Door - Evolution Mitsubishi Lancer Evolution VIII

GENERAL DESCRIPTION

The central door locking system and the power window are equipped to GSR as standard and optionally equipped to RS.

CENTRAL DOOR LOCKING SYSTEM

The central door locking system operates the door lock actuator to lock or unlock the doors using the operation of the door lock switch built into the front power window (main or sub) switch or key cylinder built into the driver's side door outside handle. The system has the following operations and features.

1. All doors can be locked or unlocked using the door lock switch built into the front power window (main or sub) switch.
2. Insert the key into the driver's key cylinder and turn once to the unlock side to unlock the driver's door. Turn the key once again to the unlock side to unlock all doors.
3. A key reminder function that automatically unlocks all doors when door lock operation is performed and the front doors are opened while the key is inserted into the ignition switch is provided.

POWER WINDOWS

When the power window (main or sub) switch is operated, the door windows will open or close. This system has the following operations and features.

1. There is a power window lock switch featured on the power window main switch to prevent the door window glass from opening/closing with the front passenger's and rear power window sub switch.
2. The power window of the door window glass can be opened/closed for 30 seconds with the timer function after the ignition switch is turned OFF. (The timer expires if the front door < LH or RH> is opened when the timer is in operation.)
3. The power window main switch contains a one-touch down switch that will automatically open the driver's window only.

CENTRAL DOOR LOCKING SYSTEM DIAGNOSIS

The central door locking system is controlled by the simplified wiring system (SWS). For troubleshooting, refer to GENERAL DESCRIPTION .

POWER WINDOW DIAGNOSIS

The power window is controlled by the simplified wiring system (SWS). For troubleshooting, refer to GENERAL DESCRIPTION .

INTRODUCTION TO GLASS AND DOOR DIAGNOSIS

Glass and door faults include water leaks and improper opening and closing. Causes for these faults can include faults in the glass, weatherstrip, drain hole, waterproof film or door installation.

GLASS AND DOOR DIAGNOSTIC TROUBLESHOOTING STRATEGY

Use these steps to plan your diagnostic strategy. If you follow them carefully, you will be sure that you have exhausted most of the possible ways to find a glass and door fault.

1. Gather information from the customer.
2. Verify that the condition described by the customer exists.
3. Find the malfunction by following the Symptom Chart. Refer to «SYMPTOM CHART»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/windows/#door-evolution__symptom-chart)
4. Verify malfunction is eliminated.

SYMPTOM CHART

SYMPTOM CHART

DIAGNOSIS

1. STEP 1. Check the door window glass installation. Q: Is the door window glass installed correctly? YES : Go to Step 2 . NO : Assemble the door window glass again (Refer to «DOOR ASSEMBLY»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/windows/#door-evolution) ). Then go to Step 3 .
2. STEP 2. Check the clearance at the top of the door window glass. Q: Is the clearance at the top of the door window glass correct? YES : Go to Step 3 . NO : Adjust the door window glass (Refer to «DOOR WINDOW GLASS ADJUSTMENT»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/windows/#door-evolution__door-window-glass-adjustment) ). Then go to Step 3 .
3. STEP 3. Retest the system. Q: Is any water leaking? YES : Return to Step 1 . NO : The procedure is complete.

1. STEP 1. Check the door window glass installation condition. Q: Is the door window glass installed correctly? YES : Go to Step 2 . NO : Assemble the door window glass again (Refer to «DOOR GLASS AND REGULATOR»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/windows/#door-evolution) ). Then go to Step 4 .
2. STEP 2. Check the door sash. Q: Is the door sash in good condition? YES : Go to Step 3 . NO : Repair or replace the door sash, then go to Step 4 .
3. STEP 3. Inspect the window regulator assembly. Q: Is the window regulator assembly in good condition? YES : Go to Step 4 . NO : Repair or replace the window regulator assembly, then go to Step 4 .
4. STEP 4. Retest the system. Q: Does the door window glass operate correctly? YES : The procedure is complete. NO : Return to Step 1 .

1. STEP 1. Check the weatherstrip. Q: Is the weatherstrip in good condition? YES : Go to Step 2 . NO : Replace the weatherstrip, then go to Step 3 .
2. STEP 2. Check the door fit (alignment). Q: Is the door fit (alignment) correct? YES : Go to Step 3 . NO : Adjust the door fit (Refer to «ON-VEHICLE SERVICE»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/windows/#door-evolution) ). Then go to Step 3 .
3. STEP 3. Retest the system. Q: Is any water leaking? YES : Return to Step 1 . NO : The procedure is complete.

1. STEP 1. Check the drain hole. Q: Is the drain hole clogged? YES : Clean the drain hole, then go to Step 3 . NO : Go to Step 2 .
2. STEP 2. Check the weatherstrip. Q: Is the weatherstrip in good condition? YES : Go to Step 3 . NO : Repair or replace the weatherstrip, then go to Step 3 .
3. STEP 3. Retest the system. Q: Is any water leaking? YES : Return to Step 1 . NO : The procedure is complete.

1. STEP 1. Adjust the latch and striker engagement. Refer to «ON-VEHICLE SERVICE»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/windows/#door-evolution) . Q: Is the latch and striker engagement adjusted? YES : Go to Step 2. NO : Adjust the latch and striker (Refer to «ON-VEHICLE SERVICE»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/windows/#door-evolution) ). Then go to Step 4 .
2. STEP 2. Check for lock rod damage. Q: Is the lock rod damaged? YES : Repair or replace the lock rod, then go to Step 4 . NO : Go to Step 3.
3. STEP 3. Check the door handle flexibility (amount of movement of handle required to open door) (Refer to «POWER WINDOW CHECK»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/windows/#door-evolution__power-window-check) . Q: Is the door handle flexibility good? YES : Go to Step 4. NO : Adjust the door handle (Refer to «POWER WINDOW CHECK»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/windows/#door-evolution__power-window-check) ). Then go to Step 4.
4. STEP 4. Retest the system. Q: Does the door open easily? YES : The procedure is complete. NO : Return to Step 1 .

1. STEP 1. Check the door hinge position. Q: Is the door hinge correct? YES : Go to Step 2. NO : Adjust the door hinge (Refer to «ON-VEHICLE SERVICE»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/windows/#door-evolution) ). Then go to Step 4 .
2. STEP 2. Check the door. Q: Is the door in good condition? YES : Go to Step 3. NO : Repair or replace door, then go to Step 4 .
3. STEP 3. Check the grease. Q: Is the door check or door hinge grease sufficient? YES : Go to Step 4. NO : Apply the grease, then go to Step 4.
4. STEP 4. Retest the system. Q: Does the door open and close correctly? YES : The procedure is complete. NO : Return to Step 1 .

Adjust the door fit (Refer to ON-VEHICLE SERVICE ). Then check that the gap has been improved.

1. STEP 1. Check the weatherstrip for holding condition. Q: Is the weatherstrip holding firmly? YES : Go to Step 2. NO : Adjust fit of door (Refer to «GLASS SLIDING MECHANISM CHECK AND ADJUSTMENT»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/windows/#door-evolution__glass-sliding-mechanism-check-and-adjustment) ). Then go to Step 5 .
2. STEP 2. Check the weatherstrip for installation condition. Q: Is the weatherstrip for installed properly? YES : Go to Step 3. NO : Repair or replace the weatherstrip. Then go to Step 5 .
3. STEP 3. Check the clearance. Q: Are the door glass and the door weatherstrip holder assembled correctly? YES : Go to Step 4. NO : Adjust the door glass and the door weatherstrip (Refer to «GLASS SLIDING MECHANISM CHECK AND ADJUSTMENT»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/windows/#door-evolution__glass-sliding-mechanism-check-and-adjustment) ). Then go to Step 5 .
4. STEP 4. Check the door. Q: Is the door deformed? YES : Replace the door, then go to Step 5. NO : Go to Step 5.
5. STEP 5. Retest the system. Q: Has the wind noise been improved? YES : Return to Step 1 . NO : This diagnosis complete.

Scheme 43

Scheme 44

Scheme 45

Scheme 46

1. Attach cloth tape to every place, such as panel seams, projections, molding seams, glass and body seams, etc. which might conceivably be the source of wind noise.
2. Road test to check that the places not covered by tape are not sources of wind noise.
3. Remove the strips of tape one by one, road testing after each is removed, until a wind noise source is discovered.
4. When a wind noise source is found, cover it again and repeat the procedure to check if there are any other noise sources.
5. If no others are found, the last remaining tape is the only wind noise source.
6. Cut the remaining piece of tape into smaller pieces, attach it again as it was before, and then remove the pieces one by one to narrow down the source.
7. Check that wind noise occurs when the last remaining tape is removed, and that noise does not occur when it is re-attached.
8. When the source(s) of the wind noise is finally located, attach butyl tape, body sealer or similar material to obstruct this source as much as possible.

Scheme 47

Scheme 48

Scheme 49

DOOR FIT ADJUSTMENT

Required Special Tools

1. MB990211: Slide Hammer
2. MB990243: Body Puller
3. MB990900 or MB991164: Door adjusting Wrench
4. MB990939: Brass Bar

Scheme 50

Scheme 51

1. Use special tool MB990900 or MB991164 to loosen the hinge mounting bolts on the body side, and then adjust the clearance around the door so that it is uniform on all sides.
2. If a door is not flush with its surrounding panels, loosen the door-side door hinge mounting bolts and obtain the flushness by moving the door. NOTE: If the door hinge mounting bolt washers are welded, grind off the welding according to the procedure below beforehand. Remove the door hinge (Refer «DOOR ASSEMBLY»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/windows/#door-evolution) ). Use a chisel or grinder to release the door hinge mounting bolt washer, which is welded to the door hinge. On completion, paint the affected area with a suitable touch-up brush to prevent corrosion. Install the door hinge (Refer «DOOR ASSEMBLY»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/windows/#door-evolution) ).
3. When the door is stiff to lock and unlock

Scheme 52

Scheme 53

1. Adjustment by using the striker (toward the inside of the vehicle and vertical direction). Install an appropriate bolt instead of the striker mounting bolt, and use special tool MB990939 and a hammer to tap the bolt to the desired direction.
2. Adjustment by using the striker (toward the outside of the vehicle). Use special tools MB990211 and MB990243 to pull the striker toward the outside of the vehicle.
3. Adjustment by using shims (forward and rearward). Increase or decrease the number of shims so that the striker engages with the door latch properly.

Scheme 54

DOOR WINDOW GLASS ADJUSTMENT

Check that the door glass moves while contacting the door glass channel when it is raised and lowered fully. If not, adjust the door window according to the following procedures.

1. Remove the door trim (Refer to «DOOR TRIM»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/exteriorinterior-trim/#door-trim-evolution) ).
2. Remove the waterproof film (Refer to «WINDOW GLASS RUNCHANNEL AND DOOR OPENING WEATHERSTRIP»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/windows/#door-evolution) ).
3. Loosen the door glass mounting screw via the adjusting hole with the door window glass fully closed, then lower the window glass a little.
4. Fully close the door window glass again and tighten the door i glass mounting screw firmly via the adjusting hole.

Scheme 55

GLASS SLIDING MECHANISM CHECK AND ADJUSTMENT

If the window glass automatically starts moving downwards at the wrong time while it is being raised, carry out the following adjustment or replacement procedures.

1. Remove the door trim (Refer to «DOOR TRIM»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/exteriorinterior-trim/#door-trim-evolution) ).
2. Remove the waterproof film (Refer to «WINDOW GLASS RUNCHANNEL AND DOOR OPENING WEATHERSTRIP»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/windows/#door-evolution) ). NOTE: Insert a cushion or similar object to prevent damage to the glass if it should happen to fall down.
3. Remove the window regulator assembly from the door window glass, and then raise and lower the door window ) glass by hand to check the operation force.
4. If the door window glass does not move up and down smoothly, check or repair the following points. Check the installation condition of the runchannel. Repair any twisting in the door sash. Check 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.
5. If repair or adjustment is not possible, replace the door assembly.

Scheme 56

POWER WINDOW TIMER FUNCTION CHECK

After the doors are closed and the ignition switch is turned to the "LOCK" (OFF) position, the power windows should work within 30 seconds. The timer expires at the point the front door is opened during that 30 second time. If not, carry out the troubleshooting (Refer to SWS DIAGNOSIS ).

POWER WINDOW OPERATING CURRENT CHECK

1. Remove the power window fuse and connect an ammeter as shown in the illustration.
2. When the power window switch is pressed to the "UP" position, a large amount of current flows at the time the window starts to close and when it is fully closed, so measure the operation current in the interval between these two points. Standard value (A): 5 +/- 1A [Power supply voltage 14.5 +/- 0.5V, 25°C(77°F)]
3. If the operation current is outside the standard value, refer to «PULSE CHECK»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/communication-devices/#simplified-wiring-system-sws-evolution) .

Scheme 57

POWER WINDOW RELAY CHECK

POWER WINDOW RELAY SPECIFIED CONDITION

Scheme 58

CIRCUIT BREAKER (INCORPORATED IN THE POWER WINDOW MOTOR) INSPECTION

1. Pull the power window switch to the UP position to fully close the door window glass, and keep pulling the switch for 10 additional seconds.
2. Release the power window switch from the UP position and immediately press it to the DOWN position . The condition of the circuit breaker is good if the door window glass starts to move downwards within 60 seconds.

POWER WINDOW CHECK

1. Operate the power window switch of each seat to check and see that the power windows operate properly. If they don't, troubleshoot (Refer to «SWS DIAGNOSIS»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/communication-devices/#simplified-wiring-system-sws-evolution) ).
2. Turn ON the power window lock switch of the power window main switch. Then operate the passenger's seat and back seat's power window sub switch to ensure that they do not operate. If they do, replace the power window main switch (Refer to «DOOR GLASS AND REGULATOR»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/windows/#door-evolution) ).

CENTRAL DOOR LOCKING SYSTEM INSPECTION

Check the following. Troubleshoot if any of the operations malfunction (Refer to SWS DIAGNOSIS ).

1. Insert the key into the driver's key cylinder and turn once counterclockwise to unlock the driver's door. Turn the key again counterclockwise to unlock all doors.
2. All doors can be locked or unlocked using the front door < RH> key cylinder key operation.
3. All door can be locked using the driver's inside door lock knob.
4. All doors can be locked using the door lock switch built into the front power window (main or sub < RH>) switch.

DOOR OUTSIDE HANDLE PLAY CHECK

1. Check that the door outside handle play is within the standard value range. Standard value (A): Front door: 2.3 +/- 2.1 mm (0.09 +/- 0.08 inch) Rear door: 1.3 +/- 1.7 mm (0.05 +/- 0.07 inch)
2. If the door outside handle play is not within the standard value range, check the door outside handle or the door latch assembly. Replace if necessary.

Scheme 59

Scheme 60

Scheme 61

1. Check that the door inside handle play is within the standard value range. Standard value (B): Front door: 10.4 +/- 9.6 mm (0.41 +/- 0.38 inch) Rear door: 10 +/- 9.6 mm (0.39 +/- 0.38 inch)
2. If the door inside handle play is outside the standard value range: Remove the door trim assembly (Refer to «DOOR TRIM»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/exteriorinterior-trim/#door-trim-evolution) ). Remove the waterproof film (Refer to «WINDOW GLASS RUNCHANNEL AND DOOR OPENING WEATHERSTRIP»(/mitsubishi/lancer-evolution/viii-2003-2005/remont/windows/#door-evolution) .) Adjust the door inside handle play with the outer cable end connecting the door inside handle and inside lock cable.

Scheme 62

<< A << STRIKER INSTALLATION

Align the center of the striker and latch to within +/-1.5 mm (0.06 inch), and install.

Scheme 63

DOOR SWITCH CHECK

DOOR SWITCH SPECIFIED CONDITION

Scheme 64

Scheme 65

Scheme 66

Required Special Tool

1. MB990480: Window Glass Holder

<< A>> WINDOW REGULATOR ASSEMBLY/POWER WINDOW REGULATOR MOTOR ASSEMBLY REMOVAL

1. Remove the door window glass installation bolts. CAUTION: If film is adhered to the door window glass, attach special tool MB990480 to the outside of the glass to prevent the film from peeling off.
2. Lift the door window glass, and attach special tool MB990480 to the glass as shown to prevent the glass from falling.
3. Remove the window regulator assembly and power window motor assembly.

Scheme 67

CENTER SASH UPPER REMOVAL

1. Remove the door outer opening weatherstrip from the center sash upper only.
2. Remove the center sash upper mounting screws, and then remove the center sash upper from the door panel.

Scheme 68

<< A << CENTER SASH UPPER INSTALLATION

Securely insert the center sash upper into the window rear sash (door).

<< B << WINDOW REGULATOR ASSEMBLY/POWER WINDOW REGULATOR MOTOR ASSEMBLY INSTALLATION

When installing the window regulator assembly, tighten the bolts to the specified torque in the order (Scheme 69)

Scheme 69

POWER WINDOW MAIN SWITCH'S FRONT < LH> SWITCH CHECK

MAIN SWITCH CONDITIONS

Note. *; Set switch to UNLOCK position

Scheme 70

SUB SWITCH CONDITIONS

Scheme 71

POWER WINDOW REGULATOR MOTOR CONTINUITY CHECK

CONTINUITY

Scheme 72

Scheme 73

<< A << DOOR CHECK INSTALLATION

Install the door check so that the identification mark faces upwards.

IDENTIFICATION MARK SPECIFICATION

Scheme 74

<< B << LOWER SASH INSTALLATION

Securely insert the rear lower sash into the window rear sash.

<< C << DOOR INSIDE HANDLE INSTALLATION

1. Install the inside lock cable to the door inside handle as follows: Install the inner cable end in the inside lock cable to the clip in the door inside handle. Turn the inside lock knob to the door lock position. Install the outer cable end to the door inside handle securely. Install the clip to the inner cable.
2. Install the inside handle rod to the door inside handle.
3. Install the door inside handle to the door.

Scheme 75

ACTUATOR OPERATION CHECK

LEVER POSITION SPECIFICATION

ACTUATOR SWITCH CHECK < LEFT SIDE>

SPECIFIED CONDITION

Scheme 76

LEVER POSITION

Scheme 77

< DRIVER'S SIDE>

DOOR LOCK KEY CYLINDER SWITCH CONDITION

Scheme 78

CENTRAL DOOR LOCK SWITCH CONTINUITY CHECK

Remove the power window switch (Refer to DOOR GLASS AND REGULATOR ).

SPECIFIED CONDITION

Scheme 79

< PASSENGER'S SIDE>

SPECIFIED CONDITION

Scheme 80

Scheme 81

Scheme 82

REMOVAL

Make a fabricated tool to remove the door weatherstrip. (Scheme 83)

Scheme 83

INSTALLATION

The clip color identifies the left and right weatherstrips, so be sure to use the colors for the correct door.

CLIP COLOR IDENTIFICATION

See also:
• GENERAL DESCRIPTION
• DOOR TRIM
• SYMPTOM CHART
• INSPECTION PROCEDURE 1: WATER LEAK THROUGH DOOR WINDOW GLASS
• DOOR WINDOW GLASS ADJUSTMENT
• POWER WINDOW CHECK
• GLASS SLIDING MECHANISM CHECK AND ADJUSTMENT