2007 MITSUBISHI LANCER EVOLUTION Service Repair Manual

BODY -Fender42-5
FENDER
REMOVAL AND INSTALLATION
Pre-removal and Post-installation OperationsDFront Bumper Removal and Installation (Refer to
GROUP 51.)DFront Deck Garnish Removal and Installation (Refer
to GROUP 51.)
13
2 4
5
Removal steps
DSide air dam (Refer to GROUP
51.)
1. Splash shield
AA""BA2. Side turn signal lamp (Refer to
GROUP 54A.)3. Deck garnish (Refer to GROUP
51-Windshield Wiper and Washer)
"AA4. Fender
5. Front fender bracket

BODY -Fender42-6
REMOVAL SERVICE POINTS
AA"SIDE TURN SIGNAL LAMP REMOVAL
Use the special tool to release the claw part of the fender
panel and remove the side turn signal lamp.
INSTALLATION SERVICE POINT
"AAFENDER INSTALLATION
Caution
Use the special parts as the aluminum fender uses special
coatings on the fender mounting bolt and the washer.
"BASIDE TURN SIGNAL LAMP INSTALLATION
Engage the hook into the fender panel, and then install the
side turn signal lamp.
Claw part
A
Section A - A
A
Front of vehicle
Side turn signal lamp
Fender panel
MB990784
MB990784
Claw Hook
Fender
panel
Fender
panel
Front of vehicle

BODY -Fuel Filler Door42-7
FUEL FILLER DOOR
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operations
DRear Seat Removal and Installation. (Refer to GROUP
52A.)
DFront Scuff Plate (Driver’s Side), Rear Scuff Plate(Driver’s Side), Center Pillar Lower Trim (Driver’s
Side), Quarter Trim (Driver’s Side) Removal and
Installation (Refer to GROUP 52A – Trim.)
5
1
3 4 3
2
5.0±1.0 N·m
Adjustment of clearance around
fuel filler door
Removal steps
1. Fuel filler door panel assembly
2. Clip
3. Fuel filler door hook assembly4. Fuel filler door lock release cable
5. Fuel filler door lock release handle

BODY -Strut Tower Bar and Rear End Cross Bar42-8
STRUT TOWER BAR AND REAR END CROSS BAR
REMOVAL AND INSTALLATION
44±5 N·m
Strut tower bar
Rear end cross bar

BODY -Window Glass42-9
WINDOW GLASS
ADHESIVE
ItemsSpecified adhesive
Windshield3M ATD Part No. 8609 Super Fast Urethane Auto Glass Sealant or
il tRear window glass
p
equivalent
SPECIAL TOOLS
ToolNumberNameUse
MB990480Window glass
holderRemoval and Installation of Window Glass
MB990784Ornament removerRear Window Lower Molding Removal
WINDOW REPAIR
The following glass parts are installed with a liquid urethane
adhesive method:
DWindshield
DRear window glass
ITEMS NEEDED
NameRemarks
Adhesive3M ATD Part No. 8609 Super Fast Urethane Auto Glass Sealant or
equivalent
Primer3M ATD Part No. 8608 Super Fast Urethane Primer or equivalent
SpacersAvailable as service part
DamAvailable as service part
Anti-rust solvent (or Tectyl 506T...Valvoline Oil
Company)For rust prevention
Isopropyl alcoholFor grease removal from bonded surface
Steel piano wireDia. y length...0.6mm 1m For cutting adhesive
Adhesive gunFor pressing-out adhesive

BODY -Window Glass42-10
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.
WORKING PROCESS
Window glass installation procedure
Body side
Cleaning of adhesion surface
Cut off the residual adhesive until the
thickness is less than 2 mm. Clean
the adhesion surface with isopropyl al-
cohol, and let dry for 3 minutes or more.
Attaching of clip, spacer and dual
lock fastener
Attach the clip, spacer and dual lock
fastener to set the positions for the glass
to be installed.
Application of primer
Apply to the adhesion surface of the
body and let dry for 3 minutes or more.
Window glass side
Reusing the glassReplacing the glass
Cleaning of adhesion surface
Completely cut off all of the residual
adhesive. Clean the adhesion
surface with isopropyl alcohol, and
let dry for 3 minutes or more.Cleaning of adhesion surface
Clean off any dirt adhering to the adhe-
sion surface with isopropyl alcohol, and
let dry for 3 minutes or more.
Gluing of window spacer, glass stoppers and dual lock fastener
Glue the window spacer, glass stoppers and dual lock fastener along the standard position
on the glass outer circumference.
Application of primer
Apply sufficient primer evenly to the adhesion surface so that there is no patchiness. After
application, let dry for 3 to 30 minutes.
Application of adhesive
Within 30 minutes after applying the primer, apply the adhesive evenly all the way around
the inside edge of the glass.
Installing the glass
After applying the adhesive, lightly press the glass evenly so that it adheres
completely.
Cleaning
After removing any adhesive that is sticking out or adhering to the body or
glass with a spatula, etc., clean off with isopropyl alcohol.
Checking for water leaks
Carry out a shower test to check that no water will leak through.

BODY -Window Glass42-11
WINDSHIELD
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operations
DDeck Garnish Removal and Installation
(Refer to GROUP 51-Windshield Wiper and Washer.)DFront Pillar Trim Removal and Installation
(Refer to GROUP 52A.)
DHeadlining Removal and Installation
Section A - A
Section B - B
Section C - C
Sealant: 3M ATD Part No. 8609 Super Fast Urethane Auto Glass Sealant or equivalent
1
BB A
A
C
CPrimer
Primer Primer
54
2
3
3
Ceramic line
Seal line
AW0811AU
Apply the
primer and
adhesive along
the fictitious
lines (seal line)
between each
of the marks.Ceramic line
Seal line
Seal line center
Seal line center
Seal line center
Mark
5
6
Removal steps
DRoof drip molding (Refer to
GROUP 51.)
AA""AA1. Windshield
AA"2. Windshield molding"AA3. Window dam
"AA4. Glass stopper
"AA5. Spacer
"AA6. Windshield spacer

BODY -Window Glass42-12
REMOVAL SERVICE POINTS
AA"WINDSHIELD AND WINDSHEILD MOLDING
REMOVAL
1. In order to protect the body (paint surface), apply cloth
tape to all body areas around the installed windshield.
2. Use any of the following methods to cut off adhesive.

(1) Using a sharp-point drill, make hole in the windshield
adhesive.
(2) Pass the piano wire from the inside of the vehicle
through the hole.
(3) Pull the piano wire alternately from the inside and
outside along the windshield to cut the adhesive.
Caution
Do not let the piano wire touch the edge of the
windshield.

(1) Prepare a windshield knife.
(2) Align the windshield knife blade with the windshield
surface and the windshield edge while maintaining
an angle of 90 degrees between the windshield knife
blade and the windshield edge, and then cut off
adhesive by knifing parallel with the windshield edge.
Caution
Prying with a windshield knife could damage the
windshield.
Windshield knife