2005 MITSUBISHI LANCER Workshop Manual

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
BODY42-44
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

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
BODY42-46
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
BODY42-47
NOTE:
When the bolt head interferes with the rear end
trim, rasp the interference area with a round file.4. If uneven clearance is present between tailgate
and body, reposition the hinge to adjust the
clearance.
TAILGATE HANDLE PLAY CHECKM1424002400138
1. Check the tailgate handle play.
Standard value (B): 2.3 − 5.9 mm
2. If it deviates from the standard value, remove the
lower tailgate trim (Refer to GROUP 52A, tailgate
trim P.52A-19) and waterproof film (Refer to
P.42-48).
3. Remove the holder from the tailgate handle and
adjust according to the tailgate latch rod and
tailgate handle connection position.
AC203660AB
Grind here
AC201556
AC103270
A
ASection A – A
RodHolder
B
AC

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

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

TA I L G AT E
BODY42-50
TAILGATE HANDLE AND LATCH
REMOVAL AND INSTALLATIONM1424001700170
Pre-removal Operation
•Tailgate Handle Play Check (Refer to P.42-47).
Y1518AU
Y1520AU
AC305141
4
5
6
3 35
5.0 ± 1.0 N·m
9.0 ± 2.0 N·m
AB
2
1
22 ± 4 N·m
Striker removal steps
•Rear end trim (Refer to GROUP 52A,
Trims P.52A-11.)
>>A<<1. Striker
Tailgate handle and lock key cylinder
removal steps
•Lower tailgate trim (Refer to GROUP
52A, Tailgate Trim P.52A-19.)
•Waterproof film (Refer to P.42-48.)
2. Bolt (earth)
3. Tailgate latch assembly
4. Tailgate lock key cylinder
5. Tailgate handleTailgate latch removal steps
•Lower tailgate trim (Refer to GROUP
52A, Tailgate Trim P.52A-19.)
•Waterproof film (Refer to P.42-48.)
2. Bolt (earth)
3. Tailgate latch assembly
Tailgate lock actuator removal steps
•Lower tailgate trim (Refer to GROUP
52A, Tailgate Trim P.52A-19.)
•Waterproof film (Refer to P.42-48.)
6. Tailgate lock actuator