Manual MITSUBISHI LANCER IX 2006 Service Manual

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

22-1
GROUP 22
MANUAL
TRANSMISSION
CONTENTS
MANUAL TRANSMISSION (FF) . . . . . . . . . . . . . . . . . . . . . . . . .22A
MANUAL TRANSMISSION OVERHAUL . . . . . . . . . . . . . . . . . .22B

TROUBLESHOOTING
WHEEL AND TYRE31-4
WHEEL BALANCE ACCURACY
M1311001700247
PURPOSE
This section contains tips and procedures for achiev-
ing accurate wheel balance. Steering wheel vibration
and/or body shake can result if any of these proce
-
dures 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 instruc
-
tion manual should include calibration procedures. If
the calibration procedures specifically for your bal
-
ancer are missing, use the generic steps in this sec-
tion 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
wear
ACX00934
Lack of rot a tio n of tyres or worn
or out-of-a
lign m ent suspensionRota te th e tyre s, an d
check the f
r ont or
rea
r suspension
alignment
s.
Refer to GROUP
33
, On -vehicle
serv
ic e
− Front
whee
l alignment
check and
ad
justmen t
P.33-6.

Refer to GROUP
34
, On -vehicle
serv
ic e
− Rear
whee
l alignment
check and
ad
justmen t
P.34-6.
Sy mptom P robable cause Reme dy Referen ce p a g e

33-1
GROUP 33
FRONT
SUSPENSION
CONTENTS
GENERAL INFORMATIO N . . . . . . . .33-2
SERVICE SPECIFICATIONS . . . . . . .33-3
LUBRICANT . . . . . . . . . . . . . . . . . . . .33-3
SPECIAL TOOLS . . . . . . . . . . . . . . . .33-4
ON-VEHICLE SERVICE . . . . . . . . . . .33-6
FRONT WHEEL ALIGNMENT CHECK AND
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 33-6
LOWER ARM BALL JOINT AXIAL PLAY
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-7
LOWER ARM BALL JOINT COVER
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-7
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. . . . . . . . . . . . . . . . . . . . . . . . 33-16
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 inad vertent 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
PARKING BRAKES36-2
GENERAL INFORMATION
M1361000100496
The parking brake is of a mechanical rear-wheel act-
ing type, and its operation utilises a parking brake
lever.
SPECIFICATIONS
ItemSpecification
Ty p eDrum-in disc
Clearance adjustmentManual
CONSTRUCTION DIAGRAM
AC211553
AC104333
AC304152
Parking brake lever assembly
Parking brake cable
AB
Drum-in-disc brake
SERV ICE SPECI F ICA T IONS
M13610003 0038 2
ItemStandard valueLimit
Parking brake lever stroke (Operation force: Approximately 200 N)5 − 7 notches−
Rear brake lining thickness mm2.81.0
Rear drum inside diameter mm168.0169.0

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 . . . . . . . . . . . . . . . . . . . . 37-13
DRIVE BELT TENSION CHECK. . . . . . . . . 37-13
FLUID LEVEL CHECK . . . . . . . . . . . . . . . . 37-13
FLUID REPLACEMENT . . . . . . . . . . . . . . . 37-13
POWER STEERING SYSTEM AIR
BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . 37-14
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
. . . . . . . . . . . . . . . . . . . . . . . . . 37-18
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 inad vertent firing of the air bag) or to the driver and
paassenger (from renderin g 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 th is manual, and especially its GROUP 52B - Supplemental
Restraint System (SRS) before begi nning 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 (*).

AC304537
JK*
AE
ECU
COMPONENT LOCA TIONS70-3
NOTE: *: also eq uipp ed on the rear doors.
AC100209AC
A
ABS-ECU

Hydraulic unit
AC206790
A
AD
ABS-ECU
Hydraulic unit

AC301728AB
BFront-ECU
Battery
AC300571
C
ACRadiator fan
Cooling fan motor
drive control unit
AC301746
DColumn switch
(incorporating
column-ECU)
AB
AC501783AB
E
Heater control unit
or A/C-ECU

AC501828AB
I
Rocker cover
<4G6>
Water temperature
sensor unit
AC206775AF
J
Input shaft
speed sensor
Output shaft
speed sensor
Air cleaner
bracket
AC501788AB
K
Inside air
temperature
sensor
AC501789
AB
L
Photo sensor
AC501786
AB
M
Air thermo
sensor
Heater unit
AC501787AB
M
Air thermo
sensor
Heater
unit
Heater water
temperature
sensor
AC300517 AJ
N
Side impact
sensor (Front)
Centre
pillar
AC300534
AI
O
Side impact
sensor (Rear)
Rear
seat belt
SENSOR
COMPONENT LOCA TIONS70-9

DASH PANEL
CONFIGURATION DIAGRAMS80-28
DASH PANEL (CONTINUED)
AC502053
C-140C-102
C-103
C-141
C-101
C-132
C-139
C-148
C-130
C-146C-145
Y
4
Connector
symbol
-101
thru
-149
C
Connector colour
code
B : Black
BR : Brown
G : Green
GR : Grey
L : Blue
None : Milk white
O : Orange
R : Red
V : Violet
Y : Yellow
Instrument panel
wiring harness
C-131
C-133
C-147
AB
C-101(4)Hazard warning lamp switch
C-102(4)Clock
C-103(22-GR)J/C (1)
C-104(22-GR)J/C (3)
C-106(7)Instrument panel wiring harness and A/C
wiring harness combination A/C>
C-107(7)Outside /Inside air selection damper
control motor
C-108(2-R)Air bag module (squib) side>
C-109(4)Resistor
C-110(2)Blower motor
C-112(16)Instrument panel wiring harness and front
door wiring harness (RH) combination
C-114(25)Front wiring harness (RH) and instrument
panel wiring har
ness combination
C-116(9-GR*)Instrument panel wiring harness and floor
wiring harness (RH) combination
C-119(13)Instrument panel wiring harness and floor
wiring harness (RH) combination
C-122(35-GR)Engine-A/T-ECU
C-123(26-Y)Engine-ECU
C-124(26-GR)Engine-A/T-ECU
C-125(16-Y)Engine-ECU
C-126(28-GR)Engine-A/T-ECU
C-127(12-Y)Engine-ECU
C-128(30-GR)Engine-A/T-ECU
C-129(22-Y)Engine-ECU
C-130(4)Engine control oxygen sensor (Rear)
C-131(20-Y)SRS-ECU

DASH PANEL
CONFIGURATION DIAGRAMS80-34
DASH PANEL (CONTINUED)
AC502057
Y
16
C-105
C-106
C-143
C-107
C-108
A/C wiring
harness
C-109
C-149
C-110
C-144
C-111
C-113
C-115
C-117
Instrument panel
wiring harness
Control wiring
harness
C-118 C-120
C-121C-128
C-129 C-126
C-127C-124
C-125
C-122
C-123
Connector colour
code
B : Black
BR : Brown
G : Green
GR : Grey
L : Blue
None : Milk white
O : Orange
R : Red
V : Violet
Y : Yellow
3
Connector
symbol
-101
thru
-149
C
Antenna
feeder
cable
AB
C-142
C-101(4)Hazard warning lamp switch
C-102(4)Clock
C-103(22-GR)J/C (1)
C-105(13)J/C (5)
C-106(7)Instrument panel wiring harness and A/C
wiring harness combination A/C>
C-107(7)Outside /Inside air selection damper
control motor
C-108(2-R)Air bag module (squib) side>
C-109(4)Resistor <
C-110(2)Blower motor
C-111(12)Front wiring harness (LH) and control
wiring harness combination
C-113(16)Instrument panel wiring harness and front
door wiring harness (LH) combination
C-115(25)Front wiring harness (LH) and instrument
panel wiring harn
ess combination
C-117(11-B*)Instrument panel wiring harness and floor
wiring harness (LH) combination
C-118(6-L)Instrument panel wiring harness and floor
wiring harness (LH) combination
C-120(13)Instrument panel wiring harness and floor
wiring harness (LH) combination
C-121(3)Front wiring harness (LH) and instrument
panel wiring harness combination
C-122(35-GR)Engine-A/T-ECU
C-123(26-Y)Engine-ECU
C-124(26-GR)Engine-A/T-ECU
C-125(16-Y)Engine-ECU
C-126(28-GR)Engine-A/T-ECU
C-127(12-Y)Engine-ECU
C-128(30-GR)Engine-A/T-ECU
C-129(22-Y)Engine-ECU
C-134(33)J/C (6)
C-135(22-L)Instrument panel wiring harness and
control wiring harness combination