front MITSUBISHI LANCER 2005 Manual Online

DOOR
BODY42-30
DOOR INSIDE HANDLE PLAY
ADJUSTMENT
M1423001500292
1. Check that the door inside handle play is within
the standard value range.
Standard value (B):
Front door: 10.4 ± 9.6 mm
Rear door: 10 ± 9.6 mm2. If the door inside handle play is outside the
standard value range.
3. Remove the door trim assembly (Refer to GROUP
52A, Door trim P.52A-15).
4. Remove the waterproof film (Refer to P.42-39).
5. Adjust the door inside handle play with the outer
cable end connecting the door inside handle and
inside lock cable.
AC006114Y0705AUAB
A
A
BSection A – A
AC100404
AB
Clip Inner cable
Outer cable end
Inside handle rodDoor inside handle

DOOR
BODY42-31
DOOR ASSEMBLY
REMOVAL AND INSTALLATIONM1423002200283
Post-installation Operation
•Door Fit Adjustment (Refer to P.42-27.)
Y0655AU
AC006125
ACX00503
Y0652AU
5, 6
AB
<FRONT DOOR>
<REAR DOOR>
1
2
3 4
5
678
910 1
234
5
67
8
9
10 11.5 ± 0.5 N·m 1.5 ± 0.5 N·m
11 ± 2 N·m11 ± 2 N·m
11 ± 2 N·m
11 ± 2 N·m 21 ± 4 N·m 27 ± 5 N·m 21 ± 4 N·m 27 ± 5 N·m
21 ± 4 N·m 27 ± 5 N·m
21 ± 4 N·m 27 ± 5 N·m
Removal
1. Damper mail
Door assembly removal steps
2. Harness connector
3. Door check connecting bolt
4. Door assembly
5. Door upper hinge
6. Door lower hingeStriker removal steps>>A<<7. Striker
8. Striker shim
Door switch removal steps
9. Door switch cap
10. Door switch

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
BODY42-33
AC305108
NOTE
: Clip positions
: Claw positions
View A
B
B
B
B C
CC
CC
CC
C
Section B - B <FRONT DOOR>
Door trim
ClipSection C - C
AB
Door trim
Claw
7
7
7 7
A
AC305109
NOTE
: Clip positions
: Claw positions
E
E
E
E F
FF
FF
FF
F
Section E - EView D
Door trim
ClipSection F - F
Door trim
Claw
D
<REAR DOOR>
7
7 7
AB
7
Door window regulator assembly
removal steps
•Door trim assembly (Refer to GROUP
52A, Door Trim P.52A-15.)
•Waterproof film (Refer to P.42-39.)
<<A>> >>B<<1. Window regulator assembly
<<A>> >>B<<2. Power window motor assembly
Door window glass removal steps
•Window glass runchannel (Refer to
P.42-39.)
3. Door window glassStationary window glass removal
steps
•Window glass runchannel (Refer to
P.42-39.)
•Door beltline inner weatherstrip
(Refer to P.42-39.)
3. Door window glass<<B>> >>A<<4. Centre sash upper
5. Stationary window glass
6. Stationary window weatherstrip
Power window switch removal steps
7. Power window switch panel assembly

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
BODY42-36
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
BODY42-37
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

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

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

51-1
GROUP 51
EXTERIOR
CONTENTS
FRONT BUMPER ASSEMBLY . . . . .51-2
ADHESIVE . . . . . . . . . . . . . . . . . . . . . . . . . 51-2
FRONT BUMPER ASSEMBLY . . . . . . . . . . 51-2
REMOVAL AND INSTALLATION . . . . . . . . 51-2
DISASSEMBLY AND REASSEMBLY . . . . . 51-3
REAR BUMPER ASSEMBLY . . . . . .51-5
REMOVAL AND INSTALLATION . . . . . . . . 51-5
DISASSEMBLY AND REASSEMBLY . . . . . 51-7
MOULDINGS . . . . . . . . . . . . . . . . . . .51-9
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . 51-9
ADHESIVE . . . . . . . . . . . . . . . . . . . . . . . . . 51-9
MOULDINGS . . . . . . . . . . . . . . . . . . . . . . . 51-10
REMOVAL AND INSTALLATION . . . . . . . . 51-10
SIDE AIR DAM . . . . . . . . . . . . . . . . . .51-15
ADHESIVE . . . . . . . . . . . . . . . . . . . . . . . . . 51-15
SIDE AIR DAM . . . . . . . . . . . . . . . . . . . . . . 51-15
REMOVAL AND INSTALLATION . . . . . . . . 51-15
GARNISHES . . . . . . . . . . . . . . . . . . .51-17
REMOVAL AND INSTALLATION . . . . . . . . 51-17
REAR SPOILER . . . . . . . . . . . . . . . . .51-18
REMOVAL AND INSTALLATION . . . . . . . . 51-18
TAILGATE SPOILER . . . . . . . . . . . . .51-19
REMOVAL AND INSTALLATION . . . . . . . . 51-19
ROOF RAIL . . . . . . . . . . . . . . . . . . . .51-20
REMOVAL AND INSTALLATION . . . . . . . . 51-20
WINDSHIELD WIPER AND WASHER51-21
GENERAL INFORMATION . . . . . . . . . . . . . 51-21
SERVICE SPECIFICATION . . . . . . . . . . . . 51-22TROUBLESHOOTING . . . . . . . . . . . . . . . . 51-22
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . 51-22
WINDSHIELD WIPER AND WASHER . . . . 51-23
REMOVAL AND INSTALLATION . . . . . . . . 51-23
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 51-25
REAR WIPER AND WASHER . . . . . .51-28
GENERAL INFORMATION . . . . . . . . . . . . . 51-28
SERVICE SPECIFICATION . . . . . . . . . . . . 51-28
TROUBLESHOOTING . . . . . . . . . . . . . . . . 51-28
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . 51-28
REAR WIPER AND WASHER . . . . . . . . . . 51-29
REMOVAL AND INSTALLATION . . . . . . . . 51-29
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 51-30
HEADLAMP WASHER . . . . . . . . . . . .51-32
TROUBLESHOOTING . . . . . . . . . . . . . . . . 51-32
HEADLAMP WASHER . . . . . . . . . . . . . . . . 51-32
REMOVAL AND INSTALLATION . . . . . . . . 51-32
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 51-33
MARK . . . . . . . . . . . . . . . . . . . . . . . . .51-34
REMOVAL AND INSTALLATION . . . . . . . . 51-34
DOOR MIRROR . . . . . . . . . . . . . . . . .51-36
GENERAL INFORMATION . . . . . . . . . . . . . 51-36
SERVICE SPECIFICATION . . . . . . . . . . . . 51-36
SPECIAL TOOL. . . . . . . . . . . . . . . . . . . . . . 51-36
TROUBLESHOOTING . . . . . . . . . . . . . . . . 51-36
DIAGNOSIS TROUBLESHOOTING
FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51-36
TROUBLE SYMPTOM CHART . . . . . . . . . . 51-36
SYMPTOM PROCEDURES . . . . . . . . . . . . 51-37
DOOR MIRROR . . . . . . . . . . . . . . . . . . . . . 51-45
REMOVAL AND INSTALLATION . . . . . . . . 51-45
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 51-47