rear MITSUBISHI LANCER EVOLUTION 2007 Service Repair Manual

BODY -Window Glass42-18
Glass end line Glass stopper and window dam installation position
Ceramic line
Glass end
line 18 mmGlass stopper
Window dam19 mm
19 mm
Window dam Ceramic lineAlign the window
dam end with the
seal line mark.
Rear window glassAlign the glass
stopper end
with the ceramic
notch.
Section A - A
A
A
Seal line
Mark
6. Install the rear window upper molding.
7. Install the glass by the same procedure as for the
windshield. (Refer to P.42-14.)
"BAREAR WINDOW LOWER MOLDING
INSTALLATION
Install the clip into the rear window lower molding, and then
install the rear window lower molding in the body.

BODY -DoorsBODY -Doors42-19
DOORS
SERVICE SPECIFICATIONS
ItemsStandard value
Door outside handle play mmFront2.3±2.1py
Rear1.3±1.7
Power window operating current (power supply 14.5±0.5 V, 25_C) A5±1
Door inside handle play mmFront9.6±9.2py
Rear9.0±9.2
ADHESIVE
ItemsSpecified sealantRemark
Waterproof film3M ATD Part No. 8625 or equivalentRibbon sealer
SPECIAL TOOLS
ToolNumberNameUse
MB990784Ornament removerDoor trim removal
MB990480Window glass
holderRemoval of power window regulator and motor
assembly
MB990900 or
MB991164Door hinge
adjusting wrenchAdjustment of door fit
A
MB990925
A: MB990939Bearing & oil seal
installer set
A: Brass barAdjustment of door striker
MB990211Slide hammer
A
BB990241
MB990241
A: MB990243Axle shaft puller
A: Body puller

BODY -Doors42-21
3. If the door does not open and close smoothly
(1) Adjustment with the striker (inside the vehicle and
up and down directions)
Change the striker fixing bolt to a temporary bolt,
and using the special tool (MB990939) and hammer,
gently hit the top of the temporary bolt in the direction
to be adjusted.
(2) Adjustment with the striker (outside the vehicle)
Using the special tool (MB990211, MB990243), pull
the striker towards the outside of the vehicle and
adjust.
(3) Adjustment with the shim (to and fro direction)
Adjust the alignment of the door striker and door
latch using the shim of the striker attached portion.
DOOR WINDOW GLASS ADJUSTMENT
Check that the door glass operates smoothly and moves
along the door glass runchannel when the door window glass
is fully raised and fully lowered. If there is a problem, adjust
by the following procedure.
1. Remove the door trim, and waterproof film. (P.42-27)
2. With the door window glass fully closed, loosen the screw
fixing the door glass from the adjustment hole, and lower
the door window glass slightly.
3. Fully close the door window glass again, and tighten
the screw fixing the door glass from the adjustment hole.
MB990939
Striker Bolt
MB990211MB990243
Striker
StrikerShim
FrontRear
Adjusting
holeAdjusting
hole

BODY -Doors42-23
DOOR OUTSIDE HANDLE LOOSENESS
CHECK
1. Check that the looseness of the door outside handle
satisfies the standard value.
Standard value (A):
Front 2.3±2.1 mm
Rear 1.3±1.7 mm
2. Check the door outside handle and door latch assembly.
If faulty, replace.
POWER WINDOW OPERATING CURRENT
CHECK
1. Remove the power window fuse, and connect the circuit
tester as shown in the figure.
2. When the power window switch is set to the UP side,
a large amount of operating current flows when the window
is operated or closed. Therefore measure somewhere
in between excluding these positions.
Standard value: 5±1A (Power supply voltage
14.5±0.5 V, 25_C)
3. If outside the standard value, perform troubleshooting.
(Refer to GROUP 54B.)
CIRCUIT BREAKER CHECK (Incorporated in
the power window motor)
1. Set the power window switch to the UP side until the
window glass closes completely, and continue operating
the switch for more than 10 seconds.
2. Release the power window switch at the UP side, and
at the same time, press the DOWN side. Under this
condition if the window glass starts to lower within 60
seconds, the circuit breaker can be determined as good.
POWER WINDOW CHECK
Check that the power window operates. If it does not, perform
troubleshooting. (Refer to GROUP 54B.)
A

BODY -Doors42-24
DOOR INSIDE HANDLE LOOSENESS CHECK
AND ADJUSTMENT
1. Check that the door inside handle looseness satisfies
the standard value.
Standard value (A):
Front 9.6±9.2 mm
Rear 9.0±9.2 mm
2. If outside the standard value, remove the door trim.(Refer
to P.42-27.)
3. Adjust the looseness of the inside handle using the clip
joining the inside handle and rod.
A
Section B - B
B
B

BODY -Doors42-25
DOOR ASSEMBLY
REMOVAL AND INSTALLATION
Post-installation Operation
Door Adjustment (Refer to P.42-20.)


7
61 2
3 4
5
98
5
2
38
9
67
4
5, 6
21±4 N·m11±2 N·m
11±2 N·m 1.5±0.5 N·m
1.5±0.5 N·m 27±5 N·m
21±4 N·m
1
1 10
10
11±2 N·m
11±2 N·m
21±4 N·m27±5 N·m
27±5 N·m 21±4 N·m 27±5 N·m
1. Damper mail
Door assembly removal steps
2. Harness connector
3. Door check connecting bolt
4. Door assembly
5. Door upper hinge
6. Door lower hingeStriker removal steps
"AA7. Striker
8. Striker shim
Door switch removal
9. Door switch cap
10. Door switch

BODY -Doors42-27
DOOR TRIM AND WATERPROOF FILM
REMOVAL AND INSTALLATION


7
91
1011
6 9
9
3
521
2
4 8
4 87 6 5 11
103
Sealant: 3M ATD Part No. 8625 or equivalent
Removal steps
1. Cap
2. Door pull handle
3. Power window switch panel
assembly
AA"4. Door inside handle cover
AB""BA5. Clip windows>"BA6. Escutcheon power windows>
"BA7. Regulator handle power windows>
8. Door trim assembly
9. Speaker
10. Power window switch bracket
"AA11. Waterproof film

BODY -Doors42-29
B Note
Section A - A View AView B Claws positions Clips positions

Rear door trimView AView B
Door panelDoor trim Clip
D
Cap View C
D
Section C - C
Cap
ClawPull handle box
View C
B
AW0461AU
AW0772AQ
BW0465AU
Section D - D Section B - B
Door trim
Clip C
C
CC
C
C
A
A
C
C B
B Power window switch
panel assembly
Power window switch
panel assembly
ClawDoor trim Power window switch panel assembly
AW0465AU

BODY -Doors42-31
INSTALLATION SERVICE POINTS
"AAWATERPROOF FILM INSTALLATION
Apply the specified adhesive on the waterproof film as shown
in the illustration, and then glue it on the door window glass.
Specified sealant: 3M ATD Part No. 8625 or equivalent
"BAREGULATOR HANDLE/ESCUTCHEON/CLIP
INSTALLATION
1. Install the clip and escutcheon to the regulator handle.
2. Close the front door window glass fully, and then install
the regulator handle as shown in the illustration.
INSPECTION
Power window main switch uses SWS system, for the
power window main switch check, refer to GROUP 54B
- SWS.
POWER WINDOW SUB SWITCH CONTINUITY CHECK
Switch positionTerminal No.p
236
UP
DOWN
Waterproof film

Waterproof film
Front of vehicle
30_
Horizontal line

BODY -Doors42-32
DOOR GLASS AND REGULATOR
REMOVAL AND INSTALLATION
Pre-removal Operation
Door Trim and Waterproof Film Removal (Refer to
P.42-27.)Post-installation Operation
DDoor Window Glass Adjustment (Refer to P.42-21.)
DDoor Trim and Waterproof Film Installation (Refer
to P.42-27)
1
23
1


34
25 6
1 1
power windows>
power windows>
Window regulator assembly
removal steps
"BADOperation check power window>
AA""AA1. Window regulator assembly
AA""AA2. Power window motor assembly
Window glass removal steps
D. Window glass runchannel (Refer to
P.42-39, 40.)
3. Door window glassStationary window glass removal
steps
DWindow glass runchannel (Refer to
P.42-38, 39.)
DDoor window glass lower runchan-
nel (Refer to P.42-38, 39.)
3. Door window glass
AB"4. Door center sash
5. Stationary window glass
6. Stationary window weatherstrip