MITSUBISHI LANCER 2005 Workshop Manual

LUBRICANTS
POWER STEERING37-7
LUBRICANTS
M1372000400350
SEALANTS
M1372000500357
Item Specified lubricant Quantity
Power steering fluid ATF DEXRON III or DEXRON II Approximately 1.0 L
Steering gear Bearing ATF DEXRON III or DEXRON II As required
O-ring and seal ring
Oil seal
Special tool (MB991212,
MB991213)
Pinion and valve assembly
seal ring part
Bellows Silicon grease As required
Tie rod end ball joint Multipurpose grease SAE J310,
NLGI No.2 or equivalentAs required
Oil pump Friction surface of rotor vane,
cam ring and pump coverATF DEXRON III or DEXRON II As required
O-ring
Item Specified sealant
Steering shaft cover assembly bolt hole on the toeboard 3M ATD Part No.8513 or equivalent
Steering gear End plug 3M ATD Part No.8661, 8663 or
equivalent
Rack support cover

SPECIAL TOOLS
POWER STEERING37-8
SPECIAL TOOLS
M1372000600354
Tool Number Name Use
MB991897 Ball joint remover Knuckle and tie rod end ball joint
disconnection
NOTE: Steering linkage puller
(MB990635 or MB991113) is also
available to disconnect knuckle and
tie rod end ball joint.
MB990326 Preload socket Tie rod end ball joint turning torque
check
MB991548 Power steering oil
pressure gauge
adapter (Pump
side)Oil pump pressure test
MB991549 Power steering oil
pressure gauge
adapter (Hose
side)
MB990662 Power steering oil
pressure gauge
MB990784 Ornament remover Cover removal
MB990228 or
MB991006Preload socket Steering gear total pinion torque
check and adjustment
AC106827
MB990326
MB991548
MB991549
MB990662
MB990784
MB991006

SPECIAL TOOLS
POWER STEERING37-9
MB990607 Torque wrench
socket•Rack support cover removal

•Rack support adjustment

MB991621 Piston driver•Rack support cover removal

•Rack support adjustment
MB990925 Bearing and oil
seal installer set•Lower bearing removal
•Oil seal and bearing installation
•MB990927, MB990938, MB990939
(For details, refer to GROUP 26,
Special Tools P.26-4).
MB991120 Needle bearing
pullerNeedle bearing removal
MB991202 Oil seal and
bearing installer•Oil seal installation
•Needle bearing installation
•Lower bearing installation
MB991199 Oil seal and
bearing installerOil seal installation
MB991197 Bar (long type) Oil seal installation
MB991212
MB991213Oil seal protector Rack installation Tool Number Name Use
MB991621
MB990925
MB991120
MB991202
MB991199
AB
MB991197
MB991212

SPECIAL TOOLS
POWER STEERING37-10
MB991203 Oil seal and
bearing installerOil seal and bearing installation
MB991317 Seal ring installer Seal rings installation
MB990941 Torque tube
bearing installerLower oil seal installation
MB991561 Boot band crimping
toolBellows band installation
MB990776 Front axle base Tie rod end ball joint dust cover
installation Tool Number Name Use
MB991203
MB991317
MB990941
MB991561
MB990776

ON-VEHICLE SERVICE
POWER STEERING37-11
ON-VEHICLE SERVICE
STEERING WHEEL FREE PLAY CHECKM1372001000311
1. With the engine running (hydraulic operation), set
the front wheels straight ahead.
2. Measure the play on the steering wheel
circumference before the wheels start to move
when slightly moving the steering wheel in both
directions.
Limit: 30 mm
3. When the play exceeds the limit, check for the
play on the steering shaft and steering linkage
connection. Correct or replace.
4. If the free play still exceeds the limit value, set the
steering wheel straight ahead with the engine
stopped. Load 5 N towards the steering wheel
circumference and check the play.
Standard value (steering wheel play with the
engine stopped): 10 mm or less
5. If the play exceeds the standard value, remove
the steering gear (Refer to P.37-24) and check
the total pinion torque (Refer to P.37-27).
STEERING ANGLE CHECKM1372001100374
1. Place the front wheel on a turning radius gauge
and measure the steering angle.
Standard value:
2. If the steering angle is not within the standard
value, adjust the toe-in as follows.
Standard value:
at the centre of tyre tread: 1 ± 2 mm
Toe angle (per wheel): 0°03' ± 06'
3. Loosen the lock nut, and unclip the bellows.
4. Adjust the toe-in by turning the left and right tie
rod turnbuckles by the same amount (in opposite
directions).
NOTE: The toe will move out as the left
turnbuckle is turned toward the front of the vehicle
and the right turnbuckle is turned toward the rear
of the vehicle.
5. Tighten the lock nut to the specified torque, and
tighten the bellows by the clip.
Tightening torque: 40 ± 5 N⋅m
6. Recheck the steering angle.
ACX01122
AB
AC000756AB
Inner
wheelsComfort 39°30' ± 1°30'
Sport (L.H.
drive vehicles)33°40' +1°00'/-2°00'
Sport (R.H.
drive vehicles)37°00' +1°00'/-2°00'
Outer
wheels
(reference)Comfort 32°30'
Sport (L.H.
drive vehicles)28°46'
Sport (R.H.
drive vehicles)30°00'
AC006074AD
Lock nut
Clip

ON-VEHICLE SERVICE
POWER STEERING37-12
TIE ROD END BALL JOINT TURNING
TORQUE CHECK
M1372001500297
CAUTION
•Do not remove the tie rod end nut from the
ball joint. Loosen it and use special tool to
avoid possible damage to the ball joint
threads.
•Hang special tool with cord to prevent it from
falling.
1. Install special tool ball joint remover (MB991897)
as shown in the figure.
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
figure.
3. Tighten the bolt with a wrench to disconnect the
tie rod end.4. Move the ball joint stud several times and install
the nut on the stud. Using special tool preload
socket (MB990326), measure the ball joint turning
torque.
Standard value: 0.5 − 2.5 N⋅m
5. If the turning torque exceeds the standard value,
replace the tie rod end.
6. If the turning torque is under the standard value,
check the ball joint for axial play or ratcheting. If
no axial play or ratcheting, the ball joint can be
re-used.
CAUTION
Always use a new ball joint nut as it is a
self-locking nut.
7. Install the tie rod end to the knuckle, then tighten a
new self-locking nut to the specified torque.
Tightening torque: 25 ± 5 N⋅m
STATIONARY STEERING EFFORT CHECKM1372001700332
1. With the vehicle stopped on a flat and paved
surface, turn the steering wheel to the straight
ahead position.
2. Start the engine and set the engine idle speed.
Standard value: 1000 ± 100 r/min
3. Attach a spring balance to the outer
circumference of the steering wheel and measure
the steering force required to turn the steering
wheel from the straight ahead position to the left
and right (within a range of 1.5 turns). Also check
to be sure that there is no significant change in
the required steering effort.
Standard value:
Steering effort: 29 N or less
Fluctuation allowance: 5.9 N or less
4. If the measured value exceeds the standard
value, check and adjust the related parts.
AC208247AD
Cord
BoltMB991897
Nut
Ball joint
AC106821
Knob ParallelBolt
Good
Bad
AB
ACX01129
AB
MB990326
ACX01122
AB

ON-VEHICLE SERVICE
POWER STEERING37-13
STEERING WHEEL RETURN TO CENTRE
CHECK
M1372001800317
Conduct a road test:
1. Make both gradual and sudden turns and check
the steering wheel return.
2. At a vehicle speed of approximately 35 km/h, turn
the steering wheel 90°, hold a few seconds, then
release. If the steering wheel then returns 70° or
more, the return can be judged satisfactory.
NOTE: There will be a momentary feeling or
"heaviness" when the wheel is turned quickly, but
this is not abnormal (Oil pump discharge amount
is especially apt to be insufficient during idling).
DRIVE BELT TENSION CHECKM1372001900392
For vehicles with 1300 and 1600 engine, refer to
GROUP 11A, On-vehicle Service − Drive Belt
Tension Check P.11A-7.
For vehicles with 2000 engine, refer to GROUP 11C,
On-vehicle Service − Drive Belt Tension Check
P.11C-7.
FLUID LEVEL CHECKM1372002000284
1. Park the vehicle on a flat, level surface.
2. Start the engine, and then turn the steering wheel
several times to raise the temperature of the fluid
to approximately 50 − 60°C.
3. With the engine running, turn the wheel all the
way to the left and right several times.4. Check the fluid in the oil reservoir for foaming or
milkiness. Check the difference of the fluid level
when the engine is stopped, and while it is
running. If the change of the fluid level is 5 mm or
more, air bleeding should be done.
FLUID REPLACEMENTM1372002100333
1. Raise and support the front wheels.
2. Disconnect the return hose connection, and then
connect a vinyl hose to the return hose, and drain
the fluid into a container.
3. Disconnect the ignition coil connectors (Refer to
GROUP 16, Ignition Coil P.16-38or P.16-39).
4. While operating the starter motor intermittently,
turn the steering wheel all the way to the left and
right several times to drain all of the fluid.
5. Connect the return hose securely, and then
secure with the clip.
6. Fill the oil reservoir with specified fluid up to
between "MAX" and "MIN" marks, and then bleed
the air.
Specified fluid: ATF DEXRON III or DEXRON
II
POWER STEERING SYSTEM AIR
BLEEDING
M1372002200330
Perform air bleeding procedure as necessary after
replacing the steering gear or the steering fluid lines.
1. Raise and support the front wheels.
2. Disconnect the ignition coil connectors (Refer to
GROUP 16, Ignition Coil P.16-38 or P.16-39).
ACX01130
AB
70˚70˚
ACX01131While engine running While engine stoppedAC
Fluid level change: Within 5 mm
AC100369AB
Return hoseReturn hose
Vinyl hose

ON-VEHICLE SERVICE
POWER STEERING37-14
CAUTION
Perform air bleeding only while cranking the
engine. If air bleeding is performed while the
engine is running, air could enter the fluid.
During air bleeding, refill the steering fluid
supply so that the level never falls below the
"MIN" mark on the oil reservoir.
3. Turn the steering wheel all the way to the left and
right five or six times while using the starter motor
to crank the engine intermittently several times
(for 15 to 20 seconds).
4. Connect the ignition coil connectors (Refer to
GROUP 16, Ignition Coil P.16-38 or P.16-39).
5. Start the engine (idling).
6. Turn the steering wheel to the left and right until
there are no air bubbles in the oil reservoir.
7. Confirm that the fluid is not milky, and that the
level is between "MAX" and "MIN" marks.
8. Confirm that there is very little change in the fluid
level when the steering wheel is turned left and
right.
CAUTION
If the fluid level rises suddenly after the engine is
stopped, the air has not been completely bled. If
air bleeding is not complete, there will be
abnormal noises from the pump and the
flow-control valve, and this condition could
cause reduce the life of the power steering
components.
9. Confirm that the change in the fluid level is no
more than 5 mm when the engine is stopped and
when it is running.
10.If the change of the fluid level is 5 mm or more,
the air has not been completely bled from the
system. The air bleeding procedure must be
repeated.
OIL PUMP PRESSURE TESTM1372002300315
1. Disconnect the pressure hose from the oil pump,
and then connect the following special tools.
•MB990662: Power Steering Oil Pressure Gauge
•MB991548: Power Steering Oil Pressure Gauge
Adapter (pump side)
•MB991549: Power Steering Oil Pressure Gauge
Adapter (hose side)
2. Bleed air, then turn the steering wheel several
times while the vehicle is not moving so that the
temperature of the fluid rises to approximately 50
− 60°C.
3. Start the engine and idle it at 1000 ± 100 r/min.
CAUTION
The pressure gauge shut-off valve must not
remain closed for more than 10 seconds.
4. Fully close the shut-off valve of the pressure
gauge and measure the oil pump relief pressure
to confirm that it is within the standard value
range. Open it again immediately after checking
the pressure.
Standard value: 8.8 − 9.5 MPa
5. If it is not within the standard value, replace the oil
pump.
6. Check whether or not the hydraulic pressure is
the standard value when no-load conditions are
created by fully opening the shut-off valve of the
pressure gauge.
Standard value: 0.2 − 0.7 MPa
ACX01131While engine running While engine stoppedAC
Fluid level change: Within 5 mm
ACX01133
Temperature
gauge
Oil reservoir
Adapter
(MB991548)
Oil
pump
Adapter
(MB991549)
AB
Shut-off valve
(fully closed) Pressure
gauge
(MB990662)

ON-VEHICLE SERVICE
POWER STEERING37-15
7. If it is not within the standard value, the probable
cause is a malfunction of the oil line or steering
gear, so check these parts and repair as
necessary.
8. Turn the steering wheel all the way to the left or
right; then check whether or not the retention
hydraulic pressure is the standard value.
Standard value: 8.8 − 9.5 MPa
9. If not the standard value, overhaul the steering
gear. Remeasure fluid pressure.
10. Remove the special tools, and then tighten the
pressure hose to the specified torque.
Tightening torque: 57 ± 7 N⋅m
11. Bleed the system (Refer to P.37-13).
POWER STEERING PRESSURE SWITCH
CHECK
M1372007200324
1. Disconnect the pressure hose from the oil pump,
and then connect the following special tools.
•MB990662: Power Steering Oil Pressure Gauge
•MB991548: Power Steering Oil Pressure Gauge
Adapter (pump side)
•MB991549: Power Steering Oil Pressure Gauge
Adapter (hose side)2. Bleed air, and then turn the steering wheel several
times while the vehicle is not moving so that the
temperature of the fluid rises to approximately 50
− 60°C.
3. The engine should be idling.
4. Disconnect the connector for the oil pressure
switch, and place an ohmmeter at the switch.
5. Gradually close the shut-off valve of the pressure
gauge and increase the hydraulic pressure, then
check whether or not the hydraulic pressure that
activates the switch is the standard value.
Standard value: 1.5 − 2.0 MPa
6. Gradually open the shut-off valve and reduce the
hydraulic pressure; then check whether or not the
hydraulic pressure that deactivates the switch is
the standard value.
Standard value: 0.7 − 2.0 MPa
7. Remove the special tools, and then tighten the
pressure hose to the specified torque.
Tightening torque: 57 ± 7 N⋅m
8. Bleed the system (Refer to P.37-13).
TIE ROD END BALL JOINT DUST COVER
CHECK
M1372008600262
1. Press the dust cover with your finger to check
whether the dust cover is cracked or damaged.
2. If the dust cover is cracked or damaged, replace
the tie rod end.
NOTE: If the dust cover is cracked or damaged,
the ball joint could be damaged.
STEERING COLUMN SHAFT ASSEMBLY
SHOCK ABSORBING MECHANISM
CHECK
M1372013500090
If a collision accident occurs or severe impact is
applied on the steering wheel, the collision energy
absorbing mechanism may have operated. Once the
mechanism has operated, it will be inoperative even
it has suffered no apparent damage. Determine if the
steering column shaft can be reused by the following
procedure. If the collision energy absorbing
mechanism has already operated, replace the
steering column shaft assembly.
If any excessive radial free play on the steering
wheel is found with the tilt lever in the lock position,
always check the steering shaft assembly.
ACX01134
AB
Temperature
gaugeAdapter
(MB991548)
Oil reservoirOil
pump
Adapter
(MB991549) Shut-off valve
Pressure gauge
(MB990662)

ON-VEHICLE SERVICE
POWER STEERING37-16
WARNING
•If the vehicle continues to be driven after
the collision absorbing mechanism has
operated, the steering column shaft may
be damaged while it is in use.
•If there is a slack in the one-way capsule,
do not attempt to repair it but replace the
steering column shaft assembly.
Inspection Procedure
1. Remove the lower and upper column covers.
CAUTION
Do not release the tilt lever until the steering
column has been installed to complete this
inspection procedure.
2. Ensure that the tilt lever is in the lock position.
NOTE: If not, place the tilt lever in the lock
position.
3. Loosen the two steering column mounting bolts
(upper) by two turns.4. Hold the one-way capsules as shown, and then
try to lock them. If there is a slack in either of the
capsules, replace the steering column shaft
assembly.
NOTE: When installing a new steering column
shaft assembly, place the tilt lever in the lock
position, if it is not in place.
CAUTION
•Be careful that nothing is pinched between
the one-way capsules and the body.
•Do not release the tilt lever until the steering
column has been installed to complete this
inspection procedure.
5. If no problem is found during the inspection,
tighten the steering column mounting bolts to the
specified torque.
Tightening torque: 12 ± 2 N⋅m
AC304673AC304673
Steering
column
assembly
AB
Steering
column
mounting
bolt
AC304672
AC304673AC304673
AC304923AB
One way capsule