body MITSUBISHI LANCER 2006 Service Manual

HOOD
BODY42-4
HOOD
REMOVAL AND INSTALLATION
M1421001600561
Post-installation Operation
•Adjustment of Clearance Around Hood (Refer to P.42-3).
•Adjustment of Alignment of Hood Stepped Portion and
Hood Striker (Refer to
P.42-3).
•Adjustment of Hood Height (Refer to P.42-3).
AC304739
1
1
2 2
4 4
5
6
7 3
8
910
AD9.0 ± 2.0 N·m 21 ± 4 N·m
11 ± 2 N·m
21 ± 4 N·m
Removal
1.Hood bumper
2.Hood latch
3.Hood weatherstrip
Hood lock release cable removal
steps

4.Hood lock release handle
5.Hood lock release cable
Hood and hood hinge removal
steps

6.Hood insulator
7.Hood weatherstrip
•Washer hose (Refer to GROUP 51,
Windshield wiper and washer
P.51-31.)
8.Hood
9.Hood support rod
10.Hood hinge

FENDER
BODY42-6
FENDER
REMOVAL AND INSTALLATION
M1421001900302
Pre-removal and Post-installation Operation
•Front Bumper Removal and Installation (Refer to GROUP
51, Front Bumper P.51-3.)
•Front Deck Garnish Removal and Installation (Refer to
GROUP 51, Windshield Wiper and Washer P.51-31.)
•Side Air Dam Removal and Installation side air dam> (Refer to GROUP 51, Side Air Dam
P.51-14.)
AC300491AC304753
AC303863
Clip
Section A – A
AB
A A
1
23
3
4
Note
: Clip positions
Removal steps
1.Splash shield
<>>>A<<2.Side turn-signal lamp
3.Delta outer garnish
4.Fender
Removal steps (Continued)

FENDER
BODY42-7
REMOVAL SERVICE POINT
<> SIDE TURN-SIGNAL LAMP
REMOVAL
AC005980AC005980
Front of vehicleSide turn-signal lamp
MB990784
AB
Use sp ecial to ol orn a men t remover (MB9907 84) to
prize out th
e t ab from the fender , and re move the
side
turn
− signal lamp .
INSTALLA T ION SER VICE POINT
>>A<< SIDE TURN-SIGNAL LAMP
INST
ALLA TION
AC005719
Fender panel Hook
Claw
Fender panel
: Front of vehicle
AE
En gage t he claw with t he fend er p anel, and inst all
the side tu
rn-signal lamp.

FUEL FILLER LID
BODY42-8
FUEL FILLER LID
REMOVAL AND INSTALLATIONM1421002500277
Pre-removal and Post-installation Operation
•Rear Seat Removal and Installation (Refer to GROUP
52A, Rear Seat
P.52A-30.)
•Front Scuff Plate (Driver's Seat Side), Rear Scuff Plate
(Driver's Side), Centre Pillar Lower Trim (Driver's Side),
Quarter Trim (Driver's Side) Removal and Installation
(Refer to GROUP 52A, Trims
P.52A-13.)
18M0109 W0570AQ
AC005996
AC005973
3
5 4
3
2
1
5.0 ± 1.0 N·m
AC
Fuel filler lid height and clearance
adjustment
Removal steps
1.Fuel filler lid panel assembly
2.Clip
3.Fuel filler lid hook assembly
4.Fuel filler lid lock release cable
5.Fuel filler lid lock release handle
Removal steps (Continued)

STRUT TOWER BAR
BODY42-9
STRUT TOWER BAR
REMOVAL AND INSTALLATIONM1421005600091
AC304680AB
Strut tower bar44 ± 5 N·m

WINDOW GLASS
BODY42-10
WINDOW GLASS
ADHESIVEM1422000500081
ItemSpecified adhesive
Windshield3M ATD Part No.8609 Super Fast Urethane Auto Glass
Sealant or equivalent
3M ATD Part No.8608 Super Fast Urethane Primer or
equivalentRear window glass
Quarter window glass
Tailgate window glass
SPECIAL TOOLS
M1422000600293
ToolNumberNameUse
MB990480
MB990480Gl as s h o l de rRemoval and inst a llat i on of wind ow glass
MB990784
MB990784Ornament removerRemoval of rea r window lower mo ulding
WI NDOW REP A IR
M14220056 0002 7
The windshield, rear wind ow glass, q uarter window
glass an
d t a ilg ate win dow gla ss a r e att a ched by an
urethan
e-base adhe sive to the wind ow frame . This
adhesive provides improv
ed glass hold i ng a nd seal
-
ing, and also g i ve s bod y op ening s a g r eater struc-
tural strength.
ITEMS
NameRemark
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. × length... 0.6mm × 1m For cutting adhesive
Glass adhesive knifeFor cutting adhesive
Adhesive gunFor pressing-out adhesive

WINDOW GLASS
BODY42-11
HANDLING OF AUTO WINDOW SEALER
Keep the sealant in a cool place, not exposed to the
direct rays of the sun. Do not place any heavy article
on the sealant nor press it, otherwise it will become
deformed. Avoid storing the sealant for more than 6
months, because it will lose its sealing effect.
BODY PINCH-WELD FLANGE SERVICING
Before servicing the body pinch-weld flange, remove
old adhesive completely. If the flange requires paint
-
ing, bake it after painting is completed.
WINDOW GLASS INSTALLATION
Cleaning of adhesion surface
Cut off the residual adhesive until the
thickness is less than 2 mm. clean the
adhesion surface with isopropyl alcohol,
and let dry for 3 minutes or more.Cleaning of adhesion surface
Completely cut off all of the residual
adhesive. clean the adhesive surface
with isopropyl alcohol, and let dry for
3 minutes or more.Cleaning of adhesion surface
Clean off any dirt adhering to the adhesion
surface with isopropyl alcohol, and let dry
for 3 minutes or more.
Attaching of dual lock fastener
Attach the dual lock fastener to set
the positions for the glass to be installed.
Gluing of window dam, window spacer, dual lock fastener and glass stopper
Glue the window dam, window spacer, dual lock fastener and glass stopper to the glass,
following the standard position all the way around the inside edge of th\
e glass.
Application of primer
Apply the primer to the adhesion surface
of the body, and let dry for 3 minutes or
more.Application of primer
Apply sufficient primer evenly to the adhesion surface so that there is \
no patchiness.
After application, let dry for 3 to 30 minutes.
Application of adhesive
Within 30 minutes after applying the primer , apply the adhesive evenly \
all the way around
the inside edge of the glass.
Installing the glass
After applying the adhedive, lighty press the glass evenly so that it a\
dheres
completely.
Cleaning
After removing excess adhesive from the body or glass with a spatula, et\
c.
clean off with isopropyl alcohol.
Checking for water leaks
Carry out a shower test to check that no water will leaks through. Replace the glass
Reusing the glass
Window glass installation procedure
Body side
Window glass side
AC300393

WINDOW GLASS
BODY42-12
WINDSHIELD
REMOVAL AND INSTALLATION
M1422001000313
Pre-removal and Post-installation Operation
•Front Deck Garnish Removal and Installation (Refer to
GROUP 51,Windshield Wiper and Washer P.51-31.)
•Inside Rear View Mirror Removal and Installation (Refer
to GROUP 52A, Inside Rear View Mirror P.52A-25.)
•Front Pillar Trim Removal and Installation (Refer to
GROUP 52A, Trims P.52A-13.)
•Headlining Removal and Installation (Refer to GROUP
52A, Headlining P.52A-23.)
AC006003
X0111AUX0112AU
Y0496AU
12
3
4
6 1
1
3
N
N
N
N
N
AC
Y0495AU
A
A BB
C C
Ceramic line
Seal line
Seal line
Ceramic line
MarkMark
Apply the primer and
adhesive along the
fictitious lines (seal line)
between each of
the marks.
Seal line centre
Primer
Section A – A Section B – B
Section C – C
Seal line
centre
Primer
5N
5N
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
16 16
1
Seal line
centre
Primer
13

Removal steps
•Roof drip moulding (Refer to GROUP
51, Moulding
P.51-9.)
<>>>B<<1.Windshield
>>A<<2.Windshield moulding
>>A<<3.Window dam
>>A<<4.Glass stopper
>>A<<5.Spa cer
>>A<<6.Windshield spacer
WI NDOW GLASS
BO D Y42-13
REMOV A L SER V ICE POINT
<> WI NDSHIELD REMOV A L
1.T o prot ect th e body (p ain t surfa c e), a pply cloth
t ape to all bod y area s aro und th e inst a lle d
windshield.
2.Make mating marks on th e windshie l d an d body .
ACX00474
AB
3.Using p i ano wire.
(1)U sin g a sharp-po int d r ill, make a h o le in the
windshield ad hesive.
(2)P ass the p i ano wire from the inside of the
veh i cle thro ugh 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.
AC002060
AC207478
Glass adhesive knife
AD
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.
ACX00475 AB
MB990480
5. Use special tool glass holder (MB990480) to
remove the windshield.

WINDOW GLASS
BODY42-14
CAUTION•
ACX00476AB
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 windshield, remove the adhesive still adhering to the windshield, and
clean with isopropyl alcohol.
9. Clean the body side in the same way.
INSTALLATION SERVICE POINTS
>>A<< WINDSHIELD
SPACER/SPACER/GLASS STOPPER/WIN
-
DOW DAM/WINDSHIELD MOULDING
INSTALLATION
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 of the windshi eld and the body flanges.