2007 MITSUBISHI LANCER EVOLUTION to pair

STEERING - Power Steering Gear Box and Linkage37A-24
REASSEMBLY SERVICE POINTS
"AAOIL SEAL INSTALLATION
"BANEEDLE BEARING/LOWER BEARING
INSTALLATION
"CARACK ASSEMBLY INSTALLATION
1. Apply repair kit grease to the teeth of the rack assembly.
Caution
Use care not to close the vent hole in the rack with
grease.
2. Cover the serrations of the rack assembly with the special
tool.
3. Apply specified fluid to the outer surfaces of the special
tool, seal ring and O-ring.
Specified fluid:
Automatic transmission fluid DEXRONII
Caution
Do not use ATF-SPIIM and ATF-SPIII.
4. Slowly insert the rack covered with the special tool from
the power cylinder side of the gear housing.
Caution
Carefully push in the rack with the oil seal centre
and the special tool end matched. This is to avoid
the retainer spring coming off.MB991197
Gear housing
Oil seal MB991199
Needle
bearingMB990925
(MB990938)
MB991202
Lower
bearing MB990925
(MB990938)
MB991202
Vent hole
Seal ring, O-ring
MB991214 Oil seal

42-1
BODY
CONTENTS
HOOD2 .................................
ON-VEHICLE SERVICE 2..................
Adjustment of Clearance around Hood 2......
Adjustment of Alignment of Hood Stepped
Portion and Hood Striker 2..................
Adjustment of Hood Height 2.................
HOOD 3..................................
FENDER4 ..............................
SPECIAL TOOL 4.........................
FENDER 5................................
FUEL FILLER DOOR7 .................
STRUT TOWER BAR AND REAR END
CROSS BAR8 ...........................
WINDOW GLASS9 .....................
ADHESIVE 9..............................
SPECIAL TOOLS 9........................
WINDOW REPAIR 9.......................
WINDSHIELD 11...........................
REAR WINDOW GLASS 16................
DOORS19 ..............................
SERVICE SPECIFICATIONS 19.............ADHESIVES 19............................
SPECIAL TOOLS 19.......................
TROUBLESHOOTING 20...................
ON-VEHICLE SERVICE 20.................
Door Adjustment 20.........................
Door Window Glass Adjustment 21...........
Adjustment and Replacement during Power
Window Malfunction 22......................
Power Window Safety Mechanism Check 22..
Power Window Timer Function Check 22......
Door Outside Handle Looseness Check 23....
Power Window Operation Current Check 23...
Circuit Breaker Check 23....................
Power Window Check 23....................
Door Inside Handle Looseness Check and
Adjustment 24...............................
DOOR ASSEMBLY 25......................
DOOR TRIM AND
WATERPROOF FILM 27....................
DOOR GLASS AND REGULATOR 32.......
DOOR HANDLE AND LATCH 35...........
WINDOW GLASS RUNCHANNEL AND
DOOR OPENING WEATHERSTRIP 38.......
TRUNK LID41 ..........................

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 Glass42-13
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 -Doors42-22
ADJUSTMENTS AND REPLACEMENT DURING
POWER WINDOW MALFUNCTION
If the window glass does not rise but automatically descends,
adjust and replace the window glass as follows:
1. Remove the door trim and waterproof film. (P.42-27)
2. Remove the window regulator assembly from the door
window glass, and raise and lower the window glass with
your hand and check the operating force.
Remarks Insert a cushion, etc. to prevent damage of
the glass if it accidentally drops.
3. If the door window glass does not rise and descend
smoothly, perform the following check and repair.
DCheck the installation condition of the runchannel.
DStraighten twist in the door sash.
DCheck the installation condition of the lower sash
or the center sash.
NOTE
The lower sash cannot normally be adjusted, but it may
be possible to adjust the sash span slightly within the
range allowed by manufacturing tolerances by pushing
the lower sash outwards while re-installing it.
4. If repair or adjustment is not possible, replace the door
assembly.
POWER WINDOW SAFETY MECHANISM
CHECK
1. Set a wood piece of about 10 mm thick as shown in
the figure, and raise the window glass.
2. Check that the window glass descends by about 150
mm when it catches the wood piece. If it does not, perform
troubleshooting. (Refer to GROUP 54B.)
POWER WINDOW TIMER FUNCTION CHECK
9Close the door and turn the ignition switch in the OFF position,
and then check the power window operates for 30 seconds.
If it does not, perform troubleshooting.(Refer to GROUP 54B.)
Runchannel
Door
sash
Lower sash

SRS -SRS Service Precautions52B-3
SRS SERVICE PRECAUTIONS
1. In order to avoid injury to yourself or others
from accidental deployment of the air bag and
accidental operation of the seat belt with
pre-tensioner during servicing, read and
carefully follow all the precautions and
procedures described in this manual.
2. Do not use any electrical test equipment on
or near SRS components, except those
specified on P.52B-6.
3. Never Attempt to Repair the Following
Components:
DSRS air bag control unit (SRS-ECU)
DClock spring
DDriver’s and front passenger’s air bag
modules
DSeat belt with pre-tensionerNOTE
If any of these components are diagnosed as
faulty, they should only be replaced, in
accordance with the INDIVIDUAL COM-
PONENTS SERVICE procedures in this
manual. (Refer to P.52B-49.)
4. After disconnecting the negative (–) battery cable,
wait 60 seconds at least before any service and
insulate the disconnected cable with tape. The SRS
retain enough voltage to deploy the air bags for a
short time even after the disconnection of the battery.
So, serious injury may result by accidental air bag
deployment if a work is done on the SRS just after
the disconnection of the battery.
5. Do not attempt to repair the wiring harness connectors
of the SRS. If the connector(s) are diagnosed as defective,
replace the wiring harness(es). If the harness(es) are
diagnosed as faulty, replace or repair the wiring
harness(es) according to the table that follows.
Insulating tape
Battery
SRS-ECU connector

SRS -SRS Service Precautions52B-4
SRS-ECU
Terminal No.Destination of harnessCorrective action
7Instrument panel wiring harness→EarthRepair or replace each wiring
harness
8Instrument panel wiring harness→Combination meter
(SRS warning lamp)
harness
9, 10Instrument panel wiring harness→Front passenger’s air bag
module
11 , 1 2Instrument panel wiring harness→Clock spring→Driver’s air bag
module)Repair or replace the dash wiring
harness. Replace clock spring.
13Instrument panel wiring harness→Junction block (fuse No.3)Repair or replace each wiring
harness
16Instrument panel wiring harness→Junction block (fuse No.2)
harness.
20Instrument panel wiring harness→Diagnosis connector
29, 30Floor wiring harnessàDriver’s seat belt pre-tensioner
27, 28Floor wiring harnessàFront passenger’s seat belt pre-tensioner
6. Inspection of the SRS-ECU harness connector should be carried out by the following procedure.
Insert the special tool (probe, MB991222, in the harness set) into the connector from harness side
(rear side), and connect the tester to this probe. If any tool than specified is used, damage to the
harness and other components will result. Furthermore, measurement should not be carried out by
touching the probe directly against the terminals from the front of the connector. The terminals are
plated to increase their conductivity, so that if they are touched directly by the probe, the plating
may break, which will cause drops in reliability.
MB991222 SRS-ECU harness connector
SRS-ECU harness connector (rear view)
7. SRS components and seat belt with pre-tensioner should not be subjected to hart, so remove the
SRS-ECU, driver’s and front passenger’s air bag modules, clock spring, and seat belt with pre-tensioner
before drying or baking the vehicle after painting.
DSRS - ECU, air bag module, clock spring : 93Æ
or more
DSeat belt with pre-tensioner : 90Æ
or more
8. Whenever you finish servicing the SRS, check warning lamp operation to make sure that the system
functions properly. (Refer to P.52B-6.)
9. Make certain that the ignition switch is LOCK (OFF) position when the MUT-IIis connected or
disconnected.
10. If you have any questions about the SRS, please contact your local distributor.
NOTE
SERIOUS INJURY CAN RESULT FROM UNINTENDED AIR BAG DEPLOYMENT, SO USE ONLY
THE PROCEDURES AND EQUIPMENT SPECIFIED IN THIS MANUAL.

SRS -Troubleshooting52B-13

NG
spring>
Measure at the SRS-ECU connector C - 21.
DDisconnect the SRS-ECU connector C-21.
DRelease the the clock spring connector C-204.
Caution
Disconnect the connector and short-circuit the squib
circuit before releasing the short bar of the SRS-ECU
connector in the following operation.
DCable bands between terminals 11, 12 and the short bar
(width:3 mm, thickness:0.5 mm) between terminals 11 and
12 and the short bar, and release the short bar.
(See Figure A.)
Caution
As the short bar may not be releasable if inserted
insufficiently, insert more than 4 mm.
DMeasure at the harness side
DContinuity check between terminals 11 and 12
Caution
Do not directly insert a probe or other devices at the
front of the connector to avoid a possible decrease in
the contact pressure.
OK:No continuity
Check connector:C-21, C-204
MUT-II self-diag code
DRelease the clock spring connector (2 - pin) C-204.
DConnect the dummy resistor (MB991865) to the resistor harness
(MB991866).
DInsert the resistor harness
(MB991866) behind the harness side connector C-204.
Caution
Do not directly insert a probe or other devices at the front of the
connector to avoid a possible decrease in the contact pressure.
DConnect the negative ( - ) terminal of the battery
DCheck the diagnosis code again after erasing the memory.
Is code No.21 output?
Resistor harness
(MB991866)
C - 204 clock spring
harness side connector
YES Dummy resistor
(MB991865)
resistance (3Ω)
Check the clock spring (Refer to P.52B-59.)
NOYES
Replace the clock spring.Replace the driver’s air bag module
(squib).NO
Check the harness between the clock spring and the
SRS-ECU, and repair if necessary.
Check the trouble
symptoms.Correct
OK
NG NG
Replace the SRS-ECU.
OK
Figure A
Terminal
Short bar
Front view of SRS-ECU
connector C-21
(harness side)
Cable band
and etc.Section
A-A
4 mm or more
A
AConnector C-21