roof MITSUBISHI LANCER EVOLUTION 2007 Service Service Manual

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 -Doors42-22
ADJUSTMENTS AND REPLACEMENT DURING
POWER WINDOW MALFUNCTION
If the window glass does not rise but automatically descends,
adjust and replace the window glass as follows:
1. Remove the door trim and waterproof film. (P.42-27)
2. Remove the window regulator assembly from the door
window glass, and raise and lower the window glass with
your hand and check the operating force.
Remarks Insert a cushion, etc. to prevent damage of
the glass if it accidentally drops.
3. If the door window glass does not rise and descend
smoothly, perform the following check and repair.
DCheck the installation condition of the runchannel.
DStraighten twist in the door sash.
DCheck the installation condition of the lower sash
or the center sash.
NOTE
The lower sash cannot normally be adjusted, but it may
be possible to adjust the sash span slightly within the
range allowed by manufacturing tolerances by pushing
the lower sash outwards while re-installing it.
4. If repair or adjustment is not possible, replace the door
assembly.
POWER WINDOW SAFETY MECHANISM
CHECK
1. Set a wood piece of about 10 mm thick as shown in
the figure, and raise the window glass.
2. Check that the window glass descends by about 150
mm when it catches the wood piece. If it does not, perform
troubleshooting. (Refer to GROUP 54B.)
POWER WINDOW TIMER FUNCTION CHECK
9Close the door and turn the ignition switch in the OFF position,
and then check the power window operates for 30 seconds.
If it does not, perform troubleshooting.(Refer to GROUP 54B.)
Runchannel
Door
sash
Lower sash

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 -Doors42-31
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

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

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

EXTERIOR -Side Air Dam, Molding and Garnish51-9
SIDE AIR DAM, MOLDING AND GARNISH
REMOVAL AND INSTALLATION
11
ClipClip
Clip
1
Section A – A
Section B – B
Section C – C
Section F – F
Clip2,3
1
Clip
Section D – D
1
2
3 1
Clip
Section E – E
NOTE: Refer to P.51-14 for more information regarding removal and
installation of front deck garnish.
F F
A AB BC CD
D
EE
F
F B
B
B BA
A




Double-sided tape: Generic products: 5mm width, 1.2mm thickness3
AA"1. Roof drip molding
2. Delta outer garnishAB""AA3. Side air dam

EXTERIOR -Side Air Dam, Molding and Garnish51-10
REMOVAL SERVICE POINTS
AA"ROOF DRIP MOLDING REMOVAL
Use the special tool to pry the molding from the rear of the
body for removal.
Caution
Do not use the deformed mold again.
AB"SIDE AIR DAM REMOVAL
1. Attach protection tape all the way along the edges of
the double-sided tape which is still adhering to the body.
2. Use a resin spatula to scrape off the double-sided tape.
3. Peel off the protection tape.
4. Wipe the body surface and clean it with a rag moistened
with isopropyl alcohol.
INSTALLATION SERVICE POINTS
"AASIDE AIR DAM INSTALLATION
Double-sided tape affixing to the side air dam (when
reusing)
1. Scrape off the double-sided tape with a resin spatula
or gasket scraper.
2. Wipe off the side air dam adhesion surface and clean
it with a shop towel moistened with isopropyl alcohol.
3. Affix the specified double sided tape to the side air dam.
(Refer to P.51-9.)
MB990449
Protection tape
Double-sided tape