Body Repair
Contents
1. Note iX these welding points are done by manufacturer not necessary during repairs black shading indicates areas where structural adhesive is applied Adhesive Type Product name mon Epoxy structural adhesive Sumitomo 3M Auto Mix Panel Bond 8115 3 3 CHANGING WELDED PANELS ROOF JS VA AB302187AB AB302186AB Front pillar upper support Rear pillar upper support removed condition removed condition IMPORTANT POINTS TO OBSERVE WHEN DOING THE WORK REMOVAL 1 When removing the roof use a support to prevent the side panels opening out or leaning in 2 To cut weld the front or rear roof rail remove the front pillar upper support and rear pillar upper support Self piercing rivet Blind rivet 3 Using a drill 5mm make a hole in through the centre of the rivet crack it and remove Normally self piercing rivets are used but blind rivets may also be used For areas where there is adhesive use a cold chisel or similar tool to free and remove the roof Drill Roof panel AB302195 CHANGING WELDED PANELS ROOF 3 4 appropriate tool appropriate AB302218AB tool AC103143 AB302189AB Body sealant Fitting 1 Temporarily set the new roof to the body and drill holes for rivets with drill 25mm 2 Remove the roof smooth off any burring around the holes then clean the body 3 Apply structural adhesive to the body side then fit the roof Adhesive Type2. Note The panel surface should not be excessively sanded away Checking for distortions Polish with 80 120 sandpaper and check for distortion Removing distortions Remove any distortions by pressing out using a levelling hammer and a torch Note 1 Heat to approx 250 C to do this work 2 Take care when heating so that welding can be done without heating causing any discolouration CHANGING WELDED PANELS ALUMINIUM ALLOY PANELS 3 8 3 Use a damp cloth to prevent temperature rising and causing distortion or other effects in the area being heated 4 Do not use levelling hammers which are used for sheet steel as they can cause cracking 6 Finishing Finish off with 100 120 grade disk sander Note As spark marks and carbon adhesion can have an adverse effect during painting remove completely using a stainless steel wire brush Other welding 1 TIG welding The process is basically the same as MIG welding using the same arc welder but instead of using an electrode wire a rod coated with flux is used To help prevent distortion from the heat generated in welding and poor quality welding this job should be done by someone with suitable training and practice e Welding rod 5356 5556 5183 JIS classification e Diameter 1 6mm 2 Gas welding oxyacetylene In essence if gas welding can be done then a welding rod and flux for cleaning and reducing oxide inclusions can be used To help prevent dist
3. Mirage Lancer 1036F30 10 1995 Mirage Lancer 1036F52 8 1996 supplement Mirage Lancer 1036F31 1 1996 Lancer Sedia 1036K50 5 2000 Mirage Lancer 1036F32 8 1996 Lancer Sedia 1036K51 7 2000 supplement Mirage Lancer 1036F33 7 1997 Lancer Evolution VII 1036K52 5 2001 supplement Lancer 1036F34 1 1998 Lancer Sedia 1036K53 10 2001 supplement e Mirage Lancer 1036F35 10 1998 e Lancer 1036F36 1 1999 e Lancer 1036F37 12 1999 e Lancer Sedia 1036K30 5 2000 e Lancer Sedia 1036K31 7 2000 Lancer Evolution VII 1036K32 1 2001 Wiring layout diagram Service Manuals Lancer Sedia 1036K33 5 2001 Lancer Evolution VIII 1036K77 1 2003 Lancer Sedia 1036K34 5 2001 Lancer Evolution VII 1036K80 2 2004 MR Supplement Lancer Evolution VII 1036K35 1 2001 e Lancer Sedia 1036K36 5 2002 Lancer Evolution VIII 1036K37 1 2003 e Lancer 1036K38 2 2003 e Lancer 1036K39 12 2003 Lancer Evolution VIII MR 1036K40 2 2004 Service Manuals Engine Service Manuals e Lancer Sedia 1036K00 5 2000 e 466 Engine 1039G46 1 2001 e Lancer Sedia 1036K01 7 2000 e 466 Engine 1039G63 1 2003 Lancer Evolution VII 1036K02 1 2001 supplement e Lancer Sedia supplement 1036K03 5 2001 e Lancer Sedia supplement 1036K04 10 2001 Transmission Service Manuals e Lancer Evolution VII 1036K05 1 2002 e W5M51 Manual 1039M17 1 2001 supplement Transmiss
4. in mind aluminium alloy characteristics when carrying out this work 1 Repairing sheet metal 1 Heat with a torch Note a Heat to the point where heat can be felt on the rear side of panel with hand wearing a glove b Keep torch moving so as not to overheat one area CHANGING WELDED PANELS ALUMINIUM ALLOY PANELS 3 6 AB302173AB 2 When hammering note that the panels stretch easily so use a wooden or plastic hammer Note Reduce stretching and process hardening and do not leave hammer marks 2 Check for distortion Polish with 80 120 grade sandpaper checking for any distortion 3 Removing distortions Remove any distortions Using a levelling hammer and a torch correct any distortions Note 1 Heat to about 250 C to do this work 2 Be careful when heating so as not to cause discolouration when welding 3 Use a damp cloth to prevent heat increases which could result in heat affecting heated area distortion etc 4 Do not use drawing hammers which are used for sheet steel as this could result in cracking 4 Polishing Polish with a disk or a double action sander e Disk sander 100 120 e Double action sander 150 180 Note Since the material is softer than sheet steel choose a polishing material that does not scour the surface deeply Repairing cuts and tears When sheet steel panels are cut torn or have holes repair using CO MIG welding However with aluminium alloy panels
5. particularly in the case of Group 52B SRS airbags GENERAL MODEL LINE UP APPLIED VEHICLES 0 1 SECTION 0 GENERAL CONTENTS Model lin Up ccccccceeeeeeeeeeenseeeeeeeeeees 0 1 Main specifications cccsceeeeseeeeeeees 0 2 Applied vehicle numbers 000 0 1 Model line up Model Version 704 Model Grade Engine Model Transmission Fuel System GH CT9A SNDFZ O RS 4G63 W5M51 4WD 5M T MPI 2 000 DOHC 16 valve intercooler turbo SJDFZ O RS W6MAA 4WD 6 M T SJGFZ O GSR Note O Continued model Applied vehicles GH CT9A CT9A 0300001 0 2 GENERAL MAIN SPECIFICATIONS MAIN SPECIFICATIONS ITEM GH CT9A SNDFZ SJDFZ SJGFZ Class Ordinary Use Passenger vehicle Body Saloon shape Dimensions Vehicle length mm 4490 Vehicle width mm 1770 Vehicle height mm 1450 Distance between axles mm 2625 Distance between Front 15157 1515 wheels mm 1500 Rear 1515 1515 1500 Minimum ground clearance mm 140 Interior dimensions Length 1880 mm Width 1425 Height 1185 Body overhang mm Front 825 Rear 875 Driving Front Toe in mm 0 2 devices wheels Camber 1 00 30 or 2 00 30 Castor 3 55 30 King pin angle 13 45 Rear Toe in mm 3 2 wheels Camber 1 00 30 Tyre size 205 65R15 94H 235 45ZR17 235 45ZR17 Notes 1 1 in the case of vehicles fitt
6. MITSUBISHI LANCER Evolutionw M SERVICE MANUAL BODY LANCER EVOLUTION VIII MR FOREWORD This manual contains details of the main changes to the 2004 model Lancer Evolution VIII MR Only differences to the current Lancer Evolution VIII are included so please use this manual in conjunction with the related information specified on the next page This information relates to the current vehicle February 2004 Since specifications will change some of the information contained here will inevitably be superseded Note that SI units are used in this manual Old units are not shown alongside them However old units are used for some figures we have taken from existing documents Any opinions requests or questions concerning this manual should be written on the Servicing Comments Form at the end and sent to us by fax February 2004 KN MITSUBISHI MOTOR CORPORATION This manual is printed on recycled paper CONTENTS General Body construction Standard measurements Changing welded panels Rust treatment 11111 Plastics parts Body Colour siss MC Wiring layout and diagrams Reference materials 22 There are no changes to the shaded chapters so they are not included at all in this manual Related information Title No Issue date Title No Issue date New model manuals Body Service Manuals
7. Product name Epoxy structural Sumitomo 3M Auto Mix adhesive Panel Bond 8115 4 Using the appropriate tool set the rivets as follows Rivets POP rivet SD 62 HR 1 Insert the rivet into the hole in the base material roof 2 Insert the appropriate tool into Part A of the rivet 3 Using the appropriate tool use the tool handle to press the rivet flange surface down 4 Secure the rivet snapping at the thin part of A Note In places where setting rivets so that flange makes good contact is difficult it is OK to set from inside the vehicle Reference Appropriate tool use rivet 4 8mm Lobster Tools Ltd Hand riveter HR 003B 5 When adhesive is dry remove any excess adhesive then to prevent water ingress apply body sealant to cover entire rivet area and roof edge a black shading indicates body sealant Product name Sun Star Penguin Seal 353 white 3 5 CHANGING WELDED PANELS ALUMINIUM ALLOY PANELS ALUMINIUM ALLOY PANELS Repairing Aluminium Alloy Panels Precautions when working on sheet metal 1 The main differences to working with sheet steel Assuming an ordinary body shop Operation Aluminium alloy panel Sheet steel Hammering Wood or plastic hammer Sheet steel hammer Washer welding Not possible Possible Gas welding Workability is poor but possible Possible Spot welding Not possible Possible MIG welding Possible with welder using argon gas and e
8. SIONS CONTENTS General na 2 1 ROOM A TA ener 2 2 B type straight line measurements 2 2 General Together with the changes relating to roof panel replacement dimensions without the roof in place are specified B Type straight line measurements ROOF units mm Diagram shows roof assembly removed condition AB302217AB Number Measurement points Hole shapes Sizes mm Number Measurement points Hole shapes Sizes mm 90 Side roof rail inner corner 91 Side roof rail inner corner 3 1 CHANGING WELDED PANELS GENERAL SECTION 3 CHANGING WELDED PANELS CONTENTS SUMMANY ai kwa saba l ai kk a a pr n kk 3 1 Repairing aluminium alloy panels 3 5 Body construction 1 3 2 Painting aluminium alloy panels 3 10 Aluminium alloy panels ss 3 5 General Along with the change to an aluminium roof important roof replacement details have been specified CHANGING WELDED PANELS ROOF 3 2 Symbol Operation details eee Spot welding am AA MIG plug welding m two layers a three layers MIG spot welding tttttttt MIG arc welding continuous kkk Rivet Areas where rust inhibitor is applied Applied using fi holes in butt welded locations SERVICE JOINTS AB302188AB AB302185AB L A Centre pillar SE upper support AB302186AB AB302221AB AB302187AB D Front pillar upper support
9. ed with 17 inch tyres 2 in the case of vehicles fitted with 15 inch tyres 2 3 it is possible to select from 3 types of camber This is be set to 1 00 30 when shipped from the factory BODY CONSTRUCTION GENERAL BODY CONSTRUCTION SPECIAL FEATURES 1 1 SECTION 1 BODY CONSTRUCTION CONTENTS SUMMANY okin koka eisini kantavan koki mak 1 1 FOOT ii kan aka kak n kas aka k kon ae kan ki ak aki kaka 1 1 Body construction 1 1 1 DOOFS kisa stan k k na aaa ud kk 1 2 Summary e The roof and side door beams have been changed from steel to aluminium Body Construction Special Features ROOF Body is now lighter as a result of changing the roof panels to aluminium The body is also more rigid now as a result of additional support in pillar areas Roof panel Rear pillar upper support Centre pillar upper support b 9 AB302148AB Front pillar upper support shaded areas indicate parts that are the same as those used on current vehicle 1 2 BODY CONSTRUCTION BODY CONSTRUCTION SPECIAL FEATURES DOORS The body has been lightened as a result of using aluminium for the side door beams FRONT DOOR ai iM Si tre Front door side door beam AB302149AB REAR DOOR Rear door side door beam AB302150AB shaded areas indicate parts that are the same as those used on current vehicle STANDARD DIMENSIONS GENERAL B TYPE straight line measurements 2 1 SECTION 2 STANDARD DIMEN
10. ion e Lancer Sedia supplement 1036K06 5 2002 e W5M51Manual 1039M22 1 2003 transmission Supplement e Lancer Evolution VII 1036K07 1 2003 e W6MAA Manual 1039M23 1 2003 supplement transmission e Lancer supplement 1036K08 2 2003 e Lancer supplement 1036K09 12 2003 Lancer Evolution VIII MR 1036K10 2 2004 Precautions to be taken when servicing vehicles with seatbelts fitted with SRS Airbag and Pretensioners Precautions 1 Incorrect inspection or servicing of SRS airbag and pretensioner fitted seatbelt parts as well as any related components could lead to major damage or non operation as a result of sudden unintentional operation of SRS airbag and pretensioner fitted seatbelts incorrect deployment In cases where heating from painting processes occurs the SRS ECU driver side airbag module passenger side airbag module pre tensioner fitted seatbelts and cross springs should be removed 93 C and above SRS ECU driver side airbag module passenger side airbag module cross springs 90 C and above pretensioner fitted seatbelts Inspections and servicing of SRS airbag and pretensioner fitted seatbelt parts and any related components must without fail be done by a Mitsubishi Motors authorized dealer Inspections and servicing of SRS airbag and pretensioner fitted seatbelt parts and any related components must be done paying scrupulous attention to the relevant service manual
11. ortion from the heat generated in welding and poor quality welding this job should be done by someone with suitable training and practice e Welding rod 5356 5556 5183 JIS classification e Diameter 1 6mm 1 Flux is made to adhere by heating the welding rod 3 9 CHANGING WELDED PANELS ALUMINIUM ALLOY PANELS AB202114AB AB302177AB 2 Melt the flux with the torch and weld removing oxide film Note The molten welding rod flows easily so as far as possible keep the surface being welded flat 3 Flux left on the panel should be removed using a stainless steel wire brush or similar Finishing filler 1 Polish areas filled with filler using 150 180 double action sander 2 Clean away any grease on the surfaces where there is filler 3 Apply 2 part epoxy primer or for a primer pre treatment designed for use with aluminium 4 Flatten down with 180 double action sander 5 Remove grease and clean surface areas where there is filler 6 Paint filler in sheet metal and allow to dry naturally Note Do not speed up by drying at 60 C or over 7 Polish with 180 CHANGING WELDED PANELS ALUMINIUM ALLOY PANELS 3 10 Painting aluminium panels Painting on the production line Same as for painting ordinary steel plate Painting for repairs The main points for repairs in general are as follows Paint adhesion to aluminium alloy panels is not quite as good as ordinary steel plate so
12. pay careful attention to precautionary notes 1 Peeling of paint film Caution avoid harsh polishing and try not to generate heat during polishing 2 Clean and remove any grease 3 Apply wash primer 4 Dry 5 Apply primer surfacer 6 Dry Note do not speed up by drying at over 60 C 7 Polish 8 Clean remove any grease 9 Overcoat 10 Dry Note do not speed up by drying at over 60 C Remarks 1 Please refer to paint manufacturer s instructions for details 2 Same as for paint repair jobs done on stainless steel plate 6 1 BODY COLOUR GENERAL BODY COLOUR LIST DIFFERENT BODY COLOUR PAINT SECTIONS SECTION 6 BODY COLOUR CONTENTS General asian kw i na ee a kk n kk 6 1 Body colour paint sections 6 1 Body colour liSt 6 1 Rear spole Nwayo ei eect good ase pea ka 6 1 General This specifies body colour and different body colour paint sections Body Colour List Name of colour Colour symbol Colour code Colour paint Content of paint Repair symbol Paint old colour number manufacturer name Cool silver CL A31 CMA10031 Aluminium M Kansai Paint metallic Medium Gun ES A39 CMA 10039 Aluminium 2P Nippon Paint Metal grey mica mica Solid White 2E W83 AC10983 S Kansai Paint Scotia White Solid Red JW P85 AC11185 S Kansai Paint Parma Red Remarks 1 Repair symbols show only overcoat S solid M Metallic 2P 2 coa
13. quipment for Possible with CO gas and normal welding aluminium welding equipment 2 At low temperatures if subjected to a major impact strength will deteriorate and it will crack 3 Coefficient of elasticity is high so spring back force acting to make material regain original form is high 4 Rate of heat transmission is high and this can cause local thermal expansion 5 If overheated it becomes brittle and strength deteriorates If heated further it will melt without discolouration Heat treatment temperature approx 250 C Material Welding temperature Aluminium 475 C 660 C varies depending on alloy composition Sheet steel 1500 C 2500 C 6 7 8 9 Do not use general tools or sanders for sanding sheet steel Material is soft so be careful when selecting polish to use Also since polishing powder is light and easily airborne wear dust mask and goggles If strong pressure is used when using a disk sander on the alloy the friction could cause the aluminium alloy to peel off and cause clogging Disk sanders that become clogged will cause deep scratching on aluminium alloy panels so replace promptly steel fragments or dust will remain on the sander causing electro corrosion with other metal 10 With MIG welding shield the local area Sparks often difficult to see can be generated and dispersed over a wide area Repairing unevenness This is basically the same as for sheet steel However bear
14. t pearl 2 The paint manufacturers names are the names used at time of manufacturing Different Body Colour Paint Sections The different rear spoiler paint sections are specified below Rear Spoiler 2 1 1 Gun metal grey CMA1002 2 Part material colour AB302214AB RJYJ402022 22
15. use MIG or TIG welder and use argon gas inert gas as shield gas Extent of distortion from welding Gas welding large distortion gt TIG welding gt MIG welding little distortion Here we explain the MIG welding process where distortion resulting from welding is small 3 7 AB202118AB AB202113AB CHANGING WELDED PANELS ALUMINIUM ALLOY PANELS MIG welding procedure 1 Repairing sheet metal These should be repaired by heating the damaged part gently and lightly hammering The areas stretched by hammering out should be cut away using an air saw Note 1 Take care not to overstretch or damage the panel 2 The gaps at the joint areas should be as narrow as possible Welding This work should be done using equipment designed for aluminium welding or equipment that can be used for both aluminium and steel plate welding e Welding wire 5356 5556 5183 JIS classifications e Wire dia 0 8 or 1 0mm 1 Remove any grease from welding areas using white spirit or similar 2 Immediately prior to welding remove any oxidation film with a stainless steel wire brush including the rear side and carry out the work immediately after cleaning Note To minimize distortion and material melting and coming away weld a little at a time rather than welding long stretches Inspecting welded areas After finishing off areas sanded with 100 disk sander check that there are no inadequately welded parts red check
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