engine MITSUBISHI LANCER 2005 Workshop Manual

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

IGNITION SWITCH
CHASSIS ELECTRICAL54A-6
IGNITION SWITCH
GENERAL INFORMATIONM1543009901274
IGNITION KEY REMINDER BUZZER
The ignition key reminder buzzer will sound under
the following condition, and warn the driver to
remove the ignition key.
•The driver's door is opened when the ignition
switch is at "LOCK" (OFF) or "ACC" position
without removing the ignition key.
However, the lamp reminder buzzer will take
precedence over this function.
DOOR LOCK PREVENTION FUNCTION
If the key is left in the ignition switch while the driver’s
door opened or the assistant door opened, all door
are automatically unlock to prevent locking the
ignition key in the vehicle after door is locked.
IMMOBILIZER SYSTEM
The immobilizer system consists of the ignition key
with a transponder, the immobilizer-ECU, and the
engine-ECU or engine-A/T-ECU . Only
the registered ignition key permits the engine to start,
therefore, the engine can never be started by means
of a forged key or by connecting the ignition wiring
directly. The system is significantly safe and reliable
against theft. In addition, the driver has only to turn
the ignition switch to the "ON" position to activate the
immobilizer system. If the requirements for starting the engine are not satisfied, the engine will be
immobilized. If a registered ignition key is lost, all
your ignition keys need to be registered again using
MUT-II/III to ensure security (Refer to P.54A-20). An
additional ignition key can be registered as follows
(only if no ignition keys are lost):
•Using MUT-II/III (Refer to P.54A-20).
OPERATION
1. When the ignition switch is turned to "ON"
position, the engine-ECU or
engine-A/T-ECU sends a requirement for
the encrypted code to the immobilizer-ECU (at
this time, the engine is remobilized).
2. When the immobilizer-ECU receives the
requirement from the engine-ECU or
engine-A/T-ECU , the immobilizer-ECU
supplies power to the transponder inside the
ignition key via the antenna. The energized
transponder sends the encrypted code back to the
immobilizer-ECU via the antenna.
3. The immobilizer-ECU judges the encrypted code
with its code logic in itself. If they are identical, the
immobilizer-ECU sends the encrypted code to the
engine-ECU or engine-A/T-ECU.
4. If the engine-ECU or engine-A/T-ECU can
not receive the encrypted code, the engine will be
immobilized.
AC304482AB
Power
(Wireless)
Encrypted code
(Wireless) Ignition keyControl signal
Encrypted
code
TransponderImmobilizer-ECU
with an antenna
Steering lockCPU
MUT-II/III Memory Engine-ECU
Engine-A/T-ECU
CPUInjector
Ignition

IGNITION SWITCH
CHASSIS ELECTRICAL54A-7
Encrypted code registration criteria table
The ignition key contains a transponder (small
transmitter), which retains an unique encrypted code.
Under any of the conditions below, the encrypted
code should be registered in the immobilizer-ECU
again. The immobilizer-ECU can retain maximum
eight different encrypted codes. This means that
maximum eight ignition keys can be registered.
Component to be replaced Engine-A/T-ECU Immobilizer-ECU Ignition key
When engine-A/T-ECU is
replaced−Should not be
replacedShould not be replaced
Should be registered
again
When engine-A/T-ECU is
overwritten−Should not be
replacedShould not be replaced
Should be registered
again
When immobilizer-ECU is
replaceShould not be
replaced−Should not be replaced
All ignition keys should be
registered again
When ignition key is added Should not be
replacedShould not be
replaced•Additional ignition key
should be registered
•All ignition keys should
be registered again
When ignition key is lost Should not be
replacedShould not be
replacedAll the ignition keys other
than the lost one should
be registered again

IGNITION SWITCH
CHASSIS ELECTRICAL54A-11
DIAGNOSIS PROCEDURE
STEP 1. Check for presence of other key near the
key in the ignition.
Q: Is there any other key near the key in the ignition?
YES :
Move the other key well away from key
being used. Retest the system.
NO : Go to Step 2.
STEP 2. Check that the engine start using the
spare ignition key which encrypted code has
been registered.
Q: Does the engine start using the spare ignition key
for which the encrypted code has been registered?
YES :
Replace the ignition key that does not work.
Then register the password (secret code)
and encrypted code P.54A-20. Retest the
system.
NO : Go to Step 3.
STEP 3. Check whether the diagnosis code is
reset.
Q: Which diagnosis code is set, code No.11 or 12 the
encrypted code has been registered?
Code No.12 is set :
Refer toP.54A-11.
Code No.11 is set : Go to Step 4.
STEP 4. Connector check: Immobilizer-ECU
connector C-202-1.
Q: Are immobilizer-ECU connector C-202-1 in good
condition?
YES :
Replace immobilizer-ECU and Then
register the password (secret cod) and
encrypted code P.54A-20. Retest the
system.
NO : Repair or replace the damage
component(s).
Code No.12: Encrypted Codes are Not identical or not Registered
DIAGNOSIS CODE SET CONDITION
The encrypted code sent by the transponder is not
the same encrypted code which is registered in the
immobilizer-ECU.
NOTE: Diagnosis code No.12 is always set together
with MPI system diagnosis code No.P0513.
TROUBLESHOOTING HINTS
•The encrypted code in the ignition key has not
been properly registered.•Malfunction of immobilizer-ECU.
DIAGNOSIS PROCEDURE
Was the encrypted code registered?
YES :
Replace the immobilizer-ECU and then
re-register the encrypted code (Refer to
P.54A-20).
NO : Register the encrypted code (Refer to
P.54A-20).
SYMPTOM CHARTM1543007201075
AC303806
Connector: C-202-1
Harness side
AF
Symptom Inspection
procedure No.Reference page
Communication with MUT-II/III is impossible. 1
P.54A-12
The ignition key cannot be registered. 2
P.54A-18
Engine does not start (cranking but no initial combustion). 3
P.54A-18

IGNITION SWITCH
CHASSIS ELECTRICAL54A-12
SYMPTOM PROCEDURES
INSPECTION PROCEDURE 1: Communication with MUT-II/III is Impossible.
TECHNICAL DESCRIPTION (COMMENT)
•This malfunction may be caused by a defective
immobilizer-ECU, engine-ECU or
engine-A/T-ECU , or a defect in the
communication line between the
immobilizer-ECU and engine-ECU or
engine-A/T-ECU . If this malfunction
appears when the MPI system and MUT-II/III can
communicate each other, MPI system diagnosis
code No.P0513 will reset.•If the MPI system is normal, the engine control
relay can be determined as normal. In addition, if
the MPI system and MUT-II/III can communicate
each other, the circuits between the diagnosis
connector and the engine-ECU or
engine-A/T-ECU can determined as
normal.
NOTE: If this malfunction appears, MPI system
diagnosis code No.P0513 will be set.
ENGINE-ECU ENGINE
CONTROL
RELAY
ENGINE-
A/T-ECU
IMMOBILIZER-
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 POWER
SOURCE
M/T
A/T NOTE
LH drive vehicles
RH drive vehicles
Immobilizer-ECU Power Source, Earth and Engine-ECU*3 or Engine-A/T-ECU
*4
Communication Line Circuit

IGNITION SWITCH
CHASSIS ELECTRICAL54A-13
TROUBLESHOOTING HINTS
•Malfunction of the immobilizer-ECU.
•Malfunction of the engine-ECU or
engine-A/T-ECU .
•The wiring harness or connectors may have
loose, corroded, or damaged terminals, or
terminals pushed back in the connector.
DIAGNOSIS PROCEDURE
STEP 1. Check if MUT-II/III can communicate with
the MPI system and if an MPI system diagnosis
code other than P0513 is set.
Q: Can MUT-II/III communicate with the MPI system?
Is an MPI system diagnosis code other than P0513
set?
YES :
Go to Step 2.
NO : Refer to GROUP 13A, MPI Diagnosis
P.13A-15, GROUP 13B, MPI Diagnosis
P.13B-15.
STEP 2. Voltage measurement at
immobilizer-ECU connector C-202-1.
(1) Disconnect immobilizer-ECU connector C-202-1.
(2) Turn the ignition switch to the "ON" position.
(3) Measure the voltage between terminal 1 and
earth.
OK: System voltage
Q: Is the check result normal?
YES :
Go to Step 5.
NO : Go to Step 3.
STEP 3. Connector check: Immobilizer-ECU
connector C-202-1 and engine control relay
connector B-16X
Q: Are immobilizer-ECU connector C-202-1 and
engine control relay connector B-16X in good
condition?
YES :
Go to Step 4.
NO : Repair or replace the damaged
component(s). Confirm that MUT-II/III
communicates normally.AC303806
Connector: C-202-1
Harness side
AF
AC304844AB
Connector C-202-1
(Harness side)
AC303806
Connector: C-202-1
Harness side
AF
AC303796
Connector: B-16X
Harness side
AF

IGNITION SWITCH
CHASSIS ELECTRICAL54A-14
STEP 4. Check the harness wires between
immobilizer-ECU connector C-202-1 (terminal 1)
and engine control relay connector B-16X
(terminal 4).
NOTE:
Prior to the wiring harness inspection, check
intermediate connector C-13 ,
C-137 , joint connector C-12
, C-134 and
key reminder switch connector C-202, and repair if
necessary.
Q: Are the harness wires between immobilizer-ECU
connector C-202-1 (terminal 1) and engine control
relay connector B-16X (terminal 4) in good
condition?
YES :
There is no action to be taken.
NO : Replace damaged component(s). Confirm
that MUT-II/III communicates normally.
AC303806
Connector: C-202-1
Harness side
AF
AC303796
Connector: B-16X
Harness side
AF
AC303801
Connector: C-12, C-13
C-12
C-13
C-12
C-13
AC
AC303819
Connector: C-134, C-137
C-134
C-137
C-134
C-137
AC
AC303806
Connector: C-202
Harness side
AG

IGNITION SWITCH
CHASSIS ELECTRICAL54A-16
Q: Is the harness wire between immobilizer-ECU
connector C-202-1 (terminal 4) and earth in good
condition?
YES :
There is no action to be taken.
NO : Repair or replace the damaged
component(s). Confirm that MUT-II/III
communicates normally.
STEP 8. Connector check: immobilizer-ECU
connector C-202-1 and engine-ECU connector
C-127 or engine-A/T-ECU connector C-128

Q: Are immobilizer-ECU connector C-202-1 and
engine-ECU connector C-127 or
engine-A/T-ECU connector C-128 in good
condition?
YES :
Go to Step 9.
NO : Repair or replace the damaged
component(s). Confirm that MUT-II/III
communicates normally.
STEP 9. Check the harness wires between
immobilizer-ECU connector C-202-1 (terminal 3)
and engine-ECU connector C-127 (terminal 51)
or engine-A/T-ECU connector C-128
(terminal 111) .
AC303805
Connector: C-127 , C-128
C-128 (GR)
C-127 (Y)
C-127
C-128
585261556256605459535751
101 102
103 104 105 106 107
120 119 118 117 116 115 114 113 112 111 110 109 108
121 122 123 124 125 126 127 128 129 130
Harness side
AJ
AC303806
Connector: C-202-1
Harness side
AF
AC303805
Connector: C-127 , C-128
C-128 (GR)
C-127 (Y)
C-127
C-128
585261556256605459535751
101 102
103 104 105 106 107
120 119 118 117 116 115 114 113 112 111 110 109 108
121 122 123 124 125 126 127 128 129 130
Harness side
AJ
AC303806
Connector: C-202-1
Harness side
AF

IGNITION SWITCH
CHASSIS ELECTRICAL54A-17
NOTE:
Prior to the wiring harness inspection, check key
reminder switch connector C-202, intermediate
connector C-13 , C-137 drive vehicles>, and repair if necessary.Q: Are the harness wires between immobilizer-ECU
connector C-202-1 (terminal 3) and engine-ECU
connector C-127 (terminal 51) or
engine-A/T-ECU connector C-128 (terminal 111)
in good condition?
YES :
Go to Step 10.
NO : Repair or replace the damaged
component(s). Confirm that MUT-II/III
communicates normally.
STEP 10. Replace the immobilizer-ECU or
engine-ECU or engine-A/T-ECU .
Replace the immobilizer-ECU.
Q: Did the communication with MUT-II/III become
possible after replacing the immobilizer-ECU?
YES :
Register the password (secret code) and
encrypted code P.54A-20. Confirm that
MUT-II/III communicates normally
NO : Go to Step 11.
STEP 11. Recheck for malfunction.
Q: Is a malfunction eliminated?
YES :
The procedure is complete. If no
malfunctions are found in all steps, an
intermittent malfunction is suspected (Refer
to GROUP 00, How to Use
Troubleshooting/Inspection Service Points −
How to Cope with Intermittent Malfunction
P.00-5).
NO : Replace the engine-ECU or
engine-A/T-ECU .
AC303800
Connector: C-13

Harness side
AG
AC303818
AM
Connector: C-137

Harness side
AC303806
Connector: C-202
Harness side
AG

IGNITION SWITCH
CHASSIS ELECTRICAL54A-18
INSPECTION PROCEDURE 2: The Ignition Key cannot be Registered.
TECHNICAL DESCRIPTION (COMMENT)
The ignition key transponder or the immobilizer-ECU
is suspected to be defective.
TROUBLESHOOTING HINTS
•Malfunction of the ignition key
•Malfunction of immobilizer-ECU
DIAGNOSIS PROCEDURE
STEP 1. MUT-II/III diagnosis code.
Q: Does diagnosis code No.11 reset?
YES :
Refer to P.54A-9.
NO : Replace the ignition key that cannot be
registered. Then re-register the encrypted
code. (Refer to P.54A-20). Verify that the
ignition key can be registered, then Go to
Step 2.
STEP 2. Retest the system.
Q: Does registered ignition key function properly?
YES :
The procedure is complete. (If no
malfunctions are found in all steps, an
intermittent malfunction is suspected. Refer
to GROUP 00, How to Use
Troubleshooting/Inspection Service Points −
How to Cope with Intermittent Malfunction
P.00-5).
NO : Replace the immobilizer-ECU.
INSPECTION PROCEDURE 3: Engine does not Start (Cranking but no Initial Combustion).
TECHNICAL DESCRIPTION (COMMENT)
If the fuel injectors are not operating, there might be
a problem with the MPI system in addition to a
malfunction of the immobilizer system. It is normal for
this to occur if an attempt is made to start the engine
using a key that has not been properly registered.
TROUBLESHOOTING HINTS
•Malfunction of MPI system
•Malfunction of immobilizer-ECU
DIAGNOSIS PROCEDURE
STEP 1. Check the system voltage.
Measure the system voltage during cranking.
Q: Is the voltage 8 volts or more?
YES :
Go to Step 2.
NO : Check the battery. Refer to P.54A-4. The
engine should start.
STEP 2. Check the immobilizer system diagnosis
code and MPI system diagnosis code.
Q: Which diagnosis code resets, the immobilizer
system diagnosis code or the MPI system
diagnosis code?
Immobilizer system diagnosis code is set :
Refer
to P.54A-9.
MPI system diagnosis code is set : Refer to
GROUP 13A, Diagnosis P.13A-15, GROUP
13B, Diagnosis P.13B-15.
No diagnosis code is set : Go to Step 3.
STEP 3. Check the starting system.
Q: Does the engine start?
YES :
Go to Step 4.
NO : Refer to GROUP 13A, Diagnosis −
Symptom Chart P.13A-215, GROUP 13B,
Diagnosis − Symptom Chart P.13B-189. If
the malfunction is not resolved, replace the
immobilizer-ECU. Then register the
password (secret code) and encrypted
code. (Refer to P.54A-20.) The engine
should start.