curren t of th e st ator coil.
The alternator outpu t volt a ge rises as th e fie l d cur-
rent increa ses and it falls a s the field cu rrent
decre
ases. Whe n the b a ttery volt a ge (alternato r "S"
terminal volt
ag e) reaches a regulated volt ag e of
approximately 14.4
V , the field current is cut o f f.
When th
e batte ry volt age drop s be low the regulated
volt
ag e, the volt ag e regulator re gulat es th e outp u t
volt
ag e to a const ant level by contro lling the field cur
-
rent.
In addition, when th e fie l d current is const a n t, the
altern
ator ou tput volt age rise s as the e ngine spe ed
increase
s .
SYSTEM DIAGRAM
AK400308
Alternator
B
Stator coil
Engine-ECU <M/T> or
Engine-A/T-ECU <A/T>
G
SL
FR
<4G1>
Voltage regulator Charge warning lightIgnition switch
Battery
Field coil
+
–
AB
AL TERNA T O R SPECIFICA T IONS
Item4G14G6
Ty p eBattery voltage sensing
Rated output V/A12/8012/110
Voltage regulatorElectronic built-in type

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.

CHARGING SYSTEM
ENGINE ELECTRICAL16-10
EXAMPLE OF ABNORMAL WAVEFORMS
NOTE: .
1. The size of the waveform patterns differs largely, depending on the adjustment of the variable knob on the
oscilloscope.
2. Identification of abnormal waveforms is easier when th ere is a large output current (regulator is not oper-
ating). (Waveforms can be observed when the headlamps are illuminated.)
3. Check the conditions of the charging warning lamp (illuminated/not illum inated). Also, check the charging
system totally.
Abnormal waveformProblem cause
Example 1
AKX00191
Open diod e
Exampl e 2
AKX00192
Shor t in diode

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.

33-1
GROUP 33
FRONT
SUSPENSION
CONTENTS
GENERAL INFORMATIO N . . . . . . . .33-2
SERVICE SPECIFICATIONS . . . . . . .33-3
LUBRICANT . . . . . . . . . . . . . . . . . . . .33-3
SPECIAL TOOLS . . . . . . . . . . . . . . . .33-4
ON-VEHICLE SERVICE . . . . . . . . . . .33-6
FRONT WHEEL ALIGNMENT CHECK AND
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 33-6
LOWER ARM BALL JOINT AXIAL PLAY
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-7
LOWER ARM BALL JOINT COVER
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-7
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. . . . . . . . . . . . . . . . . . . . . . . . 33-16
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 inad vertent 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 (*).

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.
•
AC001085 AB
MB991238MB991237
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.
•Spring compressor body (MB991237)
•Arm set (MB991238)
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.
AC006091 AB
MB991681
MB991682
2. Use following special tools to secure the strut, and
then remove the strut nut (self-locking nut).
•Wrench (MB991681)
•Socket (MB991682)
<<B>> STRUT DISPOSAL
WARNING
Wear goggles when dril ling to protect your
eyes from flying metal debris.
AC001087
The gas must be discharged from the strut before
discarding it. Place the strut horizontally with its pis
-
ton rod extended. Then drill a hole of approximately
3 mm in diameter at the location shown in the illustra
-
tion and discharge the gas.
REASSEMBLY SERVICE POINTS
>>A<< SPRING UPPER SEAT INSTALLA-
TION
AC304396AB
Seat
Pad
If the spring upper seat peeled off the pad, adhere
the seat and the pad with a double-sided tape.

SHOCK ABSORBER ASSEMBLY
REAR SUSPENSION34-17
WARNING
Do not use an impact wrench to remove the
rear suspension coil spring nut (self-locking
nut). Vibration of the impact wrench will
cause special t ools (MB991237 and
MB991239) to slip and cause personal injury.
AC102268AC
Piston rod
2. While holding the piston rod, remove the rear
suspension coil spring nut (self-locking nut).
<<B>> REAR SUSPENSION SHOCK
ABSORBER DISPOSAL
WARNING
Wear goggles when dril ling to protect your
eyes from flying metal debris.
AC102270
AC
The gas must be discharged from the shock
absorber before discarding it. Place the shock
absorber 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<< REAR SUSPENSION SPRING
LOWER PAD INSTALLATION
AC304800AB
Spring lower pad
Stepped section
Spring seat
Align the stepped section of the spring lower pad
with the stepped section of the spring seat of the
shock absorber, and install the spring lower pad.
>>B<< REAR SUSPENSION COIL SPRING
INSTALLATION
CAUTION
Do not use an impact wrench to tighten the bolt
of special tool spring compressor body
(MB991237). It will break the special tool.
AC001070
MB991237
MB991239
AB
1. Use following special tools to compress the coil spring, and install the rear suspension coil spring
to the spring lower pad.
•Spring compressor body (MB991237)
•
AC304800AC
Less than 10 mm
Stepped section
Arm set (MB991239)