2005 MITSUBISHI LANCER specification

ON-VEHICLE SERVICE
FRONT SUSPENSION33-6
NOTE: The toe will move out as the left
turnbuckle is turned toward the front of the vehicle
and the right turnbuckle is turned toward the rear
of the vehicle.
2. Install the clip and tighten the lock nut to the
specified torque.
Tightening torque: 40 ± 5 N⋅m
3. Confirm that the toe-in is at the standard value.
4. Use a turning radius gauge to check that the
steering angle is at the standard value.
STEERING ANGLE
Standard value:
TOE-OUT ANGLE ON TURNS
To check the steering linkage, especially after the
vehicle has been involved in an accident or if an
accident is presumed, it is advisable to check the
toe-out angle on turns in addition to the wheel
alignment.
Conduct this test on the left turn as well as on the
right turn.
Standard value:
CAMBER, CASTER AND KINGPIN
INCLINATION
Standard value:NOTE: *: difference between right and left wheels
must be less than 30'
NOTE: Camber and caster are preset at the factory
and cannot be adjusted.
CAUTION
Never subject the wheel bearings to the vehicle
load when the driveshaft nuts are loosened.
NOTE:
For vehicles with aluminium wheels, attach the
camber/caster/kingpin gauge to the driveshaft by
using special tool wheel alignment gauge attachment
(MB991004). Tighten the special tool to the same
torque 245
± 29 N⋅m as the driveshaft nut.
LOWER ARM BALL JOINT AXIAL PLAY
CHECK
M1332011300074
1. Raise the vehicle.
2. Remove the stabilizer link from the lower arm.
3. Move the lower arm up and down with your hands
to check for an excessive play in the axial
direction of the ball joint. If there is an excessive
play, replace the lower arm assembly.
LOWER ARM BALL JOINT COVER
CHECK
M1332008600321
1. Press the lower arm ball joint cover with your
finger to check that there are no cracks or
damage in the lower arm ball joint cover.
2. If the lower arm ball joint cover is cracked or
damaged, replace the lower arm assembly.
NOTE: If the lower arm ball joint cover is cracked
or damaged, it is possible that there may also be
damage to the ball joint. Inner
wheelsComfort 39°30' ± 1°30'
Sport (LH drive
vehicles)33°40' +1°00'/-2°00'
Sport (RH drive
vehicles)37°00' +1°00'/-2°00'
Outer
wheels
(reference)Comfort 32°30'
Sport (LH drive
vehicles)28°46'
Sport (RH drive
vehicles)30°00'
Item Specification
Toe-out angle on turns (inner
wheel when outer wheel at 20°)21°42' ± 1°30'
Item Comfort Sport
Camber 0°05' ± 30'* -0°05' ± 30'*
Caster 2°45' ± 30'* 2°55' ± 30'*
Kingpin
inclination12°30' ± 1°30' 12°40' ± 1°30'
AC001079
MB991004
AB

34-1
GROUP 34
REAR SUSPENSION
CONTENTS
GENERAL INFORMATION . . . . . . . .34-2
SERVICE SPECIFICATIONS . . . . . . .34-3
LUBRICANT . . . . . . . . . . . . . . . . . . . .34-3
SPECIAL TOOLS . . . . . . . . . . . . . . . .34-4
ON-VEHICLE SERVICE . . . . . . . . . . .34-5
REAR WHEEL ALIGNMENT CHECK
AND ADJUSTMENT . . . . . . . . . . . . . . . . . . 34-5
CONTROL LINK PILLOW BALL BUSHING
AXIAL PLAY CHECK . . . . . . . . . . 34-6
UPPER ARM PILLOW BALL BUSHING
AXIAL PLAY CHECK . . . . . . . . . . 34-7
LOWER ARM PILLOW BALL BUSHING
AXIAL PLAY CHECK . . . . . . . . . . . . . . . . . 34-7
STABILIZER LINK BALL JOINT
DUST COVER INSPECTION . . . . . . . . . . . 34-7
CONTROL LINK, UPPER ARM AND
LOWER ARM . . . . . . . . . . . . . . . . . . .34-8
REMOVAL AND INSTALLATION . . . . . . . . 34-8
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 34-9
LOWER ARM BUSHING AND LOWER
ARM PILLOW BALL BUSHING
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . 34-10
TRAILING ARM ASSEMBLY . . . . . . .34-12
REMOVAL AND INSTALLATION . . . . . . . . 34-12
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 34-13
TRAILING ARM BUSHING
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . 34-13
SHOCK ABSORBER ASSEMBLY . . .34-15
REMOVAL AND INSTALLATION . . . . . . . . 34-15
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 34-16
DISASSEMBLY AND REASSEMBLY . . . . . 34-17
STABILIZER BAR. . . . . . . . . . . . . . . .34-20
REMOVAL AND INSTALLATION . . . . . . . . 34-20
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 34-21
STABILIZER LINK BALL JOINT
DUST COVER REPLACEMENT . . . . . . . . . 34-21

SERVICE SPECIFICATIONS
REAR SUSPENSION34-3
SPECIFICATION
COIL SPRING
SERVICE SPECIFICATIONS
M1341000300409
LUBRICANT
M1341000400172
Item Sedan Wagon
Comfort Sport Comfort Sport
Wire diameter mm 10 10 10 10
Average diameter mm 78 − 90 78 − 90 78 − 90 78 − 90
Free length mm 359 331 377 368
Item Standard value
Camber (Difference between right and left within 30')
−0°40' ± 30'
Toe-in At the centre of tyre tread mm 3 ± 2
Toe-angle (per wheel) 0°08' ± 05'
Thrust angle 0°00' ± 0°09'
Control link pillow ball bushing rotation starting torque N⋅m0.5 − 3.0
Upper arm pillow ball bushing rotation starting torque N⋅m0.5 − 3.0
Lower arm pillow ball bushing rotation starting torque N⋅m0.5 − 3.0
Protruding length of stabilizer link bolt mm 6 − 8
Stabilizer link ball joint continuous rotating torque N⋅m0.5 − 1.5
Item Specified lubricant Quantity
Stabilizer link ball joint (inside of dust cover) Multipurpose grease SAE J310, NLGI No.2
or equivalentAs required

36-1
GROUP 36
PARKING BRAKES
CONTENTS
GENERAL INFORMATION . . . . . . . .36-2
SERVICE SPECIFICATIONS . . . . . . .36-2
LUBRICANTS . . . . . . . . . . . . . . . . . .36-3
ON-VEHICLE SERVICE . . . . . . . . . . .36-3
PARKING BRAKE LEVER STROKE
CHECK AND ADJUSTMENT . . . . . . . . . . . 36-3
LINING RUNNING-IN . . . . . . . . . . . . . . . . . 36-3
PARKING BRAKE SWITCH CHECK . . . . . 36-4
PARKING BRAKE LEVER . . . . . . . . .36-5
REMOVAL AND INSTALLATION . . . . . . . . 36-5
PARKING BRAKE CABLE . . . . . . . . .36-6
REMOVAL AND INSTALLATION . . . . . . . . 36-6
PARKING BRAKE LINING AND
DRUM . . . . . . . . . . . . . . . . . . . . . . . . .36-7
REMOVAL AND INSTALLATION . . . . . . . . 36-7
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 36-9

GENERAL INFORMATION
PARKING BRAKES36-2
GENERAL INFORMATION
M1361000100496
The parking brake is of a mechanical rear-wheel
acting type, and its operation utilises a parking brake
lever.
SPECIFICATIONS
CONSTRUCTION DIAGRAM
SERVICE SPECIFICATIONS
M1361000300382
Item Specification
Type Drum-in disc
Clearance adjustment Manual
AC211553
AC104333
AC304152
Parking brake lever assembly
Parking brake cable
AB
Drum-in-disc brake
Item Standard value Limit
Parking brake lever stroke 5 − 7 notches
−
Rear brake lining thickness mm 2.8 1.0
Rear drum inside diameter mm 168.0 169.0

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 . . . . . . . . . . . . . . . . . . . . 37-13DRIVE BELT TENSION CHECK . . . . . . . . . 37-13
FLUID LEVEL CHECK . . . . . . . . . . . . . . . . 37-13
FLUID REPLACEMENT . . . . . . . . . . . . . . . 37-13
POWER STEERING SYSTEM AIR
BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . 37-13
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
. . . . . . . . . . . . . . . . . . . . . . . . . . 37-19
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 inadvertent 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
POWER STEERING37-3
GENERAL INFORMATION
M1372000100337
Power steering has been adopted in all vehicles to
make the steering system easier to handle.
FEATURES
•A 4-spoke steering wheel is used.
•MOMO leather-wrapped 3-spoke steering wheel
is used.
•A steering column has a shock absorbing
mechanism and a tilt steering mechanism.•Integral-type rack and pinion gear with high
rigidity and excellent response is used.
•A vane type pump with a fluid flow rate control
system which change steering effort according to
the engine speed is used.
•The separate plastic resin oil reservoir is used to
reduce weight and to make the fluid level
checking easier.
SPECIFICATIONS
Item Comfort Sport
Steering
wheelType 4-spoke type MOMO leather-wrapped
3-spoke type
Outside diameter mm 380 365
Maximum number of turns 3.19 2.86
3.08
Steering
columnColumn mechanism Shock absorbing mechanism and Tilt steering mechanism
Power steering type Integral type
Oil pump Type Vane pump
Basic discharge amount cm
3/rev.7.2 <1300, 1600>
8.1 <2000>7.2 <1300, 1600>
8.1 <2000>
Relief pressure MPa 8.8 8.8
Reservoir type Separate type (plastic)
Pressure switch Equipped
Steering
gearType Rack and pinion
Stroke ratio (Rack stroke/Steering
wheel maximum turning radius)45.74 45.74
Rack stroke mm 146 131
141

SERVICE SPECIFICATIONS
POWER STEERING37-6
SERVICE SPECIFICATIONS
M1372000300386
Item Standard value Limit
Steering wheel free
play mmWith engine running
−30
With engine stopped 10 or less
−
Steering angle Inner wheel Comfort 39°30' ± 1°30'
−
Sport (L.H. drive vehicles) 33°40' +1°00'/-2°00'
−
Sport (R.H. drive vehicles) 37°00' +1°00'/-2°00'
−
Outer wheel
(reference)Comfort 32°30'
−
Sport (L.H. drive vehicles) 28°46'
−
Sport (R.H. drive vehicles) 30°00'
−
Toe-in At the centre of tyre tread mm 1 ± 2
−
Toe-angle (per wheel) 0°03' ± 06'
−
Tie rod end ball joint turning torque N⋅m0.5 − 2.5
−
Tie rod swing resistance N [Tie rod swing torque N⋅m] 8 − 27 [1.5 − 4.9]
−
Stationary steering effort N [Fluctuation allowance N] 29 or less [5.9 or less]
−
Oil pump pressure
MPa (750 ± 100 r/min.)Oil pump relief pressure 8.8 − 9.5
−
Pressure under no-load conditions 0.2 − 0.7
−
Steering gear retention hydraulic pressure 8.8 − 9.5
−
Oil pressure switch operating pressure
MPaOFF → ON 1.5 − 2.0
−
ON → OFF 0.7 − 2.0
−
Steering gear total pinion torque N⋅m
[Change in torque N⋅m]1300, 1600 (Comfort) 0.8 − 2.1 [0.6 or less]
−
1600 (Sport), 2000 0.7 − 2.1 [0.6 or less]
−
Opening dimension of special tool boot band crimping tool (MB991561)
mm2.9
−
Band crimped width mm 2.4 − 2.8
−