2007 MITSUBISHI LANCER EVOLUTION service

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 -Hood42-2
HOOD
ON - VEHICLE SERVICE
ADJUSTMENT OF CLEARANCE AROUND
HOOD
ADJUSTMENT OF ALIGNMENT OF HOOD
STEPPED PORTION AND HOOD STRIKER
ADJUSTMENT OF HOOD HEIGHT
With the marker as guide, turn the hood bumper to adjust
the hood height. The hood bumper height changes approx.
3mm (new hood bumper with one complete turn).
A
A
Section A-A
16.3 mmHood
Hood bumper

BODY -Hood/Fender42-4
REMOVAL SERVICE POINTS
"AAHOOD HINGE BOLT INSTALLATION
Caution
Use the special parts as the aluminum hood uses special
coatings on the of the hood hinge bolt.
FENDER
SPECIAL TOOLS
ToolNumberNameUse
MB990784Ornament removerSide turn signal lamp removal

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 -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 Glass42-12
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

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 Glass42-17
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