2005 MITSUBISHI LANCER service

DOOR
BODY42-37
INSTALLATION SERVICE POINTS
>>A<< DOOR CHECK INSTALLATION
Install the door check so that the identification mark
faces upwards.
>>B<< LOWER SASH INSTALLATION
Securely insert the rear lower sash into the window
rear sash.
>>C<< DOOR INSIDE HANDLE
INSTALLATION
1. Install the inside lock cable to the door inside
handle as follows:
(1) Install the inner cable end in the inside lock
cable to the clip in the door inside handle.
(2) Turn the inside lock knob to the door lock
position.
(3) Install the outer cable end to the door inside
handle securely.
(4) Install the clip to the inner cable.2. Install the inside handle rod to the door inside
handle.
3. Install the door inside handle to the door.
INSPECTIONM1423004700392
FRONT DOOR LOCK ACTUATOR CHECK
Actuator Operation Check Item Identification
mark
Front Door Left door 39L
Right door 39R
Rear Door Left door 40L
Right door 40R
ACX00541
Identification mark
AB
AC100404
AB
Clip Inner cable
Outer cable end
Inside handle rodDoor inside handleLever
positionBattery connection Lever
operation
At the
"LOCK"
position•Connect terminal
No. 4 and the
negative battery
terminal.
•Connect terminal
No. 6 and the
positive battery
terminal.The lever
moves from the
"LOCK"
position to the
"UNLOCK"
position.
At the
"UNLOCK"
position•Connect terminal
No. 6 and the
negative battery
terminal.
•Connect terminal
No. 4 and the
positive battery
terminal.The lever
moves from the
"UNLOCK"
position to the
"LOCK"
position.
42
53
6 1
42
53
6 1
AC305111B
A
AB
LockUnlock
View A
View B Unlock
Lock Front door
Lever
Lever

TRUNK LID
BODY42-41
REMOVAL SERVICE POINT
<> DOOR OUTER OPENING
WEATHERSTRIP REMOVALMake a fabricated tool as shown in the illustration to
remove the door weatherstrip.
INSTALLATION SERVICE POINT
>>A<< DOOR OUTER OPENING
WEATHERSTRIP INSTALLATION
The clip colour identifies the left and right
weatherstrips so be sure to use the colours so as to
install correctly.
TRUNK LID
SPECIAL TOOLM1421000600245
ON-VEHICLE SERVICE
TRUNK LID ADJUSTMENTM1421001000042
1. If the clearance around the trunk lid panel
assembly is not uniform and locking and
unlocking of the trunk lid is difficult, make
adjustments to the trunk lid bumpers (refer to
P.42-42) and trunk lid hinges (refer to P.42-42).
2. If the clearance around the trunk lid panel
assembly is uniform, but locking and unlocking of
the trunk lid is difficult, make adjustments to the
trunk lid bumpers (refer to P.42-42) and trunk lid
striker (refer to P.42-42).
ACX00555
15 mm
8 mm
AB
4 mm
Thickness:
1 mm
Fabricated
tool
Applicable side Identification colour
Right door Pink
Left door Natural (White)
TOOL Number Name Use
MB991244 Torsion bar remover and
installerRemoval and installation of
trunk lid torsion bar
MB991244
AC202324
AC202325AC202913
A
A AA
AB
Section A – A
Trunk lid panel assembly
Side outer panel Trunk lid panel
assembly
Side outer panel

TRUNK LID
BODY42-44
REMOVAL SERVICE POINT
<> TRUNK LID TORSION BAR
REMOVAL
1. Attach the special tool to the illustrated portion of
the trunk lid torsion bar on the left hand of
the vehicle, then use the tool to detach the trunk
lid torsion bar from the trunk lid hinge
2. Remove the trunk lid torsion bar in the
same way as the trunk lid torsion bar .
INSTALLATION SERVICE POINTS
>>A<< TRUNK LID TORSION BAR
INSTALLATION
Install the trunk lid torsion bars using the following
procedure.
AC305143AB
Grease application area
62
7
AC205068AC205068
MB991244
Trunk lid torsion bar
Trunk lid torsion bar
AB
AC305282
Trunk lid torsion bar
Trunk lid torsion bar
Colour mark
A
B
Trunk lid hinge
Trunk lid torsion bar
View F
Trunk lid hinge
Hole
F
E
A
DC
B
MB991244
Trunk lid torsion bar

AB

TA I L G AT E
BODY42-46
TA I L G AT E
SERVICE SPECIFICATIONSM1421000300288
SEALANTSM1424000500098
SPECIAL TOOLM1424000600170
TROUBLESHOOTINGM1424000700207
The tailgate system is controlled by the Smart Wiring
System (SWS). For troubleshooting, refer to GROUP
54B, Troubleshooting P.54B-17 or GROUP 54C,
Troubleshooting P.54C-4.
ON-VEHICLE SERVICE
TAILGATE FIT ADJUSTMENTM1424000900137
1. If the striker and latch mesh badly, replace the
striker and striker installation blots with
replacement parts (striker: MR523105, striker
installation blot: MU000474).2. Move the replaced striker forward and backward
or to the left and right to adjust, after bolt the
striker temporarily.
3. After adjusting, tighten the bolts to the specified
torque [24 ± 4 N⋅m]. Item Standard value
Tailgate handle play 2.3 to 5.9 mm
Item Specified sealant
Tailgate waterproof film 3M ATD Part No.8633 or equivalent
Tailgate hinge 3M ATD Part No.8531 Heavy drip check sealer, 3M
ATD Part No.8646 Automotive joint and seam sealer
or equivalent
Tool Number Name Use
MB991223
A: MB991219
B: MB991220
C: MB991221
D: MB991222Harness set
A: Test harness
B: LED harness
C: LED harness
adapter
D: ProbeTerminal voltage measurement
A: For checking connector pin
contact pressure
B: For checking power supply
circuit
C: For checking power supply
circuit
D: For connecting a locally
sourced tester
MB991223
A
D C
B
AD
AC203659

TA I L G AT E
BODY42-49
INSTALLATION SERVICE POINT
>>A<< TAILGATE OPENING
WEATHERSTRIP INSTALLATION
Assemble so the tailgate opening weatherstrip
marking is at the centre of the body.
AC305322
Adhesive: 3M ATD Part No.8531 Heavy drip check sealer, 3M ATD Part No.8646 Automotive joint and seam sealer
or equivalent
AB
7
Tailgate assembly removal steps
1. Rear washer hose
2. Tailgate wiring harness
3. Waterproof film
4. Tailgate gas spring
5. Antenna feeder cable
6. Tailgate assembly
7. Tailgate hinge
8. Bumper•Rear end trim (Refer to GROUP 52A,
Trims P.52A-11.)
9. Striker
10. Dynamic damper
Tailgate opening weatherstrip removal
4. Tailgate gas spring
>>A<<11. Tailgate opening weatherstrip Tailgate assembly removal steps
AC305091
Positioning
mark
AB
Tailgate opening
weatherstrip
Rear bumper end
Tailgate opening
weatherstrip SECTION A – AA
A
Hatching

KEYLESS ENTRY SYSTEM
BODY42-51
INSTALLATION SERVICE POINT
>>A<< STRIKER INSTALLATION
Assemble so the distance between the centre of the
striker and centre of the latch is ±1.5 mm or less.
INSPECTIONM1424001200142
TAILGATE LOCK ACTUATOR CHECK
TAILGATE LATCH CHECK keyless entry system>
KEYLESS ENTRY SYSTEM
SERVICE SPECIFICATIONSM1428000300104
AC305098AB
Striker centre
StrikerLatch centre
Latch +1.5 mm
-1.5 mm
AC103292
A
View A
Unlock
Lock Lever
AC
Lever
positionBattery connection Lever
operation
At the
"LOCK"
position•Connect terminal
No.2 and the
negative battery
terminal.
•Connect terminal
No.3 and the
positive battery
terminal.The lever
moves from the
"LOCK"
position to the
"UNLOCK"
position.
At the
"UNLOCK"
position•Connect terminal
No.3 and the
negative battery
terminal.
•Connect terminal
No.2 and the
positive battery
terminal.The lever
moves from the
"UNLOCK"
position to the
"LOCK"
position.
Lever position Tester
connectionSpecified
condition
At the "LOCK"
position1 − 2 (Earth) Open circuit
At the
"UNLOCK"
positionLess than 2
ohms
AC103291
Lever
Unlock Lock
1
2
AD
Item Standard value
Voltage of transmitter battery V 2.5 − 3.2