front MITSUBISHI LANCER 2005 Workshop Manual

54A-1
GROUP 54A
CHASSIS
ELECTRICAL
CONTENTS
BATTERY. . . . . . . . . . . . . . . . . .
54A-4
SERVICE SPECIFICATIONS. . . . .
54A-4
ON-VEHICLE SERVICE. . . . . . . . .54A-4
FLUID LEVEL AND SPECIFIC
GRAVITY CHECK . . . . . . . . . . . . . . . . . 54A-4
CHARGING . . . . . . . . . . . . . . . . . . . . . . 54A-4
BATTERY TEST . . . . . . . . . . . . . . . . . . 54A-5
IGNITION SWITCH* . . . . . . . . . .54A-6
GENERAL INFORMATION . . . . . .
54A-6
SPECIAL TOOLS. . . . . . . . . . . . . .54A-8
TROUBLESHOOTING . . . . . . . . . .54A-9
IGNITION KEY REMINDER BUZZER AND
DOOR LOCK PREVENTION FUNCTION
TROUBLESHOOTING . . . . . . . . . . . . . . 54A-9
IMMOBILIZER SYSTEM
TROUBLESHOOTING . . . . . . . . . .
54A-9
DIAGNOSIS CODE CHART . . . . . . . . . . 54A-9
DIAGNOSTIC TROUBLE CODE
PROCEDURES . . . . . . . . . . . . . . . .
54A-10
SYMPTOM CHART. . . . . . . . . . . . .54A-11
SYMPTOM PROCEDURES . . . . . .54A-12
DATA LIST REFERENCE TABLE .54A-19
CHECK IMMOBILIZER-ECU . . . . .54A-19
ON-VEHICLE SERVICE . . . . . . . . .54A-20
HOW TO REGISTER ENCRYPTED
CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . 54A-20
IGNITION SWITCH . . . . . . . . . . . . . . . . 54A-27
REMOVAL AND INSTALLATION . . . . . . 54A-27
INSPECTION . . . . . . . . . . . . . . . . . . . . . 54A-28
Continued on next page
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 (*).

54A-2
COMBINATION METER
ASSEMBLY . . . . . . . . . . . . . . . .
54A-29
SERVICE SPECIFICATIONS. . . . .
54A-29
SEALANT. . . . . . . . . . . . . . . . . . . .54A-29
SPECIAL TOOLS. . . . . . . . . . . . . .54A-29
TROUBLESHOOTING . . . . . . . . . .54A-31
SYMPTOM CHART . . . . . . . . . . . . . . . . 54A-31
SYMPTOM PROCEDURES . . . . . .54A-32
ON-VEHICLE SERVICE. . . . . . . . .54A-60
SPEEDOMETER CHECK . . . . . . . . . . . 54A-60
TACHOMETER CHECK . . . . . . . . . . . . 54A-60
FUEL TANK GAUGE UNIT CHECK . . . 54A-61
ENGINE COOLANT TEMPERATURE GAUGE
UNIT CHECK . . . . . . . . . . . . . . . . . . . . . 54A-61
COMBINATION METER ASSEMBLY54A-63
REMOVAL AND INSTALLATION . . . . . 54A-63
INSPECTION . . . . . . . . . . . . . . . . . . . . . 54A-64
DISASSEMBLY AND REASSEMBLY . . 54A-65
HEADLAMP . . . . . . . . . . . . . . . .54A-66
SERVICE SPECIFICATIONS. . . . .
54A-66
TROUBLESHOOTING . . . . . . . . . .54A-66
ON-VEHICLE SERVICE. . . . . . . . .54A-66
HEADLAMP AIMING . . . . . . . . . . . . . . . 54A-66
LUMINOUS INTENSITY
MEASUREMENT . . . . . . . . . . . . . . . . . . 54A-67
BULB REPLACEMENT . . . . . . . . . . . . . 54A-68
HEADLAMP . . . . . . . . . . . . . . . . . .54A-69
REMOVAL AND INSTALLATION . . . . . 54A-69
HEADLAMP LEVELING SWITCH .54A-70
REMOVAL AND INSTALLATION . . . . . 54A-70
INSPECTION . . . . . . . . . . . . . . . . . . . . . 54A-70
FOG LAMP . . . . . . . . . . . . . . . . 54A-71
SERVICE SPECIFICATION . . . . . .
54A-71
SPECIAL TOOL . . . . . . . . . . . . . . .54A-71
TROUBLESHOOTING . . . . . . . . . .54A-71
ON-VEHICLE SERVICE . . . . . . . . .54A-71
FRONT FOG LAMP AIMING CHECK . . 54A-71
FOG LAMP . . . . . . . . . . . . . . . . . . .54A-73
REMOVAL AND INSTALLATION . . . . . . 54A-73
FOG LAMP SWITCH . . . . . . . . . . .54A-74
REMOVAL AND INSTALLATION . . . . . . 54A-74
INSPECTION . . . . . . . . . . . . . . . . . . . . . 54A-74
REAR FOG LAMP . . . . . . . . . . 54A-75
TROUBLESHOOTING . . . . . . . . . .
54A-75
SPECIAL TOOL . . . . . . . . . . . . . . .54A-75
REAR FOG LAMP . . . . . . . . . . . . .54A-76
REMOVAL AND INSTALLATION . . . . . . 54A-76
REAR FOG LAMP SWITCH . . . . . .54A-76
REMOVAL AND INSTALATION . . . . . . . 54A-76
INSPECTION . . . . . . . . . . . . . . . . . . . . . 54A-76
SIDE TURN-SIGNAL LAMP. . . 54A-77
SPECIAL TOOL . . . . . . . . . . . . . . .
54A-77
SIDE TURN-SIGNAL LAMP . . . . . .54A-77
REMOVAL AND INSTALLATION . . . . . . 54A-77
ROOM LAMP . . . . . . . . . . . . . . 54A-78
TROUBLESHOOTING . . . . . . . . . . . . . . 54A-78
Continued on next page

COMBINATION METER ASSEMBLY
CHASSIS ELECTRICAL54A-32
SYMPTOM PROCEDURES
INSPECTION PROCEDURE 1: Speedometer does not work (the other meters work).
Speedometer Circuit
IGNITION
SWITCH (IG1)
VEHICLE
SPEED
SENSORDIAGNOSIS
CONNECTORCOMBINATION
METER
ENGINE-ECU
Wire colour code
B : Black LG : Light green G : Green L : Blue W : White Y : Yellow SB : Sky blue
BR : Brown O : Orange GR : Grey R : Red P : Pink V : Violet CONTROL CIRCUIT
FRONT SIDE
NOTE
LH drive vehicles
RH drive vehicles
,

COMBINATION METER ASSEMBLY
CHASSIS ELECTRICAL54A-34
STEP 3. Connector check: Combination meter
connector C-04 and diagnosis connector C-11.
Q: Is combination meter connector C-04 and
diagnosis connector C-11 in good condition?
YES :
Go to Step 4.
NO : Repair or replace the damage
component(s).
STEP 4. Check the wiring harness between
combination meter connector C-04 (terminal 12)
and diagnosis connector C-11 (terminal 14).
NOTE:
Prior to the wiring harness inspection, joint connector
C-03 , and repair if necessary.
Q: Is the wiring harness between combination meter
connector C-04 (terminal 12) and diagnosis
connector C-11 (terminal 14) in good condition?
YES :
Go to Step 5.
NO : Repair or replace the wiring harness.
AC303798
Connector: C-04

Harness side
AT
AC303800
C-11 (B) Connector: C-11

Front side
AK
AC303814
Connector: C-04

Harness side
AT
AC303812
AD
Connector: C-11

Front side
C-11 (B)
AC303798AU
Connector: C-03, C-04
C-04
C-03 (B)
C-04 C-03 Harness side
AC303800
C-11 (B) Connector: C-11

Front side
AK
AC303814
Connector: C-04

Harness side
AT
AC303812
AD
Connector: C-11

Front side
C-11 (B)

COMBINATION METER ASSEMBLY
CHASSIS ELECTRICAL54A-37
INSPECTION PROCEDURE 2: Speedometer does not work (the other meters work).
IGNITION
SWITCH (IG1)
A/T
CONTROL
RELAY
OUTPUT
SHAFT
SPEED
SENSOR
DIAGNOSIS
CONNECOTR
ENGINE-
A/T-ECUCOMBINATION METER
ENGINE-
A/T-ECU
Wire colour code
B : Black LG : Light green G : Green L : Blue W : White Y : Yellow SB : Sky blue
BR : Brown O : Orange GR : Gray R : Red P : Pink V : Violet
FRONT SIDE
NOTE
LH drive vehicles
RH drive vehicles
CONTROL CIRCUIT
Speedometer Circuit

COMBINATION METER ASSEMBLY
CHASSIS ELECTRICAL54A-39
STEP 3. Connector check: Combination meter
connector C-04 and diagnosis connector C-11
Q: Is combination meter connector C-04 and
diagnosis connector C-11 in good condition?
YES :
Go to Step 4.
NO : Repair or replace the damage
component(s).
STEP 4. Check the wiring harness between
combination meter connector C-04 (terminal 12)
and diagnosis connector C-11 (terminal 14).
NOTE:
Prior to the wiring harness inspection, joint connector
C-03 , and repair if necessary.
Q: Is the wiring harness between combination meter
connector C-04 (terminal 12) and diagnosis
connector C-11 (terminal 14) in good condition?
YES :
Go to Step 5.
NO : Repair or replace the wiring harness.
AC303798
Connector: C-04

Harness side
AT
AC303800
C-11 (B) Connector: C-11

Front side
AH
AC303814
Connector: C-04

Harness side
AT
AC303812
AD
Connector: C-11

Front side
C-11 (B)
AC303798AU
Connector: C-03, C-04
C-04
C-03 (B)
C-04 C-03 Harness side
AC303800
C-11 (B) Connector: C-11

Front side
AH
AC303814
Connector: C-04

Harness side
AT
AC303812
AD
Connector: C-11

Front side
C-11 (B)

COMBINATION METER ASSEMBLY
CHASSIS ELECTRICAL54A-58
STEP 6. Check the wiring harness between
combination meter connector C-04 (terminal 9)
and ignition switch (IG1).
NOTE: Prior to the wiring harness inspection, check
Junction block connectors C-210 and C-212, joint
connector C-03 , and repair if
necessary.
Q: Are the wiring harness between combination meter
connector C-04 (terminal 42) and ignition switch
(IG1) in good condition?
YES :
There is no action to be taken.
NO : Repair or replace the wiring harness. Check
to see that all meters operate.
AC303798AU
Connector: C-03, C-04
C-04
C-03 (B)
C-04 C-03 Harness side
AC303814
Connector: C-04

Harness side
AT
AC303809
Connector: C-210, C-212

C-212
C-210
C-210 Harness side
C-212
AX
Front view
AC303823
Connector: C-210, C-212

C-210
C-212Front view
Harness side
C-210
C-212
AU

COMBINATION METER ASSEMBLY
CHASSIS ELECTRICAL54A-60
STEP 9. Check the wiring harness between
combination meter connector C-04 (terminal 1
and 2) and earth.
Q: Are the wiring harness between combination meter
connector C-04 (terminal 1 and 2) and earth in
good condition?
YES :
This procedure is complete.
NO : Repair or replace the wiring harness. Check
to see that all meters operate.
ON-VEHICLE SERVICE
SPEEDOMETER CHECKM1543000900423
Adjust the pressure of tyres to the specified level.
(Refer to GROUP 31, On-vehicle Service P.31-7.)
CAUTION
Do not operate the clutch suddenly. Do not
increase/decrease speed rapidly while testing.
1. Set the vehicle onto a speedometer tester and
use wheel chocks to hold the rear wheels.2. To prevent the front wheel from moving from side
to side, attach tension bars to the tie-down hook,
and secure both ends to anchor plates.
3. To prevent the vehicle from moving, attach a chain
or wire to the rear retraction hook, and make sure
the end of the chain or wire is secured.
4. Check if the speedometer indicator range is within
the standard values.
Standard value:
5. If not to the standard value, inspect for proper tyre
size. If not correct, replace the tyres with original
size tyres and retest. If correct, replace the
speedometer. If still not to standard value, replace
the vehicle speed sensor.
TACHOMETER CHECKM1543001000434
1. Attach an external high quality tachometer to the
engine speed detection connector on the harness
side (such as with a paper clip).
AC303798
Connector: C-04

Harness side
AT
AC303814
Connector: C-04

Harness side
AT
AC305135AB
Wheel stopper
Standard indicator
km/h (mph)Allowance range km/h
(mph)
20 (12) 20 − 24 (12 − 15)
40 (25) 40 − 44 (25 − 28)
80 (50) 80 − 85 (50 − 53)
120 (75) 121 − 127 (75 − 79)
160 (100) 162 − 169 (100 − 105)
200 (125) 203 − 211 (126 − 131)
AC001288
Tension bar
Front
Anchor plate
AB
AC305138AB
Engine speed
indicator
Paper clip
Probe for detection
of engine speed

HEADLAMP
CHASSIS ELECTRICAL54A-66
HEADLAMP
SERVICE SPECIFICATIONSM1542000300332
TROUBLESHOOTING M1542000701281
Features the headlamp automatic shutdown function
to avoid battery drain when the headlamps are left
on. The main features are as follows:
•Extinguishes automatically in three minutes if the
ignition switch is turned off with the lighting switch
on.
•Extinguishes in one second if the driver's door is
opened within that 3-minute period.
•If the headlamps are turned on with the ignition
switch off, the headlamps and tail lamps will
extinguish in three minutes after the driver's door
is opened or closed.
The headlamps are controlled by the Smart Wiring
System (SWS). For troubleshooting, refer to
respective Groups below.
•Not using SWS monitor: GROUP 54B, SWS
Troubleshooting P.54B-38.
•Using SWS monitor: GROUP 54C, SWS
Troubleshooting P.54C-22.
ON-VEHICLE SERVICE
HEADLAMP AIMING
M1542000900538
PRE-AIMING INSTRUCTIONS
1. Inspect for badly rusted or faulty headlamp
assemblies.
2. These conditions must be corrected before a
satisfactory adjustment can be made.
3. Inspect tyre inflation, and adjust if it is necessary.
4. If the fuel tank is not full, place a weight in luggage
room of the vehicle to simulate weight of a full
tank (0.8 kg per litre).
5. There should be no other load in the vehicle other
than driver or substituted weight of approximately
75 kg placed in driver's position.
6. Thoroughly clean the headlamp lenses.7. Place the vehicle on a level floor, perpendicular to
a flat screen 10 m away from the bulb
centre-marks on the headlamp lens.
8. Rock vehicle sideways to allow vehicle to assume
its normal position.
9. Bounce the front suspension through three (3)
oscillations by applying the body weight to hood
or bumper.
10.Four lines of adhesive tape (or equivalent
markings) are required on screen or wall:
(1) Position a vertical tape or mark so that it is
aligned with the vehicle centre line.
(2) Measure the distance from the centre-marks
on the headlamp lens to the floor. Transfer the
measurement to the screen. Horizontal tape or
mark on the screen is for reference of vertical
adjustment. Item Standard value Limit
Headlamp aiming Low beam Vertical
direction0.69° below horizontal (H)
± 0.29° from the
standard value
Horizontal
directionPosition at which the stat up point
of 15° is crossed with vertical line
(V)± 0.5° from the
standard value
Measurement of headlamp illiminous intensity cd
−30,000 cd or more
per one headlamp
AC304804
(1)
(2)
(3)
Headlamp centre line
Vehicle crntre line Screen
(3)
10 m
In the centre
of headlamps
(1)
(2)
(3)(3)
In the centre
of headlamps
AB
Vehicle centre line
ScreenHeadlamp centre line
10 m

HEADLAMP
CHASSIS ELECTRICAL54A-68
BULB REPLACEMENTM1542001300658
Headlamp Bulb
CAUTION
Do not touch the surface of the bulb with hands
or dirty gloves as the bulb may pop after a short
time. If the surface does become dirty, clean it
with alcohol or thinner, and let it dry thoroughly
before installing.
1. Disconnect the battery.
2. Disconnect the connector.
3. Remove the socket cover.
4. Remove bulb mounting spring to pull out bulb.
5. After bulb is replaced, properly reconnect
connector.
Position Lamp Bulb
CAUTION
Do not touch the bulb surface bare-handed or
with dirty gloves. If dirt is attached on surface of
the bulb, immediately use alcohol or thinner to
remove dirt, and install the bulb after well dried.
1.
Disconnect the connector.
2. Screw out position lamp socket to pull out
position lamp bulb.
Front Turn-Signal Lamp Bulb
CAUTION
Do not touch the bulb surface bare-handed or
with dirty gloves. If dirt is attached on surface of
the bulb, immediately use alcohol or thinner to
remove dirt, and install the bulb after well dried.
1.
Disconnect the connector.
2. Screw out front turn-signal lamp socket to pull out
front turn-signal lamp bulb.
AC300667AC300667
Headlamp bulb
AB
Spring
AC300668
Position lamp
AB
AC300669
Front turn signal lamp
AB