2005 MITSUBISHI LANCER ect

POWER STEERING HOSES
POWER STEERING37-44
REMOVAL SERVICE POINT
<> EYE BOLT/RETURN TUBE
REMOVAL
CAUTION
If the joint cover grommet has been removed,
install it properly as follows.
Align the joint cover grommet notch (arrow A)
with the steering gear lug (arrow B), and then
install the steering joint cover to the steering
gear.
1. Loosen the crossmember mounting bolts and
nuts, and lower the crossmember to a position so
that the eye bolts or return tube at the steering
gear side can be removed.
NOTE: In this case, do not remove the
crossmember mounting bolts and nuts.
2. Remove the eye bolts or return tube.
INSTALLATION SERVICE POINTS
>>A<< RETURN HOSE INSTALLATION

Install the return hose so that the marking is
positioned as shown in the illustration.
>>B<< RETURN HOSE INSTALLATION
Install the return hose so that the markings are
positioned as shown in the illustration.
>>C<< SUCTION HOSE INSTALLATION
Install the suction hose (oil pump side) so that the
marking is positioned forward.
•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. Eye bolt
7. Gasket
8. Pressure hose assembly
<>9. Return tube
10. O-ringRemoval steps (Continued)
AC304922AB
A
B Joint cover
grommet
Steering gear
AC100277
ABReturn hose
AC305132AB
Return hose
Return tubeReturn hose

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
BODY42-3
HOOD
ON-VEHICLE SERVICE
ADJUSTMENT OF CLEARANCE AROUND
HOOD
M1421007200129
ADJUSTMENT OF ALIGNMENT OF HOOD
STEPPED PORTION AND HOOD
STRIKER
M1421007300126
ADJUSTMENT OF HOOD HEIGHTM1421007400123
Rotate the hood bumper by using arrow mark on the
hood bumper as a guide to adjust the hood height. If
the hood bumper is rotated just one turn, the hood
height changes by approximately 3 mm.
AC005945
AC005947
Y0215AU
X0424CA
AC005948
AB
Section A – AA
A
Hood
Hood bumper 17 mm

FENDER
BODY42-5
FENDER
SPECIAL TOOLM1421000600256
AC300865
Note
: Clip positions
Section A – A
AC
Clip
A
A
6 8
6 8
Clip positions
Tool Number Name Use
MB990784 Ornament remover Side turn-signal lamp removal
MB990784

FENDER
BODY42-6
FENDER
REMOVAL AND INSTALLATIONM1421001900302
Pre-removal and Post-installation Operation
•Front Bumper Removal and Installation (Refer to GROUP
51, Front Bumper P.51-2.)
•Front Deck Garnish Removal and Installation (Refer to
GROUP 51, Windshield Wiper and Washer P.51-23.)
•Side Air Dam Removal and Installation side air dam> (Refer to GROUP 51, Side Air Dam
P.51-15.)
AC300491
AC304753
AC303863
Clip Section A – A
AB
A A
123
3 4
Note
: Clip positions
Removal steps
1. Splash shield
<> >>A<<2. Side turn-signal lamp3. Delta outer garnish
4. FenderRemoval steps (Continued)

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
BODY42-12
WINDSHIELD
REMOVAL AND INSTALLATIONM1422001000313
Pre-removal and Post-installation Operation
•Front Deck Garnish Removal and Installation (Refer to
GROUP 51,Windshield Wiper and Washer P.51-23.)
•Inside Rear View Mirror Removal and Installation (Refer
to GROUP 52A, Inside Rear View Mirror P.52A-23.)
•Front Pillar Trim Removal and Installation (Refer to
GROUP 52A, Trims P.52A-11.)
•Headlining Removal and Installation (Refer to GROUP
52A, Headlining P.52A-21.)
AC006003
X0111AUX0112AU
Y0496AU
12
3 4
6
1 11 3
N
N
N
N
N
AC Y0495AU
A
A
BB
C
C Ceramic line
Seal line
Seal line
Ceramic line
MarkMark
Apply the primer and
adhesive along the
fictitious lines (seal line)
between each of
the marks.
Seal line centre
Primer Section A – A Section B – BSeal line
centre
Primer
Section C – C
Seal line
centre
Primer
5N
5N
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 equivalent
16
1613

WINDOW GLASS
BODY42-13
REMOVAL SERVICE POINT
<> WINDSHIELD REMOVAL
1. To protect the body (paint surface), apply cloth
tape to all body areas around the installed
windshield.
2. Make mating marks on the windshield and body.
3. Using piano wire.
(1) Using a sharp-point drill, make a hole in the
windshield adhesive.
(2) Pass the piano wire from the inside of the
vehicle through the hole.
CAUTION
Do not let the piano wire touch the edge of the
windshield.
(3) Pull the piano wire alternately from the inside
and outside along the windshield to cut the
adhesive.
CAUTION
Inserting the glass adhesive knife too deeply into
windshield adhesive may damage windshield.
4. Using glass adhesive knife
Keep glass adhesive knife at right angles with the
windshield edge, and put the blade at windshield
edge and surface. Then cut away adhesive along
the windshield edge.
5. Use special tool glass holder (MB990480) to
remove the windshield.
CAUTION•
Removal steps
•Roof drip moulding (Refer to GROUP
51, Moulding P.51-10.)
<> >>B<<1. Windshield
>>A<<2. Windshield moulding
>>A<<3. Window dam
>>A<<4. Glass stopper
>>A<<5. Spacer
>>A<<6. Windshield spacerRemoval steps (Continued)
ACX00474
AB
AC002060
AC207478
Glass adhesive knife
AD
ACX00475
AB
MB990480
ACX00476
AB