Lamp MITSUBISHI LANCER 2005 Repair Manual

MARK
EXTERIOR51-35
2. Installation procedure
(1) Use 3M ATD Part number 8906 or equivalent
to clean the mark installation surfaces on the
body.CAUTION
When attaching the marks, the ambient
temperature should be 20 − 38°C and the air
should be completely free of dust. If the ambient
temperature is lower than 20°C, the marks and
the places on the vehicle body where the marks
are to be attached should be heated to 20 − 38°C.
(2) Peel off the protection sheet on the back of the
marks to paste it on the installation position.
AC304163
2. Three-diamond mark

Centre line
of vehicleCentre line
of vehicle
Trunk lid
press linePress line112 mm
53 ± 1 mm
AC
AC304164
3. Lancer mark
Rear combination
lamp terminal
Trunk lid terminal
Tailgate terminal
33 mm
24 mm45 ± 1 mm
13 ± 1 mm19 ± 1 mm

AB

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

54A-3
REAR COMBINATION
LAMP . . . . . . . . . . . . . . . . . . . . .
54A-79
TROUBLESHOOTING . . . . . . . . . .
54A-79
SPECIAL TOOL . . . . . . . . . . . . . . .54A-79
REAR COMBINATION LAMP . . . .54A-79
REMOVAL AND INSTALLATION . . . . . 54A-79
HIGH-MOUNTED
STOP LAMP. . . . . . . . . . . . . . . .
54A-80
ON-VEHICLE SERVICE. . . . . . . . .
54A-80
HIGH-MOUNTED STOP LAMP BULB
REPLACEMENT 54A-80
HIGH-MOUNTED STOP LAMP . . .54A-81
REMOVAL AND INSTALLATION . . . . . 54A-81
LICENCE PLATE LAMP . . . . . .54A-84
REMOVAL AND INSTALLATION .
54A-84
HAZARD WARNING LAMP
SWITCH . . . . . . . . . . . . . . . . . . .
54A-85
TROUBLESHOOTING . . . . . . . . . .
54A-85
SPECIAL TOOL . . . . . . . . . . . . . . .54A-85
HAZARD WARNING LAMP SWITCH54A-86
REMOVAL AND INSTALLATION . . . . . 54A-86
INSPECTION . . . . . . . . . . . . . . . . . . . . . 54A-86
COLUMN SWITCH. . . . . . . . . . .54A-87
SPECIAL TOOL . . . . . . . . . . . . . . .
54A-87
COLUMN SWITCH. . . . . . . . . . . . .54A-87
REMOVAL AND INSTALLATION . . . . . 54A-87
INSPECTION . . . . . . . . . . . . . . . . . . . . . 54A-88
HORN . . . . . . . . . . . . . . . . . . . . 54A-89
REMOVAL AND INSTALLATION . . . . . . 54A-89
HORN RELAY CONTINUITY CHECK . . 54A-89
CLOCK . . . . . . . . . . . . . . . . . . . 54A-90
SPECIAL TOOL . . . . . . . . . . . . . . .
54A-90
CLOCK . . . . . . . . . . . . . . . . . . . . . .54A-90
REMOVAL AND INSTALLATION . . . . . . 54A-90
CIGARETTE LIGHTER . . . . . . 54A-91
INSPECTION . . . . . . . . . . . . . . . . . . . . . 54A-91
RHEOSTAT . . . . . . . . . . . . . . . 54A-91
REMOVAL AND INSTALLATION . . . . . . 54A-91
INSPECTION . . . . . . . . . . . . . . . . . . . . . 54A-92
SPEAKER. . . . . . . . . . . . . . . . . 54A-93
REMOVAL AND INSTALLATION . . . . . . 54A-93
ANTENNA . . . . . . . . . . . . . . . . 54A-94
REMOVAL AND INSTALLATION . . . . . . 54A-94
REAR WINDOW
DEFOGGER . . . . . . . . . . . . . . .
54A-95
GENERAL INFORMATION . . . . . .
54A-95
TROUBLESHOOTING . . . . . . . . . .54A-95
ON-VEHICLE SERVICE . . . . . . . . .54A-96
PRINTED HEATER LINES CHECK . . . . 54A-96
REAR WINDOW DEFOGGER
SWITCH . . . . . . . . . . . . . . . . . . . . .
54A-96
REMOVAL AND INSTALLATION . . . . . . 54A-96
INSPECTION . . . . . . . . . . . . . . . . . . . . . 54A-96

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-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

COMBINATION METER ASSEMBLY
CHASSIS ELECTRICAL54A-49
DIAGNOSIS PROCEDURE
STEP 1. Check the fuel gauge circuit.
(1) Disconnect D-13 fuel gauge unit connector.
(2) Connect a test lamp (12 V − 3.4 W) via test
harness (MB991219) between the wiring harness
connector terminals 1 and 2.
(3) Turn the ignition switch to the "ON" position.
Q: Does the test lamp illuminate?
YES :
Go to Step 4.
NO : . Go to Step 2.
STEP 2. Connector check: Combination meter
connector C-06, fuel gauge unit connector D-13
Q: Is combination meter connector C-04, fuel gauge
unit connector D-13 in good condition?
YES :
Go to Step 3.
NO : Repair or replace the damaged
component(s).
STEP 3. Check the wiring harness between
combination meter connector C-06 (terminal 51)
and fuel gauge unit connector D-13 (terminal 1).
AC305320
AB
Test lamp
(12 V - 3.4 W)
MB991219
Harness side
Fuel gauge
Earth
AC303798
Connector: C-04

Harness side
AT
AC303871
Connector: D-13

Harness sideD-13 (B)
AI
AC303917
D-13 (B) Connector: D-13

Harness side
AH
AC303798
Connector: C-06

Harness side
C-06 (L)
31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51
AV
AC303814AU
Connector: C-06

Harness side
31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51
C-06 (L)

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