window MITSUBISHI LANCER 2006 Workshop Manual

42-1
GROUP 42
BODY
CONTENTS
HOOD . . . . . . . . . . . . . . . . . . . . .42-3
ON-VEHICLE SERVICE. . . . . . . . .42-3
ADJUSTMENT OF CLEARANCE
AROUND HOOD . . . . . . . . . . . . . . . . . . 42-3
ADJUSTMENT OF ALIGNMENT OF
HOOD STEPPED PORTION AND
HOOD STRIKER . . . . . . . . . . . . . . . . . . 42-3
ADJUSTMENT OF HOOD HEIGHT . . . 42-3
HOOD . . . . . . . . . . . . . . . . . . . . . . .42-4
REMOVAL AND INSTALLATION . . . . . 42-4
FENDER . . . . . . . . . . . . . . . . . . .42-5
SPECIAL TOOL . . . . . . . . . . . . . . .42-5
FENDER . . . . . . . . . . . . . . . . . . . . .42-6
REMOVAL AND INSTALLATION . . . . . 42-6
FUEL FILLER LID . . . . . . . . . . .42-8
REMOVAL AND INSTALLATION .42-8
STRUT TOWER BAR . . . . . . . .42-9
REMOVAL AND INSTALLATION .42-9
WINDOW GLASS . . . . . . . . . . . 42-10
ADHESIVE . . . . . . . . . . . . . . . . . . .42-10
SPECIAL TOOLS . . . . . . . . . . . . . .42-10
WINDOW REPAIR . . . . . . . . . . . . .42-10
WINDSHIELD . . . . . . . . . . . . . . . . .42-12
REMOVAL AND INSTALLATION . . . . . . 42-12
REAR WINDOW GLASS
. . . . . . . . . . . . . . . . . . . .42-17
REMOVAL AND INSTALLATION . . . . . . 42-17
QUARTER WINDOW GLASS
. . . . . . . . . . . . . . . . . . .42-20
REMOVAL AND INSTALLATION . . . . . . 42-20
TAILGATE WINDOW GLASS
. . . . . . . . . . . . . . . . . . .42-23
REMOVAL AND INSTALLATION . . . . . . 42-23
DOOR . . . . . . . . . . . . . . . . . . . . 42-25
SERVICE SPECIFICA TIONS . . . . .42-25
SEALANT . . . . . . . . . . . . . . . . . . . .42-25
SPECIAL TOOLS . . . . . . . . . . . . . .42-26
Continued on next page

42-2
TROUBLESHOOTING . . . . . . . . . .42-26
ON-VEHICLE SERVICE. . . . . . . . .42-27
DOOR FIT ADJUSTMENT. . . . . . . . . . . 42-27
DOOR WINDOW GLASS
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . 42-28
GLASS SLIDING MECHANISM CHECK
AND ADJUSTMENT . . . . . . . . . . . . . . . 42-28
POWER WINDOW OPERATING
CURRENT CHECK . . . . . . . . . . . . . . . . 42-28
POWER WINDOW RELAY CHECK . . . 42-29
CIRCUIT BREAKER (INCORPORATED
IN THE POWER WINDOW MOTOR)
INSPECTION . . . . . . . . . . . . . . . . . . . . . 42-29
POWER WINDOW CHECK . . . . . . . . . . 42-29
CENTRAL DOOR LOCKING SYSTEM
INSPECTION . . . . . . . . . . . . . . . . . . . . . 42-29
DOOR OUTSIDE HANDLE PLAY
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . 42-29
DOOR INSIDE HANDLE PLAY
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . 42-30
DOOR ASSEMBLY . . . . . . . . . . . .42-31
REMOVAL AND INSTALLATION . . . . . 42-31
INSPECTION . . . . . . . . . . . . . . . . . . . . . 42-32
DOOR GLASS AND REGULATOR42-32
REMOVAL AND INSTALLATION . . . . . 42-32
INSPECTION . . . . . . . . . . . . . . . . . . . . . 42-34
DOOR HANDLE AND LATCH . . . .42-36
REMOVAL AND INSTALLATION . . . . . 42-36
INSPECTION . . . . . . . . . . . . . . . . . . . . . 42-37
WINDOW GLASS RUNCHANNEL
AND DOOR OPENING
WEATHERSTRIP . . . . . . . . . . . . . .42-39
REMOVAL AND INSTALLATION . . . . . 42-39
TRUNK LID . . . . . . . . . . . . . . . .42-41
SPECIAL TOOL . . . . . . . . . . . . . . .42-41
ON-VEHICLE SERVICE. . . . . . . . .42-41
TRUNK LID ADJUSTMENT . . . . . . . . . . 42-41
ADJUSTMENT OF CLEARANCE
AROUND TRUNK LID . . . . . . . . . . . . . . 42-42
TRUNK LID STRIKER ADJUSTMENT . 42-42
TRUNK LID HEIGHT ADJUSTMENT . . 42-42
TRUNK LID . . . . . . . . . . . . . . . . . . .42-43
REMOVAL AND INSTALLATION . . . . . . 42-43
INSPECTION . . . . . . . . . . . . . . . . . . . . . 42-45
TAILGATE . . . . . . . . . . . . . . . . 42-46
SERVICE SPECIFICATIONS . . . . .42-46
SEALANTS . . . . . . . . . . . . . . . . . . .42-46
SPECIAL TOOL . . . . . . . . . . . . . . .42-46
TROUBLESHOOTING . . . . . . . . . .42-47
ON-VEHICLE SERVICE . . . . . . . . .42-47
TAILGATE FIT ADJUSTMENT. . . . . . . . 42-47
TAILGATE HANDLE PLAY CHECK . . . . 42-47
TAILGATE . . . . . . . . . . . . . . . . . . .42-48
REMOVAL AND INSTALLATION . . . . . . 42-48
TAILGATE HANDLE AND
LATCH . . . . . . . . . . . . . . . . . . . . . .42-50
REMOVAL AND INSTALLATION . . . . . . 42-50
INSPECTION . . . . . . . . . . . . . . . . . . . . . 42-51
KEYLESS ENTRY SYSTEM . . 42-51
SERVICE SPECIFICATIONS . . . . .42-51
SPECIAL TOOLS . . . . . . . . . . . . . .42-52
TROUBLESHOOTING . . . . . . . . . .42-53
ON-VEHICLE SERVICE . . . . . . . . .42-53
KEYLESS ENTRY SYSTEM CHECK. . . 42-53
KEYLESS ENTRY SYSTEM TIMER
LOCK FUNCTION INSPECTION . . . . . . 42-53
ENABLING/DISABLING THE
ANSWERBACK FUNCTION . . . . . . . . . 42-53
HOW TO REGISTER SECRET CODE . 42-55
TRANSMITTER. . . . . . . . . . . . . . . .42-58
DISASSEMBLY AND REASSEMBLY . . 42-58
INSPECTION . . . . . . . . . . . . . . . . . . . . . 42-59

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.

Y0628AU
AC006029
10138AU
10139AU
Y0497AU
Glass stopper, spacer, windshield spacer and window dam installation position17.5 mm Glass stopper
Glass end line
Ceramic line
Align the glass
stopper end with
the ceramic notch.
Align the window
dam and with the
seal line mark.
13 mm
Glass end line
Mark
Seal line
Ceramic line Window dam
AB
AA Windshield
Seal line
centre
14 mm
Windshield spacer
Section A – A
Section B – B
BB 14 mm
Spacer
Align the spacer
and with glass
end line
Align the windshield
spacer end with the
ceramic notch.
WI NDOW GLASS
BO D Y42-15
2.Th e inn e r side of the wind shield is curve d ,
th erefore, make a p o int t o assemble th e gla s s
stoppe r and windsh i eld sp acer withou t any lif ting
an d assemble in the positio n sho w n in th e Fig u re
of the instru ctio ns.
3.In st all the win d shield moulding .
>>B< 1.Wh en replacing th e windshie l d, te mpora r ily se t
th e windshie l d ag ainst the b ody , an d pla c e a
matin g ma rk on the wind shield a nd bod y .
CAUTION
•The primer strengthens the adhesive, so be
sure to apply it evenly around the entire cir
-
cumference. 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.

WINDOW GLASS
BODY42-17
REAR WINDOW GLASS
REMOVAL AND INSTALLATION
M1422001600111
Pre-removal and Post-installation Operation
•High-mounted Stop Lamp Assembly Removal and Instal-lation (Refer to GROUP 54A,
High-Mounted Stop Lamp
P.54A-84.)
•Rear Pillar Trim and Rear Shelf Trim Removal and Instal-
lation (Refer to GROUP 52A, Trims P.52A-13.)
•Headlining Removal and Installation (Refer to GROUP
52A, Headlining
P.52A-23.)
Y0500AU
Y0502AUY0501AU
Y0564AU
AC006056
1 1
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.51-9.)
<>>>B<<1.Rear window lower moulding
2.Clip
3.Grommet A
4.Grommet B
5.Grommet C
6.Connecting the harness connector
<>>>A<<7.Rear window glass
>>A<<8.Rear window upper moulding
Removal steps (Continued)