Mitsubishi LANCER EVOLUTION 2003 Operating instructions

GROUP INDEX

BODY CONSTRUCTION . . . . . . . . .

BODY DIMENSIONS . . . . . . . . . . . . .

WELDED PANEL REPLACEMENT. .

CORROSION PROTECTION . . . . . .

SYNTHETIC-RESIN PARTS . . . . . . .

BODY COLOR . . . . . . . . . . . . . . . . . .

WIRING AND PIPING DIAGRAM . . .

REFERENCE MATERIAL . . . . . . . . .

BASE OF BODY REPAIR . . . . . . . . .

2003

MITSUBISHI

LANCER

EVOLUTION VIII

BODY

REPAIR MANUAL

FOREWORD

This manual has been prepared for the use of all

service mechanics engaged in the body repair service.

Body dimensions, welded panel replacement

procedures, body sealing application instructions, and

all the other information required to provide quick and

accurate body repair service are contained herein.

One especially important point is the welding method.

All of the vehicle’s original strength and durability can

be maintained by following the welding procedures

contained in this manual.

Now that, in order to maximize the efficiency of the

repair work, first, both the extent of the damage and

the replacement parts that are needed must be

calculated accurately, and then the actual work must

be performed accurately and efficiently.

The publications shown on the following page are also

available, and should be used in conjunction with this

manual.

Mitsubishi Motors Corporation reserves the right to make changes in

design or to make additions to or improvements in its products without

imposing any obligations upon itself to install them on its products

previously manufactured.

ã2003 Mitsubishi MotorsCorporationPrinted inUSA MSSP-260B-2003

Technical Information

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1-1

GROUP 1

BODY

CONSTRUCTION

CONTENTS

BODY COMPONENTS. . . . . . . . . . . . 1-2

BODY MAIN CROSS-SECTIONAL

VIEWS . . . . . . . . . . . . . . . . . . . . . . . . 1-4

MAINTENANCE, SERVICEABILITY . 1-6

BODY CONSTRUCTION

CHARACTERISTICS . . . . . . . . . . . . . 1-8

FRONT BODY. . . . . . . . . . . . . . . . . . . . . . . 1-8

ROOF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

SIDE BODY. . . . . . . . . . . . . . . . . . . . . . . . . 1-14

REAR BODY. . . . . . . . . . . . . . . . . . . . . . . . 1-16

UNDER BODY. . . . . . . . . . . . . . . . . . . . . . . 1-17

DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20

SILENCER APPLICATION

LOCATIONS . . . . . . . . . . . . . . . . . . . . 1-21

LOCATIONS USING URETHANE FOAM

AND FOAM MATERIAL . . . . . . . . . . . 1-22

STIFFENER AND DAMP SHEET

APPLICATION LOCATIONS . . . . . . . 1-24

THEFT PROTECTION . . . . . . . . . . . . 1-25

BODY COMPONENTS

BODY CONSTRUCTION

1-2

BODY COMPONENTS

M4010001000102

AB202151AB

: Anti-corrosion steel panels

: High-tensile steel panels

25 55

2324

72 7374

76 77

31 32 33

11 12

78 79

83 82

5051

52 53 54

BODY COMPONENTS

BODY CONSTRUCTION 1-3

1. HEADLAMP SUPPORT PANEL

2. HOOD LOCK STAY

3. FRONT END CROSSMEMBER

4. FRONT END UPPER BAR

5. HEADLAMP SUPPORT PANEL SIDE

6. FRONT FENDER SHIELD

7. FRONT UPPER FRAME INNER

8. UPPER FRAME BULKHEAD FRONT

9. UPPER FRAME BULKHEAD

10. UPPER FRAME BULKHEAD REAR

11. FRONT SIDEMEMBER INNER

12. ENGINE MOUNT BRACKET

13. FRONT SIDEMEMBER REAR

14. FRONT SIDEMEMBER OUTER

15. SPRING HOUSE PANEL

16. DASH PANEL

17. DASH PANEL SILENCER

18. DASH PANEL REINFORCEMENT

19. UPPER FRAME TO FRONT PILLAR BRACE

20. UPPER FRAME EXTENSION OUTER

21. UPPER FRAME EXTENSION INNER

22. COWL TOP LOWER PANEL

23. COWL TOP INNER PANEL

24. COWL TOP UPPER PANEL

25. FRONT DECK CROSSMENBER

26. HOOD INNER PANEL

27. HOOD OUTER PANEL

28. FRONT ROOF RAIL

29. FRONT ROOF BOW

30. ROOF PANEL

31. ROOF BOW FRONT REINFORCEMENT

32. REAR ROOF BOW

33. REAR ROOF RAIL

34. SEAT BACK PLATE

35. REAR SEAT BACK PANEL

36. REAR SHELF PANEL

37. REAR SEAT BACK BRACE

38. TRUNK LID OUTER PANEL

39. TRUNK LID INNER PANEL

40. TRUNK LID HINGE

41. QUARTER INNER EXTENSION REAR

42. QUARTER CORNER PANEL

43. REAR COMBINATION LAMP HOUSING

44. SIDE ROOF RAIL INNER

45. ROOF SIDE RAIL REINFORCEMENT CENTER

46. FRONT PILLAR INNER UPPER

47. FRONT PILLAR INNER LOWER

48. CENTER PILLAR INNER

49. SIDE OUTER PANEL

50. REAR WHEEL HOUSE INNER PANEL

51. QUARTER INNER PANEL

52. REAR FLOOR SIDE BRACE

53. QUARTER OUTER EXTENSION LOWER

54. FUEL FILLER DOOR

55. REAR END PANEL OUTER

56. REAR END PANEL INNER

57. REAR DOOR OUTER PANEL

58. REAR DOOR SIDE DOOR BEAM LOWER

59. REAR DOOR SIDE DOOR BEAM UPPER

60. REAR DOOR INNER PANEL

61. FRONT DOOR OUTER PANEL

62. FRONT DOOR SIDE DOOR BEAM

63. FRONT DOOR INNER PANEL

64. FENDER PANEL

65. FRONT FLOOR CROSSMEMBER REAR

66. FRONT FLOOR CROSSMEMBER FRONT

67. FRONT FLOOR SIDE SILL INNER

68. FRONT FLOOR SIDEMEMBER

69. BACKBONE REINFORCEMENT

70. INSTRUMENT PANEL CENTER BRACKET

REINFORCEMENT

71. FRONT FLOOR PAN

72. FRONT FLOOR EXTENSION PANEL REAR

73. REAR FLOOR EXTENSION

74. REAR FLOOR PAN

75. SEAT BACK PLATE EXTENSION

76. JACK BRACKET

77. SPARE TIRE BRACKET

78. TOWING HOOK REINFORCEMENT

79. REAR FLOOR SIDEMEMBER EXTENSION

80. CROSSMEMBER CENTER SUPPORT

81. REAR FLOOR CROSSMEMBER

82. REAR FLOOR SIDEMEMBER

83. REAR SEAT BACK REINFORCEMENT

BODY MAIN CROSS-SECTIONAL VIEWS

BODY CONSTRUCTION

1-4

BODY MAIN CROSS-SECTIONAL VIEWS

M4010002000105

AB201974

AB201984

ROOF PANEL

MAP LAMP

BRACKET

FRONT ROOF RAIL

AB201886AB

SIDE ROOF

RAIL INNER

SIDE OUTER

PANEL

FRONT PILLAR INNER

REINFORCEMENT

FRONT PILLAR

REINFORCEMENT UPPER

FRONT

PILLAR

REINFORCE-

MENT

UPPER (B)

ROOF

PANEL

AB200255AC

COWL TOP

LOWER PANEL

COWL TOP

UPPER

PANEL

COWL TOP

INNER PANEL

AB200256AC

FRONT END CROSSMEMBER

REIFORCEMENT

FRONT

END

CROSS-

MENBER

INNER

FRONT END

CROSSMENBER

OUTER

AB201985AB

FRONT PILLAR REINFORCEMENT

LOWER FRONT PILLAR

INNER LOWER

SIDE OUTER PANEL

AB200258AC

FRONT

FLOOR

SIDE SILL

INNER

SIDE SILL

REINFORCEMENT

SUPPORT

SIDE SILL OUTER

REINFORCEMENT

CENTER

SIDE OUTER PANEL

BODY MAIN CROSS-SECTIONAL VIEWS

BODY CONSTRUCTION 1-5

AB201911AB

AB201887AB

G(STANDARD ROOF)

SIDE OUTER

PANEL

FRONT

PILLAR

INNER

UPPER

FRONT PILLAR

INNER REINFORCEMENT

UPPER

FRONT PILLAR INNER UPPER

REINFORCEMENT

FRONT

PILLAR

REINFORCE-

MENT UPPER

(B)

FRONT PILLAR

REINFORCEMENT

UPPER

AB202122AB

G(SUNROOF)

SIDE OUTER PANEL

FRONT PILLAR

INNER UPPER

FRONT PILLAR

REINFORCEMENT

UPPER

AB201986

CENTER PILLAR

REINFORCEMENT

CENTER PILLAR

SEATBELT

REINFORCEMENT

CENTER PILLAR

INNER

SIDE

OUTER

PANEL

AB201988AB

SIDE OUTER

PANEL

REAR PILLAR

INNER

AB200264AC

SIDE OUTER

PANEL

QUARTER

INNER PANEL

REAR WHEEL

HOUSE INNER

PANEL

AB201989AB

REAR END

PANEL

OUTER

REAR END

PANEL

INNER

MAINTENANCE, SERVICEABILITY

BODY CONSTRUCTION

1-6

MAINTENANCE, SERVICEABILITY

M4010003000120

FENDER SHIELD

A positioning hole, marking and cut-out has been

added on the front fender shield, front upper frame

inner, front side member gusset rear and dash panel

to improve assembling workability when replacing

the panel.

AB202152AB

MAINTENANCE, SERVICEABILITY

BODY CONSTRUCTION 1-7

SIDE STRUCTURE

A panel positioning cut-out has been added on the

door opening to improve assembling workability

when replacing the panel.

SIDE OUTER PANEL

The extra parts are supplied in 4 different cut forms

as a result of employing the integrated side-frame

side outer panel.

AB200202AB

PANEL POSITIONING NOTCH

AB202025AB

AB202024

CENTER PILLAR OUTER

FRONT PILLAR OUTER

SIDE SILL OUTER

QUARTER OUTER

BODY CONSTRUCTION CHARACTERISTICS

BODY CONSTRUCTION

1-8

BODY CONSTRUCTION CHARACTERISTICS

FRONT BODY M4010010000092

HEADLAMP SUPPORT

By adopting a steel sheet with variable thickness* for

the front end crossmember outer, the steel sheet

thickness on the right side of the vehicle has been

increased to improve safety in collision and body

rigidity.

NOTE: *: Steel sheets with different thickness

welded to form one steel sheet.

AB201017AB

5 3

1. FRONT END UPPER BAR

2. SENSOR BRACKET

3. HEADLAMP SUPPORT PANEL

4. HOOD LOCK STAY

5. FRONT END CROSSMEMBER INNER

REINFORCEMENT

6. A/C CONDENSER BRACKET

7. RADIATOR BRACKET

8. FRONT END CROSSMEMBER INNER

9. FRONT END CROSSMEMBER OUTER

10. SHIPPING HOOK

10. FRONT END CROSSMEMBER REINFORCEMENT

BODY CONSTRUCTION CHARACTERISTICS

BODY CONSTRUCTION 1-9

FENDER SHIELD

The cross section of the front sidemember has been

increased and a steel sheet with variable thickness*

has been adopted for the front sidemember inner to

increase the thickness of the cabinet side in the aim

to improve safety in collision, body rigidity, and real-

ize lightweight.

NOTE: *: Steel sheets with different thickness

welded to form one steel sheet.

The spring house panel has been designed to be

directly installed with the cowl top lower panel, and

the body rigidity of the suspension attachment holder

has been increased to improve operational stability

and quietness.

AB202153AB

RIGHT SIDE

LEFT SIDE9

764

1. HEADLAMP SUPPORT PANEL SIDE

2. FRONT FENDER SHIELD

3. ENGINE MOUNT REINFORCEMENT

4. UPPER FRAME BULKHEAD FRONT

5. FRONT UPPER FRAME INNER

6. UPPER FRAME BULKHEAD

7. UPPER FRAME BULKHEAD REAR

8. SPRING HOUSE BRACKET REINFORCEMENT

9. SPRING HOUSE BRACKET

10. SPRING HOUSE PANEL

11. FRONT SIDEMEMBER

12. TRANSMISSION MOUNT REINFORCEMENT

OUTER

AB200275AC

COWL TOP

LOWER PANEL

SPRING

HOUSE

BRACKET SPRING HOUSE

PANEL

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