flange MITSUBISHI LANCER 2005 Workshop Manual

ON-VEHICLE SERVICE
ENGINE LUBRICATION12-5
5. Use the respective tool in the following table to
remove the engine oil filter.
6. Clean the filter bracket side mounting surface.
7. Apply a small amount of engine oil to the O-ring of
the new engine oil filter.
8. Once the O-ring of the engine oil filter is touching
the flange, use the respective tool in the following
table to tighten to the specified torque.9. Install the engine oil pan drain plug and refill the
engine oil (Refer to P.12-4).
10.Race the engine 2−3 times, and check to be sure
that no engine oil leaks from installation section of
the engine oil filter.
OIL PRESSURE CHECKM1121002300368
1. Check engine oil quantity.
2. Remove the oil pressure switch terminal. Number Special tool
MD348631 <4G1> Oil filter wrench (MB991828)
or equivalent
MD365876 <4G1>
MD360935 <4G1> Oil filter wrench (MB991396)
or equivalent
MD136466 <4G6> Commercially- available tool
MD322508 <4G6>
MD356000 <4G6> Oil filter wrench (MB991610)
or equivalent
AC000093
MB991396
<4G1>,
MB991828
<4G1>,
MB991610
<4G6> or
commercially-
available tool
AI
AC103250AD
O-ring
Number Special tool Tightening torque
MD348631
<4G1>Oil filter wrench
(MB991828) or
equivalentApproximately 3/4
turn (16 ± 4 N⋅m)
MD365876
<4G1>
MD360935
<4G1>Oil filter wrench
(MB991396) or
equivalentApproximately 1 turn
(14 ± 2 N⋅m)
MD136466
<4G6>Commercially-
available toolApproximately 3/4
turn (17 ± 3 N⋅m)
MD322508
<4G6>
MD356000
<4G6>Oil filter wrench
(MB991610) or
equivalentApproximately 3/4
turn (14 ± 2 N⋅m)
AK101640
<4G1>
Oil pressure
switch
Oil filter
AD
AK300647
AB
<4G6>
Oil filter bracket
Oil pressure switch

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
BODY42-14
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 windshield, remove the
adhesive still adhering to the windshield, and
clean with isopropyl alcohol.
9. Clean the body side in the same way.
INSTALLATION SERVICE POINTS
>>A<< WINDSHIELD
SPACER/SPACER/GLASS
STOPPER/WINDOW DAM/WINDSHIELD
MOULDING 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 of the windshield and the body flanges.
Y0628AU
AC006029
10138AU
10139AU
Y0497AU
Glass stopper, spacer, windshield spacer and window dam installation position
17.5 mmGlass stopper
Glass end line
Ceramic line
Align the glass
stopper end with
the ceramic notch.
Align the window
dam and with the
seal line mark.
13 mm
Glass end line
Mark
Seal line
Ceramic line
Window dam
AB
A
AWindshield
Seal line
centre14 mm
Windshield spacer Section A – A
Section B – B
B
B
14 mm
Spacer
Align the spacer
and with glass
end line
Align the windshield
spacer end with the
ceramic notch.

WINDOW GLASS
BODY42-15
2. The inner side of the windshield is curved,
therefore, make a point to assemble the glass
stopper and windshield spacer without any lifting
and assemble in the position shown in the Figure
of the instructions.
3. Install the windshield moulding.
>>B<<WINDSHIELD INSTALLATION
1. When replacing the windshield, temporarily set
the windshield against the body, and place a
mating mark on the windshield and body.
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.
•Do not apply the primer on the remaining
adhesive because of weakening the adhesive.
2. Soak a sponge in the primer, and apply evenly to
the windshield in the specified places. If the
adhesive does not remain on the body flange
surface because of the panel replacement on the
body side, apply evenly to the body side in the
specified places.
3. Allow the windshield to dry for at least three
minutes after applying primer.4. Fill a sealant gun with adhesive. Then apply the
adhesive evenly around the windshield within 30
minutes after applying the primer.
NOTE: Cut the tip of the sealant gun nozzle into a
V shape to simplify adhesive application.
5. Align the mating marks on the windshield and the
body, and lightly press the windshield evenly so
that it adheres completely.
6. Use a spatula or similar tool to remove any
excessive adhesive. Clean the surface with
isopropyl alcohol. Avoid moving the vehicle until
the adhesive sets.
7. Bond the windshield to the body, and install the
roof drip moulding quickly before the adhesive
cures. (Refer to GROUP51, Moulding P.51-10.)
CAUTION
•Do not move the vehicle unless absolutely
necessary.
•When testing for water leakage, do not pinch
the end of the hose to spray the water.
8. Wait 30 minutes or more, and then test for water
leakage.
ACX00480
10 mm
15 mm
AB

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)

WINDOW GLASS
BODY42-24
2. Assemble the window spacer, glass stopper and
window dam to the tailgate window glass location
shown.3. Assemble the dual lock fastener according to the
standard location of the tailgate flange.
4. Assemble the dual lock fastener to the quarter
window glass relative to the tailgate flange dual
lock fastener.
>>B<< TAILGATE WINDOW GLASS
INSTALLATION
Install the tailgate window glass in the same way as
for the windshield installation (Refer to P.42-12).
AC107207
AC107207
Y1484AUY1484AU
AC304816
AB
Glass stopper Glass spacer
Seal lineCeramic lineCeramic lineGlass end line
Glass end line Window spacer, glass stopper and window dam installation position
Align the glass spacer and with
the tailgate window glass mark.
Position the window side dam
2 mm inside from the tailgate
window glass end.
Butt the ends of
the window lower
and side dams.
Align the glass stopper and with
the tailgate window glass mark.
Seal line
Seal line 22 mm 14.5 mm
2 mm
Tailgate window glass
Window lower dam Window side dam
AC304849AB
Dual lock fastener Flange convex at the tailgate flange

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