service MITSUBISHI LANCER EVOLUTION 2007 Service Repair Manual

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 -Doors42-33
REMOVAL SERVICE POINTS
AA"WINDOW REGULATOR ASSEMBLY/POWER
WINDOW MOTOR ASSEMBLY REMOVAL
1. Loosen the door window glass assembly mounting bolts.
2. Raise the door window glass assembly, and then adhere
the special tool on the glass as shown in the illustration
to prevent from falling.
CautionFor the door window glass adhered film and
etc., use the special tool from outside the door glass
to prevent unstucking.
3. Remove the power window regulator and motor assembly.
AB"DOOR CENTER SASH REMOVAL
1. Remove only the section of the door outer opening
weatherstrip
2. Remove the center sash upper mounting screws, and
then remove the center sash upper from the door panel.
INSTALLATION SERVICE POINTS
"AAWINDOW REGULATOR ASSEMBLY/POWER
WINDOW MOTOR ASSEMBLY INSTALLATION
When installing the window regulator assembly, tighten he
bolts at the specified torque in the order shown in the
illustration.
MB990480
Door outer opening
weatherstrip
Door center sash
A18X0127

1
2 4
3
56
1
2
34
5 67

BODY -Doors42-35
DOOR HANDLE AND LATCH
REMOVAL AND INSTALLATION
Pre-removal Operation
Door Trim Removal (Refer to P.42-27.)Post-installation Operation
DDoor Inside Handle Looseness Check (Refer to
P.42-24.)
DDoor Outside Handle Looseness Check (Refer to
P.42-23.)
DDoor Trim Installation (Refer to P.42-27.)

3
5
4 72
6
1
5.9±1.0 N·m
8.9±1.9 N·m
2
1
75 6
2.5±0.5 N·m
2.5±0.5 N·m
Door handle and door latch
removal steps
"CA1. Door inside handle
DWaterproof film (Refer to P.42-27.)
DDoor window glass lower runchan-
nel (Refer to P.42-38, 39.)
DDoor center sash (Refer to
P.42-32.)2. Door outside handle
3. Key cylinder
"BA4. Lower sash
5. Door latch assembly
6. Link
Door check removal steps
DWaterproof film (Refer to P.42-27.)
"AA7. Door check
INSTALLATION SERVICE POINTS
"AADOOR CHECK INSTALLATION
Install with the following identification marks upward.
ItemsIdentification mark
Front doorLeft side21L
Right side21R
Rear doorLeft side36L
Right side36R
Identification
mark

BODY -Doors42-39
Sectional view of
clip positionSectional view of
clip position
5
4 3
21

Section A - A
Door
6
A
A
6
BB
Section B - B
Door
23
Door inner opening weatherstrip
removal steps
DScuff plate (Refer to GROUP 52A.)
DCenter pillar lower trim (Refer to
GROUP 52A.)
1. Door inner opening weatherstrip
Door outer opening weatherstrip
removal steps
2. Retainer weatherstrip
AA""AA3. Door outer opening weatherstrip
Door window glass runchannel
removal
4. Door window glass runchannelDoor beltline inner weatherstrip
removal steps
DDoor trim (Refer to P.42-27.)
5. Door beltline inner weatherstrip
Door beltline molding removal
steps
DDoor window glass (Refer to
P.42-32.)
DStationary glass (Refer to P.42-32.)
6. Door beltline molding
REMOVAL SERVICE POINT
AA"DOOR OUTER OPENING WEATHERSTRIP
REMOVAL
Make a tool as shown and remove the weatherstrip from
the door panel.15mm
4mm
8mm
Thickness
1mm

BODY -Doors42-40
INSTALLATION SERVICE POINTS
"AADOOR OUTER OPENING WATHERSTRIP
INSTALLATION
The clip colour identifies the left and right weatherstrips so
be sure to use the colours as install correctly.
Applicable sideIdentification colour
Right doorPink
Left doorNatural (White)

BODY -Trunk lid42-42
Grease application area
67
2
REMOVAL SERVICE POINT
AA"TRUNK LID TORSION BAR REMOVAL
Insert the tire lever into the torsion bar, and then pull upward
the tire lever to remove the torsion bar as shown in the
illustration.
NOTE
As the left and right trunk lid torsion bars are crossed at
the center, first remove the front trunk lid torsion bar at
the center.
INSTALLATION SERVICE POINTS
"AATRUNK LID TORSION BAR INSTALLATION
Install the trunk lid torsion bar by the following procedure.
1. Ensure that there is the identification color at the center
of the trunk lid torsion bar.
Trunk lid torsion barIdentification color
Left side-
Right sideRed
Caution
As the trunk lid torsion bar (Right side) is painted
with differentiation color in the middle to differentiate
between RH and LH, be careful when installing.
2. Install the trunk lid torsion bar (Left side) as follows.
(1) For terminal A, insert the trunk lid hinge (Left side)
into the fixed hole B
(2) For terminal C, touch the trunk lid hinge (Right side)
against portion E.
(3) For terminal D, insert the trunk lid hinge (Right side)
into portion F until portion G while twisting with the
tool such as a tire lever, etc.
(4) For terminal C, set the trunk lid hinge (Right side)
at portion H while twisting with the tool such as a
tire lever etc.
3. Install the trunk lid torsion bar (Right side) in the same
way as above.
Trunk lid torsion bar
Tire lever
Tire lever
D
Trunk lid torsion
bar
H
Identification
color
Trunk lid torsion bar
(Right side)
Trunk lid torsion bar
(Left side) Trunk lid hinge (Left side)
A
BC
D
Trunk lid hinge
(Right side)
C
F
G
E
Trunk lid torsion bar (Left side)

51-1
EXTERIOR
CONTENTS
FRONT BUMPER 2....................
ADHESIVE 2..............................
FRONT BUMPER 2........................
REAR BUMPER 6.....................
SIDE AIR DAM, MOLDING AND
GARNISH 8...........................
SPECIAL TOOL 8.........................
ADHESIVE 8..............................
SIDE AIR DAM MOLDING GARNISH 9.....
REAR SPOILER 11....................
ADHESIVE 11.............................REAR SPOILER 12........................
WINDSHIELD WIPER AND WASHER 13.
SERVICE SPECIFICATIONS 13.............
TROUBLESHOOTING 13...................
ON - VEHICLE SERVICE 13.................
WINDSHIELD WIPER AND WASHER 14......
MARKS 20............................
OUTSIDE MIRROR 23.................
SPECIAL TOOL 23........................
OUTSIDE MIRROR 23......................

EXTERIOR -Front Bumper51-4
Front air dam Front bumper face
A
A
Front air dam
Front bumper
lower plate
Double-sided tape: Generic products: 10mm width, 1.2mm thicknessSection A – A
DISASSEMBLY SERVICE POINTS
AA"RIVET REMOVAL
Use the drill (ø4.0 mm) to make a hole in the rivet for removal.
AB"FRONT AIR DAM REMOVAL
The same procedures are applied as that of the removal
of side air dam. (Refer to P.51-10.)
REASSEMBLY SERVICE POINTS
"AAFRONT AIR DAM INSTALLATION
The same procedures are applied as that of the installation
of side air dam. (Refer to P.51-10.)
Drill
RivetFront
bumper
face

EXTERIOR -Rear Bumper51-7
DISASSEMBLY AND REASSEMBLY
1 32
54
Disassembly steps
1. License plate bracket
2. Rear bumper center reinforcement
AA""AA3. Rivet4. Rear bumper side plate
5. Rear bumper face
DISASSEMBLY SERVICE POINTS
AA"RIVET REMOVAL
Use the drill (ø 4.0 mm) to make a hole in the rivet for removal.
Drill
RivetFront
bumper
face

EXTERIOR -Rear Bumper / Side Air Dam, Molding and Garnish51-8
REASSEMBLY SERVICE POINTS
"AARIVET INSTALLATION
Use the recommended tool shown in the illustration to secure
the rivet in the following procedure.
1. Insert the rivet into the main materials (rear bumper face
and rear bumper side plate.)
2. Insert the recommended tool into Part A of the rivet.
3. Maneuver the handle of the tool pressing the flange of
the rivet.
4. Particles of Part A of the rivet are cut off to be secured.
SIDE AIR DAM, MOLDING AND GARNISH
SPECIAL TOOL
ToolNumberNameApplication
MB990449Window molding
removerRemoval of roof drip molding
ADHESIVE
ApplicationBrand
Side air damDouble-sided tape [5 mm width 1.2 mm thickness]
Riveter
Bumper side
plate
Part A
Riveter
Rivet
Flange part
1
2
3
4Bumper face
Rivet
Bumper face