head unit MITSUBISHI LANCER 2005 Workshop Manual

WINDOW GLASS
BODY42-12
WINDSHIELD
REMOVAL AND INSTALLATIONM1422001000313
Pre-removal and Post-installation Operation
•Front Deck Garnish Removal and Installation (Refer to
GROUP 51,Windshield Wiper and Washer P.51-23.)
•Inside Rear View Mirror Removal and Installation (Refer
to GROUP 52A, Inside Rear View Mirror P.52A-23.)
•Front Pillar Trim Removal and Installation (Refer to
GROUP 52A, Trims P.52A-11.)
•Headlining Removal and Installation (Refer to GROUP
52A, Headlining P.52A-21.)
AC006003
X0111AUX0112AU
Y0496AU
12
3 4
6
1 11 3
N
N
N
N
N
AC Y0495AU
A
A
BB
C
C Ceramic line
Seal line
Seal line
Ceramic line
MarkMark
Apply the primer and
adhesive along the
fictitious lines (seal line)
between each of
the marks.
Seal line centre
Primer Section A – A Section B – BSeal line
centre
Primer
Section C – C
Seal line
centre
Primer
5N
5N
Units: mm
Adhesive: 3M ATD Part No. 8609 Super Fast Urethane Auto Glass Sealant or equivalent and
3M ATD Part No. 8608 Super Fast Urethane Primer or equivalent
16
1613

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

ON-VEHICLE SERVICE
HEATER, AIR CONDITIONER AND VENTILATION55-74
REFRIGERANT LEAK REPAIR
PROCEDURE
M1552001500277
LOST CHARGE
If the system has lost all charge due to a leak:
1. Evacuate the system (Refer to P.55-72).
2. Charge the system with approximately 480 − 520
g of refrigerant.
3. Check for leaks.
4. Discharge the system.
5. Repair leaks.
CAUTION
Replacement filter-drier units must be sealed
while in storage. The drier used in these units will
saturate water quickly upon exposure to the
atmosphere. When installing a drier, have all
tools and supplies ready for quick assembly to
avoid keeping the system open any longer than
necessary.
6. Replace receiver drier.
7. Evacuate and charge system.
LOW CHARGE
If the system has not lost all of its refrigerant charge;
locate and repair all leaks. If it is necessary to
increase the system pressure to find the leak
(because of an especially low charge) add
refrigerant. If it is possible to repair the leak without
discharging the refrigerant system, use the
procedure for correcting low refrigerant level.
HANDLING TUBING AND FITTINGS
Kinks in the refrigerant tubing or sharp bends in the
refrigerant hose lines will greatly reduce the capacity
of the entire system. High pressures are produced in
the system when it is operating. Extreme care must
be exercised to make sure that all connections are
pressure tight. Dirt and moisture can enter the
system when it is opened for repair or replacement of
lines or components. The following precautions must
be observed. The system must be completely
discharged before opening any fitting of connection
in the refrigeration system. Open fittings with caution
even after the system has been discharged. If any
pressure is noticed as a fitting is loosened, allow
trapped pressure to bleed off very slowly.
Never attempt to rebend formed lines to fit. Use the
correct line for the installation you are servicing. A
good rule for the flexible hose lines is keep the radius
of all bends at least 10 times the diameter of the
hose.Sharper bends will reduce the flow of refrigerant. The
flexible hose lines should be routed so that they are
at least 80 mm from the exhaust manifold. It is good
practice to inspect all flexible hose lines at least once
a year to make sure they are in good condition and
properly routed.
On standard plumbing fittings with O-rings, these
O-rings are not reusable.
COMPRESSOR NOISE CHECKM1552008700272
You must first know the conditions when the noise
occurs. These conditions are: weather, vehicle
speed, in gear or neutral, engine temperature or any
other special conditions.
Noises that develop during A/C operation can often
be misleading. For example: what sounds like a
failed front bearing or connecting rod, may be
caused by loose bolts, nuts, mounting brackets, or a
loose clutch assembly. Verify accessory drive belt
tension (power steering or alternator).
Improper accessory drive belt tension can cause a
misleading noise when the compressor is engaged
and little or no noise when the compressor is
disengaged.
Drive belts are speed-sensitive. That is, at different
engine speeds, and depending upon belt tension,
belts can develop unusual noises that are often
mistaken for mechanical problems within the
compressor.
ADJUSTMENT
1. Select a quiet area for testing. Duplicate
conditions as much as possible. Switch the
compressor on and off several times to clearly
identify compressor noise. To duplicate high
ambient conditions (high head pressure), restrict
air flow through the condenser. Install a manifold
gauge set to make sure discharge pressure
doesn't exceed 2,070 kPa.
2. Tighten all compressor mounting bolts, clutch
mounting bolt, and compressor drive belt. Check
to assure clutch coil is tight (no rotation or
wobble).
3. Check refrigerant hoses for rubbing or
interference that can cause unusual noises.
4. Check refrigerant charge (Refer to P.55-69).
5. Recheck compressor noise as in Step 1.
6. If noise still exists, loosen compressor mounting
bolts and retighten. Repeat Step 1.
7. If noise continues, replace compressor and repeat
Step 1.

ENGINE COMPARTMENT
CONFIGURATION DIAGRAMS80-6
ENGINE COMPARTMENT
ENGINE COMPARTMENT M1801000301298
AC301122AB
A-02
A-03
A-04X
A-05X
A-09X
A-10X
A-11X
A-12
A-13
A-14
A-15
A-16
A-17
A-18 A-19 A-20 A-21Front wiring
harness (LH)
12Front wiring
harness (RH) A-01
A-32
A-31
A-29
A-28
A-27
A-26
A-25
A-23 A-24 A-22
1
Front bumper
wiring harness Connector colour
code
B : Black
BR : Brown
G : Green
GR : Gray
L : Blue
None : Milk white
O : Orange
R : Red
V : Violet
Y : Yellow
Connector
symbol
A
A-01 (2-GR) Side turn signal lamp (RH)
A-02 (2-GR) Side turn signal lamp (LH)
A-03 (2-B) Wheel speed sensor (Front: LH)
A-04X (4) Front fog lamp relay or spare connector
(for front fog lamp)
A-05X (4) Horn relay
A-09X (4) Fan control relay
A-10X (11) Front-ECU
A-11X (11) Front-ECU
A-12 (2-B) Front wiring harness (LH) and control
wiring harness combination
A-13 (12-B) Front wiring harness (LH) and control
wiring harness combination
A-14 (3-B) Headlamp (LH)
A-15 (6-B) Front combination lamp (LH)
A-16 (2) Front turn signal lamp (LH)A-17 (2-B) Front fog lamp (LH)
A-18 (3-GR) Cooling fan motor drive control unit
A-19 (1-B) Horn (HI)
A-20 (2-B) Front wiring harness (LH) and front
bumper wiring harness combination
A-21 (1-B) Horn (LO)
A-22 (2-B) Front fog lamp (RH)
A-23 (2) Front turn signal lamp (RH)
A-24 (1) Spare connector (for front fog lamp)
A-25 (6-B) Front combination lamp (RH)
A-26 (2) Windshield washer motor
A-27 (2-G) Rear washer motor
A-28 (2-B) Headlamp washer motor
A-29 (3-B) Headlamp (RH)
A-31 (2-BR) Dual pressure switch
A-32 (2-B) Wheel speed sensor (Front: RH)

ENGINE COMPARTMENT
CONFIGURATION DIAGRAMS80-7
ENGINE COMPARTMENT M1801000301306
AC301125
Front wiring
harness (RH) A-01
A-32
A-31
A-29 A-30
A-27
A-26
A-25
A-23 A-24 A-22
1
Front bumper
wiring harness Connector colour
code
B : Black
BR : Brown
G : Green
GR : Gray
L : Blue
None : Milk white
O : Orange
R : Red
V : Violet
Y : Yellow
Connector
symbol
A
AB
A-02
A-03
A-04X
A-05X
A-09X
A-10X
A-11X
A-12
A-14
A-15
A-16
A-17
A-18 A-19 A-20 A-21Front wiring
harness (LH)
12
A-01 (2-GR) Side turn signal lamp (RH)
A-02 (2-GR) Side turn signal lamp (LH)
A-03 (2-B) Wheel speed sensor (Front: LH)
A-04X (4) Front fog lamp relay or spare connector
(for front fog lamp)
A-05X (4) Horn relay
A-09X (4) Fan control relay
A-10X (11) Front-ECU
A-11X (11) Front-ECU
A-12 (2-B) Front wiring harness (LH) and control
wiring harness combination
A-14 (3-B) Headlamp (LH)
A-15 (6-B) Front combination lamp (LH)
A-16 (2) Front turn signal lamp (LH)
A-17 (2-B) Front fog lamp (LH)A-18 (3-GR) Cooling fan motor drive control unit
A-19 (1-B) Horn (HI)
A-20 (2-B) Front wiring harness (LH) and front
bumper wiring harness combination
A-21 (1-B) Horn (LO)
A-22 (2-B) Front fog lamp (RH)
A-23 (2) Front turn signal lamp (RH)
A-24 (1) Spare connector (for front fog lamp)
A-25 (6-B) Front combination lamp (RH)
A-26 (2) Windshield washer motor
A-27 (2-G) Rear washer motor
A-29 (3-B) Headlamp (RH)
A-30 (2-GR) No connection
A-31 (2-BR) Dual pressure switch
A-32 (2-B) Wheel speed sensor (Front: RH)

CENTRALIZED JUNCTION
CIRCUIT DIAGRAMS90-11
20 Front-ECU (Tail lamp
relay)Fuse 7.5 Brown A/C-ECU, ashtray illumination lamp,
cigarette lighter illumination lamp,
combination meter, fog lamp switch,
front turn signal lamp, hazard warning
switch, headlamp assembly (RH),
headlamp levelling switch, heated
seat switch, heater control unit,
licence plate lamp, rear combination
lamp, rheostat, side turn signal lamp
and spare connector (for audio)
21 7.5 Brown Combination meter, headlamp
assembly (LH), licence plate lamp,
position lamp (LH) and rear
combination lamp (LH)
22 Battery/ Alternator
(Fusible link No.26)10 Red Combination meter, column switch,
ETACS-ECU and front-ECU
23 Ignition switch (ACC) 10 Red Clock, ETACS-ECU and spare
connector (for audio)
24
−−−−
25 Battery/ Alternator
(Fusible link No.26)20 Yellow Heated seat assembly and heated
seat switch
26 Alternator Fusible
link100 <4G1>
120 <4G6>−Battery, fusible link No.1, 2, 3, 4, 5,
fuse No.6, 7, 8, 9, 10, 11, 12, 13, 14,
15, 22 (relay box) and front-ECU No. Power supply circuit Name Rated
capacity (A)Housing
colourLoad circuit
AC208462
Front of vehicle
(Relay box in engine compartment)
1
6
7 8 9 10 1112 13141524
4 25
2316
1718
1920
2123 225
AO

METER AND GAUGE
CIRCUIT DIAGRAMS90-87
METER AND GAUGE
M1901003501072
RELAY
BOXBATTERYFRONT-ECU
(TAIL LAMP RELAY)
TAIL LAMP,
POSITION LAMP,
LICENCE PLATE
LAMP AND LIGHTING
MONITOR BUZZER
ODO/TRIP
ENGINE
SPEED
DETECTION
CONNECTOR ENGINE-
ECU
ENGINE-
A/T-ECU
DIAGNOSIS
CONNECTOR
·TAIL LAMP, POSITION LAMP,
LICENCE PLATE LAMP AND
LIGHTING MONITOR BUZZER
·WINDSHIELD WIPER
AND WASHER ·FRONT FOG LAMP
·HEADLAMP
·HEADLAMP
LEVELLING SYSTEM
·REAR FOG LAMP
IGNITION
SWITCH (IG1)
COMBINATION
METER
CONTROL CIRCUIT
ENGINE
COOLANT
TEMPERATURE
GAUGE UNITFUEL
GAUGE
UNIT
NOTE
: SEDAN
: WAGON
: M/T
: A/T
FRONT SIDE : EXCEPT 4G6
: 4G6
WHITE METER>

METER AND GAUGE
CIRCUIT DIAGRAMS90-89
METER AND GAUGE
M1901003501083
DIAGNOSIS
CONNECTOR
RELAY
BOXBATTERYFRONT-ECU
TAIL
LAMP RELAY
TAIL LAMP,
POSITION LAMP,
LICENCE PLATE
LAMP AND LIGHTING
MONITOR BUZZERTAIL LAMP,
POSITION LAMP,
LICENCE PLATE
LAMP AND LIGHTING
MONITOR BUZZER
ODO/TRIP
ENGINE
SPEED
DETECTION
CONNECTOR ENGINE-
ECU
ENGINE-
A/T-ECU
RHEOSTAT ·TAIL LAMP, POSITION LAMP,
LICENCE PLATE LAMP AND
LIGHTING MONITOR BUZZER
·WINDSHIELD WIPER
AND WASHER
WINDSHIELD WIPER
AND WASHER ·FRONT FOG LAMP
·HEADLAMP
·HEADLAMP
LEVELLING SYSTEM
·REAR FOG LAMP
IGNITION
SWITCH (IG1)
COMBINATION
METER
CONTROL CIRCUIT
ENGINE
COOLANT
TEMPERATURE
GAUGE UNITFUEL
GAUGE
UNIT
NOTE
: SEDAN
: WAGON
: M/T
: A/T
: EXCEPT 4G6
: 4G6
FRONT
SIDE ·TAIL LAMP, POSITION LAMP,
LICENCE PLATE LAMP AND
LIGHTING MONITOR BUZZER
·TURN-SIGNAL LAMP AND
HAZARD WARNING LAMP
·WINDSHIELD WIPER
AND WASHER ·FRONT FOG LAMP
·HEADLAMP
·REAR FOG LAMP
·REAR WIPER AND WASHER

FUEL WARNING LAMP, OIL PRESSURE WARNING LAMP AND BRAKE WARNING LAMP
CIRCUIT DIAGRAMS90-91
FUEL WARNING LAMP, OIL PRESSURE WARNING LAMP
AND BRAKE WARNING LAMP
M1901018700121
BATTERYIGNITION
SWITCH (IG1)
RELAY
BOX
CONTROL CIRCUIT
·FRONT
FOG LAMP
·TAIL LAMP,
POSITION LAMP,
LICENCE PLATE
LAMP AND LIGHTING
MONITOR BUZZER ·HEADLAMP
·WINDSHIELD
WIPER AND
WASHER ·REAR
FOG LAMP ·HEADLAMP
LEVELLING
SYSTEM
FUEL
TANK
GAUGE
UNIT
·HEADLAMP
WASHER
COMBINATION
METER
BRAKE FLUID
LEVEL INDICATOR
SWITCH
ENGINE OIL
PRESSURE
SWITCHPARKING
BRAKE
SWITCH
Wire colour code
B : Black LG : Light green G : Green L : Blue W : White Y : Yellow SB : Sky blue
BR : Brown O : Orange GR : Grey R : Red P : Pink V : Violet

FUEL WARNING LAMP, OIL PRESSURE WARNING LAMP AND BRAKE WARNING LAMP
CIRCUIT DIAGRAMS90-92
FUEL WARNING LAMP, OIL PRESSURE WARNING LAMP
AND BRAKE WARNING LAMP
M1901018700132
Wire colour code
B : Black LG : Light green G : Green L : Blue W : White Y : Yellow SB : Sky blue
BR : Brown O : Orange GR : Grey R : Red P : Pink V : Violet COMBINATION
METER
BRAKE FLUID
LEVEL INDICATOR
SWITCH
ENGINE OIL
PRESSURE
SWITCHPARKING
BRAKE
SWITCH RELAY
BOX BATTERYIGNITION
SWITCH (IG1)
CONTROL CIRCUIT
·FRONT
FOG LAMP
·TAIL LAMP,
POSITION LAMP,
LICENCE PLATE
LAMP AND LIGHTING
MONITOR BUZZER ·HEADLAMP
·WINDSHIELD
WIPER AND
WASHER ·REAR
FOG LAMP
·TURN-SIGNAL LAMP
AND HAZARD
WARNING LAMP
FUEL
TANK
GAUGE
UNIT
·REAR WIPER
AND WASHER
·FRONT
FOG LAMP
·TAIL LAMP,
POSITION LAMP,
LICENCE PLATE
LAMP AND LIGHTING
MONITOR BUZZER ·HEADLAMP
·WINDSHIELD
WIPER AND
WASHER ·REAR
FOG LAMP ·HEADLAMP
LEVELLING
SYSTEM