2005 MITSUBISHI LANCER Head lamp

EXHAUST MANIFOLD
INTAKE AND EXHAUST15-7
INSPECTIONM1151003100616
Check the following points; replace the part if a
problem is found.
Inlet Manifold Check
1. Check for damage or cracking of any part.2. Clogging of the negative pressure (vacuum) outlet
port, or clogging of the exhaust gas recirculation
passages.
3. Using a straight edge and feeler gauge, check for
distortion of the cylinder head installation surface.
Standard value: 0.15 mm or less
Limit: 0.20 mm
EXHAUST MANIFOLD
REMOVAL AND INSTALLATION <4G1>M1151003300568
8. Battery wiring harness clamp
9. Inlet manifold stay
10. Inlet manifold
11. Inlet manifold gasket
12. Emission vacuum hose & pipe and
emission solenoid valve assembly
13. EGR valve
14. EGR valve gasketRemoval steps (Continued)
AC30366250 ± 10 N·m 24 ± 4 N·m
35 ± 6 N·m17 ± 2 N·m 29 ± 3 N·m
N
3
7
12 4
N
6
8
44 ± 5 N·m
AB
9
5N
29 ± 3 N·m
29 ± 3 N·m
29 ± 3 N·m
(Engine oil)

CHARGING SYSTEM
ENGINE ELECTRICAL16-4
2. Turn the ignition switch to the "LOCK" (OFF)
position.
3. Disconnect the negative battery cable.
4. Connect a clamp-type DC test ammeter with a
range of 0 − 120 A to the alternator "B" terminal
output wire.
NOTE: The way of disconnecting the alternator
output wire and of connecting the ammeter is
possibly not found the problem that the output
current is dropping due to the insufficient
connection between terminal "B" and the output
wire.
5. Connect a digital-type voltmeter between the
alternator "B" terminal and the battery (+)
terminal. [Connect the (+) lead of the voltmeter to
the "B" terminal and the connect the (-) lead of the
voltmeter to the battery (+) cable].
6. Reconnect the negative battery cable.
7. Connect a tachometer or the MUT-II/III (Refer to
GROUP 11A − On-vehicle Service − Idle speed
check <4G1> P.11A-11 or GROUP 11C −
On-vehicle Service − Idle speed check <4G6>
P.11C-11).
8. Leave the hood open.
9. Start the engine.
10.With the engine running at 2,500 r/min, turn the
headlamps and other lamps on and off to adjust
the alternator load so that the value displayed on
the ammeter is slightly above 30 A.Adjust the engine speed by gradually decreasing
it until the value displayed on the ammeter is 30
A. Take a reading of the value displayed on the
voltmeter at this time.
Limit: maximum 0.3 V
NOTE: When the alternator output is high and the
value displayed on the ammeter does not
decrease until 30 A, set the value to 40 A. Read
the value displayed on the voltmeter at this time.
When the value range is 40 A, the limit is
maximum 0.4 V.
11.If the value displayed on the voltmeter is above
the limit value, there is probably a malfunction in
the alternator output wire, so check the wiring
between the alternator "B" terminal and the
battery (+) terminal (including fusible link).
If a terminal is not sufficiently tight or if the
harness has become discolored due to
overheating, repair and then test again.
12.After the test, run the engine at idle.
13.Turn off all lamps and the ignition switch.
14.Remove the tachometer or the MUT-II/III.
15.Disconnect the negative battery cable.
16.Disconnect the ammeter and voltmeter.
17.Connect the negative battery cable.

CHARGING SYSTEM
ENGINE ELECTRICAL16-6
7. Connect a tachometer or the MUT-II/III (Refer to
GROUP 11A − On-vehicle Service − Idle speed
check <4G1> P.11A-11 or GROUP 11C −
On-vehicle Service − Idle speed check <4G6>
P.11C-11).
8. Leave the hood open.
9. Check that the reading on the voltmeter is equal
to the battery voltage.
NOTE: If the voltage is 0 V, the cause is probably
an open circuit in the wire or fusible link between
the alternator "B" terminal and the battery (+)
terminal.
10.Turn the light switch on to turn on headlamps and
then start the engine.
11.Immediately after setting the headlamps to high
beam and turning the heater blower switch to the
high revolution position, increase the engine
speed to 2,500 r/min and read the maximum
current output value displayed on the ammeter.
Limit: 70 % of normal current outputNOTE: .
•For the nominal current output, refer to the
Alternator Specifications.
•Because the current from the battery will soon
drop after the engine is started, the above step
should be carried out as quickly as possible in
order to obtain the maximum current output
value.
•The current output value will depend on the
electrical load and the temperature of the
alternator body.
•If the electrical load is small while testing, the
specified level of current may not be output
even though the alternator is normal. In such
cases, increase the electrical load by leaving
the headlamps turned on for some time to
discharge the battery or by using the lighting
system in another vehicle, and then test again.
•The specified level of current also may not be
output if the temperature of the alternator body
or the ambient temperature is too high. In such
cases, cool the alternator and then test again.
12.The reading on the ammeter should be above the
limit value. If the reading is below the limit value
and the alternator output wire is normal, remove
the alternator from the engine and check the
alternator.
13.Run the engine at idle after the test.
14.Turn the ignition switch to the "LOCK" (OFF)
position.
15.Remove the tachometer or the MUT-II/III.
16.Disconnect the negative battery cable.
17.Disconnect the ammeter and voltmeter.
18.Connect the negative battery cable.

CHARGING SYSTEM
ENGINE ELECTRICAL16-10
EXAMPLE OF ABNORMAL WAVEFORMS
NOTE: .
1. The size of the waveform patterns differs largely, depending on the adjustment of the variable knob on the
oscilloscope.
2. Identification of abnormal waveforms is easier when there is a large output current (regulator is not
operating). (Waveforms can be observed when the headlamps are illuminated.)
3. Check the conditions of the charging warning lamp (illuminated/not illuminated). Also, check the charging
system totally.
Abnormal waveform Problem cause
Example 1 Open diode
Example 2 Short in diode
AKX00191
AKX00192

POWER STEERING GEAR BOX AND LINKAGE
POWER STEERING37-24
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-210). 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.37-13.)
•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.33-5.)
AC304920
AB
57 ± 7 N·m
15 ± 3 N·m 70 ± 10 N·m
7
3 8
5
6
9
1024
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 hose4. Return tube
5. O-ring
6. Return tube
7. Eye bolt
8. Pressure hose assembly
9. Clamp
10. Steering gear and linkageRemoval steps (Continued)

WINDOW GLASS
BODY42-16
REAR WINDOW GLASS
REMOVAL AND INSTALLATIONM1422001600111
Pre-removal and Post-installation Operation
•High-mounted Stop Lamp Assembly Removal and
Installation (Refer to GROUP
54A, High-Mounted Stop Lamp P.54A-81.)
•Rear Pillar Trim and Rear Shelf Trim Removal and
Installation (Refer to GROUP 52A, Trims P.52A-11.)
•Headlining Removal and Installation (Refer to GROUP
52A, Headlining P.52A-21.)
Y0500AU
Y0502AUY0501AU
Y0564AU
AC006056
11 7
7
AB
6
25
4 9
7 3
N
2N
2N
N
4N
N
3N3N
NN
2N
Ceramic line
Mark
Apply the primer and
adhesive along the
fictitious lines (seal line)
between each of
the marks.Section A – A
Section B – B
Seal line
centre
Primer
8N
10N
Adhesive: 3M ATD Part No. 8609 Super Fast Urethane Auto Glass Sealant or equivalent and
3M ATD Part No. 8608 Super Fast Urethane Primer or equivalent
16 mm
A
A
B
B
Removal steps
•Roof drip moulding (Refer to GROUP
51, Moulding P.51-10.)
<> >>B<<1. Rear window lower moulding
2. Clip
3. Grommet A4. Grommet B
5. Grommet C
6. Connecting the harness connector<> >>A<<7. Rear window glass
>>A<<8. Rear window upper mouldingRemoval steps (Continued)