Motor oil MITSUBISHI LANCER 2006 Workshop Manual

AC303473
18
17 15
20
12
9
13
5
2
9
3
4
1
10
6
10
12 ± 2 N·m
AC
12 ± 2 N·m
16
19
8
11
7
Radiator removal steps
1.Drain plug
2.Radiator cap
3.Radiator condenser tank hose
4.Radiator condenser tank assembly
<>>>A<<5.Radiator upper hose
<>>>A<<6.Radiator lower hose
7.Cooling fan motor drive control unit
connector
8.T/M oil cooler line hose connection

9.Radiator support upper insulator
•Radiator and cooling fan motor &
shroud assembly
10.Radiator support lower insulator
11 .T/M oil cooler line hose
12.Cooling fan motor & shroud
assembly
13.Radiator assembly
Cooling fan motor removal
steps

3.Radiator condenser tank hose
<>>>A<<5.Radiator upper hose
7.Cooling fan motor drive control unit
connector
12.Cooling fan motor & shroud
assembly
15.Cooling fan (L.H.)
16.Cooling fan (R.H.) A/C>
17.Cooling fan motor drive control unit
18.Cooling fan motor (L.H.)
19.Cooling fan motor (R.H.) with A/C>
20.Cooling fan shroud
RADIA T OR
ENGINE COOLING14-34
REMOV A L SER VICE POINT
<> RADIAT OR UPPER HOSE/RADIA-
TO R LOW E R HOSE DISCONNECTION
AC200641AC
Mating marks
Make mating marks on the rad i ator hose and th e
hose
cla m p. Disconnect the ra diat or hoses.
Cooling fan motor removal steps
(Continued)

RADIATOR
ENGINE COOLING14-35
INSTALLATION SERVICE POINT
>>A<< RADIATOR LOWER HOSE/RADIA-
TOR UPPER HOSE CONNECTION
AC200642
Mating marks
Projection
Cooling water hose fitting
or thermostat case assembly
AK
Radiator hose
1.In sert ra diato r lower h o se as fa r as th e projection
o f the cooling wate r inlet hose fit t ing.
2.In sert radia t or up per h o se as far a s t he pro j ection
o f the th ermost at ca se asse mbly .
3.Align th e ma ting marks on the rad i ator hose and
h o se clamp, an d then conn ect the radiator h o se.
REMOVA L AND INST ALLA TION <4G6>
M11 4100 1501 17 1
Pre-removal and Post-installation Operation
•Engine Coolant Draining and Supplying (Refer to
P.14-21).
•Air Cleaner Assembly Removal and Installation (Refer to
GROUP 15
P.15-3).
AC504783
1
12 ± 2 N·m
10
2
3
4
5
6
7
8
9
9
10
11 13
15
18
16
17
12
AB
5.4 ± 0.4 N·m
Radiator removal steps
1.Drain plug
2.Radiator cap
3.Radiator condenser tank hose
4.Radiator condenser tank assembly
<>>>A<<5.Radiator upper hose
<>>>A<<6.Radiator lower hose
7.Cooling fan motor drive control unit
connector
8.T/M oil cooler line hose connection

9.Radiator support upper insulator
•Radiator and cooling fan motor &
shroud assembly
10.Radiator support lower insulator
11 .T/M oil cooler line hose
Radiator removal steps

16-1
GROUP 16
ENGINE
ELECTRICAL
CONTENTS
CHARGING SYSTEM . . . . . . . .16-2
GENERAL INFORMATION . . . . . .16-2
SERVICE SPECIFICATIONS. . . . .16-3
SPECIAL TOOL . . . . . . . . . . . . . . .16-3
ON-VEHICLE SERVICE. . . . . . . . .16-3
ALTERNATOR OUTPUT LINE VOLTAGE
DROP TEST . . . . . . . . . . . . . . . . . . . . . 16-3
OUTPUT CURRENT TEST . . . . . . . . . . 16-5
REGULATED VOLTAGE TEST . . . . . . . 16-7
WAVEFORM CHECK USING AN
OSCILLOSCOPE . . . . . . . . . . . . . . . . . . 16-9
ALTERNATOR ASSEMB LY . . . . .16-12
REMOVAL AND INSTALLATION
<4G1> . . . . . . . . . . . . . . . . . . . . . . . . . . 16-12
REMOVAL AND INSTALLATION
<4G6> . . . . . . . . . . . . . . . . . . . . . . . . . . 16-13
DISASSEMBLY AND REASSEMBLY . . 16-15
INSPECTION . . . . . . . . . . . . . . . . . . . . . 16-17
STARTING SYSTEM . . . . . . . . .16-19
GENERAL INFORMATION . . . . . .16-19
SERVICE SPECIFICATIONS. . . . .16-20
STARTER MOTOR ASSEMBLY . .16-21
REMOVAL AND INSTALLATION
<4G1> . . . . . . . . . . . . . . . . . . . . . . . . . . 16-21
REMOVAL AND INSTALLATION
<4G6> . . . . . . . . . . . . . . . . . . . . . . . . . . 16-22
STARTER MOTOR ASSEMBLY
INSPECTION . . . . . . . . . . . . . . . . . . . . . 16-23
DISASSEMBLY AND REASSEMBLY . . 16-26
INSPECTION . . . . . . . . . . . . . . . . . . . . . 16-27
IGNITION SYSTEM . . . . . . . . . 16-30
GENERAL INFORMATION . . . . . .16-30
SERVICE SPECIFICATIONS . . . . .16-31
SPECIAL TOOL . . . . . . . . . . . . . . .16-31
ON-VEHICLE SERVICE . . . . . . . . .16-32
IGNITION COIL (WITH BUILT-IN
POWER TRANSISTOR) CHECK . . . . . . 16-32
RESISTIVE CORD CHECK . . . . . . . . . . 16-32
SPARK PLUG CHECK AND CLEANING
<4G1>. . . . . . . . . . . . . . . . . . . . . . . . . . . 16-32
SPARK PLUG CHECK AND CLEANING
<4G6>. . . . . . . . . . . . . . . . . . . . . . . . . . . 16-33
CAMSHAFT POSITION SENSOR
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . 16-33
CRANK ANGLE SENSOR CHECK . . . . 16-33
DETONATION SENSOR CHECK . . . . . 16-33
IGNITION SECONDARY VOLTAGE
WAVEFORM CHECK USING AN
OSCILLOSCOPE . . . . . . . . . . . . . . . . . . 16-33
IGNITION COIL RELAY CHECK . . . . . . 16-37
IGNITION COIL . . . . . . . . . . . . . . . .16-38
REMOVAL AND INSTALLATION
<4G1>. . . . . . . . . . . . . . . . . . . . . . . . . . . 16-38
REMOVAL AND INSTALLATION
<4G6>. . . . . . . . . . . . . . . . . . . . . . . . . . . 16-39
CAMSHAFT POSITION SENSOR .16-40
REMOVAL AND INSTALLATION . . . . . . 16-40
CRANKSHAFT POSITION SENSOR16-41
REMOVAL AND INSTALLATION
<4G1>. . . . . . . . . . . . . . . . . . . . . . . . . . . 16-41
REMOVAL AND INSTALLATION
<4G6>. . . . . . . . . . . . . . . . . . . . . . . . . . . 16-42
DETONATION SENSOR . . . . . . . .16-43
REMOVAL AND INSTALLATION . . . . . . 16-43

STARTING SYSTEM
ENGINE ELECTRICAL16-19
STARTING SYSTEM
GENERAL INFORMATIONM1162000100202
If the ignition switch is turned to the "START" posi-
tion, current flows in the pull-in and holding coils pro-
vided inside magnetic switch, attracting the plunger,
When the plunger is attracted, the lever connected to
the plunger is actuated to engage the starter clutch.
On the other hand, attracting the plunger will turn on
the magnetic switch, allowing the "B" terminal and
"M" terminal to conduct. Thus, current flows to
engage the starter motor.
When the ignition switch is returned to the "ON" posi-
tion after starting the engine, the starter clutch is dis-
engaged from the ring gear.
An overrunning clutch is provided between the pinion
and the armature shaft, to prevent damage to the
starter.
SYSTEM DIAGRAM
AK202970
Pull-in coilHolding coil
Plunger
Lever
Pinion gear
Overrunning clutch
Yo k e
Brush Armature
Ignition switch
Battery
+
–
AB
B
M S

STARTING SYSTEM
ENGINE ELECTRICAL16-23
STARTER MOTOR ASSEMBLY INSPECTION
M1162001100205
PINION GAP ADJUSTMENT
AK300648AB
<4G1>
Switch
S M
Wire Battery
Starter
motor
B
AKX01238
<4G6>
B
M S
battery Switch
Starter
motorWire
AG
1.
Disco nnect the field coil wire f r om th e M-te rmin al
of the magnet ic switch.
2.Conn ect a 12-volt b a ttery between the S-termina l
an d M-t e rminal.
CAUTION
This test must be performed quickly (in less than
10 seconds) to prevent the coil from burning.
3. Set the switch to "ON", and the pinion will move out.
AKX00198
Stopper
Pinion gap
Pinion
AC
4. Check the pinion-to-stopper clearance (pinion
gap) with a feeler gauge.
Standard value: 0.5 − 2.0 mm
AKX00199
5. If the pinion gap is out of specification, adjust by adding or removing gasket(s) between the
magnetic switch and front bracket.
MAGNETIC SWITCH PULL-IN TEST
AK300649AB
<4G1>
SM
Wire Battery
Starter
motor
B
AKX01242
<4G6>
SB
M
Battery
Starter
motorWire
AF
1. Disconnect the field coil wire from the M-terminal
of the magnetic switch.
CAUTION
This test must be performed quickly (in less than
10 seconds) to prevent the coil from burning.
2. Connect a 12-volt battery between the S-terminal and M-terminal.
3. If the pinion moves out, the pull-in coil is good. If it doesn't, replace the magnetic switch.

STARTING SYSTEM
ENGINE ELECTRICAL16-24
MAGNETIC SWITCH HOLD-IN TEST
AK300650AB
<4G1>S
B MWire
Battery
Starter
motor
AKX01244
<4G6>
SB
M
Battery
Starter
motorWire
AF
1.
Disco nnect the field coil wire f r om th e M-te rmin al
of the magnet ic switch.
CAUTION
This test must be performed quickly (in less than
10 seconds) to prevent the coil from burning.
2. Connect a 12-volt battery between the S-terminal and body.
3. Manually pull out the pinion as far as the pinion stopper position.
4. If the pinion remains out, everything is in order. If
the pinion moves in, the hold-in circuit is open.
Replace the magnetic switch.
FREE RUNNING TEST
AK300651AB
<4G1>
S
A
M
V
B
Carbon-pile rheostat
Battery
Voltmeter Ammeter
Starter
motor
AKX01246
<4G6> S
M B Ammeter
Carbon-pile
rheostat
Battery
Starter
motor Voltmeter
AF
A
V
1. Place the starter motor in a vise equipped with soft jaws and connect a fully-charged 12-volt
battery to the starter motor as follows:
2. Connect a test ammeter (100-ampere scale) and carbon pile rheostat in series between the battery
(+) terminal and starter motor terminal.
3. Connect a voltmeter (15-volt scale) across the starter motor.
4. Rotate the rheostat to full-resistance position.
5. Connect the battery c able from the battery (-)
terminal to the starter motor body.
6. Adjust the rheostat until the battery voltage shown
on the voltmeter is 11 V.
7. Confirm that the maximum amperage is within the specifications and that the starter motor turns
smoothly and freely.
Current:
<4G1> maximum 95 Amps
<4G6> maximum 90 Amps

STARTING SYSTEM
ENGINE ELECTRICAL16-25
MAGNETIC SWITCH RETURN TEST
AK300652AB
<4G1>S
B MWire
Battery
Starter
motor
AKX01248
<4G6>
SB
M
Battery
Starter
motorWire
AF
1.
Disco nnect the field coil wire f r om th e M-te rmin al
o f the magnet ic switch.
CAUTION
This test must be performed quickly (in less than
10 seconds) to prevent the coil from burning.
2. Connect a 12-volt battery between the M-terminal and body.
WARNING
Be careful not to ge t your fingers caught
when pulling out the pinion.
3. Pull the pinion out and release. If the pinion
quickly returns to its original position, everything is
operating properly. If it doesn't, replace the
magnetic switch.

ON-VEHICLE SERVICE
POWER STEERING37-14
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).
CAUTION
Perform air bleeding only while cranking the
engine. If air bleeding is performed while the
engine is running, air could enter the fluid. Dur
-
ing 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 wh ile 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 abnor
-
mal noises from the pump and the flow-control
valve, and this condition could cause reduce the
life of the power steering components.
ACX01131With engine running With engine stoppedAC
Fluid level change: Within 5 mm
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 TEST
M1372002300315
ACX01133
Temperature
gauge
Oil reservoir
Adapter
(MB991548)
Oil
pump Adapter
(MB991549)
AB
Shut-off valve
(fully closed)
Pressure
gauge
(MB990662)
1. Disconnect the pressure hose from the oil pump,
and then connect the following special tools.
•Power steering oil pressure gauge (MB990662)
•Power steering oil pressure gauge adapter (pump
side) (MB991548)
•Power steering oil pressure gauge adapter (hose
side) (MB991549)
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 750 ± 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.

TAILGATE
BODY42-48
TA I L G AT E
REMOVAL AND INSTALLATION
M1424001100178
CAUTION
•Do not disassemble or throw the tailgate gas spring into fire.
•Punch a hole in the gas spring before disposal to release the gas inside.
•
Pre-removal Operation
•Tailgate Spoiler Assembly Removal (Refer to GROUP 51,
Tailgate Spoiler
P.51-26).
•Tailgate Trim Assembly Removal (Refer to GROUP 52A,
Tailgate Trim
P.52A-21).
•Rear Wiper Motor Removal (R efer to GROUP 51, Rear
Wiper and Washer
P.51-36).
Post-installation Operation
•Tailgate Fit Adjustment (Refer to P.42-47).
•Rear Wiper Motor Installation (Refer to GROUP 51, Rear
Wiper and Washer P.51-36).
•Tailgate Trim Assembly Installation (Refer to GROUP
52A, Tailgate Trim P.52A-21).
•Tailgate Spoiler Assembly Installation (Refer to GROUP
51, Tailgate Spoiler P.51-26).
AC304836
7
3
4
1
6
8
12 ± 2 N·m 13 ± 2 N·m22 ± 4 N·m
AD
Sealant: 3M ATD Part No. 8633 or equivalent9.0 ± 2.0 N·m
2
712 ± 2 N·m
5
7
9
5.0 ± 1.0 N·m
3
10
Ensure the tailgate gas spring piston rod does not come into contact with foreign material.

ENGINE AND TRANSMISSION
CONFIGURATION DIAGRAMS80-14
ENGINE AND TRANSMISSION <4G1-MPI (RHD)>
M1801000401950
AC301132AD
B-02
B-03B-04 B-05
B-22
B-23
B-24
B-25
B-26
Control wiring
harnessB-09
Connector colour
code
B : Black
BR : Brown
G : Green
GR : Grey
L : Blue
None : Milk white
O : Orange
R : Red
V : Violet
Y : Yellow*
Connector
symbol
-01
thru
-26
B
Earth cable
B-01(5-GR)Windshield wiper motor
B-02(2-GR)Fuel injector 1
B-03(2-GR)Fuel injector 2
B-04(2-GR)Fuel injector 3
B-05(2-GR)Fuel injector 4
B-06(3-GR)Throttle body throttle sensor
B-07(3-B)Vehicle speed sensor
B-09(2-GR)Brake fluid level indicator switch
B-10X(1)Engine speed detection connector
B-14X(4)Ignition coil relay
B-15X(4)A/T control relay
B-16X(4)Engine control relay