roof MITSUBISHI LANCER 2005 User Guide

TA I L G AT E
BODY42-46
TA I L G AT E
SERVICE SPECIFICATIONSM1421000300288
SEALANTSM1424000500098
SPECIAL TOOLM1424000600170
TROUBLESHOOTINGM1424000700207
The tailgate system is controlled by the Smart Wiring
System (SWS). For troubleshooting, refer to GROUP
54B, Troubleshooting P.54B-17 or GROUP 54C,
Troubleshooting P.54C-4.
ON-VEHICLE SERVICE
TAILGATE FIT ADJUSTMENTM1424000900137
1. If the striker and latch mesh badly, replace the
striker and striker installation blots with
replacement parts (striker: MR523105, striker
installation blot: MU000474).2. Move the replaced striker forward and backward
or to the left and right to adjust, after bolt the
striker temporarily.
3. After adjusting, tighten the bolts to the specified
torque [24 ± 4 N⋅m]. Item Standard value
Tailgate handle play 2.3 to 5.9 mm
Item Specified sealant
Tailgate waterproof film 3M ATD Part No.8633 or equivalent
Tailgate hinge 3M ATD Part No.8531 Heavy drip check sealer, 3M
ATD Part No.8646 Automotive joint and seam sealer
or equivalent
Tool Number Name Use
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: For checking connector pin
contact pressure
B: For checking power supply
circuit
C: For checking power supply
circuit
D: For connecting a locally
sourced tester
MB991223
A
D C
B
AD
AC203659

TA I L G AT E
BODY42-47
NOTE:
When the bolt head interferes with the rear end
trim, rasp the interference area with a round file.4. If uneven clearance is present between tailgate
and body, reposition the hinge to adjust the
clearance.
TAILGATE HANDLE PLAY CHECKM1424002400138
1. Check the tailgate handle play.
Standard value (B): 2.3 − 5.9 mm
2. If it deviates from the standard value, remove the
lower tailgate trim (Refer to GROUP 52A, tailgate
trim P.52A-19) and waterproof film (Refer to
P.42-48).
3. Remove the holder from the tailgate handle and
adjust according to the tailgate latch rod and
tailgate handle connection position.
AC203660AB
Grind here
AC201556
AC103270
A
ASection A – A
RodHolder
B
AC

TA I L G AT E
BODY42-49
INSTALLATION SERVICE POINT
>>A<< TAILGATE OPENING
WEATHERSTRIP INSTALLATION
Assemble so the tailgate opening weatherstrip
marking is at the centre of the body.
AC305322
Adhesive: 3M ATD Part No.8531 Heavy drip check sealer, 3M ATD Part No.8646 Automotive joint and seam sealer
or equivalent
AB
7
Tailgate assembly removal steps
1. Rear washer hose
2. Tailgate wiring harness
3. Waterproof film
4. Tailgate gas spring
5. Antenna feeder cable
6. Tailgate assembly
7. Tailgate hinge
8. Bumper•Rear end trim (Refer to GROUP 52A,
Trims P.52A-11.)
9. Striker
10. Dynamic damper
Tailgate opening weatherstrip removal
4. Tailgate gas spring
>>A<<11. Tailgate opening weatherstrip Tailgate assembly removal steps
AC305091
Positioning
mark
AB
Tailgate opening
weatherstrip
Rear bumper end
Tailgate opening
weatherstrip SECTION A – AA
A
Hatching

TA I L G AT E
BODY42-50
TAILGATE HANDLE AND LATCH
REMOVAL AND INSTALLATIONM1424001700170
Pre-removal Operation
•Tailgate Handle Play Check (Refer to P.42-47).
Y1518AU
Y1520AU
AC305141
4
5
6
3 35
5.0 ± 1.0 N·m
9.0 ± 2.0 N·m
AB
2
1
22 ± 4 N·m
Striker removal steps
•Rear end trim (Refer to GROUP 52A,
Trims P.52A-11.)
>>A<<1. Striker
Tailgate handle and lock key cylinder
removal steps
•Lower tailgate trim (Refer to GROUP
52A, Tailgate Trim P.52A-19.)
•Waterproof film (Refer to P.42-48.)
2. Bolt (earth)
3. Tailgate latch assembly
4. Tailgate lock key cylinder
5. Tailgate handleTailgate latch removal steps
•Lower tailgate trim (Refer to GROUP
52A, Tailgate Trim P.52A-19.)
•Waterproof film (Refer to P.42-48.)
2. Bolt (earth)
3. Tailgate latch assembly
Tailgate lock actuator removal steps
•Lower tailgate trim (Refer to GROUP
52A, Tailgate Trim P.52A-19.)
•Waterproof film (Refer to P.42-48.)
6. Tailgate lock actuator

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

MOULDINGS
EXTERIOR51-11
REMOVAL SERVICE POINT
<> ROOF DRIP MOULDING REMOVAL
CAUTION
If the moulding has become warped, it should not
be reused.
Use special tool window moulding remover
(MB990449) to lever out the moulding.
AC304340
1
1
A
A
A
A
AB
B
B
C
C
C
C
B
B
N
N
N
2
N2
4
3
N3
N4
N
6
9
7
N
6N
N
7N
N9


Removal
•Front deck garnishes (Refer to
P.51-23.)
Roof drip moulding removal steps
<> >>C<<1. Roof drip moulding
>>B<<2. Front drip moulding clip A
>>B<<3. Front drip moulding clip B
>>B<<4. Front drip moulding clip C
>>B<<5. Rear drip moulding clip
>>A<<6. Drip moulding clip A
>>A<<7. Drip moulding clip B
>>A<<8. Drip moulding clip C
9. Roof drip moulding clip Roof drip moulding removal steps
AC304375MB990449AB

MOULDINGS
EXTERIOR51-12
INSTALLATION SERVICE POINTS
>>A<< DRIP MOULDING CLIP C/DRIP
MOULDING CLIP B/DRIP MOULDING
CLIP A INSTALLATION
1. The drip moulding clips A, B and C differ
according to where they are used, so check the
identification colour before installation.
2. After installing the clip to the front pillar outer in
alignment with its section A, cut from section B.
>>B<< REAR DRIP MOULDING
CLIP/FRONT DRIP MOULDING CLIP
C/FRONT DRIP MOULDING CLIP
B/FRONT DRIP MOULDING CLIP A
INSTALLATION
The front drip moulding clips A, B, C and rear drip
moulding clip differ according to where they are
used, so check the identification colour before
installation.
>>C<< ROOF DRIP MOULDING
INSTALLATION
Install the clips to the roof drip moulding before
installing the moulding to the vehicle body. Applicable location Identification colour
Drip moulding clip A Yellow
Drip moulding clip B Blue
Drip moulding clip C Milky white
AC304374
Front pillar outer
Section B
Section A
AB
Applicable location Identification colour
Front drip moulding clip A Orange
Front drip moulding clip B Purple
Front drip moulding clip C Blue
Rear drip moulding clip Grey

ROOF RAIL
EXTERIOR51-20
ROOF RAIL
REMOVAL AND INSTALLATIONM1511016600187
AC303725
1
4
2
3
AB
A A
A BC
C
B
DDEF EF
AC303828
Section A – A Section B – B Section C – C
Section D – D Section E – E Section F – F
1
4
4
11
4
3
3
4
4
2
4
Claw
Claw
Claw
Claw
Claw
Claw
ClawClaw
Claw
Claw
Claw
AB
Removal steps
1. Front roof rail cover
2. Centre roof rail cover3. Rear roof rail cover
4. Roof rail Removal steps (Continued)

REAR WIPER AND WASHER
EXTERIOR51-29
REAR WIPER AND WASHER
REMOVAL AND INSTALLATION
M1511008500345
NOTE: For removal and installation of the wiper and
washer switch, refer to GROUP 54A, Column switch
P.54A-87.
AC304515
2.5 ± 0.4 N·m
9.8 ± 2.0 N·m
7.4 ± 1.4 N·m
3
2
1 4
5
AB
Wiper blade assembly removal steps
>>A<<1. Wiper arm and blade assembly
>>B<<2. Wiper blade
Rear wiper motor removal steps
•Tailgate trim lower (Refer to GROUP
52A, Tailgate trim P.52A-19.)
•Tailgate waterproof film (Refer to
GROUP 42, Tailgate P.42-48.)
3. Rear wiper motor assembly
Rear washer nozzle removal steps
•High-mounted stop lamp assembly
(Refer to GROUP 54A, High-mounted
stop lamp P.54A-81.)
4. Rear washer nozzleWasher hose removal steps
•Front scuff plate, rear scuff plate, cowl
side trim and quarter trim (Refer to
GROUP 52A, Trims P.52A-11.)
•Tailgate lower trim, tailgate proof film
(Refer to GROUP 52A, Tailgate trim
P.52A-19.)
•High-mounted stop lamp assembly
(Refer to GROUP 54A, High-mounted
stop lamp P.54A-81.)
5. Rear washer hose

ANTENNA
CHASSIS ELECTRICAL54A-94
ANTENNA
REMOVAL AND INSTALLATIONM1544002900529

Pre-removal and Post-installation Operation
•Front pillar trim, Rear pillar trim, Centre pillar trim lower,
Centre pillar trim upper (Refer to GROUP 52A − Trims
P.52A-11.)
•Headlining Removal and Installation (Refer to GROUP
52A, Headlining P.52A-21.)
AC305315AB
1
23
1. Roof antenna poleRemoval steps
2. Roof antenna base
•Instrument panel assembly (Refer to
GROUP 52A, Instrument panel assembly
P.52A-2.)
3. Antenna feeder cable