front suspension MITSUBISHI LANCER 2005 Workshop Manual

GROUP INDEX
00General . . . . . . . . . . . . . . . . . . . . . . . .
11Engine. . . . . . . . . . . . . . . . . . . . . . . . .
12Engine Lubrication . . . . . . . . . . . . . .
13Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . .
14Engine Cooling . . . . . . . . . . . . . . . . .
15Intake and Exhaust . . . . . . . . . . . . . .
16Engine Electrical . . . . . . . . . . . . . . . .
17Engine and Emission Control . . . . .
21Clutch . . . . . . . . . . . . . . . . . . . . . . . . .
22Manual Transmission . . . . . . . . . . . .
23Automatic Transmission. . . . . . . . . .
26Front Axle . . . . . . . . . . . . . . . . . . . . . .
27Rear Axle . . . . . . . . . . . . . . . . . . . . . .
31Wheel and Tyre . . . . . . . . . . . . . . . . .
32Power Plant Mount . . . . . . . . . . . . . .
33Front Suspension . . . . . . . . . . . . . . .
34Rear Suspension . . . . . . . . . . . . . . . .
35Service Brakes . . . . . . . . . . . . . . . . . .
36Parking Brakes . . . . . . . . . . . . . . . . .
37Power Steering . . . . . . . . . . . . . . . . .
42Body . . . . . . . . . . . . . . . . . . . . . . . . . .
51Exterior . . . . . . . . . . . . . . . . . . . . . . . .
52 . . . . . . . . . .
54Chassis Electrical . . . . . . . . . . . . . . .
55 . . . . . . .
70Component Locations. . . . . . . . . . . .
80Configration Diagrams . . . . . . . . . . .
90Circuit Diagrams . . . . . . . . . . . . . . . .

LANCER /
LANCER WAGON
WORKSHOP MANUAL
FOREWORD
This Workshop manual contains procedures for
service mechanics, including removal, disassembly,
inspection, adjustment, reassembly and installation.
Use the following manuals in combination with this
manual as required.
TECHNICAL INFORMATION MANUAL
PYME0302
PYME0302-A
WORKSHOP MANUAL
CHASSIS GROUP PWME0302
BODY REPAIR MANUAL
PBME0302
PBME0302-A
PARTS CATALOGUE
B606K005A_
All information, illustrations and product descriptions
contained in this manual are current as at the time of
publication. We, however, reserve the right to make
changes at any time without prior notice or obligation.
Mitsubishi Motors Corporation May 2004
Heater, Air Conditioner and
Ventilation Interior and Supplemental
Restraint System (SRS)

SPECIAL TOOLS
FRONT AXLE26-5
MB990685 Torque wrench Measurement of hub starting torque
MB990326 Preload socket
MB990810 Side bearing
puller•Removal of the centre bearing
bracket
•Removal of the wheel bearing inner
race (outside)
MB991460 Plug Prevention of transmission fluid drain
and of entry of foreign objects
MB991561 Boot band
crimping toolBJ boot (resin boot) band installation
MB990925 Bearing and oil
seal installer set•Removal of the wheel bearing
•Removal and installation of the
centre bearing
•Press-fitting of the dust seal outer,
inner
MB990890 Rear suspension
bushing base•Installation of the wheel bearing
•Press-fitting of the dust seal outer,
inner
MB990883 Rear suspension
bushing arborInstallation of the wheel bearing Tool Number Name Use
MB990326
MB990810
MB991561
MB990925
MB990890
MB990883

FRONT AXLE HUB ASSEMBLY
FRONT AXLE26-13
REASSEMBLY SERVICE POINTS
>>A<< WHEEL BEARING INSTALLATION
1. Fill the wheel bearing with multipurpose grease.
2. Apply a thin coating of multipurpose grease to the
knuckle and bearing contact surfaces.
CAUTION
Press the outer race when pressing-in the wheel
bearing. Otherwise the wheel bearing will be
damaged.
3. Press-in the bearing by using the following special
tools.
•Rear suspension bushing arbor (MB990883)
•Rear suspension bushing base (MB990890)
>>B<< HUB STARTING TORQUE CHECK
1. Tighten the following special tools to the specified
torque, and then press-in the hub into the knuckle.
•Front hub remover and installer (MB991017)
•Spacer (MB991000)
2. Rotate the hub in order to seat the bearing.3. Measure the hub starting torque by using the
following special tools.
•Torque wrench (MB990685)
•Preload socket (MB990326)
Limit: 1.8 N⋅m
4. The starting torque must be within the limit and
the hub rotation must be smooth.
>>C<< WHEEL BEARING AXIAL PLAY
CHECK
1. Measure to determine whether the wheel bearing
axial play is within the limit or not by using the
following special tools.
•Front hub remover and installer (MB991017)
•Spacer (MB991000)
Limit: 0.05 mm
2. If the play is not within the limit range while the nut
is tightened to 245 ± 29 N⋅m, the bearing, hub
and/or knuckle have probably not been installed
correctly. Replace the bearing and re-install.
INSPECTIONM1261002000078
•Check the front hub and brake disc mounting
surfaces for galling and contamination.
•Check the knuckle inner surface for galling and
cracks.
AC102511
MB990883
MB990890
AC
AC210929AC
MB991000 MB991017
245 ± 29 N·m
Tighten the nut
with the bolt secured
AC100136
MB990685
MB990326
AB
AC100137
MB991000
MB991017
245 ± 29 N·m
AB Tighten the nut
with the bolt
secured

TROUBLESHOOTING
WHEEL AND TYRE31-4
WHEEL BALANCE ACCURACYM1311001700247
PURPOSE
This section contains tips and procedures for
achieving accurate wheel balance. Steering wheel
vibration and/or body shake can result if any of these
procedures are not carefully observed.
1. Wheels and tyres must be properly mounted on a
balancer in order to achieve correct balance.
Centring the wheel on the shaft of the balancer is
essential for proper mounting.
2. Off-the-car wheel balancers must be calibrated
periodically to ensure good balancing results. An
inaccurately calibrated balancer could cause
unnecessary replacement of tyres, shocks,
suspension components, or steering components.
Check your balancer's calibration approximately
every 100 balances. Your wheel balancer's
instruction manual should include calibration
procedures. If the calibration procedures specifically
for your balancer are missing, use the generic steps
in this section for zero calibration, static balance, and
dynamic balance checks. The wheel balancer
calibration checks are also described in the
flowchart. (Refer to P.31-6).
PROCEDURE
1. Confirm that the balancer's cone and the wheel
mounting cone are undamaged and free of dirt
and rust.
2. On this vehicle, the wheel's centre hole on the
hub side has a chamfered edge. Use a
back-mounting cone on your wheel balancer to
centre the wheel on the balancer shaft.
3. Install a wheel mounting cone. The appropriate
size cone for this vehicle is 67.0 mm.
4. Before balancing the wheel, remove any wheel
weights from both sides. Also check both sides for
any damage.
5. When installing wheel weights, hammer them at a
straight (not diagonal) angle. Scalloped
wearLack of rotation of tyres or worn
or out-of-alignment suspensionRotate the tyres, and
check the front or
rear suspension
alignments.
Refer to GROUP
33, On-vehicle
service − Front
wheel alignment
check and
adjustment P.33-5.

Refer to GROUP
34, On-vehicle
service − Rear
wheel alignment
check and
adjustment P.34-5. Symptom Probable cause Remedy Reference page
ACX00934

GENERAL INFORMATION
POWER PLANT MOUNT32-2
GENERAL INFORMATION
M1321000100340The engine mounting system employs the inertial
axis four-point suspension method, which is field
proven.
•The optimised locations of the front and rear roll
mounts well distribute their loads thereby
reducing engine idling vibrations.•The fore-and-aft, liquid-filled engine mount of
cylinder type is adopted to reduce engine shake
for improved riding comfort.
CONSTRUCTION DIAGRAM
AC107318
Y0290AU
AC303563
Engine front
mounting bracketTransmission mounting
body side bracket
Engine rear roll stopper bracket
Engine front roll stopper bracket
AB

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 (*).

GENERAL INFORMATION
FRONT SUSPENSION33-2
GENERAL INFORMATION
M1332000100407
The front suspension is a McPherson strut with coil
spring. The shock absorber is gas-filled hydraulic
double-acting type.
CONSTRUCTION DIAGRAM
SPECIFICATIONS
COIL SPRING
NOTE: .
•The*mark indicates optional item.
AC304023
AC304022
AC304754
Lower arm assembly
Front axle No.1
crossmember Stabilizer bar
Strut (shock absorber) Coil spring
AB

Strut cover Strut damper
Strut damper
Item Sedan Wagon
Comfort Sport Comfort Sport
Wire diameter mm 13 13 13 <1600-M/T>
14 1600-A/T,
2000>14
13 <1600>
*
14 <2000>*
Average diameter mm 160 160 160 160
Free length mm 330 321 330 <1600-M/T>
338 <1600-A/T>
338 <2000>314 <1600>
321 <2000>
330 <1600>
*
338 <2000>*

SERVICE SPECIFICATIONS
FRONT SUSPENSION33-3
SERVICE SPECIFICATIONS
M1332000300586
NOTE: *: difference between right and left wheels must be less than 30'
LUBRICANT
M1332000400152
ItemStandard value
Toe-in At the centre of tyre tread mm 1 ± 2
Toe-angle (per wheel) 0°03' ± 06'
Toe-out angle on turns (inner wheel when outer wheel at 20°)21°42' ± 1°30'
Steering angle Inner wheel Comfort 39°30' ± 1°30'
Sport (LH drive vehicles) 33°40' +1°00'/-2°00'
Sport (RH drive vehicles) 37°00' +1°00'/-2°00'
Outer wheel (reference) Comfort 32°30'
Sport (LH drive vehicles) 28°46'
Sport (RH drive vehicles) 30°00'
Camber Comfort 0°05' ± 30'*
Sport -0°05' ± 30'*
Caster Comfort 2°45' ± 30'*
Sport 2°55' ± 30'*
Kingpin inclination Comfort 12°30' ± 1°30'
Sport 12°40' ± 1°30'
Lower arm ball joint rotation starting torque N⋅m0 − 3.9
Protruding length of stabilizer link thread part mm 22 ± 1.5
Item Specified lubricant Quantity
Lower arm ball joint Lip portion of ball joint cover Multipurpose grease SAE J310,
NLGI No.2 or equivalentAs required
Inside of ball joint cover

SPECIAL TOOLS
FRONT SUSPENSION33-4
SPECIAL TOOLS
M1332000600297
Tool Number Name Use
MB991004 Wheel alignment gauge
attachmentWheel alignment
measurement with aluminium wheels>
A: MB991237
B: MB991238A: Spring compressor
body
B: Arm setCoil spring compression
MB991680
A: MB991681
B: MB991682Wrench set
A: Wrench
B: SocketStrut assembly
disassembly and
reassembly
MB991006 Preload socket Lower arm ball joint
rotation starting torque
check
MB990800 Ball joint remover and
installerLower arm ball joint cover
installation
MB991004
MB991237
A
B
MB991680
A
B
MB991006
MB990800

ON-VEHICLE SERVICE
FRONT SUSPENSION33-5
ON-VEHICLE SERVICE
FRONT WHEEL ALIGNMENT CHECK AND
ADJUSTMENT
M1331000900682
Measure wheel alignment with alignment equipment
on a level surface. The front suspension, steering
system, wheels, and tyres should be serviced to
normal condition before measuring wheel alignment.
TOE-IN
Standard value:
at the centre of tyre tread: 1 ± 2 mm
Toe angle (per wheel): 0°03' ± 06'
1. Adjust the toe-in by undoing the clip and lock nut,
and turning the left and right tie rod turnbuckles by
the same amount (in opposite directions). MB990883 Rear suspension bushing
arborLower arm bushing (rear)
removal and press-fitting
MB990972 Torsion bar bushing
remover base
MB990887 Ring
MB990890 Rear suspension bushing
base
MB991897 Ball joint remover Knuckle and tie rod end
ball joint disconnection
NOTE: Steering linkage
puller (MB990635 or
MB991113) is also
available to disconnect
knuckle and tie rod end
ball joint. Tool Number Name Use
MB990883
MB990971
MB990890
AC106827
AC006074AD
Lock nut
Clip