clock MITSUBISHI LANCER 2005 Workshop Manual
[x] Cancel search | Manufacturer: MITSUBISHI, Model Year: 2005, Model line: LANCER, Model: MITSUBISHI LANCER 2005Pages: 788, PDF Size: 45.98 MB
Page 2 of 788
WARNINGS REGARDING SERVICING OF SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) EQUIPPED VEHICLES
(1) 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 passenger (from rendering the SRS inoperative).
(2) The SRS components and seat belt with pretensioner should not be subjected to heat, so
remove the SRS-ECU, driver’s and front passenger’s air bag modules, clock spring, side air bag
modules, and seat belt -pre-tensioner before drying or baking the vehicle after painting.
• SRS-ECU, air bag module and clock spring 93°C or more
• Seat belt with pre-tensioner: 90°C or more
(3) Service or maintenance of any SRS component or SRS-related component must be performed
only at an authorized MITSUBISHI dealer.
(4) 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
Section titles with asterisks (*) in the table of contents in each group indicate operations requiring warnings.
Page 36 of 788
ON-VEHICLE SERVICE
ENGINE COOLING14-22
ON-VEHICLE SERVICE
ENGINE COOLANT LEAK CHECKM1141001000300
WARNING
When pressure testing the cooling system,
slowly release cooling system pressure to
avoid getting burned by hot coolant.
CAUTION
•Be sure to completely clean away any
moisture from the places checked.
•When the tester is taken out, be careful not to
spill any coolant.
•Be careful when installing and removing the
tester and when testing not to deform the
filler neck of the radiator.
1. Check that the coolant level is up to the filler neck.
Install a radiator tester and apply 160 kPa
pressure, and then check for leakage from the
radiator hose or connections.
2. If there is leakage, repair or replace the
appropriate part.
RADIATOR CAP VALVE OPENING
PRESSURE CHECK
M1141001300389
NOTE: Be sure that the cap is clean before
testing. Rust or other foreign material on the cap
seal will cause an improper reading.
1. Use a cap adapter to attach the cap to the tester.2. Increase the pressure until the indicator of the
gauge stops moving.
Minimum limit: 83 kPa
Standard value: 93 − 123 kPa
3. Replace the radiator cap if the reading does not
remain at or above the limit.
ENGINE COOLANT REPLACEMENTM1141001200434
WARNING
When removing the radiator cap, use care to
avoid contact with hot coolant or steam.
Place a shop towel over the cap and turn the
cap counterclockwise a little to let the
pressure escape through the vinyl tube.
After relieving the steam pressure, remove
the cap by slowly turning it
counterclockwise.
1. Drain the water from the radiator, heater core and
engine after unplugging the radiator drain plug
and removing the radiator cap.
2. Drain the water in the water jacket by unplugging
the drain plug of the cylinder block.
3. Remove the radiator condenser tank and drain
the coolant.
4. Drain the coolant then clean the path of the
coolant by injecting water into the radiator from
the radiator cap area.
ACX01844
Cap adapter
Adapter
AC
AC211643AB
Cap adapter
AC208283AC
Cylinder block
drain plug
<4G1>
Inlet side
AC303355
<4G6>
Inlet side
Cylinder block
drain plug
AB
Page 92 of 788
STARTING SYSTEM
ENGINE ELECTRICAL16-28
2. Measure the diameter of the commutator.
Standard value: 29.4 mm
Limit: 28.8 mm
3. Measure the depth of the undercut between
segments.
Standard value: 0.5 mm
Limit: 0.2 mm
BRUSH HOLDER
Push the brush into the brush holder to make sure
that the spring is working on the brush.
If the spring is not working, replace the brush holder.
OVERRUNNING CLUTCH
1. Make sure that the pinion cannot be turned
counterclockwise and can be turned clockwise
freely.
2. Check the pinion for abnormal ware and damage.
BRUSHES
1. Check the commutator contacting surface of each
brush for abnormal roughness. Also check the
height of the brush. Replace the brush holder if
the height is lower than the limit.
Limit: 7.0 mm
2. When the contact surface of the brush is rectified
or the brush holder is replaced, recondition the
contact surface with sandpaper wrapped around
the commutator.
ARMATURE COIL
1. Check the armature coil for short circuit as
follows:
AK202715
AK202711
SegmentUndercut
Mica
AB
AK201187
AK202710
Free
Lock
AB
AK202846
Brush
height
AB
Page 178 of 788
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).
Page 183 of 788
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 (*).
Page 196 of 788
STABILIZER BAR
FRONT SUSPENSION33-14
STABILIZER BAR
REMOVAL AND INSTALLATIONM1332004000468
CAUTION
•Before removing the steering wheel and air bag module assembly, 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 Operation
•Steering Wheel and Air Bag Module Assembly Removal
(Comfort: refer to GROUP 37, Steering Wheel
P.37-17/Sport: refer to GROUP 37, Steering Wheel
P.37-19).
•Clock Spring Removal (Refer to GROUP 52B, Air Bag
Modules and Clock Spring P.52B-210).
•Centermember Removal (Refer to GROUP 32, Engine
Roll Stopper, Centermember P.32-7).
•Front Exhaust Pipe Removal (Refer to GROUP 15,
Exhaust Pipe and Main Muffler P.15-11).Post-installation Operation
•Front Exhaust Pipe Installation (Refer to GROUP 15,
Exhaust Pipe and Main Muffler P.15-11).
•Centermember Installation (Refer to GROUP 32, Engine
Roll Stopper, Centermember P.32-7).
•Clock Spring Installation (Refer to GROUP 52B, Air Bag
Modules and Clock Spring P.52B-210).
•Steering Wheel and Air Bag Module Assembly Installation
(Comfort: refer to GROUP 37, Steering Wheel
P.37-17/Sport: refer to GROUP 37, Steering Wheel
P.37-19).
•Check the dust covers for cracks or damage by pushing it
with your finger.
•Checking Steering Wheel Position with Wheels Straight
Ahead
•Front Wheel Alignment Check and Adjustment (Refer to
P.33-5).
Page 206 of 788
ON-VEHICLE SERVICE
REAR SUSPENSION34-6
If camber is not within the standard value, adjust by
following procedures.
1. Disconnect the conjunction of the control link and
the trailing arm.
2. Carry out adjustment by turning the camber
adjusting bolt (lower arm assembly mounting bolt
which is located on the inner side of the body).
NOTE: .
•LH: Clockwise viewed from the front → (+)
camber
•RH: Clockwise viewed from the front → (-)
camber
•The scale has gradations of approximately 14'.
CAUTION
To prevent bushings from breakage, the
connecting bolt should be temporarily tightened,
and then fully tightened to 90 ± 10 N⋅m with the
vehicle on the earth in the unladen condition.
3. Tighten the control link to the trailing arm.
4. After adjusting the camber, the toe should be
adjusted.
TOE-IN
Standard value:
At the centre of tyre tread: 3 ± 2 mm
Toe angle (per wheel): 0°08' ± 05'If toe-in is not within the standard value, adjust by
following procedures.
CAUTION
To prevent bushings from breakage, the control
link mounting nut should be temporarily
tightened, and then fully tightened to 120 ± 10
N⋅m with the vehicle on the earth in the unladen
condition.
Carry out adjustment by turning the toe adjusting bolt
(control link mounting bolt which is located on the
inner side of the body).
NOTE: .
•LH: Clockwise viewed from the front → Toe-in
•RH: Clockwise viewed from the front → Toe-out
•Turning the toe adjusting bolt by one groove of
the scale, toe can be changed approximately 2.6
mm (single side toe angle equivalent to 16').
CONTROL LINK PILLOW BALL BUSHING
AXIAL PLAY CHECK
M1341018500011
1. Raise the vehicle.
2. Move the control link up and down with your
hands to check for an excessive play in the axial
direction of the pillow ball bushing. If there is an
excessive play, replace the control link (Refer to
P.34-8).
AC006159AC
Camber adjusting bolt
Lower arm
assembly
AC006160
AC
Connecting bolt
AC006145AD
Control link Toe adjusting boltControl link
Control link
mounting nut
AC304398ABControl link pillow ball bushing
Front of
vehicle
Page 235 of 788
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
REMOVAL AND INSTALLATION
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 (*).
Page 251 of 788
STEERING WHEEL
POWER STEERING37-17
STEERING WHEEL
REMOVAL AND INSTALLATION
M1372011400183
WARNING
•Before removing the steering wheel and air bag module assembly, refer to GROUP 52B,
Service Precautions (P.52B-5) and Air Bag Module and Clock Spring (P.52B-210).
•When removing and installing the steering wheel, do not let it bump against the air bag
module.
NOTE: For air bag module removal, refer to GROUP
52B, Air Bag Module and Clock Spring P.52B-210.
Post-installation Operation
•Checking Steering Wheel Position with Wheels Straight
Ahead
AC107402AB
50 ± 5 N·m
1 2
2
1
12
A
AB
BTa b
Ta b Section A - A
Section B - B
Removal steps
<>1. Cover
<>2. Steering wheel and air bag module
assembly
Page 252 of 788
