roof MITSUBISHI LANCER 2005 Workshop Manual
[x] Cancel search | Manufacturer: MITSUBISHI, Model Year: 2005, Model line: LANCER, Model: MITSUBISHI LANCER 2005Pages: 788, PDF Size: 45.98 MB
Page 291 of 788
WINDOW GLASS
BODY42-13
REMOVAL SERVICE POINT
<> WINDSHIELD REMOVAL
1. To protect the body (paint surface), apply cloth
tape to all body areas around the installed
windshield.
2. Make mating marks on the windshield and body.
3. Using piano wire.
(1) Using a sharp-point drill, make a hole in the
windshield adhesive.
(2) Pass the piano wire from the inside of the
vehicle through the hole.
CAUTION
Do not let the piano wire touch the edge of the
windshield.
(3) Pull the piano wire alternately from the inside
and outside along the windshield to cut the
adhesive.
CAUTION
Inserting the glass adhesive knife too deeply into
windshield adhesive may damage windshield.
4. Using glass adhesive knife
Keep glass adhesive knife at right angles with the
windshield edge, and put the blade at windshield
edge and surface. Then cut away adhesive along
the windshield edge.
5. Use special tool glass holder (MB990480) to
remove the windshield.
CAUTION•
Removal steps
•Roof drip moulding (Refer to GROUP
51, Moulding P.51-10.)
<> >>B<<1. Windshield
>>A<<2. Windshield moulding
>>A<<3. Window dam
>>A<<4. Glass stopper
>>A<<5. Spacer
>>A<<6. Windshield spacerRemoval steps (Continued)
ACX00474
AB
AC002060
AC207478
Glass adhesive knife
AD
ACX00475
AB
MB990480
ACX00476
AB
Page 293 of 788
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<
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
Page 294 of 788
WINDOW GLASS
BODY42-16
REAR WINDOW GLASS
REMOVAL AND INSTALLATIONM1422001600111
Pre-removal and Post-installation Operation
•High-mounted Stop Lamp Assembly Removal and
Installation
54A, High-Mounted Stop Lamp P.54A-81.)
•Rear Pillar Trim and Rear Shelf Trim Removal and
Installation (Refer to GROUP 52A, Trims P.52A-11.)
•Headlining Removal and Installation (Refer to GROUP
52A, Headlining P.52A-21.)
Y0500AU
Y0502AUY0501AU
Y0564AU
AC006056
11 7
7
AB
6
25
4 9
7 3
N
2N
2N
N
4N
N
3N3N
NN
2N
Ceramic line
Mark
Apply the primer and
adhesive along the
fictitious lines (seal line)
between each of
the marks.Section A – A
Section B – B
Seal line
centre
Primer
8N
10N
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
16 mm
A
A
B
B
Removal steps
•Roof drip moulding (Refer to GROUP
51, Moulding P.51-10.)
<> >>B<<1. Rear window lower moulding
2. Clip
3. Grommet A4. Grommet B
5. Grommet C
6. Connecting the harness connector<> >>A<<7. Rear window glass
>>A<<8. Rear window upper mouldingRemoval steps (Continued)
Page 303 of 788
DOOR
BODY42-25
DOOR
SERVICE SPECIFICATIONSM1423000300091
SEALANTM1423000500095
SPECIAL TOOLSM1423000600337
ItemStandard value
Power window operation current (Power supply voltage 14.5 ± 0.5 V, at 25 °C) A 5 ± 1
Door outside handle play mm Front door 2.6 ± 2.5
Rear door 1.3 ± 1.3
Door inside handle play mm Front door 10.4 ± 9.6
Rear door 10 ± 9.6
Item Specified sealant
Door waterproof film 3M ATD Part No.8633 or equivalent
Tool Number Name Use
MB990480 Window glass holder Removal of power window regulator
assembly
MB990900 or
MB991164Door hinge adjusting
wrenchDoor alignment
MB990925
A: MB990939Bearing and oil seal
installer set
A: Brass barDoor striker adjustment
MB990211 Sliding hammer
MB990241
A: MB990243Axle shaft puller
A: Body puller
MB990480
MB990900
MB990925AF
A
MB990211
MB990241
A
AE
Page 306 of 788
DOOR
BODY42-28
DOOR WINDOW GLASS ADJUSTMENTM1423001000327
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-15).
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.
4. Fully close the door window glass again and
tighten the door glass mounting screw firmly via
the adjusting hole.
GLASS SLIDING MECHANISM CHECK
AND ADJUSTMENT
M1429000900091
If the window glass automatically starts moving
downwards at the wrong time while it is being raised,
carry out the following adjustment or replacement
procedures.
1. Remove the door trim assembly (Refer to GROUP
52A, Door trim P.52A-15).
2. Remove the waterproof film (Refer to P.42-39).
3. Remove the window regulator assembly from the
door window glass, and then raise and lower the
door window glass by hand to check the operation
force.
NOTE: Insert a cushion or similar object to
prevent damage to the glass if it should happen to
fall down.4. If the door window glass does not move up and
down smoothly, check or repair the following
points.
•Check the installation condition of the
runchannel.
•Repair any twisting in the door sash.
•Check the installation condition of the lower sash
or the centre sash.
NOTE: The lower sash cannot normally be
adjusted, but it may be possible to adjust the sash
span slightly within the range allowed by
manufacturing tolerances by pushing the lower
sash outwards while re-installing it.
5. If repair or adjustment is not possible, replace the
door assembly.
POWER WINDOW OPERATING CURRENT
CHECK
M1429001100184
1. Remove the power window fuse and connect an
ammeter as shown in the illustration.
2. When the power window switch is pressed to the
“UP” position, a large amount of current flows at
the time the window starts to close and when it is
fully closed, so measure the operation current in
the interval between these two points.
Standard value (A): 5 ± 1A (Power supply
voltage 14.5 ± 0.5V, 25°C)
Y0238AUY0239AUAC006112
AB
Adjusting
holeAdjusting
hole
AC003777
RunchannelDoor
sash
Lower
sash
AB
AC006115AB
Page 308 of 788
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
Page 311 of 788
DOOR
BODY42-33
AC305108
NOTE
: Clip positions
: Claw positions
View A
B
B
B
B C
CC
CC
CC
C
Section B - B
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
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.)
<> >>B<<1. Window regulator assembly
<> >>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<> >>A<<4. Centre sash upper
5. Stationary window glass
6. Stationary window weatherstrip
Power window switch removal steps
7. Power window switch panel assembly
Page 314 of 788
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
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)
Page 317 of 788
DOOR
BODY42-39
WINDOW GLASS RUNCHANNEL AND
DOOR OPENING WEATHERSTRIP
REMOVAL AND INSTALLATIONM1423003100290
AC304409AB
Section A – A
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<<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
Page 318 of 788
DOOR
BODY42-40
AC304418AB
Section A – A
Door
: Sectional view of
clip position
: Sectional view of
clip position
6 2 4
5
7
A A
3
Section B – B
Door
6
3
6
BB
Sealant: 3M ATD Part No.8633 or equivalent
1
1
Waterproof film removal steps
•Door trim assembly (Refer to GROUP
52A, Door trim P.52A-15).
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
•Rear door check mounting bolt (Door
side) (Refer to P.42-31.)
3. Retainer weatherstrip
<> >>A<<4. Door outer opening weatherstripDoor window glass runchannel
removal
5. Door window glass runchannel
Door beltline inner weatherstrip
removal steps
•Rear door trim (Refer to GROUP 52A,
Door trim P.52A-15.)
•Centre sash upper (Refer to P.42-32.)
6. Door beltline inner weatherstrip
Door beltline moulding removal steps
•Door window glass (Refer to
P.42-32.)
•Stationary glass (Refer to P.42-32.)
7. Door beltline moulding