rear MITSUBISHI LANCER 2005 Repair Manual

POWER STEERING HOSES
POWER STEERING37-43
<RH drive vehicles>
•Centermember (Refer to GROUP 32,
Engine Roll Stopper Centermember
P.32-7).
•Front exhaust pipe (Refer to GROUP
15, Exhaust Pipe and Main Muffler
P.15-11).
4. Steering gear and joint connecting
bolt
5. Rear roll stopper connecting bolt
6. Rear roll stopper (Refer to GROUP
32, Engine Roll Stopper
Centermember P.32-7).
<<A>>7. Eye boltRemoval steps (Continued)
8. Gasket
9. Pressure hose assembly
10. Return tube
>>A<<11. Return hose
<<A>>12. Return tube
13. O-ringRemoval steps (Continued)
AC304698AB
15 ± 3 N·m
18 ± 2 N·m
167 ± 9 N·m 12 ± 2 N·m
49 ± 10 N·m 12 ± 2 N·m
57 ± 7 N·m*
3 1
2
9
10
7
5 6
24
8857 ± 7 N·m
167 ± 9 N·m
Crossmember12 ± 2 N·m <1300, 1600>
<2000>
7
6
57 ± 7 N·m
7 6
57 ± 7 N·m
7
6
57 ± 7 N·m
12 ± 2 N·m
Removal steps
1. Oil reservoir
>>C<<2. Suction hose
>>B<<3. Return hose•Clock spring (Refer to GROUP 52B,
Air Bag Modules and Clock Spring
P.52B-210). Removal steps (Continued)

POWER STEERING HOSES
POWER STEERING37-44
REMOVAL SERVICE POINT
<<A>> EYE BOLT/RETURN TUBE
REMOVAL
CAUTION
If the joint cover grommet has been removed,
install it properly as follows.
Align the joint cover grommet notch (arrow A)
with the steering gear lug (arrow B), and then
install the steering joint cover to the steering
gear.
1. Loosen the crossmember mounting bolts and
nuts, and lower the crossmember to a position so
that the eye bolts or return tube at the steering
gear side can be removed.
NOTE: In this case, do not remove the
crossmember mounting bolts and nuts.
2. Remove the eye bolts or return tube.
INSTALLATION SERVICE POINTS
>>A<< RETURN HOSE INSTALLATION
<LH DRIVE VEHICLES>
Install the return hose so that the marking is
positioned as shown in the illustration.
>>B<< RETURN HOSE INSTALLATION
Install the return hose so that the markings are
positioned as shown in the illustration.
>>C<< SUCTION HOSE INSTALLATION
Install the suction hose (oil pump side) so that the
marking is positioned forward.
•Centermember (Refer to GROUP 32,
Engine Roll Stopper Centermember
P.32-7).
•Front exhaust pipe (Refer to GROUP
15, Exhaust Pipe and Main Muffler
P.15-11).
4. Steering gear and joint connecting
bolt
5. Rear roll stopper connecting bolt
<<A>>6. Eye bolt
7. Gasket
8. Pressure hose assembly
<<A>>9. Return tube
10. O-ringRemoval steps (Continued)
AC304922AB
A
B Joint cover
grommet
Steering gear
AC100277
ABReturn hose
AC305132AB
Return hose
Return tubeReturn hose <L.H. drive vehicles> <R.H. drive vehicles>

42-1
GROUP 42
BODY
CONTENTS
HOOD . . . . . . . . . . . . . . . . . . . . .
42-3
ON-VEHICLE SERVICE. . . . . . . . .
42-3
ADJUSTMENT OF CLEARANCE
AROUND HOOD . . . . . . . . . . . . . . . . . . 42-3
ADJUSTMENT OF ALIGNMENT OF
HOOD STEPPED PORTION AND
HOOD STRIKER . . . . . . . . . . . . . . . . . . 42-3
ADJUSTMENT OF HOOD HEIGHT . . . 42-3
HOOD . . . . . . . . . . . . . . . . . . . . . . .42-4
REMOVAL AND INSTALLATION . . . . . 42-4
FENDER . . . . . . . . . . . . . . . . . . .42-5
SPECIAL TOOL . . . . . . . . . . . . . . .
42-5
FENDER . . . . . . . . . . . . . . . . . . . . .42-6
REMOVAL AND INSTALLATION . . . . . 42-6
FUEL FILLER LID . . . . . . . . . . .42-8
REMOVAL AND INSTALLATION .
42-8
STRUT TOWER BAR . . . . . . . .42-9
REMOVAL AND INSTALLATION .
42-9
WINDOW GLASS . . . . . . . . . . . 42-9
ADHESIVE . . . . . . . . . . . . . . . . . . .
42-9
SPECIAL TOOLS . . . . . . . . . . . . . .42-9
WINDOW REPAIR . . . . . . . . . . . . .42-10
WINDSHIELD . . . . . . . . . . . . . . . . .42-12
REMOVAL AND INSTALLATION . . . . . . 42-12
REAR WINDOW GLASS . . . . . . . .42-16
REMOVAL AND INSTALLATION . . . . . . 42-16
QUARTER WINDOW GLASS . . . .42-19
REMOVAL AND INSTALLATION . . . . . . 42-19
TAILGATE WINDOW GLASS . . . .42-22
REMOVAL AND INSTALLATION . . . . . . 42-22
DOOR . . . . . . . . . . . . . . . . . . . . 42-25
SERVICE SPECIFICATIONS . . . . .
42-25
SEALANT . . . . . . . . . . . . . . . . . . . .42-25
SPECIAL TOOLS . . . . . . . . . . . . . .42-25
Continued on next page

FUEL FILLER LID
BODY42-8
FUEL FILLER LID
REMOVAL AND INSTALLATIONM1421002500277
Pre-removal and Post-installation Operation
•Rear Seat Removal and Installation (Refer to GROUP
52A, Rear Seat P.52A-28.)
•Front Scuff Plate (Driver's Seat Side), Rear Scuff Plate
(Driver's Side), Centre Pillar Lower Trim (Driver's Side),
Quarter Trim (Driver's Side) Removal and Installation
(Refer to GROUP 52A, Trims P.52A-11.)
18M0109W0570AQ
AC005996
AC005973
3
54
3
2 1
5.0 ± 1.0 N·m
AC
Fuel filler lid height and clearance
adjustment
Removal steps
1. Fuel filler lid panel assembly
2. Clip
3. Fuel filler lid hook assembly4. Fuel filler lid lock release cable
5. Fuel filler lid lock release handleRemoval steps (Continued)

STRUT TOWER BAR
BODY42-9
STRUT TOWER BAR
REMOVAL AND INSTALLATIONM1421005600091
WINDOW GLASS
ADHESIVEM1422000500081
SPECIAL TOOLSM1422000600293
AC304680AB
Strut tower bar44 ± 5 N·m
Item Specified adhesive
Windshield 3M ATD Part No.8609 Super Fast Urethane Auto Glass
Sealant or equivalent
3M ATD Part No.8608 Super Fast Urethane Primer or
equivalent Rear window glass
Quarter window glass
Tailgate window glass
Tool Number Name Use
MB990480 Glass holder Removal and installation of window glass
MB990784 Ornament remover Removal of rear window lower moulding
MB990480
MB990784

WINDOW GLASS
BODY42-10
WINDOW REPAIRM1422005600027
The windshield, rear window glass, quarter window
glass and tailgate window glass are attached by an
urethane-base adhesive to the window frame. This
adhesive provides improved glass holding and
sealing, and also gives body openings a greater
structural strength.
ITEMS
HANDLING OF AUTO WINDOW SEALER
Keep the sealant in a cool place, not exposed to the
direct rays of the sun. Do not place any heavy article
on the sealant nor press it, otherwise it will become
deformed. Avoid storing the sealant for more than 6
months, because it will lose its sealing effect.
BODY PINCH-WELD FLANGE SERVICING
Before servicing the body pinch-weld flange, remove
old adhesive completely. If the flange requires
painting, bake it after painting is completed. Name Remark
Adhesive 3M ATD Part No.8609 Super Fast Urethane Auto Glass Sealant or
equivalent
Primer 3M ATD Part No.8608 Super Fast Urethane Primer or equivalent
Spacers Available as service part
Dam Available as service part
Anti-rust solvent (or Tectyl
506T.Valvoline Oil Company)For rust prevention
Isopropyl alcohol For grease removal from bonded surface
Steel piano wire Dia. × length... 0.6mm × 1m For cutting adhesive
Glass adhesive knife For cutting adhesive
Adhesive gun For pressing-out adhesive

WINDOW GLASS
BODY42-12
WINDSHIELD
REMOVAL AND INSTALLATIONM1422001000313
Pre-removal and Post-installation Operation
•Front Deck Garnish Removal and Installation (Refer to
GROUP 51,Windshield Wiper and Washer P.51-23.)
•Inside Rear View Mirror Removal and Installation (Refer
to GROUP 52A, Inside Rear View Mirror P.52A-23.)
•Front Pillar Trim Removal and Installation (Refer to
GROUP 52A, Trims P.52A-11.)
•Headlining Removal and Installation (Refer to GROUP
52A, Headlining P.52A-21.)
AC006003
X0111AUX0112AU
Y0496AU
12
3 4
6
1 11 3
N
N
N
N
N
AC Y0495AU
A
A
BB
C
C Ceramic line
Seal line
Seal line
Ceramic line
MarkMark
Apply the primer and
adhesive along the
fictitious lines (seal line)
between each of
the marks.
Seal line centre
Primer Section A – A Section B – BSeal line
centre
Primer
Section C – C
Seal line
centre
Primer
5N
5N
Units: mm
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
1613

WINDOW GLASS
BODY42-16
REAR WINDOW GLASS
REMOVAL AND INSTALLATIONM1422001600111
Pre-removal and Post-installation Operation
•High-mounted Stop Lamp Assembly Removal and
Installation <Rear Shelf Mounted Type> (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.)
<<A>> >>B<<1. Rear window lower moulding
2. Clip
3. Grommet A4. Grommet B
5. Grommet C
6. Connecting the harness connector<<B>> >>A<<7. Rear window glass
>>A<<8. Rear window upper mouldingRemoval steps (Continued)

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
BODY42-18
5. Install the glass stopper and window dam to the
specified positions so that there are no adrift or
bent surfaces inside the rear window glass.
6. Install the rear window upper moulding.
7. Install the glass in the same manner as the
windshield. (Refer to P.42-12.)>>B<< REAR WINDOW LOWER
MOULDING INSTALLATION
Install the clips to the rear window lower moulding,
and then fix the rear window moulding to the vehicle
body.
Y0630AU
Y0629AU
AC006075
Glass stopper and window dam installation position
Glass stopper
18 mm
Glass end line
Align the glass
stopper end with
the ceramic notch.
Ceramic line
Rear window
glass
A
ASection A - A
19 mmWindow dam Align the window
dam end with
the ceramic notch.
Mark
Seal line
Ceramic
line
Window dam
19 mm
AB