2005 MITSUBISHI LANCER head

TA I L G AT E
BODY42-47
NOTE:
When the bolt head interferes with the rear end
trim, rasp the interference area with a round file.4. If uneven clearance is present between tailgate
and body, reposition the hinge to adjust the
clearance.
TAILGATE HANDLE PLAY CHECKM1424002400138
1. Check the tailgate handle play.
Standard value (B): 2.3 − 5.9 mm
2. If it deviates from the standard value, remove the
lower tailgate trim (Refer to GROUP 52A, tailgate
trim P.52A-19) and waterproof film (Refer to
P.42-48).
3. Remove the holder from the tailgate handle and
adjust according to the tailgate latch rod and
tailgate handle connection position.
AC203660AB
Grind here
AC201556
AC103270
A
ASection A – A
RodHolder
B
AC

51-1
GROUP 51
EXTERIOR
CONTENTS
FRONT BUMPER ASSEMBLY . . . . .51-2
ADHESIVE . . . . . . . . . . . . . . . . . . . . . . . . . 51-2
FRONT BUMPER ASSEMBLY . . . . . . . . . . 51-2
REMOVAL AND INSTALLATION . . . . . . . . 51-2
DISASSEMBLY AND REASSEMBLY . . . . . 51-3
REAR BUMPER ASSEMBLY . . . . . .51-5
REMOVAL AND INSTALLATION . . . . . . . . 51-5
DISASSEMBLY AND REASSEMBLY . . . . . 51-7
MOULDINGS . . . . . . . . . . . . . . . . . . .51-9
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . 51-9
ADHESIVE . . . . . . . . . . . . . . . . . . . . . . . . . 51-9
MOULDINGS . . . . . . . . . . . . . . . . . . . . . . . 51-10
REMOVAL AND INSTALLATION . . . . . . . . 51-10
SIDE AIR DAM . . . . . . . . . . . . . . . . . .51-15
ADHESIVE . . . . . . . . . . . . . . . . . . . . . . . . . 51-15
SIDE AIR DAM . . . . . . . . . . . . . . . . . . . . . . 51-15
REMOVAL AND INSTALLATION . . . . . . . . 51-15
GARNISHES . . . . . . . . . . . . . . . . . . .51-17
REMOVAL AND INSTALLATION . . . . . . . . 51-17
REAR SPOILER . . . . . . . . . . . . . . . . .51-18
REMOVAL AND INSTALLATION . . . . . . . . 51-18
TAILGATE SPOILER . . . . . . . . . . . . .51-19
REMOVAL AND INSTALLATION . . . . . . . . 51-19
ROOF RAIL . . . . . . . . . . . . . . . . . . . .51-20
REMOVAL AND INSTALLATION . . . . . . . . 51-20
WINDSHIELD WIPER AND WASHER51-21
GENERAL INFORMATION . . . . . . . . . . . . . 51-21
SERVICE SPECIFICATION . . . . . . . . . . . . 51-22TROUBLESHOOTING . . . . . . . . . . . . . . . . 51-22
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . 51-22
WINDSHIELD WIPER AND WASHER . . . . 51-23
REMOVAL AND INSTALLATION . . . . . . . . 51-23
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 51-25
REAR WIPER AND WASHER . . . . . .51-28
GENERAL INFORMATION . . . . . . . . . . . . . 51-28
SERVICE SPECIFICATION . . . . . . . . . . . . 51-28
TROUBLESHOOTING . . . . . . . . . . . . . . . . 51-28
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . 51-28
REAR WIPER AND WASHER . . . . . . . . . . 51-29
REMOVAL AND INSTALLATION . . . . . . . . 51-29
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 51-30
HEADLAMP WASHER . . . . . . . . . . . .51-32
TROUBLESHOOTING . . . . . . . . . . . . . . . . 51-32
HEADLAMP WASHER . . . . . . . . . . . . . . . . 51-32
REMOVAL AND INSTALLATION . . . . . . . . 51-32
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 51-33
MARK . . . . . . . . . . . . . . . . . . . . . . . . .51-34
REMOVAL AND INSTALLATION . . . . . . . . 51-34
DOOR MIRROR . . . . . . . . . . . . . . . . .51-36
GENERAL INFORMATION . . . . . . . . . . . . . 51-36
SERVICE SPECIFICATION . . . . . . . . . . . . 51-36
SPECIAL TOOL. . . . . . . . . . . . . . . . . . . . . . 51-36
TROUBLESHOOTING . . . . . . . . . . . . . . . . 51-36
DIAGNOSIS TROUBLESHOOTING
FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51-36
TROUBLE SYMPTOM CHART . . . . . . . . . . 51-36
SYMPTOM PROCEDURES . . . . . . . . . . . . 51-37
DOOR MIRROR . . . . . . . . . . . . . . . . . . . . . 51-45
REMOVAL AND INSTALLATION . . . . . . . . 51-45
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 51-47

HEADLAMP WASHER
EXTERIOR51-32
HEADLAMP WASHER
TROUBLESHOOTINGM1511000700356
The headlamp washer is controlled by the Smart
Wiring System (SWS). For troubleshooting, refer to
GROUP 54B, Troubleshooting P.54B-17 or GROUP
54C, Troubleshooting P.54C-4.
HEADLAMP WASHER
REMOVAL AND INSTALLATIONM1511009700063
AC304608AB
10N
2
4
56
8
7
1
9
11
9
1
10N
4.9 ± 0.7 N·m 4.9 ± 0.7 N·m
3
Removal steps
•Washer fluid draining
1. Headlamp washer hose connection
2. Under cover side panel (R.H)
3. Splash shield mounting clip (R.H)4. Headlamp washer motor
connection
5. Headlamp washer joint
6. Headlamp washer hose Removal steps (Continued)

HEADLAMP WASHER
EXTERIOR51-33
INSPECTIONM1511009800082
HEADLAMP WASHER MOTOR CHECK
1. Remove the headlamp washer motor connector.
2. Check to see that the water is vigorously sprayed
when connecting the positive battery terminal to
terminal number 1 and terminal number 2 to the
negative battery terminal.
7. Headlamp washer motor
8. Headlamp washer gasket
•Front bumper (Refer to P.51-2).
9. Headlamp washer actuator
assembly
10. O-ring
11. Headlamp washer hose assembly Removal steps (Continued)
AC304136AB
12

54A-2
COMBINATION METER
ASSEMBLY . . . . . . . . . . . . . . . .
54A-29
SERVICE SPECIFICATIONS. . . . .
54A-29
SEALANT. . . . . . . . . . . . . . . . . . . .54A-29
SPECIAL TOOLS. . . . . . . . . . . . . .54A-29
TROUBLESHOOTING . . . . . . . . . .54A-31
SYMPTOM CHART . . . . . . . . . . . . . . . . 54A-31
SYMPTOM PROCEDURES . . . . . .54A-32
ON-VEHICLE SERVICE. . . . . . . . .54A-60
SPEEDOMETER CHECK . . . . . . . . . . . 54A-60
TACHOMETER CHECK . . . . . . . . . . . . 54A-60
FUEL TANK GAUGE UNIT CHECK . . . 54A-61
ENGINE COOLANT TEMPERATURE GAUGE
UNIT CHECK . . . . . . . . . . . . . . . . . . . . . 54A-61
COMBINATION METER ASSEMBLY54A-63
REMOVAL AND INSTALLATION . . . . . 54A-63
INSPECTION . . . . . . . . . . . . . . . . . . . . . 54A-64
DISASSEMBLY AND REASSEMBLY . . 54A-65
HEADLAMP . . . . . . . . . . . . . . . .54A-66
SERVICE SPECIFICATIONS. . . . .
54A-66
TROUBLESHOOTING . . . . . . . . . .54A-66
ON-VEHICLE SERVICE. . . . . . . . .54A-66
HEADLAMP AIMING . . . . . . . . . . . . . . . 54A-66
LUMINOUS INTENSITY
MEASUREMENT . . . . . . . . . . . . . . . . . . 54A-67
BULB REPLACEMENT . . . . . . . . . . . . . 54A-68
HEADLAMP . . . . . . . . . . . . . . . . . .54A-69
REMOVAL AND INSTALLATION . . . . . 54A-69
HEADLAMP LEVELING SWITCH .54A-70
REMOVAL AND INSTALLATION . . . . . 54A-70
INSPECTION . . . . . . . . . . . . . . . . . . . . . 54A-70
FOG LAMP . . . . . . . . . . . . . . . . 54A-71
SERVICE SPECIFICATION . . . . . .
54A-71
SPECIAL TOOL . . . . . . . . . . . . . . .54A-71
TROUBLESHOOTING . . . . . . . . . .54A-71
ON-VEHICLE SERVICE . . . . . . . . .54A-71
FRONT FOG LAMP AIMING CHECK . . 54A-71
FOG LAMP . . . . . . . . . . . . . . . . . . .54A-73
REMOVAL AND INSTALLATION . . . . . . 54A-73
FOG LAMP SWITCH . . . . . . . . . . .54A-74
REMOVAL AND INSTALLATION . . . . . . 54A-74
INSPECTION . . . . . . . . . . . . . . . . . . . . . 54A-74
REAR FOG LAMP . . . . . . . . . . 54A-75
TROUBLESHOOTING . . . . . . . . . .
54A-75
SPECIAL TOOL . . . . . . . . . . . . . . .54A-75
REAR FOG LAMP . . . . . . . . . . . . .54A-76
REMOVAL AND INSTALLATION . . . . . . 54A-76
REAR FOG LAMP SWITCH . . . . . .54A-76
REMOVAL AND INSTALATION . . . . . . . 54A-76
INSPECTION . . . . . . . . . . . . . . . . . . . . . 54A-76
SIDE TURN-SIGNAL LAMP. . . 54A-77
SPECIAL TOOL . . . . . . . . . . . . . . .
54A-77
SIDE TURN-SIGNAL LAMP . . . . . .54A-77
REMOVAL AND INSTALLATION . . . . . . 54A-77
ROOM LAMP . . . . . . . . . . . . . . 54A-78
TROUBLESHOOTING . . . . . . . . . . . . . . 54A-78
Continued on next page

BATTERY
CHASSIS ELECTRICAL54A-5
BATTERY TESTM1541001200506
BATTERY TESTING PROCEDURE
STEP 1. Check the battery cables.
Remove the negative cable, then the positive cable.
Check for dirty or corroded connections.
Q: Are the battery cables dirty or have corroded
connections?
YES :
Clean the battery cables. Then go to Step 2.
NO : Go to Step 2.
STEP 2. Check the battery post.
Check for loose battery post.
Q: Are the battery post faulty?
YES :
Replace the battery. Then go to Step 4.
NO : Go to Step 3.
STEP 3. Check the battery case and cover.
(1) Remove the hold-downs and shields.
(2) Check for broken/cracked case or cover.
Q: Is the battery case or cover faulty?
YES :
Replace the battery. Then go to Step 4.
NO : Go to Step 4.
STEP 4. Check the open circuit voltage.
(1) Turn headlamps on for 15 seconds.
(2) Turn headlamps off for two minutes to allow
battery positive voltage to stabilize.
(3) Disconnect the battery cables.
(4) Read open circuit voltage.
Q: Is open circuit voltage 12.4 volts or more?
YES :
Go to Step 6.
NO : Go to Step 5.
STEP 5. Charge battery.
Q: Charging the battery?
YES :
Go to Step 6.
NO : Charge the battery at 5 amps for 15 hours.
Then re-test, go to Step 4.
STEP 6. Check the load test.
(1) Connect a load tester to the battery.
(2) Load the battery at the recommended discharge
rate (See LOAD TEST RATE CHART) for 15
seconds.
(3) Read voltage after 15 seconds, then remove
load.
(4) Compare the measured value with the minimum
voltage. (See LOAD TEST CHART.)
Q: Is the voltage higher than minimum voltage?
NO :
Replace the battery. Then go to Step 4.
YES : The battery is normal.
LOAD TEST RATE CHART
LOAD TEST CHARTBattery type 55D23L 75D23L
Charging time when fully discharged h
(5-amp. rated current charging)11 11
Load test (Amps) 260 260
Temperature °C 21 and
above16 10 4
−1−7−12−18
Minimum voltage 9.6 9.5 9.4 9.3 9.1 8.9 8.7 8.5

IGNITION SWITCH
CHASSIS ELECTRICAL54A-28
REMOVAL SERVICE POINT
<> STEERING LOCK CYLINDER
REMOVAL
1. Insert the key in the steering lock cylinder and turn
it to the "ACC" position.
2. Using a small Phillips head screwdriver, pull the
steering lock cylinder toward you.
INSPECTIONM1544009700203
IGNITION SWITCH CONTINUITY CHECK
Disconnect ignition switch connector C-201 without
removing the ignition switch. Then check the
continuity.
KEY REMINDER SWITCH CONTINUITY
CHECK
Disconnect key reminder switch connector C-202
without removing the ignition switch and key
reminder switch. Then check the continuity.
AC304831AB
Locking pin
AC304833AB
Switch
position Tester
connectionSpecified
condition
"LOCK" (OFF) 1 − 2, 1 − 3,
1 − 4, 1− 5,
1 − 6, 2 − 3,
2 − 4, 2− 5,
2 − 6, 3 − 4,
3 − 5, 3 − 6,
4 − 5, 4 − 6,
5 − 6Open circuit
"ACC" 1 − 6 Less than 2
ohms
"ON" 1 − 2, 1 − 4,
1 − 6, 2 − 4,
2 − 6, 4 − 6Less than 2
ohms
"START" 1 − 2, 1 − 5,
2 − 5Less than 2
ohms
Status of
ignition keyTester
connectionSpecified
condition
Removed 4 − 6 Less than 2
ohms
Inserted 4 − 6 Open circuit
AC304834AB