check engine MITSUBISHI LANCER 2005 Repair Manual

GENERAL INFORMATION
POWER STEERING37-3
GENERAL INFORMATION
M1372000100337
Power steering has been adopted in all vehicles to
make the steering system easier to handle.
FEATURES
•A 4-spoke steering wheel is used.
•MOMO leather-wrapped 3-spoke steering wheel
is used.
•A steering column has a shock absorbing
mechanism and a tilt steering mechanism.•Integral-type rack and pinion gear with high
rigidity and excellent response is used.
•A vane type pump with a fluid flow rate control
system which change steering effort according to
the engine speed is used.
•The separate plastic resin oil reservoir is used to
reduce weight and to make the fluid level
checking easier.
SPECIFICATIONS
Item Comfort Sport
Steering
wheelType 4-spoke type MOMO leather-wrapped
3-spoke type
Outside diameter mm 380 365
Maximum number of turns 3.19 2.86
3.08
Steering
columnColumn mechanism Shock absorbing mechanism and Tilt steering mechanism
Power steering type Integral type
Oil pump Type Vane pump
Basic discharge amount cm
3/rev.7.2 <1300, 1600>
8.1 <2000>7.2 <1300, 1600>
8.1 <2000>
Relief pressure MPa 8.8 8.8
Reservoir type Separate type (plastic)
Pressure switch Equipped
Steering
gearType Rack and pinion
Stroke ratio (Rack stroke/Steering
wheel maximum turning radius)45.74 45.74
Rack stroke mm 146 131
141

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)

POWER STEERING GEAR BOX AND LINKAGE
POWER STEERING37-24
POWER STEERING GEAR BOX AND LINKAGE
REMOVAL AND INSTALLATIONM1372010900237
WARNING
Before removing the steering gear, refer to GROUP 52B, Service Precautions (P.52B-5) and
Air Bag Module and Clock Spring (P.52B-210). Centre the front wheels. Failure to do so may
damage the SRS clock spring and render the SRS system inoperative, risking serious injury.
Pre-removal Operation
•Power Steering Fluid Draining (Refer to P.37-13.)Post-installation Operation
•Check the dust cover for cracks or damage by pushing it
with your finger.
•Power Steering Fluid Supplying (Refer to P.37-13.)
•Power Steering Fluid Line Bleeding (Refer to P.37-13.)
•Checking Steering Wheel Position with Wheels Straight
Ahead.
•Front Wheel Alignment Adjustment (Refer to GROUP 33,
On-vehicle Service − Front Wheel Alignment Check and
Adjustment P.33-5.)
AC304920
AB
57 ± 7 N·m
15 ± 3 N·m 70 ± 10 N·m
7
3 8
5
6
9
1024
1
12 ± 2 N·m
12 ± 2 N·m

Removal steps
1. Crossmember (Refer to GROUP 32,
Crossmember P.32-8).
•Engine rear roll stopper bracket (Refer
to GROUP 32, Engine Roll Stopper
and Centermember P.32-7).
>>A<<2. Joint cover grommet
3. Return hose4. Return tube
5. O-ring
6. Return tube
7. Eye bolt
8. Pressure hose assembly
9. Clamp
10. Steering gear and linkageRemoval 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)

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

IGNITION SWITCH
CHASSIS ELECTRICAL54A-11
DIAGNOSIS PROCEDURE
STEP 1. Check for presence of other key near the
key in the ignition.
Q: Is there any other key near the key in the ignition?
YES :
Move the other key well away from key
being used. Retest the system.
NO : Go to Step 2.
STEP 2. Check that the engine start using the
spare ignition key which encrypted code has
been registered.
Q: Does the engine start using the spare ignition key
for which the encrypted code has been registered?
YES :
Replace the ignition key that does not work.
Then register the password (secret code)
and encrypted code P.54A-20. Retest the
system.
NO : Go to Step 3.
STEP 3. Check whether the diagnosis code is
reset.
Q: Which diagnosis code is set, code No.11 or 12 the
encrypted code has been registered?
Code No.12 is set :
Refer toP.54A-11.
Code No.11 is set : Go to Step 4.
STEP 4. Connector check: Immobilizer-ECU
connector C-202-1.
Q: Are immobilizer-ECU connector C-202-1 in good
condition?
YES :
Replace immobilizer-ECU and Then
register the password (secret cod) and
encrypted code P.54A-20. Retest the
system.
NO : Repair or replace the damage
component(s).
Code No.12: Encrypted Codes are Not identical or not Registered
DIAGNOSIS CODE SET CONDITION
The encrypted code sent by the transponder is not
the same encrypted code which is registered in the
immobilizer-ECU.
NOTE: Diagnosis code No.12 is always set together
with MPI system diagnosis code No.P0513.
TROUBLESHOOTING HINTS
•The encrypted code in the ignition key has not
been properly registered.•Malfunction of immobilizer-ECU.
DIAGNOSIS PROCEDURE
Was the encrypted code registered?
YES :
Replace the immobilizer-ECU and then
re-register the encrypted code (Refer to
P.54A-20).
NO : Register the encrypted code (Refer to
P.54A-20).
SYMPTOM CHARTM1543007201075
AC303806
Connector: C-202-1
Harness side
AF
Symptom Inspection
procedure No.Reference page
Communication with MUT-II/III is impossible. 1
P.54A-12
The ignition key cannot be registered. 2
P.54A-18
Engine does not start (cranking but no initial combustion). 3
P.54A-18