Group 80 MITSUBISHI LANCER 2005 Owners Manual

DOOR
BODY42-36
DOOR HANDLE AND LATCH
REMOVAL AND INSTALLATIONM1423004600328
Pre-removal Operation
•Door Trim Removal (Refer to GROUP 52A, Door trim
P.52A-15.)Post-installation Operation
•Door Inside Handle Play Check (Refer to P.42-30.)
•Door Outside Handle Play Check (Refer to P.42-29.)
•Door Trim Installation (Refer to GROUP 52A, Door trim
P.52A-15.)
AC305110
<FRONT DOOR><REAR DOOR>
5
5.0 ± 1.0 N·m
1
4
9
2
AB
45 2
3
87
5.0 ± 1.0 N·m
1 6
9
NN
89.0 ± 2.0 N·m9.0 ± 2.0 N·m
Door handle and door latch assembly
removal steps
>>C<<1. Door inside handle
•Waterproof film (Refer to P.42-39.)
2. Door outside handle
3. Door lock key cylinder
>>B<<4. Lower sash
5. Door latch assembly6. Inside lock cable (Front door)
7. Inside lock rod (Rear door)
8. Inside handle rod
Door check removal steps
•Waterproof film (Refer to P.42-39.)>>A<<9. Door check Door handle and door latch assembly
removal steps (Continued)

DOOR
BODY42-39
WINDOW GLASS RUNCHANNEL AND
DOOR OPENING WEATHERSTRIP
REMOVAL AND INSTALLATIONM1423003100290
<FRONT DOOR>
AC304409AB
Section A – A
<Front door>
Sealant: 3M ATD Part No.8633 or equivalentDoor
: Sectional view of
clip position
: Sectional view of
clip position
6 2
1
4
365
A A
1
Waterproof film removal steps
•Door trim assembly, speaker (Refer to
GROUP 52A, Trims P.52A-11).
1. Waterproof film
Door inner opening weatherstrip
removal steps
•Scuff plate, centre pillar lower trim
and cowl side trim (Refer to GROUP
52A, Trims P.52A-11.)
2. Door inner opening weatherstrip
(Body side)
Door outer opening weatherstrip
removal steps
•Front door check mounting bolt (Door
side) (Refer to P.42-31.)
<<A>> >>A<<3. Door outer opening weatherstripDoor window glass runchannel
removal
4. Door window glass runchannel
Door beltline inner weatherstrip
removal steps
•Front door trim(Refer to GROUP 52A,
Door trim P.52A-15.)
5. Door beltline inner weatherstrip
Door beltline moulding removal steps
•Door mirror assembly (Refer to
GROUP 51, Door mirror P.51-45.)
•Door window glass (Refer to
P.42-32.)
6. Door beltline moulding

DOOR
BODY42-40
<REAR DOOR>
AC304418AB
Section A – A
Door
: Sectional view of
clip position
: Sectional view of
clip position
6 2 4
5
7
A A
3
Section B – B <Rear door>
Door
6
3
6
BB
Sealant: 3M ATD Part No.8633 or equivalent
1
1
Waterproof film removal steps
•Door trim assembly (Refer to GROUP
52A, Door trim P.52A-15).
1. Waterproof film
Door inner opening weatherstrip
removal steps
•Scuff plate, centre pillar lower trim
and cowl side trim (Refer to GROUP
52A, Trims P.52A-11.)
2. Door inner opening weatherstrip
(Body side)
Door outer opening weatherstrip
removal steps
•Rear door check mounting bolt (Door
side) (Refer to P.42-31.)
3. Retainer weatherstrip
<<A>> >>A<<4. Door outer opening weatherstripDoor window glass runchannel
removal
5. Door window glass runchannel
Door beltline inner weatherstrip
removal steps
•Rear door trim (Refer to GROUP 52A,
Door trim P.52A-15.)
•Centre sash upper (Refer to P.42-32.)
6. Door beltline inner weatherstrip
Door beltline moulding removal steps
•Door window glass (Refer to
P.42-32.)
•Stationary glass (Refer to P.42-32.)
7. Door beltline moulding

TRUNK LID
BODY42-43
TRUNK LID
REMOVAL AND INSTALLATIONM1421002200180
AC301676
Y0636AU
Y0637AU
AB
1
2
3
45
5
6
7 89
10
99
11
12
8.9 ± 1.9 N·m A
A
B
B15 mm
14 mm
5Section A - A
Section B - B
Trunk lid weatherstrip removal steps
•Rear end trim (Refer to GROUP 52A,
Trims P.52A-11.)
>>B<<1. Trunk lid weatherstrip
Trunk lid release cable and trunk lid
release handle removal steps
•Rear end trim (Refer to GROUP 52A,
Trims P.52A-11.)
•Trunk rear side trim (LH) (Refer to
GROUP 52A, Trims P.52A-11.)
•Front scuff plate (LH) (Refer to
GROUP 52A, Trims P.52A-11.)
•Cowl side trim (LH) (Refer to GROUP
52A, Trims P.52A-11.)
•Rear scuff plate (LH) (Refer to
GROUP 52A, Trims P.52A-11.)
•Centre pillar lower trim (Refer to
GROUP 52A, Trims P.52A-11.)
•Rear seat (Refer to GROUP 52A,
Rear seat assembly P.52A-28.)
•Accelerator pedal stopper (Refer to
GROUP 17, Accelerator pedal
P.17-3.)
2. Trunk lid release handle
3. Trunk lid release cableTrunk lid striker removal steps
•Rear end trim (Refer to GROUP 52A,
Trims P.52A-11.)
4. Trunk lid striker
Trunk lid panel removal steps
•Licence plate garnish (Refer to
GROUP 51, Garnishes P.51-17.)
5. Trunk lid bumper
•Rear spoiler (Refer to GROUP 51,
Rear spoiler P.51-18.)
6. Trunk lid lock cylinder
7. Trunk lid latch assembly
8. Trunk lid hinge mounting bolt
9. Trunk lid panel assembly
Trunk lid latch removal
7. Trunk lid latch assembly
Trunk lid hinge removal steps
•Rear shelf trim (Refer to GROUP
52A, Trims P.52A-11.)
•Rear seat (Refer to GROUP 52A,
Rear seat assemblyP.52A-28.)
9. Trunk lid panel assembly
<<A>> >>A<<10. Trunk lid torsion bar (RH)
<<A>> >>A<<11. Trunk lid torsion bar (LH)
12. Trunk lid hinge

TA I L G AT E
BODY42-46
TA I L G AT E
SERVICE SPECIFICATIONSM1421000300288
SEALANTSM1424000500098
SPECIAL TOOLM1424000600170
TROUBLESHOOTINGM1424000700207
The tailgate system 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.
ON-VEHICLE SERVICE
TAILGATE FIT ADJUSTMENTM1424000900137
1. If the striker and latch mesh badly, replace the
striker and striker installation blots with
replacement parts (striker: MR523105, striker
installation blot: MU000474).2. Move the replaced striker forward and backward
or to the left and right to adjust, after bolt the
striker temporarily.
3. After adjusting, tighten the bolts to the specified
torque [24 ± 4 N⋅m]. Item Standard value
Tailgate handle play 2.3 to 5.9 mm
Item Specified sealant
Tailgate waterproof film 3M ATD Part No.8633 or equivalent
Tailgate hinge 3M ATD Part No.8531 Heavy drip check sealer, 3M
ATD Part No.8646 Automotive joint and seam sealer
or equivalent
Tool Number Name Use
MB991223
A: MB991219
B: MB991220
C: MB991221
D: MB991222Harness set
A: Test harness
B: LED harness
C: LED harness
adapter
D: ProbeTerminal voltage measurement
A: For checking connector pin
contact pressure
B: For checking power supply
circuit
C: For checking power supply
circuit
D: For connecting a locally
sourced tester
MB991223
A
D C
B
AD
AC203659

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

TA I L G AT E
BODY42-48
TAILGATE
REMOVAL AND INSTALLATIONM1424001100178
CAUTION
•Do not disassemble or throw the tailgate gas spring into fire.
•Punch a hole in the gas spring before disposal to release the gas inside.
•Ensure the tailgate gas spring piston rod does not come into contact with foreign material.
Pre-removal Operation
•Tailgate Spoiler Assembly Removal (Refer to GROUP 51,
Tailgate Spoiler P.51-19).
•Tailgate Trim Assembly Removal (Refer to GROUP 52A,
Tailgate Trim P.52A-19).
•Rear Wiper Motor Removal (Refer to GROUP 51, Rear
Wiper and Washer P.51-29).Post-installation Operation
•Tailgate Fit Adjustment (Refer to P.42-46).
•Rear Wiper Motor Installation (Refer to GROUP 51, Rear
Wiper and Washer P.51-29).
•Tailgate Trim Assembly Installation (Refer to GROUP
52A, Tailgate Trim P.52A-19).
•Tailgate Spoiler Assembly Installation (Refer to GROUP
51, Tailgate Spoiler P.51-19).
AC304836
7
3
4 1
6
8
12 ± 2 N·m
13 ± 2 N·m22 ± 4 N·m
AB
Sealant: 3M ATD Part No. 8633 or equivalent9.0 ± 2.0 N·m
2
712 ± 2 N·m
5
7
9
5.0 ± 1.0 N·m
5.0 ± 1.0 N·m
3
11
10

TA I L G AT E
BODY42-49
INSTALLATION SERVICE POINT
>>A<< TAILGATE OPENING
WEATHERSTRIP INSTALLATION
Assemble so the tailgate opening weatherstrip
marking is at the centre of the body.
AC305322
Adhesive: 3M ATD Part No.8531 Heavy drip check sealer, 3M ATD Part No.8646 Automotive joint and seam sealer
or equivalent
AB
7
Tailgate assembly removal steps
1. Rear washer hose
2. Tailgate wiring harness
3. Waterproof film
4. Tailgate gas spring
5. Antenna feeder cable
6. Tailgate assembly
7. Tailgate hinge
8. Bumper•Rear end trim (Refer to GROUP 52A,
Trims P.52A-11.)
9. Striker
10. Dynamic damper
Tailgate opening weatherstrip removal
4. Tailgate gas spring
>>A<<11. Tailgate opening weatherstrip Tailgate assembly removal steps
AC305091
Positioning
mark
AB
Tailgate opening
weatherstrip
Rear bumper end
Tailgate opening
weatherstrip SECTION A – AA
A
Hatching

TA I L G AT E
BODY42-50
TAILGATE HANDLE AND LATCH
REMOVAL AND INSTALLATIONM1424001700170
Pre-removal Operation
•Tailgate Handle Play Check (Refer to P.42-47).
Y1518AU
Y1520AU
AC305141
4
5
6
3 35
5.0 ± 1.0 N·m
9.0 ± 2.0 N·m
AB
2
1
22 ± 4 N·m
Striker removal steps
•Rear end trim (Refer to GROUP 52A,
Trims P.52A-11.)
>>A<<1. Striker
Tailgate handle and lock key cylinder
removal steps
•Lower tailgate trim (Refer to GROUP
52A, Tailgate Trim P.52A-19.)
•Waterproof film (Refer to P.42-48.)
2. Bolt (earth)
3. Tailgate latch assembly
4. Tailgate lock key cylinder
5. Tailgate handleTailgate latch removal steps
•Lower tailgate trim (Refer to GROUP
52A, Tailgate Trim P.52A-19.)
•Waterproof film (Refer to P.42-48.)
2. Bolt (earth)
3. Tailgate latch assembly
Tailgate lock actuator removal steps
•Lower tailgate trim (Refer to GROUP
52A, Tailgate Trim P.52A-19.)
•Waterproof film (Refer to P.42-48.)
6. Tailgate lock actuator

KEYLESS ENTRY SYSTEM
BODY42-53
TROUBLESHOOTINGM1428000700287
The keyless entry system 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.
ON-VEHICLE SERVICE
KEYLESS ENTRY SYSTEM CHECKM1428001400096
Check the system as described below. If the system
does not work, carry out troubleshooting. Refer to
GROUP 54B, Troubleshooting P.54B-17, refer to
GROUP 54C, Troubleshooting P.54C-4.
•Operate the transmitter to check that the doors
and tailgate can be locked and unlocked.
•Operate the transmitter to check that the
answerback function works in response to door
and tailgate <Wagon> locking/unlocking.
NOTE: The adjustment function allows you to
change the answerback setting as follows. Prior
to that check, confirm which setting is activated.
.
•The hazard warning lamps flash twice when
locked and once when unlocked. The room
lamp flashes twice when locked and
illuminates for 15 seconds when unlocked.
•The hazard warning lamps do not flash when
locked and flash once when unlocked. The
room lamp flashes twice when locked and
illuminates for 15 seconds when unlocked.
•The hazard warning lamps flash twice when
locked and do not flash when unlocked. The
room lamp flashes twice when locked and
illuminates for 15 seconds when unlocked.
•The hazard warning lamps do not flash when
both locked and unlocked. The room lamp
flashes twice when locked and illuminates for
15 seconds when unlocked.
KEYLESS ENTRY SYSTEM TIMER LOCK
FUNCTION INSPECTION
M1428004000138
Push the transmitter unlock button and check to see
that the doors and tailgate <Wagon> lock within 30
seconds. If it doesn't, then execute troubleshooting
remedies. Refer to GROUP 54B, Troubleshooting
P.54B-17, refer to GROUP 54C, Troubleshooting
P.54C-4.
ENABLING/DISABLING THE
ANSWERBACK FUNCTION
M1428003200214
If the keyless entry system locks or unlocks the
doors, the room lamp flashes or illuminates, the
hazard warning lamp flashes (hazard answerback
function). The hazard answerback function can be
enabled or disabled according to the following
procedure:
ENABLING/DISABLING THE HAZARD
ANSWERBACK FUNCTION
The hazard answerback function can be enabled or
disabled by one of the two following procedures.
<When using the transmitter after
diagnosis connector (1) is earthed>
1. Enter the hazard answerback customize mode by
performing one of the following steps. If the
ETACS-ECU enters the customize mode, its
buzzer will sound once.
(1) Turn the ignition switch to “LOCK”(OFF)
position.
(2) Turn off the hazard warning lamp switch.
CAUTION
Before connecting or disconnecting the earth,
turn the ignition switch to the "LOCK" (OFF)
position.
(3) Connect the diagnosis connector to the
special tool diagnosis code check harness
(MB991529).
(4) Close the driver's side door.
(5) Keep the windshield washer switch on for at
least ten seconds. Then the ETACS-ECU
buzzer will sound once.
2. If the transmitter “LOCK” button is pushed
consecutively twice (within two seconds), the
ETACS-ECU buzzer will sound, indicating that the
hazard answerback function can be enabled or
disabled when the doors are locked.
AC305133AB
Diagnosis
connector
MB991529Steering shaft