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General <Body and Chassis> - Except Evolution: Other Mitsubishi Lancer IX

Oem General Information 46 illustrations ~5329 words

ON-VEHICLE SERVICE

The "ON-VEHICLE SERVICE" section has procedures for performing inspections and adjustments of particularly important components. These procedures are done with regard to maintenance and servicing, but other inspections (looseness, play, cracking, damage, etc). must also be performed.

SERVICE PROCEDURES

The service steps are arranged in numerical order. Attention to be paid in performing vehicle service are described in detail in SERVICE POINTS.

STANDARD VALUE

Indicates the value used as the standard for judging whether or not a part or adjustment is correct.

LIMIT

Shows the maximum or minimum value for judging whether or not a part or adjustment is acceptable.

REFERENCE VALUE

Indicates the adjustment value prior to starting the work (presented in order to facilitate assembly and adjustment procedures, and so they can be completed in a shorter time).

DANGER, WARNING, AND CAUTION

DANGER, WARNING, and CAUTION call special attention to a necessary action or to an action that must be avoided. The differences among DANGER, WARNING, and CAUTION are as follows

  1. If a DANGER is not followed, the result is severe bodily harm or even death.
  2. If a WARNING is not followed, the result could be bodily injury.
  3. If a CAUTION is not followed, the result could be damage to the vehicle, vehicle components or service equipment.

VERIFY THE COMPLAINT

  1. Make sure the customer's complaint and the service writer's work order description are understood before starting work.
  2. Make sure the correct operation of the system is understood. Read the service manual description to verify normal system operation.
  3. Operate the system to see the symptoms. Look for other symptoms that were not reported by the customer, or on the work order, that may be related to the problem.

DETERMINE POSSIBLE CAUSES

Compare the confirmed symptoms to the diagnostic symptom indexes to find the right diagnosis procedure.

If the confirmed symptoms cannot be found on any symptom index, determine other possible causes.

  1. Analyze the system diagrams and list all possible causes for the problem symptoms.
  2. Rank all these possible causes in order of probability, based on how much of the system they cover, how likely they are to be the cause, and how easy they will be to check. Be sure to take experience into account. Consider the causes of similar problems seen in the past. The list of causes should be ranked in order from general to specific, from most-likely to least-likely, and from easy-to-check to hard-to-check.

FIND THE PROBLEM

After the symptoms have been confirmed, and probable causes have been identified, the next step is to make step-by-step checks of the suspected system components, junctions, and links in logical order.

Use the diagnostic procedures in the service manual whenever possible. Follow these procedures carefully to avoid missing an important step in the diagnosis sequence. It might be the skipped step that leads to the solution of the problem.

If the service manual doesn't have step-by-step procedures to help diagnose the problem, make a series of checks based on the ranked list of probable causes. Troubleshooting checks should be made in the order that the list of causes was ranked

  1. general to specific
  2. most-likely to least-likely
  3. easy-to-check to hard-to-check

REPAIR THE PROBLEM

When the step-by-step troubleshooting checks find a fault, perform the proper repairs. Make sure to fix the root cause of the problem, not just the symptom. Just fixing the symptom, without fixing the root cause, will cause the symptom to eventually return.

VERIFY THE REPAIR

After repairs are made, recheck the operation of the system to confirm that the problem is eliminated. Be sure to check the system thoroughly. Sometimes new problems are revealed after repairs have been made.

MEASURES TO TAKE AFTER REPLACING THE ECU

If the trouble symptoms have not disappeared even after replacing the ECU, repeat the inspection procedure from the beginning.

CONNECTOR MEASUREMENT SERVICE POINTS

Turn the ignition switch to the "LOCK" (OFF) position when connecting and disconnecting the connectors. Turn the ignition switch to "ON" when measuring, unless there are instructions to the contrary.

Waterproof Connectors

Be sure to use special tool, MB998459. Never insert a test probe from the harness side, as this will reduce the waterproof performance and result in corrosion.

Scheme 30

Scheme 30: Waterproof Connectors
Scheme 30: Waterproof Connectors

Ordinary (non-waterproof) Connectors

Check by inserting the multi-meter test probe from the harness side. Note that if the connector (control unit, etc). is too small to permit insertion of the test probe, it should not be forced; use the backprobing tool for this purpose.

Scheme 31

Scheme 31: Ordinary (non-waterproof) Connectors
Scheme 31: Ordinary (non-waterproof) Connectors

HOW TO COPE WITH INTERMITTENT MALFUNCTIONS

Most intermittent malfunctions occur under certain conditions. If those conditions can be identified, the cause will be easier to find.

TO COPE WITH INTERMITTENT MALFUNCTION

  1. Ask the customer about the malfunction Ask what it feels like, what it sounds like, etc. Then ask about driving conditions, weather, frequency of occurrence, and so on.
  2. Determine the conditions from the customer's responses Typically, almost all intermittent malfunctions occur from conditions like vibration, temperature and/or moisture change, poor connections. From the customer's responses, it should be reasoned which condition is most likely.
  3. Use simulation test Use the simulation tests below to attempt to duplicate the customer's complaint. Determine the most likely circuit(s) and perform the simulation tests on the connectors and parts of that circuit(s). Be sure to use the inspection procedures provided for diagnostic trouble codes and trouble symptoms. For temperature and/or moisture condition related intermittent malfunctions, try to change the conditions of the suspected circuit components, then use the simulation tests below.
  4. Verify the intermittent malfunction is eliminated Repair the malfunctioning part and try to duplicate the condition(s) again to verify the intermittent malfunction has been eliminated.

SIMULATION TESTS

Note. In case of difficulty in finding the cause of the intermittent malfunction, the data recorder function in the scan tool is effective.

For these simulation tests, shake, then gently bend, pull, and twist the wiring of each of these examples to duplicate the intermittent malfunction.

  1. Shake the connector up-and-down, and right-and-left.
  2. Shake the wiring harness up-and-down, and right-and-left. Especially, check the splice points of wiring harnesses carefully. Refer to «SPLICES»(ref-156493-S40486393112003071800000) .
  3. Shake the part or sensor.

Scheme 32

Scheme 32
Scheme 32

VEHICLES FOR FEDERAL EMISSION REGULATION

VIN (EXCEPT SEQUENCE NUMBER)BRANDENGINE DISPLACEMENTMODEL CODE
JA3AJ16E_3UMITSUBISHI LANCER2.0LCS6ASRSEL2M
JA3AJ26E_3UCS6ASNMEL2M
CS6ASRMEL2M
JA3AJ36E_3UCS6ASRDEL2M
JA3AJ86E_3UCS6ASNHEL2M
CS6ASRHEL2M

VEHICLE IDENTIFICATION NUMBER LIST

VEHICLES FOR CALIFORNIA EMISSION REGULATION

VIN (EXCEPT SEQUENCE NUMBER)BRANDENGINE DISPLACEMENTMODEL CODE
JA3AJ16E_3UMITSUBISHI LANCER2.0LCS6ASRSEL7M
JA3AJ26E_3UCS6ASNMEL7M
CS6ASRMEL7M
JA3AJ36E_3UCS6ASRDEL7M
JA3AJ86E_3UCS6ASNHEL7M
CS6ASRHEL7M

VEHICLES FOR CALIFORNIA EMISSION REGULATION

VEHICLES FOR CANADA EMISSION REGULATION

VIN (EXCEPT SEQUENCE NUMBER)BRANDENGINE DISPLACEMENTMODEL CODE
JA3AJ16E_3UMITSUBISHI LANCER2.0LCS6ASRSEL3M
JA3AJ26E_3UCS6ASNMEL3M
CS6ASRMEL3M
JA3AJ36E_3UCS6ASRDEL3M
JA3AJ86E_3UCS6ASNHEL3M
CS6ASRHEL3M

EMISSION REGULATION

VEHICLE SAFETY CERTIFICATION LABEL

The vehicle safety certification label is attached to the face of the left door sill.

This label indicates the month and year of manufacture, Gross Vehicle Weight Rating (GVWR), front and rear Gross Axle Weight Rating (GAWR), and Vehicle Identification Number (VIN).

Scheme 33

Scheme 33: VEHICLE SAFETY CERTIFICATION LABEL
Scheme 33: VEHICLE SAFETY CERTIFICATION LABEL

ENGINE MODEL STAMPING

The engine model is stamped on the cylinder block.

These engine model numbers are as shown as follows.

ENGINE MODELENGINE DISPLACEMENT
4G942.0L

ENGINE MODEL STAMPING

The engine serial number is stamped near the engine model number.

Scheme 34

Scheme 34
Scheme 34

THEFT PROTECTION

In order to protect against theft, a Vehicle Identification Number (VIN) is attached as a plate or label to the following major parts of the engine and transaxle, as well as main outer panels

Engine cylinder block, Transaxle housing, Fender, Doors, Trunk lid, Quarter panel, Hood, Bumpers In addition, a theft-protection label is attached to replacement parts for the body outer panel main components, and the same data is stamped into replacement parts for the engine and the transaxle.

CAUTIONCautions regarding panel repairs: When repainting original parts, do so after first masking the theft-protection label. After painting, be sure to peel off the masking tape. The theft-protection label for replacement parts is covered by masking tape, so such parts can be painted as is. The masking tape should be removed after painting is finished. The theft-protection label should not be removed from original parts or replacement parts.

Scheme 35

Scheme 35
Scheme 35

Scheme 36

Scheme 36: LOCATIONS
Scheme 36: LOCATIONS

Scheme 37

Scheme 37
Scheme 37

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

  1. Items to review when servicing SRS Be sure to read «AIR BAG RESTRAINT SYSTEMS»(ref-160459) . For safe operation, please follow the directions and heed all warnings. Wait at least 60 seconds after disconnecting the battery cable before doing any further work. The SRS system is designed to retain enough voltage to deploy the air bag even after the battery has been disconnected. Serious injury may result from unintended air bag deployment if work is done on the SRS system immediately after the battery cable is disconnected. Warning labels must be heeded when servicing or handling SRS components. Warning labels can be found in the following locations. Sun visor Glove box Center pillar SRS-ECU Steering wheel Clock spring Joint cover Air bag module (Driver's or front passenger's) Side-airbag module (Driver's side or front passenger's side) Side impact sensor Seat belt pre-tensioner Always use the designated special tools and test equipment. Store components removed from the SRS in a clean and dry place. The air bag module should be stored on a flat surface and placed so that the pad surface is facing upward. Never attempt to disassemble or repair the SRS components (SRS-ECU, air bag module, side impact sensor, clock spring and seat belt pre-tensioner). If there is a defect, replace the defective part. Whenever you finish servicing the SRS, check the SRS warning light operation to make sure that the system functions properly. Be sure to deploy the air bag before disposing of the air bag module or disposing of a vehicle equipped with an air bag. (Refer to «DISPOSAL PROCEDURES»(ref-160459-S10682005482004021000000) ).
  2. Observe the following when carrying out operations on places where SRS components are installed, including operations not directly related to the SRS air bag. When removing or installing parts, do not allow any impact or shock to occur to the SRS components. If heat damage may occur during paint work, remove the SRS components. After reinstalling them, check the SRS warning light operation to make sure that the system functions properly. SRS-ECU, air bag module, clock spring, side impact sensor: 93°C (200°F) or more Seat belt pre-tensioner: 90°C (194°F) or more

SERVICING ELECTRICAL SYSTEM

WARNINGBattery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING.

Scheme 38

Scheme 38
Scheme 38
  1. Note the following before proceeding with working on the electrical system. Never perform unauthorized modifications to any electrical device or wiring. Such modifications might lead to a vehicle malfunction, over-capacity or short-circuit that could result in a fire in the vehicle. CAUTION: Before connecting or disconnecting the negative battery cable, be sure to turn the ignition switch to the "LOCK" (OFF) position and turn off the lights. (If this is not done, there is the possibility of semiconductor parts being damaged). After completion of the work (and the negative battery terminals is connected), warm up the engine and allow it to idle for approximately 10 minutes under the conditions described below in order to stabilize engine control conditions, and then check to be sure that the idle is satisfactory.
  2. When servicing the electrical system, disconnect the negative cable terminal from the battery. Engine coolant temperature: 85 - 95°C (185 - 203°F) Lights and all accessories: OFF Transaxle: "N" or "P" position Steering wheel: straight-forward position

VEHICLE WASHING

If high-pressure car-washing equipment or steam car-washing equipment is used to wash the vehicle, be sure to maintain the spray nozzle at a distance of at least approximately 40 cm (16 inches) from any plastic parts and all opening parts (doors, luggage compartment, etc).

Scheme 39

Scheme 39: VEHICLE WASHING
Scheme 39: VEHICLE WASHING

APPLYING ANTI-CORROSION AGENT OR OTHER UNDERCOAT AGENTS

Be careful not to apply oil or grease to the heated oxygen sensor. If applied, the sensor may malfunction. Protect the heated oxygen sensor with a cover before applying anti-corrosion agent, etc.

FRONT TOWING PICKUP

CAUTIONThis vehicle cannot be towed by a wrecker using sling-type equipment; otherwise the bumper may become deformed. If this vehicle is towed, use wheel lift or flat bed equipment.

The vehicle may be towed on its rear wheels for extended distances provided the parking brake is released. It is recommended that vehicles be towed using the front pickup whenever possible.

Scheme 40

Scheme 40
Scheme 40

REAR TOWING PICKUP

CAUTIONThis vehicle cannot be towed by a wrecker using sling-type equipment; otherwise the lower arm may become deformed. If this vehicle is towed, use a wheel lift or flat bed equipment. Do not use the steering column lock to secure the front wheels for towing. Make sure the transaxle is in Neutral if vehicle will have drive wheels on the ground. If these requirements cannot be met, the front wheels must be placed on a tow dolly.

Automatic transmission vehicle may be towed on the front wheels at speeds not to exceed 50 km/h (30 mph) for distances not to exceed 30 km (18 miles).

Scheme 41

Scheme 41
Scheme 41

TOWING WHEN KEYS ARE NOT AVAILABLE

When a locked vehicle must be towed and keys are not available, the vehicle may be lifted and towed from the front, provided the parking brake is released. If not released, the rear wheels should be placed on a tow dolly.

SAFETY PRECAUTIONS

The following precautions should be taken when towing the vehicle

  1. DO NOT LIFT OR TOW THE VEHICLE BY ATTACHING TO OR WRAPPING AROUND THE BUMPER.
  2. Any loose, protruding, or damaged parts such as hoods, doors, fenders, trim, etc. should be secured or removed prior to moving the vehicle.
  3. Refrain from going under a vehicle when it is lifted by the towing equipment, unless the vehicle is adequately supported by safety stands.
  4. Never allow passengers to ride in a towed vehicle.
  5. State and local rules and regulations must be followed when towing a vehicle.

FLOOR JACK

CAUTIONNever support any point other than the specified one, or that point will be deformed. For lifting, put rubber or similar material between the side sill and rigid rack, or the side sill area will be damaged.

Scheme 42

Scheme 42
Scheme 42

POST TYPE

Special care should be taken when raising the vehicle on a frame contact type hoist. The hoist must be equipped with the proper adapters in order to support the vehicle at the proper locations.

CAUTIONWhen service procedures require removing rear suspension, fuel tank and spare tire, place additional weight on rear end of vehicle or anchor vehicle to hoist to prevent tipping when the location of the center of gravity changes.

Scheme 43

Scheme 43
Scheme 43

Scheme 44

Scheme 44: GENERAL DATA AND SPECIFICATIONS
Scheme 44: GENERAL DATA AND SPECIFICATIONS

ENGINE OIL

CAUTIONTest results submitted to EPA have shown that laboratory animals develop skin cancer after prolonged contact with used engine oil. Accordingly, the potential exists for humans to develop a number of skin disorders, including cancer, from such exposure to used engine oil. Therefore, when changing engine oil, be careful not to touch it as much as possible. Protective clothing and gloves, that cannot be penetrated by oil, should be worn. The skin should be thoroughly washed with soap and water, or use waterless hand cleaner, to remove any used engine oil. Do not use gasoline, thinners, or solvents.

Either of the following engine oils should be used

  1. Engine oil displaying ILSAC certification mark.
  2. Engine oil conforming to the API classification SJ EC or SJ/CD EC.

For further details, refer to LUBRICANT SELECTION .

LUBRICANTS AND GREASES

Semi-solid lubricants bear the NLGI designation and are further classified as grades 0, 1, 2, 3, etc.

Whenever "Chassis Lubricant" is specified, Multipurpose Grease, NLGI grade Number 2, should be used.

FUEL USAGE STATEMENT

CAUTIONUsing leaded gasoline in this car will damage the catalytic converters and heated oxygen sensors, and affect the warranty coverage validity.

This vehicle must use unleaded gasoline only.

This vehicle has a fuel filler tube which is especially designed to accept only the smaller-diameter unleaded gasoline dispensing nozzle.

The 2.0L model is designed to operate on unleaded gasoline having a minimum octane rating of 87 [(MON + RON)/2], or 91 RON.

Note. MON: Motor Octane Number RON: Research Octane Number

GASOLINE CONTAINING ALCOHOL

Some gasoline sold at service stations contain alcohol although they may not be so identified.

Using fuels containing alcohol is not recommended unless the nature of the blend can be determined as being satisfactory.

Gasohol: A mixture of 10% ethanol (grain alcohol) and 90% unleaded gasoline may be used in your vehicle. If driveability problems are experienced as a result of using gasohol, it is recommended that the vehicle be operated on gasoline.

Methanol: Do not use gasoline containing methanol (wood alcohol). Using this type of alcohol can result in vehicle performance deterioration and damage critical parts in the fuel system components. Fuel system damage and performance problems resulting from the use of gasoline containing methanol may not be covered by the new vehicle warranty.

GASOLINE CONTAINING METHYL TERTIARY BUTYL ETHER (MTBE)

Unleaded gasoline containing 15% or less MTBE may be used in your vehicle. (Fuel containing MTBE over 15% in volume may cause reduced engine performance and produce vapor lock or hard starting.

MATERIALS ADDED TO FUEL

Indiscriminate use of fuel system cleaning agents should be avoided. Many of these materials intended for gum and varnish removal may contain highly active solvents or similar ingredients that can be harmful to gasket and diaphragm materials used in fuel system component parts.

RECOMMENDED LUBRICANTS

LUBRICANTSPECIFICATIONREMARK
Engine oilEngine oil displaying ILSAC certification mark ("Starburst" symbol) conforming to API classification SJ EC or SJ/CD ECFor further details, refer to LUBRICANT SELECTION .
Manual transaxleAPI classification GL-4SAE grade number: SAE75W-90 or 75W/85W
Automatic transaxleMITSUBISHI genuine ATF SP III
Power steering fluidGENUINE MITSUBISHI POWER STEERING FLUID
BrakesConforming to DOT 3 or DOT 4
Engine coolantMITSUBISHI genuine coolant or an equivalent
Door hinges, back door hingesEngine oil

RECOMMENDED LUBRICANTS AND LUBRICANT CAPACITIES

CAUTIONNever use nondetergent or straight mineral oil. Oil Identification Symbol

Use only engine oils displaying the ILSAC certification mark ("Starburst" symbol) on the container.

Scheme 45

Scheme 45
Scheme 45

If these oils are not available, an API classification SJ EC or SJ/CD EC can be used.

Scheme 46

Scheme 46
Scheme 46

Oil Viscosity

The SAE grade number indicates the viscosity of the oil. A proper SAE grade number should be selected according to ambient temperature.

Scheme 47

Scheme 47: Oil Viscosity
Scheme 47: Oil Viscosity

COOLANT

Relationship between Coolant Concentration and Specific Gravity

CAUTIONIf the concentration of the coolant is below 30%, the anti-corrosion property will be adversely affected. In addition, if the concentration is above 60%, both the anti-freeze and engine cooling properties will decrease, affecting the engine adversely. For these reasons, be sure to maintain the concentration level within the specified range. Do not use a mixture of different brands of anti-freeze.
COOLANT TEMPERATURE °C (°F) AND SPECIFIC GRAVITYFREEZING TEMPERATURESAFE OPERATING TEMPERATURECOOLANT CONCENTRATION (SPECIFIC VOLUME)
10 (50)20 (68)30 (86)40 (104)50 (122)°C (°F)°C (°F)%
1.0541.0501.0461.0421.03616 (3.2)11 (12.2)30
1.0631.0581.0541.0491.04420 (-4)15 (5)35
1.0711.0671.0621.0571.05225 (-13)20 (-4)40
1.0791.0741.0691.0641.05830 (-22)25 (-13)45
1.0871.0821.0761.0701.06436 (-32.8)31 (-23.8)50
1.0951.0901.0841.0771.07042 (-44)37 (-35)55
1.1031.0981.0921.0841.07650 (-58)45 (-49)60

SELECTION OF COOLANT

Example

The safe operating temperature is -15°C (5°F) when the specific gravity is 1.058 at the coolant temperature of 20°C (68°F)

1. FUEL SYSTEM (TANK, PIPE LINE AND CONNECTION, AND FUEL TANK FILLER TUBE CAP) (CHECK FOR LEAKS)

Check for damage or leakage in the fuel lines and connections.

2. FUEL HOSES (CHECK CONDITION)

  1. Inspect the surface of fuel hoses for heat and mechanical damage. Hard and brittle rubber, cracking, tears, cuts, abrasions and excessive swelling indicate deterioration of the rubber.
  2. If the fabric casing of the rubber hose is exposed by cracks and abrasions in the fuel system, the hoses should be replaced.

4. EVAPORATIVE EMISSION CONTROL SYSTEM (EXCEPT EVAPORATIVE EMISSION CANISTER) (CHECK FOR CLOGGING)

If the fuel-vapor vent line is clogged or damaged, fuel vapor will escape into the atmosphere causing excessive emissions. Disconnect the line at both ends, and blow it clean with compressed air. Remove the fuel tank filler tube cap from the filler tube and check to see if there is evidence that the seal makes improper contact to the filler tube.

Scheme 48

Scheme 48: 5. SPARK PLUGS (REPLACE)
Scheme 48: 5. SPARK PLUGS (REPLACE)
  1. Spark plugs must spark properly to assure proper engine performance and reduce exhaust emission level. Therefore, they should be replaced periodically with new ones. Few the list below: Spark plug type IDENTIFICATION MAKER IDENTIFICATION NO. NGK BKR5E-11 DENSO K16PR-U11 CHAMPION RC10YC4
  2. The new plugs should be checked for the proper gap. Spark plug gap: 1.0 - 1.1 mm (0.039 - 0.043 inch)
  3. Install the spark plugs and tighten to 25 N+/-m (18 ft-lb)

< When using the tension gauge >

Use a belt tension gauge to check that the belt tension is within the standard value.

Standard value

ITEMWHEN CHECKEDDURING ADJUSTMENTDURING REPLACEMENT
Tension N (lb)294 - 490 (66 - 110)343 - 441 (77 - 99)588 - 784 (132 - 176)

DURING ADJUSTMENT

Scheme 49

Scheme 49
Scheme 49

< Belt deflection check >

Apply approximately 100 N (22 pound) of force to the middle of the drive belt between the pulleys (at the place indicated by the arrow) and check that the amount of deflection is within the standard value.

Standard value

Scheme 50

Scheme 50: < Belt deflection check >
Scheme 50: < Belt deflection check >
ITEMWHEN CHECKEDDURING ADJUSTMENTDURING REPLACEMENT
Deflection (Reference value) mm (in)9.7 - 12.9 (0.38 - 0.51)10.5 - 12.0 (0.41 - 0.47)6.7 - 8.5 (0.26 - 0.33)

DURING ADJUSTMENT

Scheme 51

Scheme 51: Generator Drive Belt Tension Adjustment
Scheme 51: Generator Drive Belt Tension Adjustment
  1. Loosen the nut of the generator pivot bolt.
  2. Loosen the lock bolt.
  3. Turn the adjusting bolt to adjust the belt vibration frequency, belt tension or deflection to the standard value. CAUTION: Check after turning the crankshaft one or more rotations clockwise. Standard value: DURING ADJUSTMENT ITEM WHEN CHECKED DURING ADJUSTMENT DURING REPLACEMENT Vibration frequency Hz 143 - 185 155 - 175 203 - 234 Tension N (lb) 294 - 490 (66 - 110) 343 - 441 (77 - 99) 588 - 784 (132 - 176) Deflection (Reference value) mm (in) 9.7 - 12.9 (0.38 - 0.51) 10.5 - 12.0 (0.41 - 0.47) 6.7 - 8.5 (0.26 - 0.33)
  4. Tighten the lock bolt. Tightening torque: 23 +/- 2 N+/-m (16 +/- 2 ft-lb)
  5. Tighten the nut of the generator pivot bolt. Tightening torque: 44 +/- 10 N+/-m (33 +/- 7 ft-lb)
  6. Tighten the adjusting bolt. Tightening torque: 5.0 +/- 1.0 N+/-m (44 +/- 8 in-lb)

< When using a tension gauge >

Use a belt tension gauge to check that the belt tension is within the standard value.

Apply approximately 100 N (22 pound) of force to the middle of the drive belt between the pulleys (at the place indicated by the arrow) and check that the amount of deflection is within the standard value.

Standard value

ITEMWHEN CHECKEDDURING ADJUSTMENTDURING REPLACEMENT
Vibration frequency Hz114 - 139121 - 133145 - 166
Tension N (lb)392 - 588 (88 - 132)441 - 539 (99 - 121)637 - 833 (143 - 187)
Deflection (Reference value) mm (in)10.0 - 12.0 (0.39 - 0.47)10.0 - 11.0 (0.39 - 0.43)7.0 - 9.0 (0.27 - 0.35)

DURING ADJUSTMENT

If the tension or deflection is outside the standard value, adjust by the following procedure.

Scheme 52

Scheme 52
Scheme 52
  1. Loosen the tension pulley fixing nut A behind the tension pulley.
  2. Adjust the belt deflection amount using the adjusting bolt B.
  3. Tighten the fixing nut A. Tightening torque: 26 +/- 4 N+/-m (19 +/- 3 ft-lb) CAUTION: Check after turning the crankshaft one or more rotations clockwise.
  4. Check the belt deflection amount and tension, and readjust if necessary.

9. ENGINE OIL (CHANGE)

Use the specified oil. (Refer to ENGINE OIL ).

Scheme 53

Scheme 53: 9. ENGINE OIL (CHANGE)
Scheme 53: 9. ENGINE OIL (CHANGE)

Scheme 54

Scheme 54
Scheme 54
  1. After warming up the engine, remove the oil filler cap. WARNING: Use care, oil could be hot.
  2. Remove the drain plug to allow the engine oil to drain.
  3. Replace the drain plug gasket with a new one, and then tighten the drain plug to the specified torque. Tightening torque: 39 +/- 5 N+/-m (29 +/- 4 ft-lb) NOTE: Install the drain plug gasket so it faces in the direction shown in the illustration.
  4. Pour new engine oil in through the oil filler tube. Engine oil capacity: 3.5 dm 3 (3.7 quarts) [add 0.3 dm 3 (0.32 quarts) if replacing the oil filter.]
  5. Start the engine and run it at idle for a few minutes.
  6. Stop the engine and check to ensure that the engine oil level is within the level range indicated on the dip stick.

Engine Oil Filter Selection

This vehicle is equipped with a full-flow, throw-away oil filter.

The same type of filter is recommended as a replacement filter for this vehicle. It is possible, particularly in cold weather, that this vehicle may develop high oil pressure for a short duration. Make sure that any replacement filter used on this vehicle is a high-quality filter. The filter must withstand a pressure of 1,765 kPa (256 psi) [manufacturer's specifications] to avoid filter and ultimately engine damage. The following is a high-quality filter and is strongly recommended for use on this vehicle: Mitsubishi Engine Oil Filter Part number MD136466, MD322508, MD325714, MD332687, MD360935 and MD365876.

Any replacement oil filter should be installed in accordance with the oil filter manufacturer's installation instructions.

Scheme 55

Scheme 55: Oil Filter Replacement
Scheme 55: Oil Filter Replacement

Scheme 56

Scheme 56
Scheme 56
  1. Drain the engine oil by removing the oil drain plug.
  2. Use an oil filter wrench to remove the engine oil filter.
  3. Clean the contact surface of the filter bracket.
  4. Lubricate the O-ring of the new oil filter with a small amount of new engine oil.
  5. Screw on the oil filter by hand until it touches the surface of the flange and then tighten it with an oil filter wrench. TIGHTENING TORQUE NUMBER SPECIAL TOOL TIGHTENING TORQUE MD360935 MB991396 or equivalent Approximately one turn [14 +/- 2 N+/-m (124 +/- 18 in-lb)] MD325714 MD332687 MD365876 MB991396 or equivalent Approximately 3/4 turn [16 +/- 4 N+/-m (12 +/- 3 ft-lb)] MD136466 MD322508 General service tool Approximately 3/4 turn [17 +/- 3 N+/-m (34 +/- 2 ft-lb)]
  6. Add new engine oil through the oil filler.

Check oil level

Inspect each component for evidence of leakage. Check the oil level by removing the filler plug.

Scheme 57

Scheme 57: Check oil level
Scheme 57: Check oil level
  1. Remove the filler plug.
  2. Check that the oil is not noticeably dirty, and that it has a suitable viscosity.
  3. Tighten the filler plug to the specified torque. Tightening torque: 32 +/- 2 N+/-m (24 +/- 1 ft-lb)

Scheme 58

Scheme 58: Change oil
Scheme 58: Change oil
  1. Remove the filler plug.
  2. Remove the drain plug and drain the oil.
  3. Tighten the drain plug to the specified torque. Tightening torque: 32 +/- 2 N+/-m (24 +/- 1 ft-lb)
  4. Fill with Hypoid gear oil SAE 75W-90 or 75W-85W conforming to API classification GL-4 until the level comes to the lower portion of filler plug hole. Quantity: 2.2 dm 3 (2.3 quarts)
  5. Tighten the filler plug to the specified torque. Tightening torque: 32 +/- 2 N+/-m (24 +/- 1 ft-lb)

Scheme 59

Scheme 59: Checking A/T fluid level
Scheme 59: Checking A/T fluid level

Scheme 60

Scheme 60
Scheme 60
  1. Drive the vehicle until the A/T fluid temperature rises to the normal temperature [70 - 80°C (158 - 176°F)]. NOTE: The A/T fluid temperature is measured with MUT-II. NOTE: If it takes some amount of time until the A/T fluid reaches its normal operating temperature [70 - 80 °C (158 - 176 °F)], check the A/T fluid level by referring to the left diagram.
  2. Park the vehicle on a level surface.
  3. Move the selector lever through all positions to fill the torque converter and the hydraulic circuits with A/T fluid, and then move the selector lever to the "N" position.
  4. After wiping off any dirt from around the dipstick, remove the dipstick and check the condition of the A/T fluid. NOTE: If the fluid smells as if it is burnt, it means that the A/T fluid has been contaminated by fine particles from the bushings and friction materials. A transaxle overhaul and cooler line flushing may be necessary.
  5. Check that the A/T fluid level is at the "HOT" mark on the dipstick. If the A/T fluid level is lower than this, pour in more MITSUBISHI genuine ATF SP-III or equivalent until the level reaches the "HOT" mark. NOTE: If the A/T fluid level is too low, the oil pump will draw in air along with the A/T fluid, which will cause bubbles to form. If the A/T fluid level is too high, rotating components inside the transaxle will churn the fluid and air into a foamy liquid. Both conditions (level too low or too high) will cause the hydraulic pressure to drop, which will result in late shifting and slipping of the clutches and brakes. In either case, air bubbles can interfere with normal valve, clutch, and brake operation. Also, foaming can cause A/T fluid to escape from the transaxle vent where it may be mistaken for a leak.
  6. Securely insert the dipstick. NOTE: The A/T fluid should always be replaced when: When overhauling the transaxle When the oil is noticeably dirty or burnt (vehicle was driven under severe conditions)

13. ENGINE COOLANT (CHANGE)

Check the cooling system parts such as the radiator, heater and oil cooler hoses, thermostat and their connections for leakage and damage.

Scheme 61

Scheme 61: Changing Coolant
Scheme 61: Changing Coolant

Scheme 62

Scheme 62
Scheme 62
  1. Set the temperature control knob to the "HOT" position.
  2. Run the engine until the engine coolant warms, and then stop the engine. WARNING: When removing the radiator cap, use care to avoid contact with hot coolant or steam. Place a shop towel over the cap and turn the cap counterclockwise a little to let the pressure escape through the vinyl tube. After relieving the steam pressure, remove the cap by slowly turning it counterclockwise.
  3. Remove the radiator cap, radiator drain plug and if equipped engine coolant drain plug to drain the coolant.
  4. Remove the reserve tank and drain the coolant.
  5. After completely draining the coolant, reinstall the drain plugs and flush the engine and radiator using a radiator cleaning fluid.
  6. After the flushing is completed, completely drain the cleaning fluid and install the radiator and engine drain plugs. CAUTION: Do not use alcohol or methanol anti-freeze or any engine coolants mixed with alcohol or methanol anti-freeze. The use of an improper anti-freeze can cause corrosion of the aluminum components.
  7. By referring to the section on coolant, select an appropriate concentration for safe operating temperature within the range of 30 to 60%. Use special tool MB991871 to refill the coolant. A convenient mixture is a 50% water and 50% antifreeze solution [freezing point: -31°C (-32.8°F)]. Recommended antifreeze: MITSUBISHI GENUINE Part number MD970389 or equivalent Quantity: 5.0 dm 3 (5.3 quarts) NOTE: For how to use special tool MB991871, refer to its manufacturer's instructions.
  8. Reinstall the radiator cap.
  9. Start the engine and let it warm up until the thermostat opens.
  10. After repeatedly revving the engine up to 3,000 r/min several times, then stop the engine.
  11. Remove the radiator cap after the engine has become cold, and pour in coolant up to the brim. Reinstall the cap. CAUTION: Do not overfill the reserve tank.
  12. Add coolant to the reserve tank between the "FULL" and "LOW" mark if necessary.

16. BRAKE HOSES (CHECK FOR DETERIORATION OR LEAKS)

Inspection of brake hoses should be included in all brake service operations.

The hoses should be checked for

Scheme 63

Scheme 63: 16. BRAKE HOSES (CHECK FOR DETERIORATION OR LEAKS)
Scheme 63: 16. BRAKE HOSES (CHECK FOR DETERIORATION OR LEAKS)
  1. Incorrect length, severe surface cracking, pulling, scuffing or worn spots. (If the fabric casing of the hoses is exposed by cracks or abrasion in the rubber hose cover, the hoses should be replaced. Eventual deterioration of the hose and possible bursting failure may occur).
  2. Incorrect installation, twisting or interference with wheel, tire or chassis.

Scheme 64

Scheme 64: 17. BALL JOINT AND STEERING LINKAGE SEALS (INSPECT FOR GREASE LEAKS AND DAMAGE)
Scheme 64: 17. BALL JOINT AND STEERING LINKAGE SEALS (INSPECT FOR GREASE LEAKS AND DAMAGE)
  1. These components, which are permanently lubricated at the factory, do not require periodic lubrication. Damaged seals and boots should be replaced to prevent leakage or grease contamination.
  2. Inspect the dust cover and boots for proper sealing, leakage and damage. Replace them if defective.

Scheme 65

Scheme 65: 18. DRIVE SHAFT BOOTS (INSPECT FOR GREASE LEAKS AND DAMAGE)
Scheme 65: 18. DRIVE SHAFT BOOTS (INSPECT FOR GREASE LEAKS AND DAMAGE)
  1. These components, which are permanently lubricated at the factory, do not require periodic lubrication. Damaged seals and boots should be replaced to prevent leakage or grease contamination.
  2. Inspect the dust cover and boots for proper sealing, leakage and damage. Replace them if defective.

SRS Warning Light Check

Turn the ignition key to the "ON" position. Does the "SRS" warning light illuminate for about seven seconds, and then remain off for at least five seconds after turning OFF? If yes, the SRS system is functioning properly. If no, refer to AIR BAG RESTRAINT SYSTEMS .

Scheme 66

Scheme 66: SRS Warning Light Check
Scheme 66: SRS Warning Light Check

SRS Component Visual Check

WARNINGWait at least 60 seconds after disconnecting the battery cable before doing any further work. The SRS system is designed to retain enough voltage to deploy the air bag for a short time even after the battery has been disconnected. Serious injury may result from unintended air bag deployment if work is done on the SRS system immediately after the battery cable is disconnected.
WARNINGBattery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING.

Scheme 67

Scheme 67
Scheme 67
  1. Turn the ignition switch to the "LOCK" (OFF) position, disconnect the negative battery cable and tape the terminal.
  2. Remove the floor console assembly. (Refer to «FRONT FLOOR CONSOLE ASSEMBLY - LANCER»(ref-183638) ).
  3. Disconnect a connector from the SRS-ECU.

Side Impact Sensors

WARNINGIf the side impact sensor is not installed securely and correctly, the side-airbag may not operate normally. If a dent, crack, deformation or rust is detected, replace with a new sensor.
  1. Check the side impact sensor and bracket for dents, cracks or deformation. The side impact sensors are located inside the center pillars (LH/RH).
  2. Check the connector for damage, and terminal for deformation.
  3. Check that there is no bending or corrosion in the center pillars (LH/RH).

Note. The illustration shows the left side impact sensor (LH). The position of the side impact sensor (RH) is symmetrical to this.

Scheme 68

Scheme 68
Scheme 68

SRS Air Bag Control Unit (SRS-ECU)

WARNINGThe SRS may not activate if the SRS-ECU (with built-in safing G-sensor and analog G-sensor) is not installed properly, which could result in serious injury or death to the vehicle's driver and front passenger.
  1. Check the SRS-ECU case and brackets for dents, cracks, deformation or rust.
  2. Check the connector for damage, and check the terminals for deformation or rust. Replace the SRS-ECU if it fails the visual checks above. (Refer to «SRS ELECTRONIC CONTROL UNIT (ECU)»(ref-160459-S21166735852004021000000) ).

Scheme 69

Scheme 69
Scheme 69

Air Bag Module, Steering Wheel and Clock Spring

WARNINGThe removed air bag module should be stored in a clean, dry place with the pad cover face up.

Scheme 70

Scheme 70
Scheme 70

Scheme 71

Scheme 71
Scheme 71

Scheme 72

Scheme 72
Scheme 72

Scheme 73

Scheme 73
Scheme 73
  1. Remove the air bag module, steering wheel and clock spring. (Refer to «DRIVER-SIDE AIR BAG MODULE & CLOCKSPRING»(ref-160459-S18313971602004021000000) ).
  2. Check the pad cover for dents, cracks or deformation.
  3. Check the connector for damage and deformed terminals, and check the harness for binding.
  4. Check the air bag inflator case for dents, cracks or deformation.
  5. Check the harness (built into the steering wheel) and connectors for damage, and check the terminals for deformation.
  6. Check the clock spring connectors and protective tube for damage, and terminals for deformities.
  7. Visually check the case for damage. WARNING: If the clock spring's mating mark is not properly aligned, the steering wheel may not completely rotate during a turn, or the flat cable within the clock spring may be severed, obstructing normal operation of the SRS and possibly leading to serious injury to the vehicle's driver and front passenger.
  8. Align the mating marks of the clock spring first. After turning the front wheels to the straight-ahead position, install the clock spring to the column. Mating Marks Alignment; After turning the clock spring fully clockwise, turn it approximately 3 turns counterclockwise until the mating marks are aligned.
  9. Install the steering column covers, steering wheel and air bag module. (Refer to «DRIVER-SIDE AIR BAG MODULE & CLOCKSPRING»(ref-160459-S18313971602004021000000) ).
  10. Check the steering wheel for noise, binding or difficult operation. WARNING: The SRS may not activate if any of the above components are not installed properly, which could result in serious injury or death to the vehicle's driver and front passenger.
  11. Check the steering wheel for excessive free play. REPLACE ANY PART IF IT FAILS VISUAL INSPECTION. (Refer to «DRIVER-SIDE AIR BAG MODULE & CLOCKSPRING»(ref-160459-S18313971602004021000000) ).

Seat belt with pre-tensioner

WARNINGIf the seat belt pre-tensioner is not installed securely and correctly, the seat belt pre-tensioner may not operate normally. If a dent, crack, deformation or rust is detected, replace with a new seat belt pre-tensioner.
  1. Check the seat belt pre-tensioner for dents or deformation.
  2. Check that the seat belt pre-tensioner is installed correctly to the vehicle body.

Scheme 74

Scheme 74: Wiring Harness
Scheme 74: Wiring Harness
  1. Check the connector for poor connection. WARNING: The SRS system may not operate if SRS harnesses or connectors are damaged or improperly connected, which could result in serious injury or death to the vehicle's driver and front passenger.
  2. Check the harness for binding; check the connectors for damage; and the terminals for deformation. REPLACE ANY CONNECTOR OR HARNESS THAT FAILS THE VISUAL INSPECTION. (Refer to «AIR BAG SAFETY PRECAUTIONS»(ref-160459-S17126993652004021000000) ).

20. EXHAUST SYSTEM (CONNECTIONS, PIPES AND CONVERTER HEAT SHIELDS) (CHECK AND SERVICE AS REQUIRED)

  1. Check for holes and exhaust gas leaks due to damage, corrosion, etc.
  2. Check the joints and connections for looseness and exhaust gas leaks.
  3. Check the rubber hangers and brackets for damage.

21. TIRES (ROTATE)

Rotate tires regularly to equalize tire wear and help extend tire life. Recommended tire rotation is every 12,000 km (7,500 miles) under normal driving conditions and every 9,600 km (6,000 miles) in severe driving conditions.

Timing for the rotation may vary according to vehicle condition, road surface conditions, and individual driver's habits.

When rotating tires, check for uneven wear, damage, and wheel alignment. Abnormal wear is usually caused by incorrect tire pressure, improper wheel alignment, out-of balance wheels, or severe braking.

The first rotation is the most important, to achieve more uniform wear for all tires on the vehicle.

Scheme 75

Scheme 75: 21. TIRES (ROTATE)
Scheme 75: 21. TIRES (ROTATE)

MAIN SEALANT AND ADHESIVE TABLE

APPLICATION3M(tm) NO.LOCTITE(R)/PERMATEX(R)NO.
ENGINE AND DRIVETRAINBetween rocker cover and camshaft bearing cap. Between rocker cover, semicircular packing and cylinder head. Between oil pressure switch and engine.3M(tm) AAD Part No. 8660 Ultrapro High Temp. Silicone Gasket or 3M(tm) AAD Part No. 8679 Black/8678 Black Press-In- Place Silicone gasket stripsPermatex(R) Ultra Black 598, No.82180
Between engine coolant temperature switch, engine coolant temperature sensor, thermo valve, thermo switch, joint, engine coolant temperature gauge unit (large-size) and engine3M(tm) AAD Part No. 8731 Medium Strength Blue ThreadlockerLOCTITE(R)242 Blue Service Tool Removable 24200
Between oil pan and engine block3M(tm) AAD Part No. 8672, 3M(tm) AAD Part No. 8704 or 3M(tm) AAD Part No. 8679/ 3M(tm) AAD Part No. 8678 orPERMATEX(R) Ultra Gray 599, No.82194
WEATHER-STRIPPING FOR GLASSBetween tempered glass, body flanges, and weatherstrip3M(tm) AAD Part No. 8509 Auto Bedding and Glazing Compound or 3M(tm) AAD Part No. 8633 Windo-weld Resealant
WEATHER-STRIPPING FOR GLASSBetween laminated glass and weatherstrip3M(tm) AAD Part No. 8633
INTERIORAdhesive of vinyl chloride cloth3M(tm) AAD Part No. 8088 General Trim Adhesive or 3M(tm) AAD Part No. 8064 Vinyl Trim AdhesivePermatex(R) Vinyl Repair Kit No.81786
Adhesion of door weatherstrip3M(tm) AAD Part No. 8001 (yellow) or 3M(tm) AAD Part No. 8008 (black) Super Weatherstrip Adhesive or 3M(tm) AAD Part No. 8011 Black Weatherstrip AdhesivePERMATEX(R) Super Black Weatherstrip Adhesive No.82, 81850
Sealing of various grommets and packing3M(tm) AAD Part No. 8509 or 3M(tm) AAD Part No. 8678
Adhesion of headliners and various interior decorative materials3M(tm) AAD Part No. 8088 General Trim Adhesive or 3M(tm) AAD Part No. 8090 Super Trim AdhesivePERMATEX(R) Spray Adhesive No.82019

MAIN SEALANT AND ADHESIVE

APPLICATION3M(tm) NO.LOCTITE(R)/PERMATEX(R)NO.
BODY SEALANTSSealing of sheet metal joints, drip rail, floor, side panels, trunk, front panel, tail gate hinge3M(tm) AAD Part No. 8531 Heavy Drip-Check Sealer (gray) or 3M(tm) AAD Part No. 8302 Ultrapro Autobody Sealant (clear) or 3M(tm) AAD Part No. 8361 Urethane A/B Sealant (gray or white)
Miscellaneous body sealants (originally mounted w/ adhesive tape) Waterproof door film Fender panel Splash shield Mud guard Rear combination lamp3M(tm) AAD Part No. 8633 Windo-weld Resealant
Fuel Tank and Pad3M(tm) AAD Part No. 8088 General Trim Adhesive or 3M(tm) AAD Part No. 8090 Super Trim AdhesivePERMATEX(R) Spray Adhesive No.82019
CHASSIS SEALANTSealing of various flange faces and threaded parts. Packing of fuel gauge unit3M(tm) AAD Part No. 8730 High Strength Red Thread lock or 3M(tm) AAD Part No. 8731 Medium Strength Blue ThreadlockerLOCTITE(R)272 High Strength and High Temperature 27200
Sealing of various threaded parts, dust covers. Differential carrier packing, dust covers and ball joint and linkage. Packing and shims of steering box, sealing of rack support cover and top cover of steering box housing, seal of junction face of knuckle arm flange3M(tm) AAD Part No. 8672 Ultrapro High Temp. Silicone Gasket or 3M(tm) AAD Part No. 8679 (black) or 3M(tm) AAD Part No. 8678 (black) Press-In-Place Silicone gasket strips 3M(tm) AAD Part No. 8661 or 3M(tm) AAD Part No. 8663 Super Silicone sealantPERMATEX(R) The Right Stuff No.25223
Seal of brake shoe hold-down pin and wheel cylinder of drum brakes3M(tm) AAD Part No. 8633 Windo-weld Resealant

MAIN SEALANT AND ADHESIVE

APPLICATION3M(tm) NO.LOCTITE(R)/PERMATEX(R)NO.
QUICK FIX ADHESIVE3M(tm) AAD Part No. 8155 Quick Fix AdhesiveLOCTITE(R)Quicktite Super Glue 21309
ANAEROBIC STRONG SEALING AGENTFixing of various threads, bolts, screws. Fixing of differential drive gear bolt, Connecting of tilt steering bolt. Fan, pulley, gear sealing of small gaps and flange faces3M(tm) AAD Part No. 8730 High Strength Threadlocker or 3M(tm) AAD Part No. 8731 Medium Strength ThreadlockerLOCTITE(R)271, High-Strength Threadlocker 27100 or 27200
UNDERCOATING AGENT3M(tm) AAD Part No. 8883 Rubberized Undercoating Aerosol or 3M(tm) AAD Part No. 8864 Body Schutz Undercoating (qt)PERMATEX(R) Heavy-Duty Undercoating 81833

MAIN SEALANT AND ADHESIVE

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