MITSUBISHI LANCER 2006 Workshop Manual

DOOR
BODY42-39
WINDOW GLASS RUNCHANNEL AND
DOOR OPENING WEATHERSTRIP
REMOVAL AND INSTALLATION
M1423003100290

AC304409AB
Section A – A

Sealant: 3M ATD Part No.8633 or equivalent Door
: 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-13).
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-13.)
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 weatherstrip
Door 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-17.)
5.Door beltline inner weatherstrip
Door beltline moulding removal steps
•Door mirror assembly (Refer to
GROUP 51, Door mirror
P.51-50.)
•Door window glass (Refer to
P.42-32.)
6.Door beltline moulding

DOOR
BODY42-40

AC304418AB
Section A – ADoor
: Sectional view of clip position
: Sectional view of clip position
7
2
4
5
7
A A
3
Section B – B

Door
4
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-17).
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-13.)
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 weatherstrip
Door 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-17.)
•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

TRUNK LID
BODY42-41
REMOVAL SERVICE POINT
<> DOOR OUTER OPENING WEATH-
ERSTRIP REMOVAL
ACX00555
15 mm8 mm
AB
4 mm
Thickness:
1 mm
Fabricated
tool
Make a fabricated to ol as sh own in t he illustratio n to
remove the
door wea t herstrip.
INSTALLA T ION SER VICE POINT
>>A<< DOOR OUTER OPENING WEA T H-
ERSTRIP INST ALLA TION
The clip colour id entif ies the le f t and right weath e r-
strips so b e su re to use the colours so a s to inst all
correctly
.
Applicable sideIdentification colour
Right doorPink
Left doorNatural (White)
TRUNK LI D
SPECIAL T O OLM14210006 0024 5
ToolNumberNameUse
MB991244
MB991244Torsion bar remover and
installerRemoval and installation of
trunk lid torsion bar
ON-VEHICLE SER V ICE
TRUNK LID ADJUSTMENTM14210010 0004 2
1.If the cleara n ce a r ound t he trun k lid p anel
asse mbly is not unifo rm an d locking and
un lockin g of th e trunk lid is dif f icult, make
ad justmen t s to the trunk lid bumpers (refer to
P.42-42) and trunk lid hin ges (r efer to P.42-42).
2.If the cleara n ce a r ound t he trun k lid p anel
asse mbly is uniform, but locking a nd un locking of
th e trunk lid is dif f icul t, make adjustment s to the
tru n k lid bu mpe r s (refe r to
P.42-42) and trunk lid
striker (refer to P.42-42).
AC202324
AC202325AC202913
A
A
AA
AB
Section A – A
Trunk lid panel assembly
Side outer panel
Trunk lid panel
assembly
Side outer panel

TRUNK LID
BODY42-42
3. If there is a difference in height between the side outer panels and the side edges of the trunk lid
panel assembly, check the trunk lid hinges and, if
necessary, replace them
4. If the clearance around the trunk lid panel assembly is not uniform, and the trunk lid can be
locked and unlocked smoothly, make adjustments
to the trunk lid bumpers (refer to
P.42-42) and
trunk lid hinges (Refer to P.42-42).
5. If the locking and unlocking of the trunk lid still is difficult after making the above adjustments,
adjust the trunk lid striker (Refer to
P.42-42).
ADJUSTMENT OF CLEARANCE AROUND
TRUNK LID
M1421008100039
AC202897
Trunk lid panel
assembly
Trunk lid hinge
AB
Loosen the trunk lid p a nel a sse mbly mounting bolt s
and move
the trun k lid p anel assembly to make t he
clea
rance aroun d the t r unk lid u n iform.
TRUNK LID STRIKER ADJUSTMENT
M14210082 0003 6
AC202898
Trunk lid striker
AB
After checking the trunk lid relea s e cable for pro per
routin
g, lo osen the trun k lid striker mo untin g bolt s .
Ch
ange th e position of t he trunk lid st rike r relat i ve to
the trun
k lid la tch a s sembly so tha t trunk lid lockin g
and un
lockin g ef f o rt is corre ct.
TRUNK LID HEIGHT ADJUSTMENT
M14210083 0003 3
AC305144
Section A - A
Trunk lid bumper
Trunk lid panel assembly
A
A
Trunk lid bumper Trunk lid panel assembly
AB
14 mm
T
u rn each trun k lid bumper u n til the he ight shown in
the dra
w ing is reached. If the t r unk lid p a n e l he ight
on one
sid e is dif f erent from that on the oth e r side
(even
a f t e r th e t r un k lid bu mp ers have be en ad ju st ed
to the h
e igh t ind i ca ted in the dra w ing), tu rn the trunk
lid bumper(s)
slight ly to make fine adjustment s to the
trunk lid p
a nel h e ight .
NOTE: Whe n the b u mpe r is new , one full turn o f the
trunk lid bumper ch anges t he height appro x imately 3
mm.
T
u
rn it clockwise to r educe height. T u rn it anti
-
clockwise to increase height.

TRUNK LID
BODY42-43
TRUNK LID
REMOVAL AND INSTALLATION
M1421002200180
AC301676
Y0636AU
Y0637AU
AB
8.9 ± 1.9 N·m
A
AB
B 15 mm
14 mm
Section A - A
Section B - B
9
5
6
4
12
9
59
7
11
10
8 3 5 1
2
Trunk lid weatherstrip removal steps
•Rear end trim (Refer to GROUP 52A,
Trims
P.52A-13.)
>>B<<1.Trunk lid weatherstrip
Trunk lid release cable and trunk lid
release handle removal steps

•Rear end trim (Refer to GROUP 52A,
Trims
P.52A-13.)
•Trunk rear side trim (LH) (Refer to
GROUP 52A, Trims
P.52A-13.)
•Front scuff plate (LH) (Refer to
GROUP 52A, Trims
P.52A-13.)
•Cowl side trim (LH) (Refer to GROUP
52A, Trims
P.52A-13.)
•Rear scuff plate (LH) (Refer to
GROUP 52A, Trims
P.52A-13.)
•Centre pillar lower trim (Refer to
GROUP 52A, Trims
P.52A-13.)
•Rear seat (Refer to GROUP 52A,
Rear seat assembly
P.52A-30.)
•Accelerator pedal stopper (Refer to
GROUP 17, Accelerator pedal
P.17-3.)
2.Trunk lid release handle
3.Trunk lid release cable
Trunk lid striker removal steps
•Rear end trim (Refer to GROUP 52A,
Trims
P.52A-13.)
4.Trunk lid striker
Trunk lid panel removal steps
•Licence plate garnish (Refer to
GROUP 51, Garnishes
P.51-16.)
5.Trunk lid bumper
•Rear spoiler (Refer to GROUP 51,
Rear spoiler
P.51-25.)
6.Trunk lid lock cylinder
7.Trunk lid latch assembly
8.Trunk lid hinge mounting bolt
9.Trunk lid panel assembly
Trunk lid latch removal
7.Trunk lid latch assembly
Trunk lid hinge removal steps
•Rear shelf trim (Refer to GROUP
52A, Trims
P.52A-13.)
•Rear seat (Refer to GROUP 52A,
Rear seat assembly
P.52A-30.)
9.Trunk lid panel assembly
<>>>A<<10.Trunk lid torsion bar (RH)
<>>>A<<11 .Trunk lid torsion bar (LH)
12.Trunk lid hinge

AC305143AB
Grease application area
62
7
TRUNK LID
BODY42-44
REMOV A L SER V ICE POINT
<> TRUNK LID T O RSION BAR
REMOV
A L
AC205068AC205068
MB991244
Trunk lid torsion bar
Trunk lid torsion bar
AB
1. Att a ch the special tool to the illustrat ed port i on o f
th e trunk lid torsion b a r on the lef t ha nd of
th e veh i cle, the n use the t ool to det ach the tru n k
lid to rsio n bar from the trun k lid h i nge
2.Remove the tru n k lid to rsio n bar in the
same wa y as the t r unk lid t o rsion bar .
INSTALLA T ION SER VICE POINTS
>>A<< TRUNK LID T O RSION BAR
INST
ALLA TION
AC305282
Trunk lid torsion bar
Trunk lid torsion bar
Colour mark
A
B
Trunk lid hinge
Trunk lid torsion bar
View F
Trunk lid hinge
Hole
F
E
A
DC
B
MB991244
Trunk lid torsion bar

AB
Inst all the t r unk lid torsion bars using t he followin g
proce
dure.

TRUNK LID
BODY42-45
CAUTION
Install the trunk lid torsion bar before the
trunk lid torsion bar . If the sequence is
reversed, the trunk lid torsion bar will not
be able to be installed because the special tool
will interfere with the trunk lid torsion bar
during installation of the trunk lid torsion bar
.
1. Identify the LH and RH torsion bars by the colour mark made at the centre of each torsion bar.
Trunk lid torsion barMark
colour
LHVehicles with rear spoilerGreen
Vehicles without rear spoilerWhite
green
RHVehicles with rear spoilerYe l l o w
Vehicles without rear spoilerRed
2. Insert the left end of the trunk lid torsion bar in the hole in the trunk lid hinge .
3. Press portion A of the trunk lid torsion bar
right end against point A on the trunk lid hinge
as shown in View F in the drawing.
4. Twist the portion B of the trunk lid torsion bar right end using the special tool until it is
moved from point B and pressed against point C
of the trunk lid hinge as shown in View F.
Then force the portion into point D.
5. Twist the portion A of the trunk lid torsion bar right end until it reaches point E on the trunk
lid hinge as shown in View F.
6. Attach the trunk lid torsion bar to the trunk lid hinge using the same method as the
trunk lid torsion bar .
>>B<< TRUNK LID WEATHERSTRIP
INSTALLATION
AC006104AB
Joint
section
Marking
section
Install the trunk lid weatherstrip so that the marking
and the joint are aligned with the body centre line,
INSPECTION
M1421004800133
TRUNK LID LATCH SWITCH CONTINUITY
CHECK
AC305142AB
Trunk lid latch assembly
Switch positionTester
connectionSpecified
condition
ON (Latch open)1 − Earth Less than 2
ohms
OFF (Latch shut)Open circuit

TAILGATE
BODY42-46
TA I L G AT E
SERVICE SPECIFICATIONSM1421000300288
ItemStandard value
Tailgate handle play (mm)2.3 − 5.9
SEALANTS
M1424000500098
ItemSpecified sealant
Tailgate waterproof film3M ATD Part No.8633 or equivalent
Tailgate hinge3M ATD Part No.8531 Heavy drip check sealer, 3M
ATD Part No.8646 Automotive joint and seam sealer
or equivalent
SPECIAL TOOLM1424000600170
ToolNumberNameUse
MB991223
A
D C
B
AZ
DO NOT USE
MB991223
A: MB9912 19
B: MB991220
C: MB99122 1
D: MB991222
Harness set
A: Te st harn e ss
B: LED harness
C: LED harness
adapt er
D: Probe
Te rminal volt a ge measu r emen t
A: For che cking connector pin
cont act pressure
B: For che cking po we r sup p ly
circuit
C: Fo r checking po we r supp ly
circuit
D: Fo r conn ecting a loca lly
sourced tester
MB992006
MB992 006Extra fine probeCont inuity check an d vo lt age
measurement at
harness wire or
conn
ector

TAILGATE
BODY42-47
TROUBLESHOOTING
M1424000700207
The tailgate system is controlled by the Smart Wiring
System (SWS). For troubleshooting, refer to GROUP
54B, Troubleshooting
P.54B-15 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).
AC203659
2.Move the rep l aced strike r forward a nd backward
or to the lef t and right to adjust, af te r bolt the
striker temporarily .
3.Af ter ad justing, tighte n the bolt s t o the specifie d
to rque [2 4
± 4 N⋅m].
NOTE:
AC203660AB
Grind here
When the bolt head interfe r es wit h the re ar end
trim, ra
sp th e int e rference are a with a round file .
AC201556
4.If uneven clearan ce is pre s en t between t a ilga te
a nd bod y , reposition the hing e to ad just the
clear ance .
TA ILGA TE HANDLE PLA Y CHECKM14240024 0013 8
AC103270
A
A Section A – A
RodHolder
B
AC
1. Check t he t a ilgate h andle play .
St andard va lue (B): 2.3 − 5.9 mm
2.If it de via t es fro m the st anda rd va lue, r e move the
lower t a ilgate trim (Refe r to GROUP 52A, t a ilgate
trim
P.52A-21) and waterproo f film (Refer to
P.42-48).
3.Remove the ho lder f r om th e t a ilg ate ha ndle and
a d just according to the t a ilgate latch rod an d
t a ilgate handle co nnection position .

TAILGATE
BODY42-48
TA I L G AT E
REMOVAL AND INSTALLATION
M1424001100178
CAUTION
•Do not disassemble or throw the tailgate gas spring into fire.
•Punch a hole in the gas spring before disposal to release the gas inside.
•
Pre-removal Operation
•Tailgate Spoiler Assembly Removal (Refer to GROUP 51,
Tailgate Spoiler
P.51-26).
•Tailgate Trim Assembly Removal (Refer to GROUP 52A,
Tailgate Trim
P.52A-21).
•Rear Wiper Motor Removal (R efer to GROUP 51, Rear
Wiper and Washer
P.51-36).
Post-installation Operation
•Tailgate Fit Adjustment (Refer to P.42-47).
•Rear Wiper Motor Installation (Refer to GROUP 51, Rear
Wiper and Washer P.51-36).
•Tailgate Trim Assembly Installation (Refer to GROUP
52A, Tailgate Trim P.52A-21).
•Tailgate Spoiler Assembly Installation (Refer to GROUP
51, Tailgate Spoiler P.51-26).
AC304836
7
3
4
1
6
8
12 ± 2 N·m 13 ± 2 N·m22 ± 4 N·m
AD
Sealant: 3M ATD Part No. 8633 or equivalent9.0 ± 2.0 N·m
2
712 ± 2 N·m
5
7
9
5.0 ± 1.0 N·m
3
10
Ensure the tailgate gas spring piston rod does not come into contact with foreign material.