low oil pressure MITSUBISHI LANCER 2005 Workshop Manual

GENERAL INFORMATION
ENGINE LUBRICATION12-2
GENERAL INFORMATION
M1121000100357
The lubrication method is a fully force-fed, full-flow
filtration type. The engine oil pump is a trochoid type
which is driven by the crankshaft <4G1>.The engine
oil pump is a gear type which is driven by the
crankshaft via the balancer timing belt <4G6>.
ENGINE OILS
Health Warning
Prolonged and repeated contact with mineral oil will
result in the removal of natural fats from the skin,
leading to dryness, irritation and dermatitis. In
addition, used engine oil contains potentially harmful
contaminants which may cause skin cancer.
Adequate means of skin protection and washing
facilities must be provided.
Recommended Precautions
The most effective precaution is to adapt working
practices which prevent, as far as practicable, the
risk of skin contact with mineral oils, for example by
using enclosed systems for handling used engine oil
and by degreasing components, where practicable,
before handling them. Other precautions:
•Avoid prolonged and repeated contact with oils,
particularly used engine oils.
•Wear protective clothing, including impervious
gloves where practicable.•Avoid contaminating clothes, particularly
underpants, with oil.
•Do not put oily rags in pockets, the use of overalls
without pockets will avoid this.
•Do not wear heavily soiled clothing and
oil-impregnated foot-wear. Overalls must be
cleaned regularly and kept separate from
personal clothing.
•Where there is a risk of eye contact, eye
protection should be worn, for example, chemical
goggles or face shields; in addition an eye wash
facility should be provided.
•Obtain first aid treatment immediately for open
cuts and wounds.
•Wash regularly with soap and water to ensure all
oil is removed, especially before meals (skin
cleansers and nail brushes will help). After
cleaning, the application of preparations
containing lanolin to replace the natural skin oils
is advised.
•Do not use petrol, kerosine, diesel fuel, gas oil,
thinners or solvents for cleaning skin.
•Use barrier creams, applying them before each
work period, to help the removal of oil from the
skin after work.
•If skin disorders develop, obtain medical advice
without delay.
SERVICE SPECIFICATION
M1121000300232
LUBRICANT
M1121000400433
Item Standard value
Oil pressure kPa at idle 29 or more
at 3,500 r/min 294 − 686
Item Specification
Engine oil ACEA classification A1, A2 or A3
Engine oil API classification SG or higher
Engine oil quantity L 4G1 Oil filter 0.3
To t a l 3 . 3
4G6 Oil filter 0.3
To t a l 4 . 3

ON-VEHICLE SERVICE
ENGINE LUBRICATION12-5
5. Use the respective tool in the following table to
remove the engine oil filter.
6. Clean the filter bracket side mounting surface.
7. Apply a small amount of engine oil to the O-ring of
the new engine oil filter.
8. Once the O-ring of the engine oil filter is touching
the flange, use the respective tool in the following
table to tighten to the specified torque.9. Install the engine oil pan drain plug and refill the
engine oil (Refer to P.12-4).
10.Race the engine 2−3 times, and check to be sure
that no engine oil leaks from installation section of
the engine oil filter.
OIL PRESSURE CHECKM1121002300368
1. Check engine oil quantity.
2. Remove the oil pressure switch terminal. Number Special tool
MD348631 <4G1> Oil filter wrench (MB991828)
or equivalent
MD365876 <4G1>
MD360935 <4G1> Oil filter wrench (MB991396)
or equivalent
MD136466 <4G6> Commercially- available tool
MD322508 <4G6>
MD356000 <4G6> Oil filter wrench (MB991610)
or equivalent
AC000093
MB991396
<4G1>,
MB991828
<4G1>,
MB991610
<4G6> or
commercially-
available tool
AI
AC103250AD
O-ring
Number Special tool Tightening torque
MD348631
<4G1>Oil filter wrench
(MB991828) or
equivalentApproximately 3/4
turn (16 ± 4 N⋅m)
MD365876
<4G1>
MD360935
<4G1>Oil filter wrench
(MB991396) or
equivalentApproximately 1 turn
(14 ± 2 N⋅m)
MD136466
<4G6>Commercially-
available toolApproximately 3/4
turn (17 ± 3 N⋅m)
MD322508
<4G6>
MD356000
<4G6>Oil filter wrench
(MB991610) or
equivalentApproximately 3/4
turn (14 ± 2 N⋅m)
AK101640
<4G1>
Oil pressure
switch
Oil filter
AD
AK300647
AB
<4G6>
Oil filter bracket
Oil pressure switch

GENERAL INFORMATION
ENGINE COOLING14-2
GENERAL INFORMATION
M1141000100371The cooling system is designed to keep every part of
the engine at appropriate temperature in whatever
condition the engine may be operated. The cooling
method is of the water-cooled, pressure forced
circulation type in which the water pump pressurizes
coolant and circulates it throughout the engine. If the
coolant temperature exceeds the prescribed temperature, the thermostat opens to circulate the
coolant through the radiator as well so that the heat
absorbed by the coolant may be radiated into the air.
The water pump is of the centrifugal type and is
driven by the alternator drive belt from the
crankshaft. The radiator is the corrugated fin, down
flow type.
SERVICE SPECIFICATIONS
M1141000300416
LUBRICANT
M1141000400338
ItemSpecification
Radiator Performance kJ/h 4G13 Standard vehicles 137,720
Vehicles with capacity up radiator
(option)161,288
4G18 Standard vehicles 161,288
Vehicles with capacity up radiator
(option)181,800
4G63 181,800
A/T oil cooler Performance kJ/h 5,651
Item Standard value Limit
High-pressure valve opening pressure of radiator cap kPa 93 − 123 Minimum 83
Range of coolant antifreeze concentration of radiator % 30 − 60 -
Thermostat Valve opening temperature of
thermostat °C4G1 88 ± 1.5 -
4G6 82 ± 1.5 -
Full-opening temperature of
thermostat °C4G1 100 -
4G6 95 -
Valve lift mm 8.5 or more -
Item Specified coolant Quantity L
Engine coolant (including
condense tank)DIAQUEEN SUPER LONG LIFE COOLANT
or an equivalent4G1 5.0
4G6 7.0

EXHAUST MANIFOLD
INTAKE AND EXHAUST15-7
INSPECTIONM1151003100616
Check the following points; replace the part if a
problem is found.
Inlet Manifold Check
1. Check for damage or cracking of any part.2. Clogging of the negative pressure (vacuum) outlet
port, or clogging of the exhaust gas recirculation
passages.
3. Using a straight edge and feeler gauge, check for
distortion of the cylinder head installation surface.
Standard value: 0.15 mm or less
Limit: 0.20 mm
EXHAUST MANIFOLD
REMOVAL AND INSTALLATION <4G1>M1151003300568
8. Battery wiring harness clamp
9. Inlet manifold stay
10. Inlet manifold
11. Inlet manifold gasket
12. Emission vacuum hose & pipe and
emission solenoid valve assembly
13. EGR valve
14. EGR valve gasketRemoval steps (Continued)
AC30366250 ± 10 N·m 24 ± 4 N·m
35 ± 6 N·m17 ± 2 N·m 29 ± 3 N·m
N
3
7
12 4
N
6
8
44 ± 5 N·m
AB
9
5N
29 ± 3 N·m
29 ± 3 N·m
29 ± 3 N·m
(Engine oil)

IGNITION SYSTEM
ENGINE ELECTRICAL16-30
IGNITION SYSTEM
GENERAL INFORMATIONM1163000100294
This system is equipped with two ignition coils (A and
B) with built-in power transistors for the No. 1 and
No. 4 cylinders and the No. 2 and No. 3 cylinders
respectively.
Interruption of the primary current flowing in the
primary side of ignition coil A generates a high
voltage in the secondary side of ignition coil A. The
high voltage thus generated is applied to the spark
plugs of No. 1 and No. 4 cylinders to generate
sparks. At the time that the sparks are generated at
both spark plugs, if one cylinder is at the
compression stroke, the other cylinder is at the
exhaust stroke, so that ignition of the compressed
air/fuel mixture occurs only for the cylinder which is
at the compression stroke.
In the same way, when the primary current flowing in
ignition coil B is interrupted, the high voltage thus
generated is applied to the spark plugs of No. 2 and
No. 3 cylinders.The engine-ECU or engine-A/T-ECU
turns the two power transistors inside the ignition
coils alternately on and off. This causes the primary
currents in the ignition coils to be alternately
interrupted and allowed to flow to fire the cylinders in
the order 1-3-4-2.
The engine-ECU or engine-A/T-ECU
determines which ignition coil should be controlled
by means of the signals from the camshaft position
sensor which is incorporated in the camshaft and
from the crank angle sensor which is incorporated in
the crankshaft. It also detects the crankshaft position
in order to provide ignition at the most appropriate
timing in response to the engine operation
conditions. It also detects the crankshaft position in
order to provide ignition at the most appropriate
timing in response to the engine operation
conditions.
When the engine is cold or operated at high
altitudes, the ignition timing is slightly advanced to
provide optimum performance.
When the automatic transmission shifts gears, the
ignition timing is also retarded in order to reduce
output torque, thereby alleviating shifting shocks.
SYSTEM DIAGRAM
AK101074
Air flow sensor
<4G6> MAP sensor <4G1>
Intake air temperatur
sensor
Engine coolant
temperature sensor
Camshaft position
sensor
Crank angle sensor
Barometric pressure
sonsor <4G6>
Detonatoin sensor
Ignition switch-STEngine-A/T-
ECU Engine-ECU
Ignition coil B
Cylinder No.
23 4
AG
1 Spark plugIgnition coil AIgnition
switch
Battery

DRIVE SHAFT ASSEMBLY
FRONT AXLE26-16
CAUTION
•Do not pull on the drive shaft; doing so will
damage the TJ; be sure to use the pry bar.
•When pulling the drive shaft out from the
transmission, be careful that the spline part of
the drive shaft does not damage the oil seal.
3. Insert a pry bar between the transmission case
and the drive shaft, and then pry and remove the
drive shaft from the transmission.4. Use special tool plug (MB991460) to prevent the
entry of foreign material into the transmission
case.
CAUTION
Do not apply pressure to the wheel bearing by
the vehicle weight to avoid possible damage
when the drive shaft is removed. If, however,
vehicle weight must be applied to the bearing in
moving the vehicle, temporarily secure the wheel
bearing by using the following special tools.
•Spacer (MB991000)
•Front hub remover and installer (MB991017)AC100141
Transmission
TJ assembly
Pry bar
AG
AC102554
MB991460
AC
AC102555
AC
MB991017 MB991000

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
. . . . . . . . . . . . . . . . . . . . . . . 37-17
REMOVAL AND INSTALLATION
. . . . . . . . . . . . . . . . . . . . . . . . . . 37-19
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 (*).

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

SERVICE SPECIFICATIONS
POWER STEERING37-6
SERVICE SPECIFICATIONS
M1372000300386
Item Standard value Limit
Steering wheel free
play mmWith engine running
−30
With engine stopped 10 or less
−
Steering angle Inner wheel Comfort 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 wheel
(reference)Comfort 32°30'
−
Sport (L.H. drive vehicles) 28°46'
−
Sport (R.H. drive vehicles) 30°00'
−
Toe-in At the centre of tyre tread mm 1 ± 2
−
Toe-angle (per wheel) 0°03' ± 06'
−
Tie rod end ball joint turning torque N⋅m0.5 − 2.5
−
Tie rod swing resistance N [Tie rod swing torque N⋅m] 8 − 27 [1.5 − 4.9]
−
Stationary steering effort N [Fluctuation allowance N] 29 or less [5.9 or less]
−
Oil pump pressure
MPa (750 ± 100 r/min.)Oil pump relief pressure 8.8 − 9.5
−
Pressure under no-load conditions 0.2 − 0.7
−
Steering gear retention hydraulic pressure 8.8 − 9.5
−
Oil pressure switch operating pressure
MPaOFF → ON 1.5 − 2.0
−
ON → OFF 0.7 − 2.0
−
Steering gear total pinion torque N⋅m
[Change in torque N⋅m]1300, 1600 (Comfort) 0.8 − 2.1 [0.6 or less]
−
1600 (Sport), 2000 0.7 − 2.1 [0.6 or less]
−
Opening dimension of special tool boot band crimping tool (MB991561)
mm2.9
−
Band crimped width mm 2.4 − 2.8
−

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)