service MITSUBISHI LANCER 2005 Workshop Manual

WINDOW GLASS
BODY42-17
REMOVAL SERVICE POINTS
<<A>> REAR WINDOW LOWER
MOULDING REMOVAL
CAUTION
If the drip moulding has become warped, it
should not be reused.
Use special tool ornament remover (MB990784) to
lever out the moulding.
<<B>> REAR WINDOW GLASS REMOVAL
Removal the rear window glass using the same
procedure as for the windshield. (Refer to P.42-12.)
INSTALLATION SERVICE POINTS
>>A<< GLASS STOPPER/WINDOW
DAM/REAR WINDOW UPPER
MOULDING/REAR WINDOW GLASS
INSTALLATION
1. When replacing the rear window glass,
temporarily set the rear window glass against the
body, and place a mating mark on the rear
window glass and body.
CAUTION
Leave the degreased parts for 3 or more minutes
to dry well, before starting on the next step. Do
not touch the degreased parts.
2. Use isopropyl alcohol to degrease the inside and
outside of the rear window glass and the body
flanges.
CAUTION
•The primer strengthens the adhesive, so be
sure to apply it evenly around the entire
circumference. However, a too thick
application will weaken the adhesive.
•Do not touch the coated surface.
3. Soak a sponge in the primer, and apply evenly to
the rear window glass and the body in the
specified places.
4. Allow the rear window glass to dry for at least 3
minutes after applying primer.
>>A<<9. Window dam
>>A<<10. Glass stopperRemoval steps (Continued)
AC006073
AB
MB990784

WINDOW GLASS
BODY42-20
REMOVAL SERVICE POINT
<<A>> QUARTER WINDOW GLASS
REMOVAL
1. Apply cloth tape to protect the quarter window
glass.
2. Use glass adhesive knife to cut away adhesive.
CAUTION
Inserting the adhesive knife too deeply into
windshield adhesive may damage quarter
window glass.
3. Keep the glass adhesive knife at right angles with
body flange (from inside the vehicle), and put the
blade at body flange. Then cut away adhesive
along the body flange.4. Make mating marks on the quarter window glass
and body.
5. Use special tool glass holder (MB990480) to
remove the quarter window glass.
CAUTION
•Be careful not to remove more adhesive than
is necessary.
•Be careful also not to damage the paintwork
on the body surface with the knife. If the
paintwork is damaged, repair the damaged
area with repair paint or anti-rust agent.
6. Use a knife to cut away the remaining adhesive so
that the thickness is within 2 mm around the entire
circumference of the body flange.
7. Finish the flange surfaces so that they are
smooth.
CAUTION
Allow the cleaned area to dry for at least three
minutes. Do not touch any surface that has been
cleaned.
8. When reusing the quarter window glass, remove
the adhesive still adhering to the quarter window
glass, and clean with isopropyl alcohol.
9. Clean the body side in the same way.
AC103600
ADCloth tape
AC002060
AC301614AB
Glass adhesive knife
AC103605AD
MB990480
ACX00476
AB

WINDOW GLASS
BODY42-21
INSTALLATION SERVICE POINTS
>>A<< GASKET/CLIP/DUAL LOCK
FASTENER INSTALLATION
1. Carry out the following procedure to re-install
quarter window glass.
CAUTION
Do not forget gasket.
(1) Fit clips into body.
(2) Cut away clip fitting convex on quarter window
glass.
NOTE: Convex gets broken when quarter
window glass is removed.
CAUTION
Leave the degreased parts for 3 or more minutes
to dry well, before starting on the next step. Do
not touch the degreased parts.
2. Use isopropyl alcohol to degrease the inside and
outside of the quarter window glass and the body
flanges.
3. Assemble the dual lock fastener according to the
standard location of the body flange.
4. Assemble the dual lock fastener to the quarter
window glass relative to the body flange dual lock
fastener.
>>B<< QUARTER WINDOW GLASS
INSTALLATION
Remove the quarter window glass using the same
procedure as for the windshield removal (Refer to
P.42-12).
AC103606
AC
Cut off these convex parts
AC304793AB
Dual lock fastener
Install the dual lock fastener
with aligning it onto the bumps
of the body flange.

WINDOW GLASS
BODY42-23
REMOVAL SERVICE POINT
<<A>> TAILGATE WINDOW GLASS
REMOVAL
Remove the tailgate window glass using the same
procedure as for the windshield (Refer to P.42-12).
INSTALLATION SERVICE POINTS
>>A<< WINDOW SPACER/GLASS
STOPPER/DUAL LOCK
FASTENER/WINDOW DAM
INSTALLATION
CAUTION
Leave the degreased parts for 3 or more minutes
to dry well, before starting on the next step. Do
not touch the degreased parts.
1. Use isopropyl alcohol to degrease the inside and
outside edges of the tailgate window glass and
the surface of the tailgate flange.
Removal steps
1. Connecting the harness connector
<<A>> >>B<<2. Tailgate window glass
>>A<<3. Window lower dam
>>A<<4. Window side dam
>>A<<5. Dual lock fastener
>>A<<6. Glass stopper
>>A<<7. Window spacerRemoval steps (Continued)

DOOR
BODY42-25
DOOR
SERVICE SPECIFICATIONSM1423000300091
SEALANTM1423000500095
SPECIAL TOOLSM1423000600337
ItemStandard value
Power window operation current (Power supply voltage 14.5 ± 0.5 V, at 25 °C) A 5 ± 1
Door outside handle play mm Front door 2.6 ± 2.5
Rear door 1.3 ± 1.3
Door inside handle play mm Front door 10.4 ± 9.6
Rear door 10 ± 9.6
Item Specified sealant
Door waterproof film 3M ATD Part No.8633 or equivalent
Tool Number Name Use
MB990480 Window glass holder Removal of power window regulator
assembly
MB990900 or
MB991164Door hinge adjusting
wrenchDoor alignment
MB990925
A: MB990939Bearing and oil seal
installer set
A: Brass barDoor striker adjustment
MB990211 Sliding hammer
MB990241
A: MB990243Axle shaft puller
A: Body puller
MB990480
MB990900
MB990925AF
A
MB990211
MB990241
A
AE

DOOR
BODY42-27
ON-VEHICLE SERVICE
DOOR FIT ADJUSTMENTM1423001100175
CAUTION
•Attach protection tape to the fender and door
edges where the hinge is installed.
•Do not rotate special tool door adjusting
wrench (MB991164) with a torque of over 98
N⋅m
1. Use the special tool door adjusting Wrench
(MB990900 or MB991164) to loosen the hinge
mounting bolts on the body side, and then adjust
the clearance around the door so that it is uniform
on all sides.
2. If a door is not flush with its surrounding panels,
loosen the door-side door hinge mounting bolts
and obtain the flushness by moving the door.
NOTE:
If the door hinge mounting bolt washers are
welded, grind off the welding according to the
procedure below beforehand.
.
1. Remove the door hinge (Refer to P.42-31).
2. Use a chisel or grinder to release the door
hinge mounting bolt washers, which are
welded to the door hinge.
3. On completion, paint the affected area with a
suitable touch-in brush to prevent corrosion.
4. Install the door hinge (Refer to P.42-31).3. When the door is stiff to lock and unlock
(1) Adjustment by using the striker (toward the
inside of the vehicle and vertical direction)
Install a temporary bolt instead of the striker
mounting bolts, and use special tool brass bar
(MB990939) and a hammer to tap the bolt to
the desired direction.
(2) Adjustment by using the striker (toward the
outside of the vehicle)
Use special tools slide hammer (MB990211)
and body puller (MB990243) to pull the striker
toward the outside of the vehicle.
(3) Adjustment by using shims (forward and
rearward)
Increase or decrease the number of shims so
that the striker engages with the door latch
properly.
AC000592
MB990900
or
MB991164
AB
AC206498
WasherBolts Washer
Door hinge
AF
Weld point Weld point
AC006109AB
Temporary
boltStriker MB990939
AC006110
StrikerMB990211
MB990243
AB
AC006111AB
Shim
Striker

DOOR
BODY42-32
INSTALLATION SERVICE POINT
>>A<< STRIKER INSTALLATION
Align the centre of the striker and latch within ±1.5
mm, and install.
INSPECTIONM1423006000322
DOOR SWITCH CHECK
DOOR GLASS AND REGULATOR
REMOVAL AND INSTALLATIONM1429001300315
AC305098AB
Striker centre
StrikerLatch centre
Latch +1.5 mm
-1.5 mm
Switch
positionTester
connectionSpecified
condition
Released (ON) 1 − switch body,
2 − switch body,
3 − switch body Less than 2
ohms
Depressed
(OFF)1 − switch body,
2 − switch body,
3 − switch body Open circuit
AC211414
123
AC
Post-installation Operation
•Door Window Glass Adjustment (Refer to P.42-28).
AC212124AB
<FRONT DOOR> <REAR DOOR>
1
23
1
2 345
6

DOOR
BODY42-34
REMOVAL SERVICE POINTS
<<A>> WINDOW REGULATOR
ASSEMBLY/POWER WINDOW
REGULATOR MOTOR ASSEMBLY
REMOVAL
1. Remove the door window glass installation bolts.
CAUTION
If film or others are adhered to the door window
glass, attach special tool window glass holder
(MB990480) to the outside of the glass to prevent
the film from peeling off.
2. Lift the door window glass, and attach special tool
window glass holder (MB990480) to the glass as
shown to prevent the glass from falling.
3. Remove the window regulator assembly and
power window motor assembly
<<B>> CENTRE SASH UPPER REMOVAL
1. Remove the door outer opening weatherstrip from
the centre sash upper only.
2. Remove the centre sash upper mounting screws,
and then remove the centre sash upper from the
door panel.
INSTALLATION SERVICE POINTS
>>A<< CENTRE SASH UPPER
INSTALLATION
Securely insert the centre sash upper into the
window rear sash (door).
>>B<< WINDOW REGULATOR
ASSEMBLY/POWER WINDOW
REGULATOR MOTOR ASSEMBLY
INSTALLATION
When installing the window regulator assembly,
tighten the bolts to the specified torque in the order
shown.
INSPECTIONM1429001400282
How to make the power window switch
learn the fully closed position of the
power window
How to make the power window switch
learn the fully closed position when the
power window switch is removed, or the
power window regulator assembly is
removed or replaced
1. If the anti-trap function (safety mechanism) is
activated consecutively three times or more, the
fully closed position that the power window switch
has learned will be erased (initialised).
2. Operate the power window switch and fully open
the door window glass.
AC100009
AB
MB990480
AC000602
Door outer
opening
weatherstrip
Door centre
sash
AB
Y1536AU
Y1476AUAC100010
AB
<FRONT DOOR>
<REAR DOOR>
1
2 34
5 67
1
2 34
56

DOOR
BODY42-37
INSTALLATION SERVICE POINTS
>>A<< DOOR CHECK INSTALLATION
Install the door check so that the identification mark
faces upwards.
>>B<< LOWER SASH INSTALLATION
Securely insert the rear lower sash into the window
rear sash.
>>C<< DOOR INSIDE HANDLE
INSTALLATION
1. Install the inside lock cable to the door inside
handle as follows:
(1) Install the inner cable end in the inside lock
cable to the clip in the door inside handle.
(2) Turn the inside lock knob to the door lock
position.
(3) Install the outer cable end to the door inside
handle securely.
(4) Install the clip to the inner cable.2. Install the inside handle rod to the door inside
handle.
3. Install the door inside handle to the door.
INSPECTIONM1423004700392
FRONT DOOR LOCK ACTUATOR CHECK
Actuator Operation Check Item Identification
mark
Front Door Left door 39L
Right door 39R
Rear Door Left door 40L
Right door 40R
ACX00541
Identification mark
AB
AC100404
AB
Clip Inner cable
Outer cable end
Inside handle rodDoor inside handleLever
positionBattery connection Lever
operation
At the
"LOCK"
position•Connect terminal
No. 4 and the
negative battery
terminal.
•Connect terminal
No. 6 and the
positive battery
terminal.The lever
moves from the
"LOCK"
position to the
"UNLOCK"
position.
At the
"UNLOCK"
position•Connect terminal
No. 6 and the
negative battery
terminal.
•Connect terminal
No. 4 and the
positive battery
terminal.The lever
moves from the
"UNLOCK"
position to the
"LOCK"
position.
42
53
6 1
42
53
6 1
AC305111B
A
AB
LockUnlock
View A
View B Unlock
Lock Front door<Left side>
<Right side>Lever
Lever

TRUNK LID
BODY42-41
REMOVAL SERVICE POINT
<<A>> DOOR OUTER OPENING
WEATHERSTRIP REMOVALMake a fabricated tool as shown in the illustration to
remove the door weatherstrip.
INSTALLATION SERVICE POINT
>>A<< DOOR OUTER OPENING
WEATHERSTRIP INSTALLATION
The clip colour identifies the left and right
weatherstrips so be sure to use the colours so as to
install correctly.
TRUNK LID
SPECIAL TOOLM1421000600245
ON-VEHICLE SERVICE
TRUNK LID ADJUSTMENTM1421001000042
1. If the clearance around the trunk lid panel
assembly is not uniform and locking and
unlocking of the trunk lid is difficult, make
adjustments to the trunk lid bumpers (refer to
P.42-42) and trunk lid hinges (refer to P.42-42).
2. If the clearance around the trunk lid panel
assembly is uniform, but locking and unlocking of
the trunk lid is difficult, make adjustments to the
trunk lid bumpers (refer to P.42-42) and trunk lid
striker (refer to P.42-42).
ACX00555
15 mm
8 mm
AB
4 mm
Thickness:
1 mm
Fabricated
tool
Applicable side Identification colour
Right door Pink
Left door Natural (White)
TOOL Number Name Use
MB991244 Torsion bar remover and
installerRemoval and installation of
trunk lid torsion bar
MB991244
AC202324
AC202325AC202913
A
A AA
AB
Section A – A
Trunk lid panel assembly
Side outer panel Trunk lid panel
assembly
Side outer panel