MITSUBISHI LANCER 2005 Workshop Manual

FRONT BUMPER ASSEMBLY
EXTERIOR51-3
DISASSEMBLY AND REASSEMBLYM1511001600460
Removal steps
1. Splash shield mounting clip
2. Radiator grill assembly
3. Front bumper assembly•Fog lamp connector connection
4. Front bumper beam assembly
5. Front bumper fixing clip Removal steps (Continued)
AC304652AC
Double-sided tape: Generic products
[ 20 mm width and 0.8 mm thickness ]
1
1
8
7
9
6
6
5
5
3
4
34
N
N
2
Removal steps
1. Front three-diamond mark
2. Under duct
3. Air intake bezel <Vehicle without fog
lamp>
4. Fog lamp bezel <Vehicle with fog
lamp><<A>> >>A<<5. Front bumper rivet
6. Front bumper side plate
7. Front bumper centre cover
8. Licence plate garnish
9. Front bumper face Removal steps (Continued)

FRONT BUMPER ASSEMBLY
EXTERIOR51-4
DISASSEMBLY SERVICE POINT
<<A>> FRONT BUMPER SIDE PLATE
ASSEMBLY REMOVAL
Use a drill (4.0 mm) to make a hole in the rivet to
break it, and then remove the rivet.
REASSEMBLY SERVICE POINT
>>A<< FRONT BUMPER SIDE PLATE
ASSEMBLY
Use the rivet tool shown in the illustration to attach
the rivet by the following procedure.
1. Insert the rivet into the base material front bumper
side plate assembly.
2. Place the recommended tool over section A of the
rivet.
3. While pushing the flange surface of the rivet with
the recommended tool, press the handle of the
tool.
4. The thin part of section A of the rivet will break
and the rivet will then be attached.
AC100411AB
Rivet Drill
Bumper face
AC305178AB
1
2
3
4Section A
Rivet
Rivet tool
Flange
Rivet Front bumper
side plateRivet tool
Front bumper
face
Front bumper face

REAR BUMPER ASSEMBLY
EXTERIOR51-5
REAR BUMPER ASSEMBLY
REMOVAL AND INSTALLATIONM1511001900397
Pre-removal and Post-installation Operation
•Rear Combination Light Removal and Installation.
<Sedan> (Refer to GROUP 54A, Rear Combination Lamp
P.54A-79.)
•Rear End Trim Removal and Installation. (Refer to
GROUP 52A, Trims P.52A-11.)
•Rear Splash Shield Removal and Installation.
AC300413
AC305045
ClipRear bumper assemblyRear bumper assembly Section A – A Section B – B
ClipRear bumper
assembly
AB
B
BA
AB
B <Sedan>

REAR BUMPER ASSEMBLY
EXTERIOR51-6
AC300199
AC305046
A
A
B
BC
C
Clip
Clip
Rear bumper
assembly
Clip Section A – A Section B – B Section C – C
Rear bumper
assembly
Rear bumper
assembly
Rear bumper assembly <Wagon>

REAR BUMPER ASSEMBLY
EXTERIOR51-7
DISASSEMBLY AND REASSEMBLYM1511002100349
AC300414
AC304191
1
2
8
N
3
4
5
6
AB
<Sedan>
AC300200
AC304193
1
2
8
N
3
4
5
7
6
AB
<Wagon>
Disassembly steps
<<A>> >>A<<1. Rivets
2. Rear bumper side plate assembly
3. Rear bumper centre reinforcement
4. Rear fog lamp bracket5. Rear fog lamp assembly
6. Rear fog lamp bezel
7. Extension
8. Rear bumper face Disassembly steps (Continued)

REAR BUMPER ASSEMBLY
EXTERIOR51-8
DISASSEMBLY SERVICE POINT
<<A>> RIVET REMOVAL
Use a drill (4.0 mm) to make a hole in the rivet to
break it, and then remove the rivet.
ASSEMBLY SERVICE POINT
>>A<< RIVET INSTALLATION
Use the rivet tool shown in the illustration to attach
the rivet by the following procedure.
1. Insert the rivet into the rear bumper face and rear
bumper side plate.
2. Insert “A” of the rivet into the rivet tool.
3. Pressing the flange surface of the rivet, move the
handle of the rivet tool.
4. The thinnest point of “A” is cut and the rivet is held
in position.
AC100411AB
Rivet Drill
Bumper face
Y0412AU
AC00587618E0192AB
1
2
3
4Section A
Rivet
Flange
Rivet Rear bumper
side plateRear bumper
face
Rear bumper face
Recommended tool
Recommended
tool

MOULDINGS
EXTERIOR51-9
MOULDINGS
SPECIAL TOOLM1511000601136
ADHESIVEM1511000500749
Tool Number Name Application
MB990449 Window moulding remover Removal of drip moulding
MB990449
Application Specified adhesive
Front fender, front and rear door mouldings Double-sided tape [a: 6 mm width 1.2 mm thickness,
b: 20 mm width 1.2 mm thickness ]

MOULDINGS
EXTERIOR51-10
MOULDINGS
REMOVAL AND INSTALLATIONM1511004700295
AC304339 Y0622AU
Y0624AUY0623AU
Y0729AU
W0740AU
Section A – A
<Sedan>Section B – B Section C – C Section D – D
Section E – E
AB
N
N
N
N
N
C
C
EE
DD
B
B
A
A
1
2
6
4
3
5
7
8
9
N
N
N
111
98
51
1
6, 7
2, 3, 4

MOULDINGS
EXTERIOR51-11
REMOVAL SERVICE POINT
<<A>> ROOF DRIP MOULDING REMOVAL
CAUTION
If the moulding has become warped, it should not
be reused.
Use special tool window moulding remover
(MB990449) to lever out the moulding.
AC304340
1
1
A
A
A
A
AB
B
B
C
C
C
C
B
B
N
N
N
2
N2
4
3
N3
N4
N
6
9
7
N
6N
N
7N
N9
<Wagon>
<Vehicle with roof rail> <Vehicle without roof rail>
Removal
•Front deck garnishes (Refer to
P.51-23.)
Roof drip moulding removal steps
<<A>> >>C<<1. Roof drip moulding
>>B<<2. Front drip moulding clip A
>>B<<3. Front drip moulding clip B
>>B<<4. Front drip moulding clip C
>>B<<5. Rear drip moulding clip
>>A<<6. Drip moulding clip A
>>A<<7. Drip moulding clip B
>>A<<8. Drip moulding clip C
9. Roof drip moulding clip Roof drip moulding removal steps
AC304375MB990449AB

MOULDINGS
EXTERIOR51-12
INSTALLATION SERVICE POINTS
>>A<< DRIP MOULDING CLIP C/DRIP
MOULDING CLIP B/DRIP MOULDING
CLIP A INSTALLATION
1. The drip moulding clips A, B and C differ
according to where they are used, so check the
identification colour before installation.
2. After installing the clip to the front pillar outer in
alignment with its section A, cut from section B.
>>B<< REAR DRIP MOULDING
CLIP/FRONT DRIP MOULDING CLIP
C/FRONT DRIP MOULDING CLIP
B/FRONT DRIP MOULDING CLIP A
INSTALLATION
The front drip moulding clips A, B, C and rear drip
moulding clip differ according to where they are
used, so check the identification colour before
installation.
>>C<< ROOF DRIP MOULDING
INSTALLATION
Install the clips to the roof drip moulding before
installing the moulding to the vehicle body. Applicable location Identification colour
Drip moulding clip A Yellow
Drip moulding clip B Blue
Drip moulding clip C Milky white
AC304374
Front pillar outer
Section B
Section A
AB
Applicable location Identification colour
Front drip moulding clip A Orange
Front drip moulding clip B Purple
Front drip moulding clip C Blue
Rear drip moulding clip Grey