group 90 MITSUBISHI LANCER 2006 Manual PDF

POWER STEERING GEAR BOX AND LINKAGE
POWER STEERING37-23
POWER STEERING GEAR BOX AND LINKAGE
REMOVAL AND INSTALLATIONM1372010900237
WARNING
Before removing the steering gear, refer to GROUP 52B, Service Precautions (P.52B-5) and
Air Bag Module and Clock Spring (P.52B-194). Centre the front wheels. Failure to do so may
damage the SRS clock spring and render the SRS system inoperative, risking serious injury.
Pre-removal Operation
•Power Steering Fluid Draining (Refer to P.37-13.)
Post-installation Operation
•Check the dust cover for cracks or damage by pushing it
with your finger.
•Power Steering Fluid Supplying (Refer to P.37-13.)
•Power Steering Fluid Line Bleeding (Refer to P.37-14.)
•Checking Steering Wheel Position with Wheels Straight
Ahead.
•Front Wheel Alignment Adjustment (Refer to GROUP 33,
On-vehicle Service
− Front Wheel Alignment Check and
Adjustment
P.33-6.)
AC304920 AB
57 ± 7 N·m
15 ± 3 N·m
70 ± 10 N·m
7
3
8
5
6
9
10 24
1
12 ± 2 N·m
12 ± 2 N·m

Removal steps
1.Crossmember (Refer to GROUP 32,
Crossmember
P.32-8).
•Engine rear roll stopper bracket (Refer
to GROUP 32, Engine Roll Stopper
and Centermember
P.32-7).
>>A<<2.Joint cover grommet
3.Return hose
4.Return tube
5.O-ring
6.Return tube
7.Eye bolt
8.Pressure hose assembly
9.Clamp
10.Steering gear and linkage
Removal steps (Continued)

AC304921AC
57 ± 7 N·m 15 ± 3 N·m
70 ± 10 N·m
3
5 2
4
1

67
Removal steps
1.Crossmember (Refer to GROUP 32,
Crossmember
P.32-8).
>>A<<2.Joint cover grommet
3.Return hose connection
4.Return tube
5.Pressure hose connection
6.Clamp
7.Steering gear and linkage
PO WE R STEER ING GEAR BOX AND LINK AGE
POWER ST E E RING37-24
INSTALLA T ION SER VICE POINT
>>A<< JOINT COVER GROMMET INST AL-
LATION
AC304922AB
A
B
Joint cover
grommet
Steering gear
Align the jo int cove r grommet n o tch (arrow A) with
the steerin
g gear lug (a rrow B), and t hen inst all the
steering joint
cover to th e ste e ring gear .
INSPECTIONM137201 10 0053 8
STEERING GEAR T O T A L PINION
T
O RQUE CHECK
CAUTION
When holding the steering gear in a vice, secure
its mounting positions. If it is secured in any
other place, the gear housing may become
deformed or damaged.
AC000996 AC
MB991006
Using special tool preload socket (MB991006), rotate
the pinion gear at the rate of one rotation in approxi
-
mately 4 to 6 seconds to check the total pinion
torque.
Standard value:
0.8 − 2.1
0.7 − 2.1
[Change in torque: 0.6 Nâ‹…m or less]

POWER STEERING OIL PUMP ASSEMBLY
POWER STEERING37-35
TIE ROD END BALL JOINT DUST COVER
REPLACEMENT
M1372008200327
If the dust cover is damaged accidentally during
service work, replace the dust cover as follows:
AC001012AB
MB990776
1.App l y specified grea se to the lip an d inside of the
d u st c o ve r .
Specified grease:
Mu l t i p u r po se g r ea se SAE J3 10 , NL GI No .2 or
equival
ent
2.Drive in the d u st cover with special tool f r ont axle
b a se (MB9907 76) unt il it is fully seated .
3.Check t he dust co ver f o r cracks or da mage by
p u shing it with your finger .
POWER STEERING OIL PUMP ASSEMBL Y
REMOVA L AND INST ALLA TIONM13720052 0029 8
Pre-removal Operation
•Power Steering Fluid Draining (Refer to P.37-13).
Post-installation Operation
•Power Steering Fluid Supplying and Bleeding (Refer to
P.37-14).
•Drive Belt Tension Check (1300, 1600: refer to GROUP
11A, On-vehicle Service
− Drive Belt Tension Check
P.11A-7/2000: refer to GROUP 11C, On-vehicle Service − Drive Belt Tension Check P.11C-7).
<1300, 1600>
AC209708
87
1 2
3 4
5
6
57 ± 7 N·m
40 ± 4 N·m
22 ± 4 N·m
N
9
40 ± 5 N·m
AC

POWER STEERING HOSES
POWER STEERING37-40
POWER STEERING HOSES
REMOVAL AND INSTALLATIONM1372005700679
CAUTION
•Before removing the clock spring, refer to GROUP 52B, Service Precautions (P.52B-5) and Air Bag
Module and Clock Spring (P.52B-194). Also, put the front wheels in straight-ahead position. Fail-
ure to do so may damage the SRS clock spring and render the SRS air bag inoperative, which
results serious driver injury.
•
Pre-removal and Post-installation Operation
•Power Steering Fluid Draining and Refilling (Refer to P.37-13). and Bleeding (Refer to P.37-14).
*: 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.

AC304699AB
15 ± 3 N·m
18 ± 2 N·m
167 ± 9 N·m
12 ± 2 N·m
49 ± 10 N·m
12 ± 2 N·m
57 ± 7 N·m*57 ± 7 N·m
3
1
2
9
1310
7 11
12
5 68
12 ± 2 N·m
12 ± 2 N·m
2
9
4
7
8
7
8
7
8
57 ± 7 N·m57 ± 7 N·m
57 ± 7 N·m
12 ± 2 N·m
167 ± 9 N·mCrossmember
12 ± 2 N·m
<1300, 1600>
<2000>
12 ± 2 N·m
Removal steps
1.Oil reservoir
>>C<<2.Suction hose
>>B<<3.Return hose
•Clock spring (Refer to GROUP 52B,
Air Bag Modules and Clock Spring
P.52B-194).
Removal steps (Continued)

POWER STEERING HOSES
POWER STEERING37-41

AC304698AB
15 ± 3 N·m18 ± 2 N·m
167 ± 9 N·m
12 ± 2 N·m
49 ± 10 N·m
12 ± 2 N·m
57 ± 7 N·m*
3
1
2 9
10
7
5
6
2 4
8 857 ± 7 N·m
167 ± 9 N·m
Crossmember 12 ± 2 N·m
<1300, 1600>
<2000>
7
6
57 ± 7 N·m
7
6
57 ± 7 N·m
7
6
57 ± 7 N·m
12 ± 2 N·m
•Centerme mbe r (Refe r to GROUP 3 2 ,
En
gin e Ro ll S t op pe r Ce nt er m e m b er
P.32-7).
•Front exha ust pi pe (Re f e r to GROUP
15
, Exhau st Pipe a nd Ma in Muf f ler
P.15-10).
4.St e e r i ng gea r a nd jo int co nn ectin g b o lt
5.Rear ro ll stopp er con n e c ting b o lt
6.Rear r o ll s t op pe r (Re f er t o GRO U P 32 ,
En
gin e Ro ll S t op pe r Ce nt er m e m b er
P.32-7).
<>7.Eye bolt
8.Gask et
9.Pressure hose ass e mbly
10.Return tu be
>>A<<11.Return hose
<>12.Return t u be
13.O-rin g
Remo va l st ep s ( C o n t i n u e d )

Removal steps
1.Oil reservoir
>>C<<2.Suction hose
>>B<<3.Return hose
•Clock spring (Refer to GROUP 52B,
Air Bag Modules and Clock Spring
P.52B-194).
•Centermember (Refer to GROUP 32,
Engine Roll Stopper Centermember
P.32-7).
•Front exhaust pipe (Refer to GROUP
15, Exhaust Pipe and Main Muffler
P.15-10).
4.Steering gear and joint connecting bolt
5.Rear roll stopper connecting bolt
<>6.Eye bolt
7.Gasket
8.Pressure hose assembly
<>9.Return tube
10.O-ring
POWE R STEERING HOSES
POWER S T E E RING37-42
REMOVA L SER V ICE POINT
<> EYE BOLT /RETURN TUBE
REMOV
A L
CAUTION
If the joint cover grommet has been removed,
install it properly as follows.
AC304922AB
A
B
Joint cover
grommet
Steering gear
Align the joint cover grommet notch (arrow A)
with the steering gear lug (arrow B), and then
install the steering joint cover to the steering
gear.
1. Loosen the crossmember mounting bolts and nuts, and lower the crossmember to a position so
that the eye bolts or return tube at the steering
gear side can be removed.
NOTE: In this case, do not remove the crossmem-
ber mounting bolts and nuts.
2. Remove the eye bolts or return tube.
INSTALLATION SERVICE POINTS
>>A<< RETURN HOSE INSTALLATION

AC100277 ABReturn hose
Install the return hose so that the marking is posi-
tioned as shown in the illustration.
>>B<< RETURN HOSE INSTALLATION
AC305132AB
Return hose
Return tubeReturn hose

Install the return hose so that the markings are posi-
tioned as shown in the illustration.
>>C<< SUCTION HOSE INSTALLATION
Install the suction hose (oil pump side) so that the
marking is positioned forward.

42-1
GROUP 42
BODY
CONTENTS
HOOD . . . . . . . . . . . . . . . . . . . . .42-3
ON-VEHICLE SERVICE. . . . . . . . .42-3
ADJUSTMENT OF CLEARANCE
AROUND HOOD . . . . . . . . . . . . . . . . . . 42-3
ADJUSTMENT OF ALIGNMENT OF
HOOD STEPPED PORTION AND
HOOD STRIKER . . . . . . . . . . . . . . . . . . 42-3
ADJUSTMENT OF HOOD HEIGHT . . . 42-3
HOOD . . . . . . . . . . . . . . . . . . . . . . .42-4
REMOVAL AND INSTALLATION . . . . . 42-4
FENDER . . . . . . . . . . . . . . . . . . .42-5
SPECIAL TOOL . . . . . . . . . . . . . . .42-5
FENDER . . . . . . . . . . . . . . . . . . . . .42-6
REMOVAL AND INSTALLATION . . . . . 42-6
FUEL FILLER LID . . . . . . . . . . .42-8
REMOVAL AND INSTALLATION .42-8
STRUT TOWER BAR . . . . . . . .42-9
REMOVAL AND INSTALLATION .42-9
WINDOW GLASS . . . . . . . . . . . 42-10
ADHESIVE . . . . . . . . . . . . . . . . . . .42-10
SPECIAL TOOLS . . . . . . . . . . . . . .42-10
WINDOW REPAIR . . . . . . . . . . . . .42-10
WINDSHIELD . . . . . . . . . . . . . . . . .42-12
REMOVAL AND INSTALLATION . . . . . . 42-12
REAR WINDOW GLASS
. . . . . . . . . . . . . . . . . . . .42-17
REMOVAL AND INSTALLATION . . . . . . 42-17
QUARTER WINDOW GLASS
. . . . . . . . . . . . . . . . . . .42-20
REMOVAL AND INSTALLATION . . . . . . 42-20
TAILGATE WINDOW GLASS
. . . . . . . . . . . . . . . . . . .42-23
REMOVAL AND INSTALLATION . . . . . . 42-23
DOOR . . . . . . . . . . . . . . . . . . . . 42-25
SERVICE SPECIFICA TIONS . . . . .42-25
SEALANT . . . . . . . . . . . . . . . . . . . .42-25
SPECIAL TOOLS . . . . . . . . . . . . . .42-26
Continued on next page

HOOD
BODY42-4
HOOD
REMOVAL AND INSTALLATION
M1421001600561
Post-installation Operation
•Adjustment of Clearance Around Hood (Refer to P.42-3).
•Adjustment of Alignment of Hood Stepped Portion and
Hood Striker (Refer to
P.42-3).
•Adjustment of Hood Height (Refer to P.42-3).
AC304739
1
1
2 2
4 4
5
6
7 3
8
910
AD9.0 ± 2.0 N·m 21 ± 4 N·m
11 ± 2 N·m
21 ± 4 N·m
Removal
1.Hood bumper
2.Hood latch
3.Hood weatherstrip
Hood lock release cable removal
steps

4.Hood lock release handle
5.Hood lock release cable
Hood and hood hinge removal
steps

6.Hood insulator
7.Hood weatherstrip
•Washer hose (Refer to GROUP 51,
Windshield wiper and washer
P.51-31.)
8.Hood
9.Hood support rod
10.Hood hinge

FENDER
BODY42-6
FENDER
REMOVAL AND INSTALLATION
M1421001900302
Pre-removal and Post-installation Operation
•Front Bumper Removal and Installation (Refer to GROUP
51, Front Bumper P.51-3.)
•Front Deck Garnish Removal and Installation (Refer to
GROUP 51, Windshield Wiper and Washer P.51-31.)
•Side Air Dam Removal and Installation side air dam> (Refer to GROUP 51, Side Air Dam
P.51-14.)
AC300491AC304753
AC303863
Clip
Section A – A
AB
A A
1
23
3
4
Note
: Clip positions
Removal steps
1.Splash shield
<>>>A<<2.Side turn-signal lamp
3.Delta outer garnish
4.Fender
Removal steps (Continued)

FUEL FILLER LID
BODY42-8
FUEL FILLER LID
REMOVAL AND INSTALLATIONM1421002500277
Pre-removal and Post-installation Operation
•Rear Seat Removal and Installation (Refer to GROUP
52A, Rear Seat
P.52A-30.)
•Front Scuff Plate (Driver's Seat Side), Rear Scuff Plate
(Driver's Side), Centre Pillar Lower Trim (Driver's Side),
Quarter Trim (Driver's Side) Removal and Installation
(Refer to GROUP 52A, Trims
P.52A-13.)
18M0109 W0570AQ
AC005996
AC005973
3
5 4
3
2
1
5.0 ± 1.0 N·m
AC
Fuel filler lid height and clearance
adjustment
Removal steps
1.Fuel filler lid panel assembly
2.Clip
3.Fuel filler lid hook assembly
4.Fuel filler lid lock release cable
5.Fuel filler lid lock release handle
Removal steps (Continued)