Air con MITSUBISHI LANCER 2005 Service Manual

TROUBLESHOOTING
WHEEL AND TYRE31-5

1. After balancing the wheel, loosen the wing nut
and turn the wheel 180° against the balancer's
hub. Then re-tighten the wing nut and check the
balance again. Repeat wheel balance if
necessary.
2. Turn the wheel again 180° against the balancer's
hub. If the wheel becomes out-of-balance each
time it is turned against the balancer's hub, the
wheel balancer may require calibration.

1. Mount an undamaged original-equipment alloy
rim and tyre assembly (wheel) onto your
off-the-car wheel balancer. Balance the wheel.
2. <>
Loosen the balancer wing nut, rotate the wheel a
half-turn (180°), and retighten the nut. Recheck
the balance.
•If the imbalance is 5g or less, the zero calibration
is OK. Rebalance the wheel, then go to Step 4 to
check static balance.
•If the imbalance is more than 5g, go to Step 3.
3. Loosen the balancer wing nut, rotate the wheel
1/4 turn (90°), and retighten the nut. Recheck the
wheel balance.
•If the imbalance is 5g or less, the wheel may not
be centred on the balancer, or the balancing
cones, the cup, and/or wing nut are damaged,
dirty, or inappropriate for the wheel. You may
need to refer to the balancer manufacturer's
instructions to verify the correct attachments.
After making the necessary corrections, recheck
the wheel balance. If OK, then go to Step 4.•If the imbalance is more than 5g, the balancer
requires calibration. Contact the balancer
manufacturer for calibration by their repair
representative.
4. <>
Attach a 5g weight to the outer rim. Recheck the
balancer. The balancer should detect 5 ± 2g of
imbalance 170 to 190° away from the 5g weight.
•If the imbalance is within specification, the static
balance calibration is correct. Go to Step 5 to
check the dynamic balance.
•If the imbalance is out of specification, the
balancer requires calibration. Contact the
balancer manufacturer for calibration by their
repair representative.
5. <>
Attach a 5g weight to the inner rim at 180°
opposite the 5g weight that was added in Step 4.
Recheck the balance. The balancer should detect
5 ± 2g of imbalance 170 to 190° away from both
the inner and outer 5g weights.
•If the imbalance is within specification, the
dynamic balance calibration is correct. The
balancer calibration checks are complete.
•If the imbalance is out of specification, the
balancer requires calibration. Contact the
balancer manufacturer for calibration by their
repair representative.
AC305700AB
Hub/shaft assemblyClamping cup
Wing nut
Standard passenger car wheel Wheel mounting cone Spring plate

CROSSMEMBER
POWER PLANT MOUNT32-8
INSTALLATION SERVICE POINTS
>>A<< ENGINE FRONT ROLL STOPPER
BRACKET INSTALLATION
Install the engine front roll stopper bracket so that its
hole points towards the front side of the vehicle.
>>B<< ENGINE MOUNTING CUSHION
STOPPER INSTALLATION <4G6>
Install the engine mounting cushion stopper as
shown.
CROSSMEMBER
REMOVAL AND INSTALLATIONM1321003200368
CAUTION
•Before removing the steering wheel and air bag module assembly, always refer to GROUP 52B -
Service Precautions P.52B-5, Air bag Module and Clock Spring P.52B-210. Also, set the front
wheels so that they are facing straight forward, and remove the ignition key. If you fail to do this,
the SRS clock spring will be damaged, causing the SRS air bag to be inoperative and serious
injury.
•*
1: 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.
•*
2: Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle
on the earth in the unladen condition.
AC005918Front of vehicleHoleACAC304315ABFront of vehicle
HoleEngine mounting
cushion stopper
Pre-removal Operation
•Centermember Removal (Refer to P.32-7).
•Front Exhaust Pipe Removal (Refer to GROUP 15,
Exhaust Pipe and Main Muffler P.15-11).
•Steering Wheel Air Bag Module Assembly Removal
(Refer to GROUP 37, Steering Wheel P.37-17).
•Power Steering Fluid Draining (Refer to GROUP 37,
On-vehicle Service P.37-13).Post-installation Operation
•Front Exhaust Pipe Installation (Refer to GROUP 15,
Exhaust Pipe and Main Muffler P.15-11).
•Centermember Installation (Refer to P.32-7).
•Clock Spring Centring (Refer to GROUP 52B, Air Bag
Modules and Clock Spring P.52B-210).
•Steering Wheel Air Bag Module Assembly Installation
(Refer to GROUP 37, Steering Wheel P.37-17).
•Power Steering Fluid Supplying (Refer to GROUP 37,
On-vehicle Service P.37-13).
•Power Steering Fluid Line Bleeding (Refer to GROUP 37,
On-vehicle Service P.37-13).
•Press the dust cover with a finger to check whether the
dust cover cracked or damaged.
•Checking Steering Wheel Position with Wheels Straight
Ahead.
•Front Wheel Alignment Check and Adjustment (Refer to
GROUP 33, On-vehicle Service P.33-5).

33-1
GROUP 33
FRONT
SUSPENSION
CONTENTS
GENERAL INFORMATION . . . . . . . .33-2
SERVICE SPECIFICATIONS . . . . . . .33-3
LUBRICANT . . . . . . . . . . . . . . . . . . . .33-3
SPECIAL TOOLS . . . . . . . . . . . . . . . .33-4
ON-VEHICLE SERVICE . . . . . . . . . . .33-5
FRONT WHEEL ALIGNMENT CHECK
AND ADJUSTMENT . . . . . . . . . . . . . . . . . . 33-5
LOWER ARM BALL JOINT AXIAL PLAY
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-6
LOWER ARM BALL JOINT COVER
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-6
STRUT ASSEMBLY . . . . . . . . . . . . . .33-7
REMOVAL AND INSTALLATION . . . . . . . . 33-7
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 33-7
DISASSEMBLY AND REASSEMBLY . . . . . 33-8
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 33-10
LOWER ARM . . . . . . . . . . . . . . . . . . .33-11
REMOVAL AND INSTALLATION . . . . . . . . 33-11
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 33-12
LOWER ARM BALL JOINT COVER
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . 33-12
LOWER ARM BUSHING (REAR)
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . 33-13
STABILIZER BAR* . . . . . . . . . . . . . . .33-14
REMOVAL AND INSTALLATION . . . . . . . . 33-14
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 33-17
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 (*).

LUBRICANTS
PARKING BRAKES36-3
LUBRICANTS
M1361000400293
ON-VEHICLE SERVICE
PARKING BRAKE LEVER STROKE
CHECK AND ADJUSTMENT
M1361000900339
1. Pull the parking brake lever with a force of
approximately 200 N and count the number of
notches.
Standard value: 5 − 7 notches
2. If the parking brake lever stroke is not the
standard value, adjust as described below.
(1) Remove the rear console assembly (Refer to
GROUP 52A, Rear Floor Console P.52A-8).
(2) Loosen the adjusting nut to move it to the
cable rod end so that the cable will be free.
(3) Remove the wheels.
(4) Complete air bleeding of brake circuit. (Refer
to GROUP 35A, On-vehicle Service, Bleeding
P.35A-6.)(5) Remove the rear wheel hub plug, and then
use a flat-tipped screwdriver to turn the shoe
slack adjuster in the direction of the arrow (the
direction which expands the shoe) so that the
disc will not rotate.
Return the shoe slack adjuster 5 notches in
the direction opposite to the direction of the
arrow.
(6) Turn the adjusting nut to adjust the parking
brake lever stroke to the standard value. After
adjusting, check that there is no space
between the adjusting nut and the parking
brake lever. Check that the adjusting nut is
secured with the nut holder.
CAUTION
If the parking brake lever stroke is below the
standard value and the braking is too firm, the
rear brakes may drag.
(7) Release the parking brake and turn the rear
wheels to check that the rear brakes are not
dragging.
LINING RUNNING-INM1361001100240
CAUTION
Carry out running-in in a place with good
visibility, and pay careful attention to safety.
Carry out running-in by the following procedure when
replacing the parking brake linings or the rear brake
disc rotors, or when brake performance is
insufficient.
1. Adjust the parking brake lever stroke to the
standard value.
Specified value: 5 − 7 notches (Operation
force: Approximately 200 N) Item Specified lubricant
Rear brake shoe and backing plate contact surface Brake grease SAE J310, NLGI No.1
Rear brake shoe assembly
Rear brake shoe slack adjuster
AC006190
Cable rod
Adjusting nut
AD
AC304403AB
Shoe slack
adjuster

37-1
GROUP 37
POWER STEERING
CONTENTS
GENERAL INFORMATION . . . . . . . .37-3
SERVICE SPECIFICATIONS . . . . . . .37-6
LUBRICANTS . . . . . . . . . . . . . . . . . .37-7
SEALANTS . . . . . . . . . . . . . . . . . . . .37-7
SPECIAL TOOLS . . . . . . . . . . . . . . . .37-8
ON-VEHICLE SERVICE . . . . . . . . . . .37-11
STEERING WHEEL FREE PLAY
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37-11
STEERING ANGLE CHECK . . . . . . . . . . . . 37-11
TIE ROD END BALL JOINT TURNING
TORQUE CHECK . . . . . . . . . . . . . . . . . . . . 37-12
STATIONARY STEERING EFFORT
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37-12
STEERING WHEEL RETURN TO
CENTRE CHECK . . . . . . . . . . . . . . . . . . . . 37-13DRIVE BELT TENSION CHECK . . . . . . . . . 37-13
FLUID LEVEL CHECK . . . . . . . . . . . . . . . . 37-13
FLUID REPLACEMENT . . . . . . . . . . . . . . . 37-13
POWER STEERING SYSTEM AIR
BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . 37-13
OIL PUMP PRESSURE TEST . . . . . . . . . . 37-14
POWER STEERING PRESSURE
SWITCH CHECK . . . . . . . . . . . . . . . . . . . . . 37-15
TIE ROD END BALL JOINT DUST COVER
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37-15
STEERING COLUMN SHAFT
ASSEMBLY SHOCK ABSORBING
MECHANISM CHECK . . . . . . . . . . . . . . . . . 37-15
STEERING WHEEL* . . . . . . . . . . . . . .37-17
REMOVAL AND INSTALLATION
. . . . . . . . . . . . . . . . . . . . . . . 37-17
REMOVAL AND INSTALLATION
. . . . . . . . . . . . . . . . . . . . . . . . . . 37-19
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 (*).

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)