service MITSUBISHI LANCER EVOLUTION 2007 Service Repair Manual

BODY -Hood/Fender42-4
REMOVAL SERVICE POINTS
"AAHOOD HINGE BOLT INSTALLATION
Caution
Use the special parts as the aluminum hood uses special
coatings on the <hood side> of the hood hinge bolt.
FENDER
SPECIAL TOOLS
ToolNumberNameUse
MB990784Ornament removerSide turn signal lamp removal

BODY -Fender42-6
REMOVAL SERVICE POINTS
AA"SIDE TURN SIGNAL LAMP REMOVAL
Use the special tool to release the claw part of the fender
panel and remove the side turn signal lamp.
INSTALLATION SERVICE POINT
"AAFENDER INSTALLATION
Caution
Use the special parts as the aluminum fender uses special
coatings on the fender mounting bolt and the washer.
"BASIDE TURN SIGNAL LAMP INSTALLATION
Engage the hook into the fender panel, and then install the
side turn signal lamp.
Claw part
A
Section A - A
A
Front of vehicle
Side turn signal lamp
Fender panel
MB990784
MB990784
Claw Hook
Fender
panel
Fender
panel
Front of vehicle

BODY -Window Glass42-9
WINDOW GLASS
ADHESIVE
ItemsSpecified adhesive
Windshield3M ATD Part No. 8609 Super Fast Urethane Auto Glass Sealant or
il tRear window glass
p
equivalent
SPECIAL TOOLS
ToolNumberNameUse
MB990480Window glass
holderRemoval and Installation of Window Glass
MB990784Ornament removerRear Window Lower Molding Removal
WINDOW REPAIR
The following glass parts are installed with a liquid urethane
adhesive method:
DWindshield
DRear window glass
ITEMS NEEDED
NameRemarks
Adhesive3M ATD Part No. 8609 Super Fast Urethane Auto Glass Sealant or
equivalent
Primer3M ATD Part No. 8608 Super Fast Urethane Primer or equivalent
SpacersAvailable as service part
DamAvailable as service part
Anti-rust solvent (or Tectyl 506T...Valvoline Oil
Company)For rust prevention
Isopropyl alcoholFor grease removal from bonded surface
Steel piano wireDia. y length...0.6mm 1m For cutting adhesive
Adhesive gunFor pressing-out adhesive

BODY -Window Glass42-12
REMOVAL SERVICE POINTS
AA"WINDSHIELD AND WINDSHEILD MOLDING
REMOVAL
1. In order to protect the body (paint surface), apply cloth
tape to all body areas around the installed windshield.
2. Use any of the following methods to cut off adhesive.
<Using the piano wire>
(1) Using a sharp-point drill, make hole in the windshield
adhesive.
(2) Pass the piano wire from the inside of the vehicle
through the hole.
(3) Pull the piano wire alternately from the inside and
outside along the windshield to cut the adhesive.
Caution
Do not let the piano wire touch the edge of the
windshield.
<Using the windshield knife>
(1) Prepare a windshield knife.
(2) Align the windshield knife blade with the windshield
surface and the windshield edge while maintaining
an angle of 90 degrees between the windshield knife
blade and the windshield edge, and then cut off
adhesive by knifing parallel with the windshield edge.
Caution
Prying with a windshield knife could damage the
windshield.
Windshield knife

BODY -Window Glass42-14
INSTALLATION SERVICE POINTS
"AAWINDSHIELD SPACER/SPACER/GLASS
STOPPER/WINDOW DAM/WINDSHIELD
MOLDING/WINDSHIELD INSTALLATION
1. When replacing the windshield, first align it with the body,
and then matchmark them.
2. Use isopropyl alcohol to clean the inside edge of the
windshield and the body flange.
3. Use a primer dampened to apply to the specified area
around the windshield and the body evenly.
4. After applying the primer, let it dry for at least 3 minutes.
Caution
(1) The primer strengthens the adhesive effect, so
that be sure to apply it. However, an excessively
thick application will weaken the adhesive effect.
(2) Never touch the primer-applied surface.
5. Ensuring that there are no bends or warpages inside
the windshield, position the glass stopper and spacer
and windshield spacer on the specified position.
Glass end line Glass stopper, Spacer, windshield spacer and window dam installation position
Ceramic line
Glass end
line 17.5 mmGlass stopper
Window dam13 mm
14 mm
Windshield
spacer Ceramic line
Windshield
Align the glass stopper end
with the ceramic notch.
Section A - A
A
ASeal line center
Seal line
MarkAlign the window
dam end with
the seal line
mark.
Section B - B
10 mmWindshield
Spacer
B
BAlign the spacer end
with the glass end line.

BODY -Window Glass42-17
REMOVAL SERVICE POINTS
AA"REAR WINDOW LOWER MOLDING REMOVAL
Pry the rear window lower molding off with the special tool.
Caution
Do not use a deformed molding.
AB"REAR WINDOW GLASS REMOVAL
Remove the rear window glass in the same manner as for
the windshield. (Refer to P42-12.)
INSTALLATION SERVICE POINTS
"AAGLASS STOPPER/WINDOW DAM/REAR WINDOW
UPPER MOLDING/REAR WINDOW GLASS
INSTALLATION
1. When replacing the rear window glass, first align it with
the body, and then matchmark them.
2. Use isopropyl alcohol to clean the inside edge of the
rear window glass and the body flange.
3. Use a primer dampened sponge to apply the primer to
the specified area around the rear window glass and
the body evenly.
4. After applying the primer, let it dry for at least 3 minutes.
Caution
(1) The primer strengthens the adhesive effect, so
that be sure to apply it. However, a too thick
application will weaken the adhesive effect.
(2) Never touch the primer-applied surface.
5. Position the glass stopper and the window dam in the
specified position, ensuring that there are no bends or
warpages inside the rear window glass.
MB990784

BODY -DoorsBODY -Doors42-19
DOORS
SERVICE SPECIFICATIONS
ItemsStandard value
Door outside handle play mmFront2.3±2.1py
Rear1.3±1.7
Power window operating current (power supply 14.5±0.5 V, 25_C) A5±1
Door inside handle play mmFront9.6±9.2py
Rear9.0±9.2
ADHESIVE
ItemsSpecified sealantRemark
Waterproof film3M ATD Part No. 8625 or equivalentRibbon sealer
SPECIAL TOOLS
ToolNumberNameUse
MB990784Ornament removerDoor trim removal
MB990480Window glass
holderRemoval of power window regulator and motor
assembly
MB990900 or
MB991164Door hinge
adjusting wrenchAdjustment of door fit
A
MB990925
A: MB990939Bearing & oil seal
installer set
A: Brass barAdjustment of door striker
MB990211Slide hammer
A
BB990241
MB990241
A: MB990243Axle shaft puller
A: Body puller

BODY -DoorsBODY -Doors42-20
Tool UseName Number
A
B
C
D
MB991223
A: MB991219
B: MB991220
C: MB991221
D: MB991222Harness set
A: Test harness
B: LED harness
C: LED harness
adapter
D: ProbeTerminal voltage measurement
A: Connector pin contact pressure check
B: Power circuit check
C: Power circuit check
D: Commercial tester connection
TROUBLESHOOTING
DIAGNOSIS FUNCTION
The power window and central door locking is controlled by the Smart Wiring System (SWS). For
troubleshooting, refer to GROUP 54B - Troubleshooting.
ON-VEHICLE SERVICE
DOOR ADJUSTMENT
1. If the gap between the door and body is inconsistent,
paste protection tape at the fender around the hinge
attached portion and at the door edge, use the special
tool to loosen the bolt fixing the door hinge at the body
side, and move the door to adjust so that the gap around
the door becomes consistent.
2. If steps exist between the door and body, use the special
tool to loosen the bolt fixing the door hinge at the door
side, and move the door and adjust the alignment of
the door surface.
Caution
Do not apply torque above 98 NSm for the special
tool (MB991164).
MB990900 or
MB991164

BODY -Doors42-26
INSTALLATION SERVICE POINTS
"AASTRIKER INSTALLATION
Align the center of the striker and latch within
±1.5 mm, and
install.
INSPECTION
DOOR SWITCH CONTINUITY CHECK
Switch positionTerminal No.p
123
Released (ON)
Depressed (OFF)
Striker center
Latch center
- 1.5 mm +1.5 mm
Latch Striker
1
2
3

BODY -Doors42-30
REMOVAL SERVICE POINTS
AA"DOOR INSIDE HANDLE COVER REMOVAL
1. Insert the driver into the tapping screw cap end of the
door inside handle cover and pry the cap the way shown
in the illustration to remove the cap, and then unscrew
the tapping screw.
2. As shown in the illustration, insert the special tool between
the door inside handle cover and door inside handle,
and then disengage the claws of the door inside handle
cover and door inside handle.
3. Insert the special tool into the door inside handle cover
end, and then pry and remove the door inside handle
cover.
AB"CLIP REMOVAL
Use a cloth to remove the clip as shown in the illustration.Tapping screw cap
MB990784 Door inside handle cover
A
AB
B
Door inside
handle cover
Door inside
handle cover ClawClaw
Claw Door trimSection A - ASection B - B
Door inside
handle coverSpecial tool
insertion
position