2005 MITSUBISHI LANCER oil

WINDOW GLASS
BODY42-10
WINDOW REPAIRM1422005600027
The windshield, rear window glass, quarter window
glass and tailgate window glass are attached by an
urethane-base adhesive to the window frame. This
adhesive provides improved glass holding and
sealing, and also gives body openings a greater
structural strength.
ITEMS
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
painting, bake it after painting is completed. Name Remark
Adhesive 3M ATD Part No.8609 Super Fast Urethane Auto Glass Sealant or
equivalent
Primer 3M ATD Part No.8608 Super Fast Urethane Primer or equivalent
Spacers Available as service part
Dam Available as service part
Anti-rust solvent (or Tectyl
506T.Valvoline Oil Company)For rust prevention
Isopropyl alcohol For grease removal from bonded surface
Steel piano wire Dia. × length... 0.6mm × 1m For cutting adhesive
Glass adhesive knife For cutting adhesive
Adhesive gun For pressing-out adhesive

WINDOW GLASS
BODY42-22
TAILGATE WINDOW GLASS
REMOVAL AND INSTALLATIONM1422003700170
Pre-removal and Post-installation Operation
•Tailgate Trim Removal and Installation (Refer to GROUP
52A, Tailgate Trim P.52A-19).
•Tailgate Spoiler Assembly Removal and Installation
(Refer to GROUP 51, Tailgate Spoiler P.51-19).
•Rear Wiper Arm Assembly Removal and Installation
(Refer to GROUP 51, Rear Wiper and Washer P.51-29).
AC304811
1
2
6 55
4 33 7
AB
N
NN
N
N
N
N
Y1522AU
Y1538AU
AC304812
Y1537AUY1537AU
AB
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 equivalentSection A – A
13
14
14 Section B – B
Section C – C A
A
CC
B
B Ceramic line
Mark Apply the primer and adhesive
along the fictitious lines (seal line)
between each of the marks.
Seal line
centrePrimer
Seal line
centrePrimer
Seal line
centre
Primer
22
2

DOOR
BODY42-25
DOOR
SERVICE SPECIFICATIONSM1423000300091
SEALANTM1423000500095
SPECIAL TOOLSM1423000600337
ItemStandard value
Power window operation current (Power supply voltage 14.5 ± 0.5 V, at 25 °C) A 5 ± 1
Door outside handle play mm Front door 2.6 ± 2.5
Rear door 1.3 ± 1.3
Door inside handle play mm Front door 10.4 ± 9.6
Rear door 10 ± 9.6
Item Specified sealant
Door waterproof film 3M ATD Part No.8633 or equivalent
Tool Number Name Use
MB990480 Window glass holder Removal of power window regulator
assembly
MB990900 or
MB991164Door hinge adjusting
wrenchDoor alignment
MB990925
A: MB990939Bearing and oil seal
installer set
A: Brass barDoor striker adjustment
MB990211 Sliding hammer
MB990241
A: MB990243Axle shaft puller
A: Body puller
MB990480
MB990900
MB990925AF
A
MB990211
MB990241
A
AE

TRUNK LID
BODY42-43
TRUNK LID
REMOVAL AND INSTALLATIONM1421002200180
AC301676
Y0636AU
Y0637AU
AB
1
2
3
45
5
6
7 89
10
99
11
12
8.9 ± 1.9 N·m A
A
B
B15 mm
14 mm
5Section A - A
Section B - B
Trunk lid weatherstrip removal steps
•Rear end trim (Refer to GROUP 52A,
Trims P.52A-11.)
>>B<<1. Trunk lid weatherstrip
Trunk lid release cable and trunk lid
release handle removal steps
•Rear end trim (Refer to GROUP 52A,
Trims P.52A-11.)
•Trunk rear side trim (LH) (Refer to
GROUP 52A, Trims P.52A-11.)
•Front scuff plate (LH) (Refer to
GROUP 52A, Trims P.52A-11.)
•Cowl side trim (LH) (Refer to GROUP
52A, Trims P.52A-11.)
•Rear scuff plate (LH) (Refer to
GROUP 52A, Trims P.52A-11.)
•Centre pillar lower trim (Refer to
GROUP 52A, Trims P.52A-11.)
•Rear seat (Refer to GROUP 52A,
Rear seat assembly P.52A-28.)
•Accelerator pedal stopper (Refer to
GROUP 17, Accelerator pedal
P.17-3.)
2. Trunk lid release handle
3. Trunk lid release cableTrunk lid striker removal steps
•Rear end trim (Refer to GROUP 52A,
Trims P.52A-11.)
4. Trunk lid striker
Trunk lid panel removal steps
•Licence plate garnish (Refer to
GROUP 51, Garnishes P.51-17.)
5. Trunk lid bumper
•Rear spoiler (Refer to GROUP 51,
Rear spoiler P.51-18.)
6. Trunk lid lock cylinder
7. Trunk lid latch assembly
8. Trunk lid hinge mounting bolt
9. Trunk lid panel assembly
Trunk lid latch removal
7. Trunk lid latch assembly
Trunk lid hinge removal steps
•Rear shelf trim (Refer to GROUP
52A, Trims P.52A-11.)
•Rear seat (Refer to GROUP 52A,
Rear seat assemblyP.52A-28.)
9. Trunk lid panel assembly
<> >>A<<10. Trunk lid torsion bar (RH)
<> >>A<<11. Trunk lid torsion bar (LH)
12. Trunk lid hinge

TRUNK LID
BODY42-45
CAUTION
Install the trunk lid torsion bar before the
trunk lid torsion bar . If the sequence is
reversed, the trunk lid torsion bar will not
be able to be installed because the special tool
will interfere with the trunk lid torsion bar
during installation of the trunk lid torsion bar
.
1. Identify the LH and RH torsion bars by the colour
mark made at the centre of each torsion bar.
2. Insert the left end of the trunk lid torsion bar
in the hole in the trunk lid hinge .
3. Press portion A of the trunk lid torsion bar
right end against point A on the trunk lid hinge
as shown in View F in the drawing.
4. Twist the portion B of the trunk lid torsion bar
right end using the special tool until it is
moved from point B and pressed against point C
of the trunk lid hinge as shown in View F.
Then force the portion into point D.
5. Twist the portion A of the trunk lid torsion bar
right end until it reaches point E on the trunk
lid hinge as shown in View F.
6. Attach the trunk lid torsion bar to the trunk
lid hinge using the same method as the
trunk lid torsion bar .
>>B<< TRUNK LID WEATHERSTRIP
INSTALLATION
Install the trunk lid weatherstrip so that the marking
and the joint are aligned with the body centre line,
INSPECTIONM1421004800133
TRUNK LID LATCH SWITCH CONTINUITY
CHECK
Trunk lid torsion bar Mark
colour
LH Vehicles with rear spoiler Green
Vehicles without rear spoiler White
green
RH Vehicles with rear spoiler Yellow
Vehicles without rear spoiler Red
Switch position Tester
connectionSpecified
condition
ON (Latch open) 1 − Earth Less than 2
ohms
OFF (Latch shut) Open circuit
AC006104AB Joint
section
Marking
section
AC305142AB
Trunk lid latch assembly

TA I L G AT E
BODY42-48
TAILGATE
REMOVAL AND INSTALLATIONM1424001100178
CAUTION
•Do not disassemble or throw the tailgate gas spring into fire.
•Punch a hole in the gas spring before disposal to release the gas inside.
•Ensure the tailgate gas spring piston rod does not come into contact with foreign material.
Pre-removal Operation
•Tailgate Spoiler Assembly Removal (Refer to GROUP 51,
Tailgate Spoiler P.51-19).
•Tailgate Trim Assembly Removal (Refer to GROUP 52A,
Tailgate Trim P.52A-19).
•Rear Wiper Motor Removal (Refer to GROUP 51, Rear
Wiper and Washer P.51-29).Post-installation Operation
•Tailgate Fit Adjustment (Refer to P.42-46).
•Rear Wiper Motor Installation (Refer to GROUP 51, Rear
Wiper and Washer P.51-29).
•Tailgate Trim Assembly Installation (Refer to GROUP
52A, Tailgate Trim P.52A-19).
•Tailgate Spoiler Assembly Installation (Refer to GROUP
51, Tailgate Spoiler P.51-19).
AC304836
7
3
4 1
6
8
12 ± 2 N·m
13 ± 2 N·m22 ± 4 N·m
AB
Sealant: 3M ATD Part No. 8633 or equivalent9.0 ± 2.0 N·m
2
712 ± 2 N·m
5
7
9
5.0 ± 1.0 N·m
5.0 ± 1.0 N·m
3
11
10

51-1
GROUP 51
EXTERIOR
CONTENTS
FRONT BUMPER ASSEMBLY . . . . .51-2
ADHESIVE . . . . . . . . . . . . . . . . . . . . . . . . . 51-2
FRONT BUMPER ASSEMBLY . . . . . . . . . . 51-2
REMOVAL AND INSTALLATION . . . . . . . . 51-2
DISASSEMBLY AND REASSEMBLY . . . . . 51-3
REAR BUMPER ASSEMBLY . . . . . .51-5
REMOVAL AND INSTALLATION . . . . . . . . 51-5
DISASSEMBLY AND REASSEMBLY . . . . . 51-7
MOULDINGS . . . . . . . . . . . . . . . . . . .51-9
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . 51-9
ADHESIVE . . . . . . . . . . . . . . . . . . . . . . . . . 51-9
MOULDINGS . . . . . . . . . . . . . . . . . . . . . . . 51-10
REMOVAL AND INSTALLATION . . . . . . . . 51-10
SIDE AIR DAM . . . . . . . . . . . . . . . . . .51-15
ADHESIVE . . . . . . . . . . . . . . . . . . . . . . . . . 51-15
SIDE AIR DAM . . . . . . . . . . . . . . . . . . . . . . 51-15
REMOVAL AND INSTALLATION . . . . . . . . 51-15
GARNISHES . . . . . . . . . . . . . . . . . . .51-17
REMOVAL AND INSTALLATION . . . . . . . . 51-17
REAR SPOILER . . . . . . . . . . . . . . . . .51-18
REMOVAL AND INSTALLATION . . . . . . . . 51-18
TAILGATE SPOILER . . . . . . . . . . . . .51-19
REMOVAL AND INSTALLATION . . . . . . . . 51-19
ROOF RAIL . . . . . . . . . . . . . . . . . . . .51-20
REMOVAL AND INSTALLATION . . . . . . . . 51-20
WINDSHIELD WIPER AND WASHER51-21
GENERAL INFORMATION . . . . . . . . . . . . . 51-21
SERVICE SPECIFICATION . . . . . . . . . . . . 51-22TROUBLESHOOTING . . . . . . . . . . . . . . . . 51-22
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . 51-22
WINDSHIELD WIPER AND WASHER . . . . 51-23
REMOVAL AND INSTALLATION . . . . . . . . 51-23
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 51-25
REAR WIPER AND WASHER . . . . . .51-28
GENERAL INFORMATION . . . . . . . . . . . . . 51-28
SERVICE SPECIFICATION . . . . . . . . . . . . 51-28
TROUBLESHOOTING . . . . . . . . . . . . . . . . 51-28
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . 51-28
REAR WIPER AND WASHER . . . . . . . . . . 51-29
REMOVAL AND INSTALLATION . . . . . . . . 51-29
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 51-30
HEADLAMP WASHER . . . . . . . . . . . .51-32
TROUBLESHOOTING . . . . . . . . . . . . . . . . 51-32
HEADLAMP WASHER . . . . . . . . . . . . . . . . 51-32
REMOVAL AND INSTALLATION . . . . . . . . 51-32
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 51-33
MARK . . . . . . . . . . . . . . . . . . . . . . . . .51-34
REMOVAL AND INSTALLATION . . . . . . . . 51-34
DOOR MIRROR . . . . . . . . . . . . . . . . .51-36
GENERAL INFORMATION . . . . . . . . . . . . . 51-36
SERVICE SPECIFICATION . . . . . . . . . . . . 51-36
SPECIAL TOOL. . . . . . . . . . . . . . . . . . . . . . 51-36
TROUBLESHOOTING . . . . . . . . . . . . . . . . 51-36
DIAGNOSIS TROUBLESHOOTING
FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51-36
TROUBLE SYMPTOM CHART . . . . . . . . . . 51-36
SYMPTOM PROCEDURES . . . . . . . . . . . . 51-37
DOOR MIRROR . . . . . . . . . . . . . . . . . . . . . 51-45
REMOVAL AND INSTALLATION . . . . . . . . 51-45
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 51-47

REAR SPOILER
EXTERIOR51-18
REAR SPOILER
REMOVAL AND INSTALLATIONM1511006100136
REMOVAL SERVICE POINT
<> HIGH-MOUNTED STOP LAMP
REMOVAL
Use the following steps to easily route high-mounted
stop lamp harness in the event of installation:
CAUTION
Ensure that the string is tightly tied.
1. Tie string on high-mounted stop lamp harness (at
connector side).
2. Carefully pull out high-mounted stop lamp.
AC303713
2 3
4
2
1
AB
1
Removal steps
•Trunk lid bumper (Refer to GROUP
42, Trunk lid P.42-43.)
1. Cap2. Gasket
3. Rear spoiler
<>4. High-mounted stop lampRemoval steps (Continued)
AC303708
Connector String
AB