2005 MITSUBISHI LANCER ect

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

DOOR
BODY42-38
Actuator Switch Check
REAR DOOR LOCK ACTUATOR CHECK
Actuator Operation Check
DOOR LOCK KEY CYLINDER SWITCH
CHECK
Lever position Tester
connectionSpecified
condition
At the "LOCK"
position1 − 2 Less than 2
ohms
1 − 3 Open circuit
At the "UNLOCK"
position1 − 2 Open circuit
1 − 3 Less than 2
ohms
23
41
56
23
41
56
AC305112B
A
AB
Rear door
LockUnlock
View A
View B UnlockLock
Lever
Lever
Lever
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.
Switch
positionTester
connectionSpecified
condition
LOCK 2 − 3 Less than 2
ohms
NEUTRAL
(OFF)1 − 2, 2 − 3 Open circuit
UNLOCK 1 − 2 Less than 2
ohms
AC101318
3 2 1

DOOR
BODY42-39
WINDOW GLASS RUNCHANNEL AND
DOOR OPENING WEATHERSTRIP
REMOVAL AND INSTALLATIONM1423003100290

AC304409AB
Section A – A

Sealant: 3M ATD Part No.8633 or equivalentDoor
: Sectional view of
clip position
: Sectional view of
clip position
6 2
1
4
365
A A
1
Waterproof film removal steps
•Door trim assembly, speaker (Refer to
GROUP 52A, Trims P.52A-11).
1. Waterproof film
Door inner opening weatherstrip
removal steps
•Scuff plate, centre pillar lower trim
and cowl side trim (Refer to GROUP
52A, Trims P.52A-11.)
2. Door inner opening weatherstrip
(Body side)
Door outer opening weatherstrip
removal steps
•Front door check mounting bolt (Door
side) (Refer to P.42-31.)
<> >>A<<3. Door outer opening weatherstripDoor window glass runchannel
removal
4. Door window glass runchannel
Door beltline inner weatherstrip
removal steps
•Front door trim(Refer to GROUP 52A,
Door trim P.52A-15.)
5. Door beltline inner weatherstrip
Door beltline moulding removal steps
•Door mirror assembly (Refer to
GROUP 51, Door mirror P.51-45.)
•Door window glass (Refer to
P.42-32.)
6. Door beltline moulding

DOOR
BODY42-40

AC304418AB
Section A – A
Door
: Sectional view of
clip position
: Sectional view of
clip position
6 2 4
5
7
A A
3
Section B – B
Door
6
3
6
BB
Sealant: 3M ATD Part No.8633 or equivalent
1
1
Waterproof film removal steps
•Door trim assembly (Refer to GROUP
52A, Door trim P.52A-15).
1. Waterproof film
Door inner opening weatherstrip
removal steps
•Scuff plate, centre pillar lower trim
and cowl side trim (Refer to GROUP
52A, Trims P.52A-11.)
2. Door inner opening weatherstrip
(Body side)
Door outer opening weatherstrip
removal steps
•Rear door check mounting bolt (Door
side) (Refer to P.42-31.)
3. Retainer weatherstrip
<> >>A<<4. Door outer opening weatherstripDoor window glass runchannel
removal
5. Door window glass runchannel
Door beltline inner weatherstrip
removal steps
•Rear door trim (Refer to GROUP 52A,
Door trim P.52A-15.)
•Centre sash upper (Refer to P.42-32.)
6. Door beltline inner weatherstrip
Door beltline moulding removal steps
•Door window glass (Refer to
P.42-32.)
•Stationary glass (Refer to P.42-32.)
7. Door beltline moulding

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
BODY42-42
3. If there is a difference in height between the side
outer panels and the side edges of the trunk lid
panel assembly, check the trunk lid hinges and, if
necessary, replace them
4. If the clearance around the trunk lid panel
assembly is not uniform, and the trunk lid can be
locked and unlocked smoothly, make adjustments
to the trunk lid bumpers (refer to P.42-42) and
trunk lid hinges (Refer to P.42-42).
5. If the locking and unlocking of the trunk lid still is
difficult after making the above adjustments,
adjust the trunk lid striker (Refer to P.42-42).
ADJUSTMENT OF CLEARANCE AROUND
TRUNK LID
M1421008100039
Loosen the trunk lid panel assembly mounting bolts
and move the trunk lid panel assembly to make the
clearance around the trunk lid uniform.
TRUNK LID STRIKER ADJUSTMENTM1421008200036
After checking the trunk lid release cable for proper
routing, loosen the trunk lid striker mounting bolts.
Change the position of the trunk lid striker relative to
the trunk lid latch assembly so that trunk lid locking
and unlocking effort is correct.
TRUNK LID HEIGHT ADJUSTMENTM1421008300033
Turn each trunk lid bumper until the height shown in
the drawing is reached. If the trunk lid panel height
on one side is different from that on the other side
(even after the trunk lid bumpers have been adjusted
to the height indicated in the drawing), turn the trunk
lid bumper(s) slightly to make fine adjustments to the
trunk lid panel height.
NOTE: When the bumper is new, one full turn of the
trunk lid bumper changes the height approximately 3
mm. Turn it clockwise to reduce height. Turn it
anticlockwise to increase height.
AC202897
Trunk lid panel
assembly
Trunk lid hinge
AB
AC202898
Trunk lid striker
AB
AC305144
Section A - A
Trunk lid bumper
Trunk lid panel assembly A
A
Trunk lid bumperTrunk lid panel assembly
AB
14 mm

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