2007 MITSUBISHI LANCER EVOLUTION Service Repair Manual

BODY -Window Glass42-13
3. Make alignment marks on the windshield and body.
4. Use the special tool to remove the windshield.
5. Use a knife to cut away remaining adhesive to 2 mm
thick or less around the entire circumference of the body
flange.
6. Smooth the flange surface.
Caution
(1) Use care not to remove more adhesive than
necessary, or the adhesive could weaken.
(2) Be careful also not to damage the paintwork on
the body surface with the knife. If the paintwork
is damaged, repair the damaged area with repair
paint or anti-rust agent.
7. When reusing windshield, remove the remaining adhesive
on the windshield completely. Then, decrease the
windshield with isopropyl alcohol.
8. Decrease the body flange in the same way.
Caution
Before the next job, leave the decreased parts for
3 minutes or more to dry. Also, do not touch any
cleaned surface.MB990480

BODY -Window Glass42-14
INSTALLATION SERVICE POINTS
"AAWINDSHIELD SPACER/SPACER/GLASS
STOPPER/WINDOW DAM/WINDSHIELD
MOLDING/WINDSHIELD INSTALLATION
1. When replacing the windshield, first align it with the body,
and then matchmark them.
2. Use isopropyl alcohol to clean the inside edge of the
windshield and the body flange.
3. Use a primer dampened to apply to the specified area
around the windshield and the body evenly.
4. After applying the primer, let it dry for at least 3 minutes.
Caution
(1) The primer strengthens the adhesive effect, so
that be sure to apply it. However, an excessively
thick application will weaken the adhesive effect.
(2) Never touch the primer-applied surface.
5. Ensuring that there are no bends or warpages inside
the windshield, position the glass stopper and spacer
and windshield spacer on the specified position.
Glass end line Glass stopper, Spacer, windshield spacer and window dam installation position
Ceramic line
Glass end
line 17.5 mmGlass stopper
Window dam13 mm
14 mm
Windshield
spacer Ceramic line
Windshield
Align the glass stopper end
with the ceramic notch.
Section A - A
A
ASeal line center
Seal line
MarkAlign the window
dam end with
the seal line
mark.
Section B - B
10 mmWindshield
Spacer
B
BAlign the spacer end
with the glass end line.

BODY -Window Glass42-15
6. Install the windshield molding.
7. Within thirty minutes after the primer application, fill a
sealant gun with the adhesive, and then apply the
adhesive evenly around the windshield.
NOTE
Cut the tip of the sealant gun nozzle into a V shape
to simplify adhesive application.
8. After applying adhesive, align the mating marks on the
windshield and the body, and then lightly press the
windshield evenly so that it adheres completely.
9. After removing any adhesive that is sticking out or adhering
to the windshield or body with spatula, etc., clean with
isopropyl alcohol. Install the windshield molding before
the adhesive sets. After the windshield is installed, wait
until the adhesive sets.
10. Adhere the windshield to the body, and install the roof
drip molding (Refer to GROUP 51.) promptly before the
adhesive sets.
11. After adhering the windshield to the body, wait 30 minutes
or more, and then test for water leakage.
Caution
(1) Move the vehicle carefully.
(2) When testing for water leakage, do not pinch the
end of the hose to spray the water.
10 mm
15 mm

BODY -Window Glass42-16
REAR WINDOW GLASS
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operations
DRear Pillar Trim Removal and Installation
(Refer to GROUP 52A.)
DHeadlining Removal and Installation
DRear Shelf Trim Removal and Installation
(Refer to GROUP 52A.)DHigh Mount Stop Lamp Assembly Removal and
Installation (Refer to GROUP 54A)
Section A - A
1
1
9 810
7
7
3
Apply the primer and
adhesive along the fictitious
lines (seal line) between
each of the marks.
Mark
Seal line center
Primer B
B
6
2
3
2
4
2
A
Section B - B
42
Sealant: 3M ATD Part No. 8609 Super Fast Urethane Auto Glass Sealant or equivalent
4
5
A
Removal steps
DRoof drip molding
(Refer to GROUP 51.)
AA""BA1. Rear window lower molding
2. Clip
3. Grommet A
4. Grommet B5. Grommet C
6. Connecting the harness connector
AB""AA7. Rear window glass
"AA8. Rear window upper molding
"AA9. Window dam
"AA10. Glass stopper

BODY -Window Glass42-17
REMOVAL SERVICE POINTS
AA"REAR WINDOW LOWER MOLDING REMOVAL
Pry the rear window lower molding off with the special tool.
Caution
Do not use a deformed molding.
AB"REAR WINDOW GLASS REMOVAL
Remove the rear window glass in the same manner as for
the windshield. (Refer to P42-12.)
INSTALLATION SERVICE POINTS
"AAGLASS STOPPER/WINDOW DAM/REAR WINDOW
UPPER MOLDING/REAR WINDOW GLASS
INSTALLATION
1. When replacing the rear window glass, first align it with
the body, and then matchmark them.
2. Use isopropyl alcohol to clean the inside edge of the
rear window glass and the body flange.
3. Use a primer dampened sponge to apply the primer to
the specified area around the rear window glass and
the body evenly.
4. After applying the primer, let it dry for at least 3 minutes.
Caution
(1) The primer strengthens the adhesive effect, so
that be sure to apply it. However, a too thick
application will weaken the adhesive effect.
(2) Never touch the primer-applied surface.
5. Position the glass stopper and the window dam in the
specified position, ensuring that there are no bends or
warpages inside the rear window glass.
MB990784

BODY -Window Glass42-18
Glass end line Glass stopper and window dam installation position
Ceramic line
Glass end
line 18 mmGlass stopper
Window dam19 mm
19 mm
Window dam Ceramic lineAlign the window
dam end with the
seal line mark.
Rear window glassAlign the glass
stopper end
with the ceramic
notch.
Section A - A
A
A
Seal line
Mark
6. Install the rear window upper molding.
7. Install the glass by the same procedure as for the
windshield. (Refer to P.42-14.)
"BAREAR WINDOW LOWER MOLDING
INSTALLATION
Install the clip into the rear window lower molding, and then
install the rear window lower molding in the body.

BODY -DoorsBODY -Doors42-19
DOORS
SERVICE SPECIFICATIONS
ItemsStandard value
Door outside handle play mmFront2.3±2.1py
Rear1.3±1.7
Power window operating current (power supply 14.5±0.5 V, 25_C) A5±1
Door inside handle play mmFront9.6±9.2py
Rear9.0±9.2
ADHESIVE
ItemsSpecified sealantRemark
Waterproof film3M ATD Part No. 8625 or equivalentRibbon sealer
SPECIAL TOOLS
ToolNumberNameUse
MB990784Ornament removerDoor trim removal
MB990480Window glass
holderRemoval of power window regulator and motor
assembly
MB990900 or
MB991164Door hinge
adjusting wrenchAdjustment of door fit
A
MB990925
A: MB990939Bearing & oil seal
installer set
A: Brass barAdjustment of door striker
MB990211Slide hammer
A
BB990241
MB990241
A: MB990243Axle shaft puller
A: Body puller

BODY -DoorsBODY -Doors42-20
Tool UseName Number
A
B
C
D
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: Connector pin contact pressure check
B: Power circuit check
C: Power circuit check
D: Commercial tester connection
TROUBLESHOOTING
DIAGNOSIS FUNCTION
The power window and central door locking is controlled by the Smart Wiring System (SWS). For
troubleshooting, refer to GROUP 54B - Troubleshooting.
ON-VEHICLE SERVICE
DOOR ADJUSTMENT
1. If the gap between the door and body is inconsistent,
paste protection tape at the fender around the hinge
attached portion and at the door edge, use the special
tool to loosen the bolt fixing the door hinge at the body
side, and move the door to adjust so that the gap around
the door becomes consistent.
2. If steps exist between the door and body, use the special
tool to loosen the bolt fixing the door hinge at the door
side, and move the door and adjust the alignment of
the door surface.
Caution
Do not apply torque above 98 NSm for the special
tool (MB991164).
MB990900 or
MB991164