Mitsubishi MOTORS Lancer Evolution 2008 Instrucciones de funcionamiento

GROUP INDEX

BODY CONSTRUCTION . . . . . . . . .

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

WELDED PANEL REPLACEMENT. .

CORROSION PROTECTION . . . . . .

SYNTHETIC-RESIN PARTS . . . . . . .

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

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

2008

MITSUBISHI

LANCER EVOLUTION

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 vehicleís 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 following also available, and should be used in

conjunction with this manual.

TECHNICAL INFORMATION MANUAL

MSSP-260B-2008

SERVICE MANUAL MSSP-206B-2008

PARTS CATALOG BUM6Y108A_

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.

All Rights, Reserved

Printed in USA

MSSP-460B-2008

MANUAL DESCRIPTION

CONTENTS

The first page of this manual contains a table of contents which lists the name of vehicle models and groups

within each model.

TEXT

The vehicles to which the information in the text pertains are generally designated according to their body

classification. In some cases, other limiting designations such as model name, type of drive system, etc., are

given. If there are no such limiting designations, the information can be assumed to cover all models.

PAGE NUMBERS

Al pages are numbered consecutively within each model. The page number can be found on the upper left or

right of each page.

SECTION TITLES

The group titles and section titles can be found at the upper center of each page.

Section title

Group title

Group number

Page number

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

SIDE BODY. . . . . . . . . . . . . . . . . . . . . . . . . 1-15

REAR BODY . . . . . . . . . . . . . . . . . . . . . . . . 1-17

ROOF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18

UNDER BODY. . . . . . . . . . . . . . . . . . . . . . . 1-20

DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24

SILENCER APPLICATION

LOCATIONS . . . . . . . . . . . . . . . . . . . . 1-25

FOAMING MATERIAL USAGE

LOCATIONS . . . . . . . . . . . . . . . . . . . . 1-26

STIFFENER AND DAMP SHEET

APPLICATION LOCATIONS . . . . . . . 1-27

THEFT PROTECTION . . . . . . . . . . . . 1-28

BODY COMPONENTS

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BODY CONSTRUCTION

1-2

BODY COMPONENTS

M4010001001309

AB700971AB

63**

61*

74**

75**

33*

52*

57*

58*

15 59

97*

99*

: Anti-corrosion steel panels

: High-tensile steel panels (*: Indicates 590MPa-high-tensile steel panels.)

(**: Indicates 980MPa-ultra-high-tensile steel panels.)

95*

BODY COMPONENTS

TSB Revision

BODY CONSTRUCTION 1-3

1. Front bumper reinforcement

2. Headlight support panel upper

3. Front body frame to side sill brace

4. Front sidemember rear

5. Front inner sidemember

6. Headlight support panel

7. Front sidemember plate

8. Front outer sidemember

9. Front sidemember extension

10. Front fender gusset

11. Headlight support panel upper

12. Front fender shield

13. Fender shield frame upper outer

14. Fender shield frame upper inner

15. Spring house panel

16. Dash panel crossmember upper

17. Dash panel crossmember lower

18. Dash panel

19. Brake pedal support reinforcement

20. Cowl top panel

21. Brake pedal support bracket

22. Front deck crossmember

23. Hood panel inner

24. Hood panel outer

25. Front door side door beam

26. Front door panel inner

27. Front door panel outer

28. Rear door side door beam

29. Rear door panel inner

30. Rear door panel outer

31. Roof rail front lower

32. Roof rail front upper

33. Roof bow center lower <Vehicles without sunroof

(aluminum panel)>

34. Roof bow center upper <Vehicles without sunroof

(aluminum panel)>

35. Roof rail rear

36. Roof panel

37. Roof panel reinforcement <Vehicles with sunroof

(steel panel)>

38. Rear shelf panel

39. Trunk lid panel inner

40. Trunk lid panel outer

41. Fuel filler door panel (Left side)

42. Rear bumper reinforcement

43. Rear bumper reinforcement

44. Rear end panel outer

45. Rear end panel inner

46. Rear bumper side bracket

47. Rear seatback bracket lower

48. Rear floor

49. Rear floor rear end crossmember

50. Rear floor crossmember

51. Rear floor side panel

52. Rear floor sidemember extension

53. Rear floor sidemember lower

54. Rear seat under floor

55. Rear seat belt reinforcement (Left side)

56. Rear seat belt reinforcement (Right side)

57. Rear floor extension

58. Rear floor rear seat under crossmember

59. Front floor crossmember rear

60. Front floor backbone reinforcement

61. Front floor crossmember front

62. Front floor

63. Front floor side sill inner

64. Front floor sidemember

65. Front floor crossmember rear center

66. Front floor crossmember front

67. Front fender

68. Headlight support panel lower

69. Radiator bracket lower

70. Side outer panel

71. Front fender bracket

72. Upper frame to front pillar brace

73. Front deck frame upper outer

74. Side sill reinforcement outer front

75. Side sill reinforcement outer rear

76. Side sill inner support front

77. Front pillar lower reinforcement

78. Front pillar inner lower

79. Front pillar inner center

80. Front upper inner pillar

81. Roof side rail inner

82. Rear seatback brace

83. Rear wheel house panel inner

84. Rear wheel house panel front lower outer

85. Quarter panel lower inner (Left side)

86. Quarter panel inner

87. Quarter panel extension inner

88. Quarter panel extension lower outer

89. Quarter panel extension outer

90. Rear combination light housing panel

91. Rear pillar reinforcement

92. Roof side rail reinforcement rear

93. Rear pillar reinforcement lower

94. Center pillar reinforcement

95. Rear door hinge reinforcement

96. Rear door hinge reinforcement support

97. Roof side rail reinforcement

98. Center pillar inner lower

99. Center pillar inner upper

BODY MAIN CROSS-SECTIONAL VIEWS

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BODY CONSTRUCTION

1-4

BODY MAIN CROSS-SECTIONAL VIEWS

M4010002001067

AB700285AB

AB601100AC

Roof panel

Roof rail

front upper

Roof rail

front lower

AB700969

Roof side rail

reinforcement

front

Side outer

panel

Center pillar

reinforcement

Roof side

rail inner

Roof side

rail support

AB601102AC

Center pillar

reinforcement

Center pillar

inner upper

Rear door hinge

reinforcement

support

Rear door hinge

reinforcement

Side outer

panel

AB700536

Roof side

rail inner

Roof side rail

reinforcement rear

Side outer panel

AB601099

Front end

crossmember

upper

Front end

crossmember lower

Front end

crossmember

bulkhead

AB700537AB

Front door hinge

reinforcement lower

Front pillar

reinforcement lower

Front pillar

inner lower

Side outer

panel

BODY MAIN CROSS-SECTIONAL VIEWS

TSB Revision

BODY CONSTRUCTION 1-5

AB700286AB

AB602354AB

Side outer

panel

Front upper

inner pillar

Roof side rail

reinforcement

front

AB601108AC

Roof panel

Roof rail rear

AB700538

Side sill

reinforcement

outer front

Side outer

panel

Front pillar

inner lower

Side sill inner

support front

AB700539AB

Side sill

reinforcement

outer rear

Side outer panel

Front floor

side sill

inner

Rear floor

side sill

inner

AB700540AB

Rear pillar

reinforcement

lower

Rear wheel

house panel

inner

Quarter

inner

panel

Side outer

panel

Quarter panel extension

lower outer

AB601110AC

Rear bumper

reinforcement

Rear end

panel outer

Rear end

panel inner

MAINTENANCE, SERVICEABILITY

TSB Revision

BODY CONSTRUCTION

1-6

MAINTENANCE, SERVICEABILITY

M4010003000948

FENDER SHIELD

A positioning hole, lug, and notch have been added

on the front end upper bar side, front upper frame

inner, upper frame extension inner, front side mem-

ber brace upper and dash panel to improve assem-

bling workability during panel replacement.

AB700964AB

MAINTENANCE, SERVICEABILITY

TSB Revision

BODY CONSTRUCTION 1-7

SIDE STRUCTURE

A panel positioning notch 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.

AB201388AB

Panel positioning notch

AB700289AB

AB700613AB

Center outer pillar

Front outer pillar

Quarter panel outer

Front floor side sill outer

BODY CONSTRUCTION CHARACTERISTICS

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BODY CONSTRUCTION

1-8

BODY CONSTRUCTION CHARACTERISTICS

FRONT BODY M4010010001200

HEADLIGHT SUPPORT

•The crush box structure, which has an octagonal

cross-section at the front end of the front side-

member, has been adopted. This structure can

effectively absorb energy upon frontal impact and

reduces the vehicle repair cost caused by a light

collision.

•The bolt-on headlight support panel upper is

used to improve maintainability.

•An aluminum front bumper reinforcement has

been adopted to improve the body rigidity, han-

dling stability, and riding comfort.

The crush box structure has been changed to

straight type with an octagon cross-section so that

the structure can effectively absorb energy from the

impact at the time of collision.

AB700911

9.0 ± 2.0 N·m

80 ± 17 in-lb

20 ± 5 N·m

15 ± 3 ft-lb

1. Front bumper reinforcement

2. Headlight support panel upper

3. Front end crossmember gusset

4. Front end crossmember upper

5. Radiator bracket lower A

6. Front end crossmember bulkhead

7. Radiator bracket lower B

8. Shipping hook front

9. Shipping reinforcement front

10. Front end crossmember lower

AB701123AB

Crush box

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