Head MITSUBISHI LANCER 2005 Owner's Manual

HEADLAMP WASHER
EXTERIOR51-33
INSPECTIONM1511009800082
HEADLAMP WASHER MOTOR CHECK
1. Remove the headlamp washer motor connector.
2. Check to see that the water is vigorously sprayed
when connecting the positive battery terminal to
terminal number 1 and terminal number 2 to the
negative battery terminal.
7. Headlamp washer motor
8. Headlamp washer gasket
•Front bumper (Refer to P.51-2).
9. Headlamp washer actuator
assembly
10. O-ring
11. Headlamp washer hose assembly Removal steps (Continued)
AC304136AB
12

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

BATTERY
CHASSIS ELECTRICAL54A-5
BATTERY TESTM1541001200506
BATTERY TESTING PROCEDURE
STEP 1. Check the battery cables.
Remove the negative cable, then the positive cable.
Check for dirty or corroded connections.
Q: Are the battery cables dirty or have corroded
connections?
YES :
Clean the battery cables. Then go to Step 2.
NO : Go to Step 2.
STEP 2. Check the battery post.
Check for loose battery post.
Q: Are the battery post faulty?
YES :
Replace the battery. Then go to Step 4.
NO : Go to Step 3.
STEP 3. Check the battery case and cover.
(1) Remove the hold-downs and shields.
(2) Check for broken/cracked case or cover.
Q: Is the battery case or cover faulty?
YES :
Replace the battery. Then go to Step 4.
NO : Go to Step 4.
STEP 4. Check the open circuit voltage.
(1) Turn headlamps on for 15 seconds.
(2) Turn headlamps off for two minutes to allow
battery positive voltage to stabilize.
(3) Disconnect the battery cables.
(4) Read open circuit voltage.
Q: Is open circuit voltage 12.4 volts or more?
YES :
Go to Step 6.
NO : Go to Step 5.
STEP 5. Charge battery.
Q: Charging the battery?
YES :
Go to Step 6.
NO : Charge the battery at 5 amps for 15 hours.
Then re-test, go to Step 4.
STEP 6. Check the load test.
(1) Connect a load tester to the battery.
(2) Load the battery at the recommended discharge
rate (See LOAD TEST RATE CHART) for 15
seconds.
(3) Read voltage after 15 seconds, then remove
load.
(4) Compare the measured value with the minimum
voltage. (See LOAD TEST CHART.)
Q: Is the voltage higher than minimum voltage?
NO :
Replace the battery. Then go to Step 4.
YES : The battery is normal.
LOAD TEST RATE CHART
LOAD TEST CHARTBattery type 55D23L 75D23L
Charging time when fully discharged h
(5-amp. rated current charging)11 11
Load test (Amps) 260 260
Temperature °C 21 and
above16 10 4
−1−7−12−18
Minimum voltage 9.6 9.5 9.4 9.3 9.1 8.9 8.7 8.5

IGNITION SWITCH
CHASSIS ELECTRICAL54A-28
REMOVAL SERVICE POINT
<> STEERING LOCK CYLINDER
REMOVAL
1. Insert the key in the steering lock cylinder and turn
it to the "ACC" position.
2. Using a small Phillips head screwdriver, pull the
steering lock cylinder toward you.
INSPECTIONM1544009700203
IGNITION SWITCH CONTINUITY CHECK
Disconnect ignition switch connector C-201 without
removing the ignition switch. Then check the
continuity.
KEY REMINDER SWITCH CONTINUITY
CHECK
Disconnect key reminder switch connector C-202
without removing the ignition switch and key
reminder switch. Then check the continuity.
AC304831AB
Locking pin
AC304833AB
Switch
position Tester
connectionSpecified
condition
"LOCK" (OFF) 1 − 2, 1 − 3,
1 − 4, 1− 5,
1 − 6, 2 − 3,
2 − 4, 2− 5,
2 − 6, 3 − 4,
3 − 5, 3 − 6,
4 − 5, 4 − 6,
5 − 6Open circuit
"ACC" 1 − 6 Less than 2
ohms
"ON" 1 − 2, 1 − 4,
1 − 6, 2 − 4,
2 − 6, 4 − 6Less than 2
ohms
"START" 1 − 2, 1 − 5,
2 − 5Less than 2
ohms
Status of
ignition keyTester
connectionSpecified
condition
Removed 4 − 6 Less than 2
ohms
Inserted 4 − 6 Open circuit
AC304834AB

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-67
NOTE: Height from the floor to the centre of
the headlamps (Reference value): 840 mm
(3) Measure the distance from the centre line of
the vehicle to the centre of each headlamp.
Transfer the measurement to the screen.
Vertical tape or mark on the screen with
reference to the centre line of each headlamp
bulb.
HEADLAMP ADJUSTMENT
CAUTION
•Do not cover a headlamp for more than three
minutes to prevent the plastic headlamp lens
deformation.
•When adjusting one headlamp beam, make
sure that another headlamp is off by
disconnecting the connector from it. When
reconnecting the connector, make sure that
the headlamp beam is not disturbed
accidentally.
1. The low-beam headlamp should project on the
screen upper edge of the beam (cut-off).
2. If not the case, turn the adjusting screws to
achieve the specified low-beam cut-off location on
the aiming screen.Standard value:
(Vertical direction) 0.69° below horizontal (H)
(Horizontal direction) Position at which the
stat up point of 15° is crossed with vertical
line (V)
Limit:
Vertical direction; ± 0.29° from the standard
value
Horizontal direction; ± 0.5° from the standard
value
LUMINOUS INTENSITY MEASUREMENTM1542001000464
1. Set the headlamps to high-beam.
2. Using a photometer, and following its
manufacturer's instruction manual, measure the
headlamp centre intensity and check to be sure
that the limit value is satisfied.
Limit: 30,000 cd or more {When a screen is
set 25m ahead of the vehicle}
NOTE: When measuring the intensity, maintain an
engine speed of 2,000 r/min., with the battery fully
charged.
There may be special local regulations pertaining to
headlamp intensity. Be sure to make any
adjustments necessary to satisfy such regulations.
If an illuminometer is used to make the
measurements, convert its values to photometer
values by using the following formula.
I =E x r
2:
•I = intensity (cd)
•E = illumination (lux)
•r = distance (m) from headlamps to illuminometer
AC300567AB
Vertical
direction
Horizontal
direction
AC300658AB
Vertical
direction
Horizontal
direction
AC305155
(H)(V)
Distance of
vertical direction
[0.69˚]Headlamp
centre
High intensity
zone
15˚
AB

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

HEADLAMP
CHASSIS ELECTRICAL54A-69
HEADLAMP
REMOVAL AND INSTALLATIONM1542001800244
REMOVAL SERVICE POINT
<> HEADLAMP ASSEMBLY
REMOVAL1. Remove the splash shield, the radiator grill, the
front bumper assembly installation clips, the
screws and the bolts as shown.
2. Slide the front bumper assembly and remove the
headlamp assembly.
Post-installation Operation
Headlamp Aiming Adjustment (Refer to P.54A-66.)
AC304719
1
AB
Removal steps
<>1. Headlamp assembly
AC300690
AC300678

HEADLAMP
CHASSIS ELECTRICAL54A-70
HEADLAMP LEVELING SWITCH
REMOVAL AND INSTALLATIONM1542013700040
INSPECTIONM1542011200908
HEAD LAMP LEVELING SWITCH
RESISTANCE CHECK
AC304661AB
2
1
Removal steps
1. Switch panel
2. Headlamp leveling switch
AC305186AB
Te r m i n a l N o . S w i t c h
positionResistance
4 - 6 0 750 ohms
1 1050 ohms
2 1410 ohms
3 1710 ohms
4 2010 ohms
5 - 6 0, 1, 2, 3, 4 2830 ohms

FOG LAMP
CHASSIS ELECTRICAL54A-71
FOG LAMP
SERVICE SPECIFICATIONM1542000300343
SPECIAL TOOLM1542000600894
TROUBLESHOOTINGM1542000701292
When the front fog lamp switch is turned to ON with
the tail lamp or the headlamp on (the tail lamp switch
or the headlamp switch is ON), the fog lamp relay
turns on, and the fog lamps will illuminate.
If the tail lamps or the headlamps are turned off with
the lighting switch OFF while the fog lamps are on,
the front fog lamps turn off at the same time to
prevent unattended operation.
If the tail lamps are turned off by the headlamp
automatic shutdown function, the fog lamps turn off
at the same time. However, if the tail lamps illuminate
again, the fog lamps do not.
The front fog lamps 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
FRONT FOG LAMP AIMING CHECKM1542001100438
After setting the vehicles to the following condition,
adjust the front fog lamp aiming.
•Check that the tyre inflation pressure is at the
value indicated on the tyre pressure labels.
•Set the vehicle to the unladen condition and park
it on a level surface.
•Have a single person (approximately 75 kg) sit in
the driver’s seat.•Run the engine at a speed of 2000 r/min to fully
charge the battery.
Turn on the front fog lamps and check that the
illumination is within the standard value range.
Standard value: Illuminates to within 40
metres
CAUTION
For the fog lamp which is not being measured,
disconnect that fog lamp’s connector if possible
so that it does not illuminate while carrying out
the adjustment. Furthermore, make sure that the
light axis does not get shifted when
re-connecting the connector.
If the value is out of the standard value, insert the
screwdriver (+) through the aiming hole on the side
under cover to adjust by turning the adjusting gear
for fog lamp aiming.
NOTE: Horizontal adjustment is not possible.
In addition, the method of checking the light axis on a
screen (simple check) is given below. Item Standard value
Front fog lamp light axis check Illuminates to within 40 metres
Tool Number Name Use
MB990784 Ornament remover Removal of instrument panel
ornament
MB990784
AC301337
Cross-tipped
screwdriver
AB