MITSUBISHI LANCER IX 2006 Service Manual

Y0630AU
Y0629AU
AC006075
Glass stopper and window dam installation positionGlass stopper
18 mm
Glass end line
Align the glass
stopper end with
the ceramic notch.
Ceramic line Rear window
glass
A
A Section A - A
19 mm
Window dam
Align the window
dam end with
the ceramic notch.
Mark
Seal line
Ceramic
lineWindow dam
19 mm
AB
W I NDOW GLASS
BO D Y42-19
5.In st all the glass sto pper a nd wind ow dam to the
specifie d positio ns so tha t there are no a d rif t or
be nt su rface s insid e the rear wind ow glass.
6.In st all the rea r window u pper mould i ng.
7.In st all the glass in the same mann er as the
win d shield . (Refer to
P.42-12.)
>>B< < REAR WINDOW LOWER
MOULDING INST
ALLA TION
Install the clip s to th e rear window lo we r mouldin g ,
and the
n fix the rear wind ow mouldin g to th e veh i cle
body
.

WINDOW GLASS
BODY42-20
QUARTER WINDOW GLASS
<WAGON>
REMOVAL AND INSTALLATION
M1422002500247
Pre-removal and Post-installation Operation
•Quarter Trim Upper Removal and Installation (Refer to
GROUP 52A, Trims
P.52A-13).
AC304783
N
N
N
12
3
N3
4
AB
Y1509AU
Y1508AU
Y1507AU
Y1485AU
Y1535AU
AC304784
AA B B
DD
C
C
Mark
Apply the primer and adhesive
along the fictitious lines (seal line)
between each of the marks.
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
1
1
1
Seal line centrePrimer
Section A – A Section B – BSeal line
centre
Primer
Section C – C Section D – D
Seal line
centre Primer
1Seal line
centre
Units: mm
Primer
16
16 1616
Ceramic line
AB
Removal steps
<<A>>>>B<<1.Quarter window glass assembly
>>A<<2.Dual lock fastener
>>A<<3.Clip
>>A<<4.Gasket
Removal steps (Continued)

WINDOW GLASS
BODY42-21
REMOVAL SERVICE POINT
<<A>> QUARTER WINDOW GLASS
REMOVAL
AC103600ADCloth tape
1.App l y cloth t a pe to p r otect the q uarter win dow
glass.
AC002060
2.Use gla ss adhesive knife to cut a w a y adh esive.
AC301614AB
Glass adhesive knife
CAUTION
Inserting the adhesive knife too deeply into wind-
shield 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.
AC103605 AD
MB990480
4. Make mating marks on the quarter window glass
and body.
5. Use special tool glass holder (MB990480) to
remove the quarter window glass.
ACX00476 AB
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.

WINDOW GLASS
BODY42-22
INSTALLATION SERVICE POINTS
>>A<< GASKET/CLIP/DUAL LOCK FAS-
TENER INSTALLATION
1. Carry out the following procedure to re-install quarter window glass.
CAUTION
Do not forget gasket.
(1) Fit clips into body.
AC103606 AC
Cut off these convex parts
(2) Cut away clip fitting convex on quarter window
glass.
NOTE: Convex gets broken when quarter win-
dow 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.
AC304793AB
Dual lock fastener
Install the dual lock fastener
with aligning it onto the bumps
of the body flange.
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).

WINDOW GLASS
BODY42-23
TAILGATE WINDOW GLASS
<WAGON>
REMOVAL AND INSTALLATION
M1422003700170
Pre-removal and Post-installation Operation
•Tailgate Trim Removal and Installation (Refer to GROUP
52A, Tailgate Trim
P.52A-21).
•Tailgate Spoiler Assembly Removal and Installation (Refer
to GROUP 51, Tailgate Spoiler
P.51-26).
•Rear Wiper Arm Assembly Removal and Installation
(Refer to GROUP 51, Rear Wiper and Washer
P.51-36).
AC304811
12
6
5
5
4
3 3
7
AB
N
NN
N
N
N
N
Y1522AU
Y1538AU
AC304812
Y1537AUY1537AU
AB
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 Section A – A
13 14
14
Section B – B
Section C – C
A
A CC
B B
Ceramic line
Mark
Apply the primer and adhesive
along the fictitious lines (seal line)
between each of the marks.
Seal line
centre
Primer
Seal line
centre Primer
Seal line
centre
Primer
2 2
2

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 spacer
WI ND OW GLAS S
BODY42-24
REMOVA L SER V ICE POINT
<<A>> TA ILGA TE WINDOW GLASS
REMOV
A L
Remove the t a ilgate window g l ass using the same
proce
dure as for th e windshie l d (Refe r to
P.42-12).
INSTALLA T ION SER VICE POINTS
>>A<< WI NDOW SP ACER/GLASS ST OP-
PER/DUAL LOCK FA STENER/WINDOW
DAM INST
ALLA TION
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.
AC107207
AC107207
Y1484AU Y1484AU
AC304816
AB
Glass stopper
Glass spacer
Seal line Ceramic line
Ceramic 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
2. Assemble the window spacer, glass stopper and
window dam to the tailgate window glass location
shown.

AC304849AB
Dual lock fastener
Flange convex at the tailgate flange
DOOR
BO
D Y42-25
3.Assemble the dua l lo ck faste ner accord ing t o the
st a ndard loca tion of the t a ilgat e flan ge.
4.Assemble the dua l lo ck faste ner to t he qua rter
win dow gla ss relative to the t a ilgate flan ge dua l
lock fastener .
>>B<< TA ILGA TE WINDOW GLASS
INST
ALLA TION
Install the t a ilgat e window g l ass in the same wa y as
for the
windsh i eld inst a lla tion ( R ef er to
P.42-12).
DOOR
SER V ICE SPECIFICA T IONS
M14230003 0009 1
ItemStandard value
Power window operation current (Power supply voltage 14.5 ± 0.5 V, at 25 °C) A5 ± 1
Door outside handle play mmFront door2.3 ± 2.1
Rear door1.3 ± 1.7
Door inside handle play mmFront door10.4 ± 9.6
Rear door10 ± 9.6
SEALANT
M14230005 0009 5
ItemSpecified sealant
Door waterproof film3M ATD Part No.8633 or equivalent

DOOR
BODY42-26
SPECIAL TOOLS
M1423000600337
ToolNumberNameUse
MB990480
MB990480Window glass ho lderRemoval of powe r window reg u lato r
assembly
MB990900
MB990900 or
MB991
164Door hin ge adjust i ng
wre
n chDoor a lign m ent
MB990925AF
AMB990925
•A: MB9909 39
Bearing and o il seal
inst
al ler set
•A: Brass bar
Door striker adjust m ent
MB990211
MB99021 1Sliding ha mme r
MB990241
A
AE
MB990241
•A: MB9902 43
Axle shaft pu ller
•A: Body puller
MB991223
A
D C
B
AZ
DO NOT USE
MB991223
A: MB9912 19
B: MB991220
C: MB99122 1
D: MB991222
Harness se t
A: Te st harness
B: LE D ha rn e s s
C: LE D ha rness ada pter
D: Probe
Te rminal volt age mea s urement
A: For checking con nector pin
c o nt ac t p r es s u re
B: For checking power supply circu i t
C: For checking power supply circu i t
D: For connecting a lo cally sourced
tester
MB992006
MB992 006Extra fine pro b eContinuity check and volt ag e
measu
r emen t at ha rness wire o r
connector
TROUBLESHOOTING
M14230007 0031 2
The door system is con t ro lled by the Smart Wiring Syst em (SWS). Fo r t r o uble s hoo tin g , re fer t o GROUP
54B, T r oublesh ootin g
P.54B-15 or GROUP
54C,
Tr o uble s hoo ting P.5 4 C - 4.

DOOR
BODY42-27
ON-VEHICLE SERVICE
DOOR FIT ADJUSTMENT
M1423001100175
CAUTION
•Attach protection tape to the fender and door
edges where the hinge is installed.
•Do not rotate special tool door adjusting
wrench (MB991164) with a torque of over 98
N
⋅m
AC000592
MB990900
or
MB991164
AB
1. Use the special tool door adjusting Wrench (MB990900 or MB991164) to loosen the hinge
mounting bolts on the body side, and then adjust
the clearance around the door so that it is uniform
on all sides.
2. If a door is not flush with its surrounding panels,
loosen the door-side d oor hinge mounting bolts
and obtain the flushness by moving the door.
NOTE:
AC206498
Washer Bolts
Washer
Door hinge
AF
Weld point
Weld point
If the door hinge mounting bolt washers are
welded, grind off the welding according to the pro
-
cedure below beforehand.
.
1. Remove the door hinge (Refer to P.42-31).
2. Use a chisel or grinder to release the door
hinge mounting bolt washers, which are
welded to the door hinge.
3. On completion, paint the affected area with a suitable touch-in brush to prevent corrosion.
4. Install the door hinge (Refer to P.42-31).
3. When the door is stiff to lock and unlock
AC006109AB
Temporary
bolts Striker
MB990939
(1) Adjustment by using the striker (toward the
inside of the vehicle and vertical direction)
Install a temporary bolt instead of the striker
mounting bolts, and use special tool brass bar
(MB990939) and a hammer to tap the bolt to
the desired direction.
AC006110
Striker MB990211
MB990243
AB
(2) Adjustment by using the striker (toward the
outside of the vehicle)
Use special tools slide hammer (MB990211)
and body puller (MB990243) to pull the striker
toward the outside of the vehicle.
AC006111AB
Shim
Striker
(3) Adjustment by using shims (forward and rearward)
Increase or decrease the number of shims so
that the striker engages with the door latch
properly.

DOOR
BODY42-28
DOOR WINDOW GLASS ADJUSTMENT
M1423001000327
Check that the door glass moves while contacting
the door glass channel when it is raised and lowered
fully. If not, adjust the door window according to the
following procedures.
1. Remove the door trim assembly (Refer to GROUP 52A, Door trim
P.52A-17).
2. Remove the waterproof film (Refer to P.42-39).
3. Loosen the door glass mounting screw via the adjusting hole with the door window glass fully
closed, then lower the window glass a little.
Y0238AUY0239AUAC006112 AB
<Front> <Rear>
Adjusting
holeAdjusting
hole
4.Fu lly close the doo r window g l ass aga in an d
tighten the do or gla s s moun ting scre w firmly via
th e adjusting ho le.
GLASS SLIDING MECHANISM CHECK
AND ADJUSTMENT
M14290009 0009 1
If the window glas s automatically st a r t s moving
downwards at the wron
g time while it is be ing raised ,
carry out th
e following adju s tment or re placeme n t
proce
dures.
1. Remo ve the do or trim assembly (Refer to GROUP
52 A, Door trim
P.52A-17).
2.Remove the water p roof film (Re f er to P.42-39).
3.Remove the win dow regulator a sse mbly from the
do or windo w glass, a nd the n raise and lower th e
door windo w glass b y han d t o che ck the op erat ion
fo rce.
NOTE: Insert a cushion or similar object t o pre-
vent da mage to the gla ss if it shou ld h app en t o f a ll
do
wn .
AC003777
Runchannel Door
sash
Lower
sash
AB
4. If the do or windo w g l ass do es no t move up and
d o wn smoothly , ch eck or rep a ir the followin g
po i n t s .
•Check the inst a lla tion condition of the runch a n-
nel.
•Repa ir a n y twisting in the do or sash.
•Check the inst allation condit i on of the lo we r sash
or th
e ce ntre sash.
NOTE: The lower sa sh canno t normally be
a
d
juste
d , bu t it ma y be po ssible to ad just th e sa sh
sp
an sligh t ly within the ran ge allowed b y manu
-
facturing tolerances by pu shing the lower sash
o
u twards wh ile r e -inst a lling it .
5.If rep a ir or a d justme nt is not po ssible , repla c e th e
d oor assembly .
POWER WINDOW OPERA T ING CURRENT
CHECK
M142900 1 1 0018 4
AC006115AB
1.Remove the po we r window fu se a nd co nnect an
a mme ter as sho w n in th e illustration .
2.Wh en the power win dow switch is presse d to the
“UP” position, a large amou nt of current flows at
th e time the window st a r t s to close and whe n it is
fu lly closed , so measure th e oper ation curren t in
th e int e rval between these two point s.
St andard va lue (A): 5 ± 1A (Power suppl y
volt
age
14.5
± 0 . 5V , 25°C)