2005 MITSUBISHI LANCER lock

POWER STEERING GEAR BOX AND LINKAGE
POWER STEERING37-36
>>N<< TIE ROD END/LOCK NUT
INSTALLATION
Screw in the tie rod end to achieve the right and left
length as illustrated. Lock with the lock nut.
NOTE: The lock nuts must be tightened securely
only after the steering gear is installed to the vehicle
and toe-in is adjusted.
>>O<< GEAR MOUNTING RUBBER
INSTALLATION
Install the gear mounting rubber to the rack housing
so that the distance is as shown in the illustration.
TIE ROD END BALL JOINT DUST COVER
REPLACEMENT
M1372008200327
If the dust cover is damaged accidentally during
service work, replace the dust cover as follows:
1. Apply specified grease to the lip and inside of the
dust cover.
Specified grease:
Multipurpose grease SAE J310, NLGI No.2 or
equivalent
2. Drive in the dust cover with special tool front axle
base (MB990776) until it is fully seated.
3. Check the dust cover for cracks or damage by
pushing it with your finger.
AC001011
AM
Lock nut Edge of bellows
assembly groove
180 mm
AC100275
AB
220 mm
AC001012
AB
MB990776

POWER STEERING HOSES
POWER STEERING37-42
POWER STEERING HOSES
REMOVAL AND INSTALLATIONM1372005700679
CAUTION
•Before removing the clock spring, refer to GROUP 52B, Service Precautions (P.52B-5) and Air Bag
Module and Clock Spring (P.52B-210). Also, put the front wheels in straight-ahead position.
Failure to do so may damage the SRS clock spring and render the SRS air bag inoperative, which
results serious driver injury.
•
*: Indicates parts which should be initially tightened, and then fully tightened after placing the
vehicle horizontally and loading the full weight of the engine on the vehicle body.

Pre-removal and Post-installation Operation
•Power Steering Fluid Draining and Refilling (Refer to
P.37-13). and Bleeding (Refer to P.37-13).
AC304699AB
15 ± 3 N·m
18 ± 2 N·m
167 ± 9 N·m 12 ± 2 N·m
49 ± 10 N·m 12 ± 2 N·m
57 ± 7 N·m*57 ± 7 N·m
3 1
2
9
13
10
711 12
568
12 ± 2 N·m12 ± 2 N·m
2
9
4 7 8
7 8
7
8
57 ± 7 N·m57 ± 7 N·m 57 ± 7 N·m
12 ± 2 N·m
167 ± 9 N·m
Crossmember 12 ± 2 N·m
<1300, 1600> <2000>
12 ± 2 N·m
Removal steps
1. Oil reservoir
>>C<<2. Suction hose
>>B<<3. Return hose•Clock spring (Refer to GROUP 52B,
Air Bag Modules and Clock Spring
P.52B-210). Removal steps (Continued)

POWER STEERING HOSES
POWER STEERING37-43

•Centermember (Refer to GROUP 32,
Engine Roll Stopper Centermember
P.32-7).
•Front exhaust pipe (Refer to GROUP
15, Exhaust Pipe and Main Muffler
P.15-11).
4. Steering gear and joint connecting
bolt
5. Rear roll stopper connecting bolt
6. Rear roll stopper (Refer to GROUP
32, Engine Roll Stopper
Centermember P.32-7).
<>7. Eye boltRemoval steps (Continued)
8. Gasket
9. Pressure hose assembly
10. Return tube
>>A<<11. Return hose
<>12. Return tube
13. O-ringRemoval steps (Continued)
AC304698AB
15 ± 3 N·m
18 ± 2 N·m
167 ± 9 N·m 12 ± 2 N·m
49 ± 10 N·m 12 ± 2 N·m
57 ± 7 N·m*
3 1
2
9
10
7
5 6
24
8857 ± 7 N·m
167 ± 9 N·m
Crossmember12 ± 2 N·m <1300, 1600>
<2000>
7
6
57 ± 7 N·m
7 6
57 ± 7 N·m
7
6
57 ± 7 N·m
12 ± 2 N·m
Removal steps
1. Oil reservoir
>>C<<2. Suction hose
>>B<<3. Return hose•Clock spring (Refer to GROUP 52B,
Air Bag Modules and Clock Spring
P.52B-210). Removal steps (Continued)

42-2
TROUBLESHOOTING . . . . . . . . . .42-26
ON-VEHICLE SERVICE. . . . . . . . .42-27
DOOR FIT ADJUSTMENT. . . . . . . . . . . 42-27
DOOR WINDOW GLASS ADJUSTMENT42-28
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
REGULATOR . . . . . . . . . . . . . . . . .
42-32
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 . . . . . . . . . .42-46
ON-VEHICLE SERVICE . . . . . . . . .42-46
TAILGATE FIT ADJUSTMENT. . . . . . . . 42-46
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

HOOD
BODY42-4
HOOD
REMOVAL AND INSTALLATIONM1421001600561
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
22
44
5 6 73 8
910
AD9.0 ± 2.0 N·m21 ± 4 N·m 11 ± 2 N·m21 ± 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 cableHood and hood hinge removal
steps
6. Hood insulator
7. Hood weatherstrip
•Washer hose (Refer to GROUP 51,
Windshield wiper and washer
P.51-23.)
8. Hood
9. Hood support rod
10. Hood hinge

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-28.)
•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-11.)
18M0109W0570AQ
AC005996
AC005973
3
54
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 assembly4. Fuel filler lid lock release cable
5. Fuel filler lid lock release handleRemoval steps (Continued)

WINDOW GLASS
BODY42-11
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 the 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 adheres
completely.
Cleaning
After removing excess adhesive from the body or glass with a spatula, etc.
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
BODY42-19
QUARTER WINDOW GLASS
REMOVAL AND INSTALLATIONM1422002500247
Pre-removal and Post-installation Operation
•Quarter Trim Upper Removal and Installation (Refer to
GROUP 52A, Trims P.52A-11).
AC304783
N
N
N
12
3
N3 4
AB
Y1509AU
Y1508AU
Y1507AU
Y1485AU
Y1535AU
AC304784
AAB B
DD
C
C
Mark
Apply the primer and adhesive
along the fictitious lines (seal line)
between each of the marks.
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
1 11
Seal line centrePrimer Section A – A Section B – BSeal line
centre
Primer
Section C – C Section D – D
Seal line
centrePrimer
1Seal line
centre
Units: mm
Primer
16
161616
Ceramic line
AB
Removal steps
<> >>B<<1. Quarter window glass assembly
>>A<<2. Dual lock fastener
>>A<<3. Clip
>>A<<4. GasketRemoval steps (Continued)