2005 MITSUBISHI LANCER Workshop Manual

GROUP INDEX
00General . . . . . . . . . . . . . . . . . . . . . . . .
11Engine. . . . . . . . . . . . . . . . . . . . . . . . .
12Engine Lubrication . . . . . . . . . . . . . .
13Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . .
14Engine Cooling . . . . . . . . . . . . . . . . .
15Intake and Exhaust . . . . . . . . . . . . . .
16Engine Electrical . . . . . . . . . . . . . . . .
17Engine and Emission Control . . . . .
21Clutch . . . . . . . . . . . . . . . . . . . . . . . . .
22Manual Transmission . . . . . . . . . . . .
23Automatic Transmission. . . . . . . . . .
26Front Axle . . . . . . . . . . . . . . . . . . . . . .
27Rear Axle . . . . . . . . . . . . . . . . . . . . . .
31Wheel and Tyre . . . . . . . . . . . . . . . . .
32Power Plant Mount . . . . . . . . . . . . . .
33Front Suspension . . . . . . . . . . . . . . .
34Rear Suspension . . . . . . . . . . . . . . . .
35Service Brakes . . . . . . . . . . . . . . . . . .
36Parking Brakes . . . . . . . . . . . . . . . . .
37Power Steering . . . . . . . . . . . . . . . . .
42Body . . . . . . . . . . . . . . . . . . . . . . . . . .
51Exterior . . . . . . . . . . . . . . . . . . . . . . . .
52 . . . . . . . . . .
54Chassis Electrical . . . . . . . . . . . . . . .
55 . . . . . . .
70Component Locations. . . . . . . . . . . .
80Configration Diagrams . . . . . . . . . . .
90Circuit Diagrams . . . . . . . . . . . . . . . .

LANCER /
LANCER WAGON
WORKSHOP MANUAL
FOREWORD
This Workshop manual contains procedures for
service mechanics, including removal, disassembly,
inspection, adjustment, reassembly and installation.
Use the following manuals in combination with this
manual as required.
TECHNICAL INFORMATION MANUAL
PYME0302
PYME0302-A
WORKSHOP MANUAL
CHASSIS GROUP PWME0302
BODY REPAIR MANUAL
PBME0302
PBME0302-A
PARTS CATALOGUE
B606K005A_
All information, illustrations and product descriptions
contained in this manual are current as at the time of
publication. We, however, reserve the right to make
changes at any time without prior notice or obligation.
Mitsubishi Motors Corporation May 2004
Heater, Air Conditioner and
Ventilation Interior and Supplemental
Restraint System (SRS)

WARNINGS REGARDING SERVICING OF SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) EQUIPPED VEHICLES
(1) 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 passenger (from rendering the SRS inoperative).
(2) The SRS components and seat belt with pretensioner should not be subjected to heat, so
remove the SRS-ECU, driver’s and front passenger’s air bag modules, clock spring, side air bag
modules, and seat belt -pre-tensioner before drying or baking the vehicle after painting.
• SRS-ECU, air bag module and clock spring 93°C or more
• Seat belt with pre-tensioner: 90°C or more
(3) Service or maintenance of any SRS component or SRS-related component must be performed
only at an authorized MITSUBISHI dealer.
(4) 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
Section titles with asterisks (*) in the table of contents in each group indicate operations requiring warnings.

00-1
GROUP 00
GENERAL
CONTENTS
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .00
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .00E

NOTES

11-1
GROUP 11
ENGINE
CONTENTS
ENGINE MECHANICAL <4G1> . . . . . . . . . . . . . . . . . . . . . . . . .11A
ENGINE OVERHAUL <4G1> . . . . . . . . . . . . . . . . . . . . . . . . . . .11B
ENGINE MECHANICAL <4G6> . . . . . . . . . . . . . . . . . . . . . . . . .11C
ENGINE OVERHAUL <4G6> . . . . . . . . . . . . . . . . . . . . . . . . . . .11D

NOTES

12-1
GROUP 12
ENGINE
LUBRICATION
CONTENTS
GENERAL INFORMATION . . . . . . . .12-2
SERVICE SPECIFICATION . . . . . . . .12-2
LUBRICANT . . . . . . . . . . . . . . . . . . . .12-2
SEALANT . . . . . . . . . . . . . . . . . . . . . .12-3SPECIAL TOOLS . . . . . . . . . . . . . . . .12-3
ON-VEHICLE SERVICE . . . . . . . . . . .12-4
ENGINE OIL CHECK . . . . . . . . . . . . . . . . . 12-4
ENGINE OIL REPLACEMENT . . . . . . . . . . 12-4
ENGINE OIL FILTER REPLACEMENT . . . . 12-4
OIL PRESSURE CHECK . . . . . . . . . . . . . . 12-5

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