MITSUBISHI LANCER 2005 Workshop Manual

POWER STEERING OIL PUMP ASSEMBLY
POWER STEERING37-37
POWER STEERING OIL PUMP ASSEMBLY
REMOVAL AND INSTALLATIONM1372005200298
<1300, 1600>
Pre-removal Operation
•Power Steering Fluid Draining (Refer to P.37-13).Post-installation Operation
•Power Steering Fluid Supplying and Bleeding (Refer to
P.37-13).
•Drive Belt Tension Check (1300, 1600: refer to GROUP
11A, On-vehicle Service − Drive Belt Tension Check
P.11A-7/2000: refer to GROUP 11C, On-vehicle Service −
Drive Belt Tension Check P.11C-7).
AC209708
87
12 34
5
6
57 ± 7 N·m
40 ± 4 N·m 22 ± 4 N·m
N
9
40 ± 5 N·m
AC
Removal steps
1. Pressure switch connector
2. A/C compressor harness connector
bracket
3. Drive belt
4. Suction hose5. Eye bolt
6. O-ring
7. Pressure hose
8. Oil pump assembly
9. Oil pump braceRemoval steps (Continued)

POWER STEERING OIL PUMP ASSEMBLY
POWER STEERING37-38
<2000>
REMOVAL SERVICE POINT
<> OIL PUMP ASSEMBLY REMOVAL
<2000>
With the engine lifted by the jack, remove the oil
pump assembly mounting bolt (lower side) at the
pulley side.
INSPECTIONM1372005300187
•Check the drive belt for cracks.
•Check the pulley for uneven rotation.
AC200116
AB
22 ± 4 N·m 12 ± 2 N·m
22 ± 4 N·m 49 ± 9 N·m57 ± 7 N·m
1
5 4 3
6 2
7
49 ± 9 N·m
Removal steps
1. Pressure switch connector
2. Drive belt
3. Suction hose
4. Pressure hose<>5. Oil pump assembly
6. A/C compressor harness
7. Power steering pump bracketRemoval steps (Continued)

POWER STEERING OIL PUMP ASSEMBLY
POWER STEERING37-39
DISASSEMBLY AND REASSEMBLYM1372005400300
CAUTION
Never disassemble the terminal assembly. It cannot be reassembled.
<1300, 1600>
AC209709AC
411
1318
10
2
98
65
73
1
18
15
10
2 11
13
10398
65
7
34
3
28 ± 1 N·m
161514
59 ± 9 N·m
1228 ± 2 N·m
17
12 ± 1 N·m
13
Oil pump seal kit Oil pump cartridge kit Oil pump pulley and shaft kit: ATF DEXRON III or DEXRON II
Disassembly steps
1. Pump cover
2. O-ring
3. Snap ring
4. Pulley and shaft
5. Vanes
>>C<<6. Cam ring
7. Rotor8. Pin
9. Side plate
>>A<<10. O-ring
>>B<<11 . O i l s e a l
12. Terminal assembly
>>A<<13. O-ring
14. Plug assemblyDisassembly steps (Continued)

POWER STEERING OIL PUMP ASSEMBLY
POWER STEERING37-40
<2000>
>>A<<15. O-ring
16. Flow control springDisassembly steps (Continued)
17. Suction connector
>>A<<18. O-ringDisassembly steps (Continued)
AC100143AF
411
12
13
28 ± 2 N·m
102
9
8
6
5
7
3
1
28 ± 1 N·m
15
16
14
59 ± 9 N·m 9.9 ± 2.1 N·m

12 ± 1 N·m

18
17
5
7
3
98
6 3 13
10
2 13
10 15 18 114
3
Oil pump seal kit Oil pump cartridge kit Oil pump pulley and shaft kit
: ATF DEXRON III or DEXRON II
Disassembly steps
1. Pump cover
2. O-ring
3. Snap ring
4. Pulley and shaft
5. Vanes
>>C<<6. Cam ring
7. Rotor
8. Pin
9. Side plate
>>A<<10. O-ring
>>B<<11 . O i l s e a l
12. Terminal assembly
>>A<<13. O-ring
14. Plug assembly
>>A<<15. O-ring
16. Flow control spring
17. Suction connector
>>A<<18. O-ringDisassembly steps (Continued)

POWER STEERING OIL PUMP ASSEMBLY
POWER STEERING37-41
REASSEMBLY SERVICE POINTS
>>A<< O-RING INSTALLATION>>B<< OIL SEAL INSTALLATION
Use following special tool to install the oil seal.
•MB990938: Bar (Snap-in type)
•MB991203: Oil Seal and Bearing Installer
>>C<< CAM RING INSTALLATION
CAUTION
Be sure to install the cam ring in the correct
direction as shown.
Install the cam ring as shown in the illustration.
INSPECTIONM1372005500200
•Check the flow control valve of the pump body for
clogging.
•Check the pulley and shaft for wear or damage.
•Check the rotor and vane groove for "stepped"
wear.
•Check the contact surface of cam ring and vanes
for "stepped" wear.
•Check the vanes for damage. No. ID × Width mm
1 15.8 × 2.4
2 21.0 × 1.9
3 14.8 × 2.4
43.8 × 1.9
5 14.8 × 1.9
AC100170
AB
Suction connectorPlug assembly
Terminal assembly Side plate
1
2
3
4
5
AC000752
MB990938
AB
MB991203
AC100171AB
Side plate side
Pump cover side

POWER STEERING HOSES
POWER STEERING37-42
POWER STEERING HOSES
REMOVAL AND INSTALLATIONM1372005700679
CAUTION
•Before removing the clock spring, refer to GROUP 52B, Service Precautions (P.52B-5) and Air Bag
Module and Clock Spring (P.52B-210). Also, put the front wheels in straight-ahead position.
Failure to do so may damage the SRS clock spring and render the SRS air bag inoperative, which
results serious driver injury.
•
*: Indicates parts which should be initially tightened, and then fully tightened after placing the
vehicle horizontally and loading the full weight of the engine on the vehicle body.

Pre-removal and Post-installation Operation
•Power Steering Fluid Draining and Refilling (Refer to
P.37-13). and Bleeding (Refer to P.37-13).
AC304699AB
15 ± 3 N·m
18 ± 2 N·m
167 ± 9 N·m 12 ± 2 N·m
49 ± 10 N·m 12 ± 2 N·m
57 ± 7 N·m*57 ± 7 N·m
3 1
2
9
13
10
711 12
568
12 ± 2 N·m12 ± 2 N·m
2
9
4 7 8
7 8
7
8
57 ± 7 N·m57 ± 7 N·m 57 ± 7 N·m
12 ± 2 N·m
167 ± 9 N·m
Crossmember 12 ± 2 N·m
<1300, 1600> <2000>
12 ± 2 N·m
Removal steps
1. Oil reservoir
>>C<<2. Suction hose
>>B<<3. Return hose•Clock spring (Refer to GROUP 52B,
Air Bag Modules and Clock Spring
P.52B-210). Removal steps (Continued)

POWER STEERING HOSES
POWER STEERING37-43

•Centermember (Refer to GROUP 32,
Engine Roll Stopper Centermember
P.32-7).
•Front exhaust pipe (Refer to GROUP
15, Exhaust Pipe and Main Muffler
P.15-11).
4. Steering gear and joint connecting
bolt
5. Rear roll stopper connecting bolt
6. Rear roll stopper (Refer to GROUP
32, Engine Roll Stopper
Centermember P.32-7).
<>7. Eye boltRemoval steps (Continued)
8. Gasket
9. Pressure hose assembly
10. Return tube
>>A<<11. Return hose
<>12. Return tube
13. O-ringRemoval steps (Continued)
AC304698AB
15 ± 3 N·m
18 ± 2 N·m
167 ± 9 N·m 12 ± 2 N·m
49 ± 10 N·m 12 ± 2 N·m
57 ± 7 N·m*
3 1
2
9
10
7
5 6
24
8857 ± 7 N·m
167 ± 9 N·m
Crossmember12 ± 2 N·m <1300, 1600>
<2000>
7
6
57 ± 7 N·m
7 6
57 ± 7 N·m
7
6
57 ± 7 N·m
12 ± 2 N·m
Removal steps
1. Oil reservoir
>>C<<2. Suction hose
>>B<<3. Return hose•Clock spring (Refer to GROUP 52B,
Air Bag Modules and Clock Spring
P.52B-210). Removal steps (Continued)

POWER STEERING HOSES
POWER STEERING37-44
REMOVAL SERVICE POINT
<> EYE BOLT/RETURN TUBE
REMOVAL
CAUTION
If the joint cover grommet has been removed,
install it properly as follows.
Align the joint cover grommet notch (arrow A)
with the steering gear lug (arrow B), and then
install the steering joint cover to the steering
gear.
1. Loosen the crossmember mounting bolts and
nuts, and lower the crossmember to a position so
that the eye bolts or return tube at the steering
gear side can be removed.
NOTE: In this case, do not remove the
crossmember mounting bolts and nuts.
2. Remove the eye bolts or return tube.
INSTALLATION SERVICE POINTS
>>A<< RETURN HOSE INSTALLATION

Install the return hose so that the marking is
positioned as shown in the illustration.
>>B<< RETURN HOSE INSTALLATION
Install the return hose so that the markings are
positioned as shown in the illustration.
>>C<< SUCTION HOSE INSTALLATION
Install the suction hose (oil pump side) so that the
marking is positioned forward.
•Centermember (Refer to GROUP 32,
Engine Roll Stopper Centermember
P.32-7).
•Front exhaust pipe (Refer to GROUP
15, Exhaust Pipe and Main Muffler
P.15-11).
4. Steering gear and joint connecting
bolt
5. Rear roll stopper connecting bolt
<>6. Eye bolt
7. Gasket
8. Pressure hose assembly
<>9. Return tube
10. O-ringRemoval steps (Continued)
AC304922AB
A
B Joint cover
grommet
Steering gear
AC100277
ABReturn hose
AC305132AB
Return hose
Return tubeReturn hose

42-1
GROUP 42
BODY
CONTENTS
HOOD . . . . . . . . . . . . . . . . . . . . .
42-3
ON-VEHICLE SERVICE. . . . . . . . .
42-3
ADJUSTMENT OF CLEARANCE
AROUND HOOD . . . . . . . . . . . . . . . . . . 42-3
ADJUSTMENT OF ALIGNMENT OF
HOOD STEPPED PORTION AND
HOOD STRIKER . . . . . . . . . . . . . . . . . . 42-3
ADJUSTMENT OF HOOD HEIGHT . . . 42-3
HOOD . . . . . . . . . . . . . . . . . . . . . . .42-4
REMOVAL AND INSTALLATION . . . . . 42-4
FENDER . . . . . . . . . . . . . . . . . . .42-5
SPECIAL TOOL . . . . . . . . . . . . . . .
42-5
FENDER . . . . . . . . . . . . . . . . . . . . .42-6
REMOVAL AND INSTALLATION . . . . . 42-6
FUEL FILLER LID . . . . . . . . . . .42-8
REMOVAL AND INSTALLATION .
42-8
STRUT TOWER BAR . . . . . . . .42-9
REMOVAL AND INSTALLATION .
42-9
WINDOW GLASS . . . . . . . . . . . 42-9
ADHESIVE . . . . . . . . . . . . . . . . . . .
42-9
SPECIAL TOOLS . . . . . . . . . . . . . .42-9
WINDOW REPAIR . . . . . . . . . . . . .42-10
WINDSHIELD . . . . . . . . . . . . . . . . .42-12
REMOVAL AND INSTALLATION . . . . . . 42-12
REAR WINDOW GLASS . . . . . . . .42-16
REMOVAL AND INSTALLATION . . . . . . 42-16
QUARTER WINDOW GLASS . . . .42-19
REMOVAL AND INSTALLATION . . . . . . 42-19
TAILGATE WINDOW GLASS . . . .42-22
REMOVAL AND INSTALLATION . . . . . . 42-22
DOOR . . . . . . . . . . . . . . . . . . . . 42-25
SERVICE SPECIFICATIONS . . . . .
42-25
SEALANT . . . . . . . . . . . . . . . . . . . .42-25
SPECIAL TOOLS . . . . . . . . . . . . . .42-25
Continued on next page

42-2
TROUBLESHOOTING . . . . . . . . . .42-26
ON-VEHICLE SERVICE. . . . . . . . .42-27
DOOR FIT ADJUSTMENT. . . . . . . . . . . 42-27
DOOR WINDOW GLASS ADJUSTMENT42-28
GLASS SLIDING MECHANISM CHECK
AND ADJUSTMENT . . . . . . . . . . . . . . . 42-28
POWER WINDOW OPERATING
CURRENT CHECK . . . . . . . . . . . . . . . . 42-28
POWER WINDOW RELAY CHECK . . . 42-29
CIRCUIT BREAKER (INCORPORATED
IN THE POWER WINDOW MOTOR)
INSPECTION . . . . . . . . . . . . . . . . . . . . . 42-29
POWER WINDOW CHECK . . . . . . . . . . 42-29
CENTRAL DOOR LOCKING SYSTEM
INSPECTION . . . . . . . . . . . . . . . . . . . . . 42-29
DOOR OUTSIDE HANDLE PLAY
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . 42-29
DOOR INSIDE HANDLE PLAY
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . 42-30
DOOR ASSEMBLY . . . . . . . . . . . .42-31
REMOVAL AND INSTALLATION . . . . . 42-31
INSPECTION . . . . . . . . . . . . . . . . . . . . . 42-32
DOOR GLASS AND
REGULATOR . . . . . . . . . . . . . . . . .
42-32
REMOVAL AND INSTALLATION . . . . . 42-32
INSPECTION . . . . . . . . . . . . . . . . . . . . . 42-34
DOOR HANDLE AND LATCH . . . .42-36
REMOVAL AND INSTALLATION . . . . . 42-36
INSPECTION . . . . . . . . . . . . . . . . . . . . . 42-37
WINDOW GLASS RUNCHANNEL AND
DOOR OPENING
WEATHERSTRIP . . . . . . . . . . . . . .
42-39
REMOVAL AND INSTALLATION . . . . . 42-39
TRUNK LID . . . . . . . . . . . . . . . .42-41
SPECIAL TOOL . . . . . . . . . . . . . . .
42-41
ON-VEHICLE SERVICE. . . . . . . . .42-41
TRUNK LID ADJUSTMENT . . . . . . . . . . 42-41
ADJUSTMENT OF CLEARANCE
AROUND TRUNK LID . . . . . . . . . . . . . . 42-42
TRUNK LID STRIKER ADJUSTMENT . 42-42
TRUNK LID HEIGHT ADJUSTMENT . . 42-42
TRUNK LID . . . . . . . . . . . . . . . . . . .42-43
REMOVAL AND INSTALLATION . . . . . . 42-43
INSPECTION . . . . . . . . . . . . . . . . . . . . . 42-45
TAILGATE . . . . . . . . . . . . . . . . 42-46
SERVICE SPECIFICATIONS . . . . .
42-46
SEALANTS . . . . . . . . . . . . . . . . . . .42-46
SPECIAL TOOL . . . . . . . . . . . . . . .42-46
TROUBLESHOOTING . . . . . . . . . .42-46
ON-VEHICLE SERVICE . . . . . . . . .42-46
TAILGATE FIT ADJUSTMENT. . . . . . . . 42-46
TAILGATE HANDLE PLAY CHECK . . . . 42-47
TAILGATE . . . . . . . . . . . . . . . . . . .42-48
REMOVAL AND INSTALLATION . . . . . . 42-48
TAILGATE HANDLE AND
LATCH . . . . . . . . . . . . . . . . . . . . . .
42-50
REMOVAL AND INSTALLATION . . . . . . 42-50
INSPECTION . . . . . . . . . . . . . . . . . . . . . 42-51
KEYLESS ENTRY SYSTEM . . 42-51
SERVICE SPECIFICATIONS . . . . .
42-51
SPECIAL TOOLS . . . . . . . . . . . . . .42-52
TROUBLESHOOTING . . . . . . . . . .42-53
ON-VEHICLE SERVICE . . . . . . . . .42-53
KEYLESS ENTRY SYSTEM CHECK. . . 42-53
KEYLESS ENTRY SYSTEM TIMER
LOCK FUNCTION INSPECTION . . . . . . 42-53
ENABLING/DISABLING
THE ANSWERBACK FUNCTION . . . . . 42-53
HOW TO REGISTER SECRET CODE . 42-55
TRANSMITTER. . . . . . . . . . . . . . . .42-58
DISASSEMBLY AND REASSEMBLY . . 42-58
INSPECTION . . . . . . . . . . . . . . . . . . . . . 42-59