Mitsubishi MOTORS Lancer Evolution 2008 Body Repair Manual Download Page 144

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ROOF

TSB Revision

WELDED PANEL REPLACEMENT

3-36

(1) Insert the rivets into the roof.
(2) Mount the recommended tool on the A-section of the

rivet.

(3) Operate the tool's handle while pushing the flange

surface of the rivet by the recommended tool.

(4) Part A of the rivet is cut and the rivet is tightened.

5. After the adhesive is dried, remove the excessive residues

and apply body sealant to the whole rivets and the roof edge
in order to prevent water leakage.

AB302218

AC205918

AB501314

Recommended tool

Roof lid rivet

Flange

surface

Recommended tool

Roof panel

AB501313

AB302189

AB302205

Body sealing

Rivet

Roof panel

Summary of Contents for Lancer Evolution 2008

Page 1: ...bility 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...

Page 2: ...ation 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 t...

Page 3: ...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 ...

Page 4: ...9 31 25 24 72 63 65 73 83 84 77 76 8 6 19 61 74 75 78 79 27 33 30 36 37 67 68 40 41 43 44 69 45 47 86 48 51 90 91 52 46 85 50 88 87 35 38 39 20 10 55 57 58 92 93 94 12 13 14 15 59 98 97 99 32 42 82 49 56 71 70 Anti corrosion steel panels High tensile steel panels Indicates 590MPa high tensile steel panels Indicates 980MPa ultra high tensile steel panels 34 96 95 ...

Page 5: ...or 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...

Page 6: ...ide rail inner B Roof side rail support AB601102AC Center pillar reinforcement Center pillar inner upper Rear door hinge reinforcement support Rear door hinge reinforcement Side outer panel C AB700536 D AB Roof side rail inner Roof side rail reinforcement rear Side outer panel AB601099 E AC Front end crossmember upper Front end crossmember lower Front end crossmember bulkhead AB700537AB F Front do...

Page 7: ...reinforcement outer front Side outer panel Front pillar inner lower Side sill inner support front AB700539AB J Side sill reinforcement outer rear Side outer panel Front floor side sill inner Rear floor side sill inner AB700540AB K Rear pillar reinforcement lower Rear wheel house panel inner Quarter inner panel Side outer panel Quarter panel extension lower outer AB601110AC L Rear bumper reinforcem...

Page 8: ...ILITY 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 ...

Page 9: ...o 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 ...

Page 10: ... 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 3 1 4 7 5 6 2 AB A 9 8 10 9 8 7 5 3 9 0 2 0 N m 80 17 in lb 20 5 N m 15 3 ft lb 1 Front bumper reinforc...

Page 11: ...acket has been adopted to efficiently absorb energy upon impact by the crushable structure and improve the pedestrian protection capability AB700410 1 16 20 24 7 8 23 AB 22 28 21 4 3 2 26 19 18 17 15 9 13 14 10 12 25 6 5 27 11 Right side AB700409 30 31 AB 34 29 23 28 27 20 26 1 4 3 2 6 5 7 8 15 9 13 14 12 16 32 33 10 Left side ...

Page 12: ...Spring house bracket reinforcement 14 Spring house bracket front 15 Spring house panel rear 16 Spring house reinforcement rear 17 Horn bracket 18 Spring house harness bracket 19 Suction hose bracket 20 Spring house panel 21 Power steering reservoir tank bracket 22 Engine mounting bracket upper 23 Front fender shield 24 Engine mounting gusset 25 Condense tank reinforcement 26 Fender gusset 27 Front...

Page 13: ...3 2 9 8 12 10 19 16 6 18 14 1 AB 17 21 5 20 4 15 7 22 23 24 11 Indicates 590MPa high tensile steel panels Right side AB700929AC 21 12 5 6 13 15 16 A B 17 22 10 4 23 11 1 Front sidemember extension 2 Front sidemember outer 3 Front brake hose bracket 4 Front sidemember reinforcement rear lower 5 Front sidemember rear bulkhead 6 Front sidemember rear 7 Height sensor bracket 8 Dash crossmember extensi...

Page 14: ...ie down reinforcement front 5 Front sidemember rear 6 Front sidemember rear bulkhead 7 Front sidemember reinforcement rear lower 8 Front sidemember outer 9 Front brake hose bracket 10 Front sidemember extension 11 Front sidemember plate 12 Front suspension crossmember bracket front 13 Front sidemember inner 14 Front sidemember brace upper 15 Transaxle mounting bracket 16 Connector bracket 17 Headl...

Page 15: ...front pillar by the upper frame to front pillar brace AB700583AC 13 20 A 8 15 22 AB700584 8 14 AC 13 B 19 12 AB602289 5 6 10 AC 9 7 8 4 1 3 2 14 12 11 13 1 Cowl top panel lower 2 Wiper B bracket 3 Cowl top stay bracket rear 4 Cowl top outer reinforcement upper 5 Cowl top panel inner 6 Cowl top panel outer 7 Deck crossmember stay bracket 8 Brake pedal support bracket 9 Clutch pedal support bracket ...

Page 16: ...34AB 2 3 12 9 10 6 1 5 4 11 7 8 14 13 Indicates 590MPa high tensile steel panels 15 16 1 Brake tube bracket 2 Harness bracket 3 Dash crossmember center 4 Dash crossmember extension 5 Canister bracket 6 Dash heat protector bracket 7 Dash panel 8 Backbone reinforcement front 9 Dash panel lower 10 Accelerator pedal bracket 11 Steering shaft bracket 12 Dash panel reinforcement 13 Clutch pedal reinforc...

Page 17: ...the roof rail exten sion A rear shelf lower brace is used to connect the spring house middle panel and rear shelf upper brace so that the body rigidity handling stability and riding comfort are improved The number of the spot welding points at the door opening has been increased to heighten the body rigidity and to improve handling stability AB700954AB 1 2 3 5 6 7 8 9 10 4 13 14 15 16 17 18 11 12 ...

Page 18: ...iddle front panel Left side 33 Filler pipe mounting bracket Left side 34 Spring house middle panel 35 Harness bracket Left side 36 Rear wheel house panel inner 37 Rear wheel house panel front lower outer 38 Curtain air bag bracket 39 Quarter panel lower inner Left side 40 Quarter inner panel 41 Quarter panel extension inner 42 Quarter panel extension lower outer 43 Rear combination light housing 4...

Page 19: ...00608AB Side sill reinforcement outer front Side sill reinforcement outer rear Rear pillar reinforcement lower Roof side rail reinforcement front Front pillar reinforcement lower Rear pillar reinforcement Roof side rail reinforcement rear Center pillar reinforcement AB700406 1 2 3 4 5 AB 6 7 18 7 N m 13 5 ft lb 1 Washer tank bracket upper 2 Rear seat hook A 3 Rear shelf panel 4 Rear shelf reinforc...

Page 20: ...he roof rail front and the roof bow center to heighten body rigidity improve handling stability and riding comfort and to reduce vibration and noise The 590 MPa class high tensile strength steel panel has been adopted for the roof bow center lower to improve the body rigidity Vehicles with out sunroof aluminum panel AB700570AB 1 2 3 4 5 5 0 1 0 N m 44 9 in lb 1 Rear bumper side bracket 2 Rear end ...

Page 21: ...luminum panel AB700863AE 11 13 12 10 14 3 4 5 2 1 6 1 Vehicles with sunroof steel panel 1 Sunvisor bracket 2 Reading light bracket 3 Roof rail front lower 4 Roof rail front upper 5 Roof panel 6 Roof rail rear 7 Roof bow center upper 8 Roof bow center lower 9 Dome light bracket 10 Roof panel reinforcement 11 Set rear bracket 12 Bracket A 13 Bracket B 14 Set front bracket ...

Page 22: ...16 Indicates 590MPa high tensile steel panels Indicates 980MPa ultra high tensile steel panels 1 Front floor 2 Front floor crossmember front reinforcement 3 Front floor crossmember front 4 Parking brake lever reinforcement 5 Backbone reinforcement 6 Parking brake cable reinforcement 7 Seat center bracket rear 8 Front floor crossmember rear 9 Seat side bracket rear 10 Seat belt reinforcement 11 Fro...

Page 23: ...B 1 3 4 2 6 8 9 12 14 11 15 13 5 10 16 7 11 16 17 Indicates 590MPa high tensile steel panels 1 Rear floor extension 2 Rear seat under floor 3 Rear floor pan rear 4 Rear seatback bracket lower 5 Rear floor crossmember upper 6 Battery bracket rear floor front 7 Battery bracket rear floor 8 Spare tire bracket 9 Rear floor rear end crossmember 10 Rear floor crossmember front 11 Fuel tank rear bracket ...

Page 24: ... the rear floor sidemember reinforcement rear floor sidemember extension rear floor side sill inner and rear floor sidemember bulk head to improve the body rigidity AB700942AB 3 4 18 21 29 13 15 27 22 25 28 30 9 7 12 6 24 1 8 31 32 33 23 10 5 26 16 17 20 19 11 2 14 Indicates 590MPa high tensile steel panels AB700587 AB700953AC 31 29 6 22 11 10 27 A B 24 25 20 19 30 28 15 12 23 18 ...

Page 25: ...support 14 Canister bracket Left side 15 Rear spring house panel lower 16 ABS sensor bracket 17 Brake hose bracket 18 Rear floor side sill inner 19 Rear suspension bracket front 20 Trailing arm bracket lower 21 Rear floor sidemember lower 22 Rear floor sidemember extension front 23 Rear tie down plate 24 Rear floor sidemember bulkhead 25 Trailing arm bracket 26 Trailing arm bulkhead 27 Rear floor ...

Page 26: ...ner 4 Front door side door beam 5 Front door window front sash 6 Front door window upper sash 7 Front door window rear sash 8 Front door latch reinforcement 9 Front door beltline inner reinforcement 10 Front door mirror reinforcement 11 Front door inside handle bracket 12 Nut plate 13 Front door checker reinforcement 14 Front door panel inner 15 Rear door panel outer 16 Rear door beltline outer re...

Page 27: ... the same performance as a steel sheet sandwich type and refers to a heat cured resin sheet that is molded into a sheet with a uniform thickness It contains degenerating resin and filler with asphalt and rubber as the main contents NOTE indicates the number of melting sheets that are used for repair AB700568AB GSR AB700568 AB700569AB MR 1 6 mm 0 063 in thick MD 12 Place a 1 6 mm 0 063 in melting s...

Page 28: ...m material may burn when heated Always observe the following instructions Never use a gas burner to burn the areas where sound dampening foam material is used When cutting the parts which are provided with sound dampening foam material ensure to use tools air saw etc that do not gener ate fire If there are residual sound dampening foam material remaining on the cut section body side remove the sou...

Page 29: ...er on the inner side of the rear door panel outer have been adopted for higher sur face rigidity NOTE The main contents of a stiffener are epoxy resin It comes in a sheet form and contains a mixture of glass fiber and filler and cures stiffens when heated No spare part of the stiffener for repair is avail able in the field If the stiffener is damaged replace it together with the panel AB700461 AB7...

Page 30: ...Trunk lid Bumpers Side outer panel Doors In addition a theft protec tion label is attached to replacement parts for main outer pan els The same data is stamped into replacement parts for the engine and the transaxle CAUTION Cautions regarding panel repairs When repainting original parts do so after first masking the theft protection label After painting be sure to peel off the masking tape The the...

Page 31: ...THEFT PROTECTION TSB Revision BODY CONSTRUCTION 1 29 LOCATIONS AC710510 D A B F E D AC E F C ...

Page 32: ...AC609841 Engine AB x AC612304AB y AC708134 x y AB Manual transaxle M T AC707965 x AB Twin clutch sportronic shift transmission TC SST y b b a a x y AC608723 View A Front fender The illustration indicates left outer side Right side is symmetrically opposite Section a a Section b b AB AC708456 AC708344 View B Hood x y AB ...

Page 33: ...HEFT PROTECTION TSB Revision BODY CONSTRUCTION 1 31 Label area x for original equipment parts y for replacement parts AC612302 View C Trunk lid x y AB AC710511 x AB View D Front bumper AC710513 View D y ...

Page 34: ... outer side Right side is symmetrically opposite AB x AC611136 View F The illustration indicates left outer side Right side is symmetrically opposite AB y AC608731AC Front door both side G c c x View G Section c c y The illustration indicates left outer side Right side is symmetrically opposite AC608734 Rear door both side H d d x View H Section d d y The illustration indicates left outer side Rig...

Page 35: ...UREMENT METHODS 2 2 TYPE A PROJECTED DIMENSIONS 2 4 UNDER BODY 2 4 SUSPENSION INSTALLATION DIMENSIONS 2 8 TYPE B ACTUAL MEASUREMENT DIMENSIONS 2 10 UNDER BODY 2 10 SUSPENSION INSTALLATION DIMENSIONS 2 12 FRONT BODY 2 14 SIDE BODY 2 18 REAR BODY 2 20 INTERIOR 2 22 ...

Page 36: ...measuring tape etc NOTE Make the lengths of the tracking gauge probes the same A Aí Do not bend or twist the measuring tape Insert the tracking gauge probes securely into the measure ment holes When the standard dimensions in the illustration are enclosed by rectangle this indicates that the symmetrical left and right positions have the same dimensions When using a notch for dimension measurement ...

Page 37: ...BODY DIMENSIONS AND MEASUREMENT METHODS TSB Revision BODY DIMENSIONS 2 3 NOTES ...

Page 38: ... 44 0 1 028 40 5 1 124 44 3 1 138 44 8 1 218 48 0 1 025 40 4 1 080 42 5 1 369 53 9 1 254 49 4 1 195 47 0 1 342 52 8 1 120 44 1 1 079 42 5 763 30 0 641 25 2 686 27 0 No Standard measurement point Hole shape Size mm in 1 Center of front end crossmember lower water draining hole left side Round 8 0 31 2 Center of front end crossmember lower water draining hole right side Round 8 0 31 3 Center of fron...

Page 39: ...nd 16 0 63 12 Center of rear floor sidemember lower positioning hole rear Round 25 0 98 13 Center of rear floor sidemember extension water draining hole left side Center of rear shipping bracket mounting hole right side Round 14 0 55 No Standard measurement point Hole shape Size mm in AB700418AB 5 3 4 6 7 8 9 10 12 11 13 1 2 mm in 105 4 1 100 3 9 157 6 2 105 4 1 230 9 1 154 6 1 347 13 7 354 13 9 3...

Page 40: ...TYPE A PROJECTED DIMENSIONS TSB Revision BODY DIMENSIONS 2 6 AB700474AB 10 AB700475AB 11 12 12 11 AB700973AB 13 ...

Page 41: ...TYPE A PROJECTED DIMENSIONS TSB Revision BODY DIMENSIONS 2 7 NOTES ...

Page 42: ...3 9 1 323 52 1 No Standard measurement point Hole shape Size mm in 4 Center of front axle crossmember mounting hole front Round 15 5 0 61 5 Center of front sidemember rear water draining hole Round 16 0 63 9 Center of front floor sidemember positioning hole rear Round 16 0 63 14 Center of front shock absorber mounting hole Round 80 3 15 15 Center of front axle crossmember mounting hole rear Round ...

Page 43: ...34 3 06 0 AB A B 4 5 9 15 16 17 14 18 20 19 1 087 42 8 540 21 3 100 3 9 mm in Vehicle center Vehicle center 767 30 2 294 11 6 510 20 1 284 11 2 354 13 9 162 6 4 217 8 5 105 4 1 1 223 48 1 1 066 42 0 464 18 3 489 19 3 785 30 9 187 7 4 187 7 4 683 26 9 Standard line AB700472 4 AB AB700479 5 15 AB 15 5 AB601180 9 AB AB700478AB 14 AB700480 16 17 16 17 AB AB700481 18 20 20 18 AB ...

Page 44: ... 34 5 990 39 0 487 19 2 1 262 49 7 567 22 3 378 14 9 350 13 8 644 25 4 mm in 1 022 40 2 545 21 5 399 15 7 460 18 1 894 35 2 101 4 0 102 4 0 616 24 3 616 24 3 222 8 7 348 13 7 669 26 3 740 29 1 856 33 7 932 36 7 AB700577 1 2 3 4 6 5 7 9 10 11 12 13 8 AB 566 22 3 960 37 8 971 38 2 966 38 0 1 415 55 7 1 118 44 0 1 046 41 2 1 124 44 3 1 225 48 2 1 027 40 4 1 080 42 5 1 371 54 0 1 255 49 4 1 209 47 6 1...

Page 45: ...0 43 7 Center of propeller shaft mounting hole right side Round 11 0 43 8 Center of front floor sidemember positioning hole front Round 16 0 63 9 Center of front floor sidemember positioning hole rear Round 16 0 63 10 Center of rear floor sidemember lower positioning hole front Oblong 33 9 18 1 335 0 71 11 Center of rear suspension bracket front water draining hole Round 16 0 63 12 Center of rear ...

Page 46: ... 47 4 1 120 44 1 1 120 44 1 1 333 52 5 No Standard measurement point Hole shape Size mm in 4 Center of front axle crossmember mounting hole front Round 15 5 0 61 5 Center of front sidemember rear water draining hole Round 16 0 63 9 Center of front floor sidemember positioning hole rear Round 16 0 63 15 Center of front axle crossmember mounting hole rear Round 15 5 0 61 16 Center of trailing arm mo...

Page 47: ...TYPE B ACTUAL MEASUREMENT DIMENSIONS TSB Revision BODY DIMENSIONS 2 13 AB700472 4 AB AB700479 5 15 AB 15 5 AB601180 9 AB AB700480 16 17 16 17 AB AB700481 18 20 20 18 AB ...

Page 48: ...16 7 509 20 0 327 12 9 Body center point 401 15 8 1 060 41 7 336 13 2 329 13 0 392 15 4 891 35 1 391 15 4 901 35 5 913 35 9 1 438 56 6 1 486 58 5 1 494 58 8 1 Vehicles without sunroof aluminum panel 2 Vehicles with sunroof steel panel Body center point mm in 877 34 5 901 35 5 AB700602AB 21 23 22 24 25 28 30 31 34 35 36 38 26 27 29 32 33 37 1 449 57 0 819 32 2 1 558 61 3 896 35 3 781 30 7 732 28 8 ...

Page 49: ...ower Round 9 0 35 27 Center of front bumper reinforcement mounting hole right upper Round 9 0 35 28 Center of front sidemember inner positioning notch left side 29 Center of front sidemember inner positioning notch right side 30 Center of headlight support panel upper mounting hole left front Round 6 6 0 26 31 Center of headlight support panel upper mounting hole left rear Round 6 6 0 26 32 Center...

Page 50: ...ODY DIMENSIONS 2 16 AB700488 21 22 21 22 AB AB700489 23 AB AB700434 24 25 25 24 AB AB700435 26 27 27 26 AB AB700436 28 AB AB700437 29 AB AB601016 30 31 31 30 AB AB700438 32 33 33 32 AB AB601020 34 35 35 34 AB AB700439 36 AB AB601022 37 AB AB700440 38 AB ...

Page 51: ...TYPE B ACTUAL MEASUREMENT DIMENSIONS TSB Revision BODY DIMENSIONS 2 17 AB601235 39 AB AB700849 40 AB AB601024 41 AD ...

Page 52: ... 9 640 25 2 No Standard measurement point Hole shape Size mm in 42 Front pillar positioning notch upper 43 Front pillar positioning notch lower 44 Roof side rail positioning notch front 45 Side sill positioning notch front 46 Center pillar positioning notch upper 47 Center pillar positioning notch lower 48 Roof side rail positioning notch rear 49 Side sill positioning notch rear 50 Quarter panel p...

Page 53: ... door lower hinge mounting hole Round 11 0 43 56 Center of rear door switch mounting hole Round 5 0 20 No Standard measurement point Hole shape Size mm in AB601025 42 AC AB700484 43 53 43 53 AB AB601027 44 46 44 46 AC AB601028 45 AC AB601030 47 55 47 55 AC AB601031 48 AC AB700485 49 AB AB601033 50 AC AB700486 51 56 51 56 AB AB700487 52 AB AB601029 54 AC ...

Page 54: ...6 1 244 49 0 198 7 8 1 252 49 3 1 190 46 9 1 100 43 3 655 25 8 1 268 49 9 990 39 0 117 4 6 Body center point AB700991AB 59 61 60 62 64 63 65 66 67 Body center point 1 346 53 0 606 23 9 1 050 41 3 295 11 6 649 25 6 1 232 48 5 1 189 46 8 1 458 57 4 761 30 0 778 30 6 505 19 9 507 20 0 No Standard measurement point Hole shape Size mm in 57 Corner of roof panel Vehicles without sunroof aluminum panel 5...

Page 55: ...riker mounting hole left side Round 6 6 0 26 65 Center of trunk lid latch striker mounting hole right side Round 6 6 0 26 66 Center of rear bumper reinforcement mounting hole upper Round left side Oblong right side 15 0 59 left side 15 17 0 59 0 67 right side 67 Center of rear bumper reinforcement mounting hole lower Round 15 0 59 No Standard measurement point Hole shape Size mm in AB700850AB 57 A...

Page 56: ... 1 1 357 53 4 mm in 1 430 56 3 1 430 56 3 1 430 56 3 1 430 56 3 1 430 56 3 AB700600 68 45 43 42 44 50 47 46 48 69 51 49 AB 1 179 46 4 1 073 42 2 735 28 9 783 30 8 1 135 44 7 1 059 41 7 1 130 44 5 1 190 46 9 720 28 3 834 32 8 Body center point Body center point AB700462AB 71 70 59 69 1 004 39 5 659 25 9 720 28 3 593 23 3 1 076 42 4 1 067 42 0 Body center point Body center point ...

Page 57: ... notch lower 48 Roof side rail positioning notch rear 49 Side sill positioning notch rear 50 Quarter panel positioning notch upper 51 Quarter panel positioning notch lower 59 Body center point of rear shelf panel 68 Center of parking brake lever mounting hole Body center point Round 11 0 43 69 Body center point of rear floor extension 70 Center of rear shock absorber mounting hole Round 14 0 55 71...

Page 58: ...TYPE B ACTUAL MEASUREMENT DIMENSIONS TSB Revision BODY DIMENSIONS 2 24 AB700485 49 AB AB601033 50 AC AB700858 51 AB AB601056AC 59 AB601063 68 AC AB700463 69 AB AB700464 70 AB AB700465AB 71 ...

Page 59: ...dard measurement point Hole shape Size mm in 72 Center of deck crossmember mounting hole left upper Round 13 0 51 73 Center of deck crossmember mounting hole left lower Round 13 0 51 74 Center of deck crossmember mounting hole right upper Round 9 0 35 75 Center of deck crossmember mounting hole right lower Round 9 0 35 AB601067 72 73 72 73 AC AB601066 74 75 74 75 AC ...

Page 60: ...NOTES ...

Page 61: ...ING DIMENSIONS FOR OPENINGS 9 25 STANDARD PROCEDURES FOR SHEET METAL WORK 9 26 USING A FRAME STRAIGHTENER 9 27 FRAME REPAIR PROCEDURES 9 28 NOTES REGARDING REPAIR WORK 9 31 HEAT WITHSTAND TEMPERATURES OF RESIN PLASTIC PARTS 9 34 HOW TO DISTINGUISH TYPES OF PLASTICS 9 36 CORROSION PROTECTION 9 37 ANTICORROSION TREATMENT AT THE FACTORY 9 37 ANTICORROSION TREATMENT AT THE TIME OF BODY REPAIR WORK 9 4...

Page 62: ...nection is made by applying external pres sure while the part where the weld is to be made is in a molten or semi molten condition BRAZING Brazing is a method of welding in which the weld connection is made by supplying a filler metal which is molten at a temperature lower than the melting temperature of the base metal at the place where the joining is to be made without melting the base metal its...

Page 63: ...welds is short there is little occurrence of distortion of the panel due to heat PROCEDURE There are three basic stages in electric resistance spot weld ing 1 Initial pressure application stage This stage precedes the current application Applying pressure to the steel panels through the electrode tips ensures a uniform contact resistance and a smoother current flow 2 Current application stage Whil...

Page 64: ...m 0 063 inch continues to increase proportionately between points B and C however for thin panels 1 6 mm 0 063 inch or less the weld strength reaches a peak very quickly and will increase only slightly even if the current level increases between points B and C Then for both thick panels and thin panels the mol ten metal will scatter if the current level increases past a certain point AB301468 Smal...

Page 65: ...e short circuit diverted to the previous weld point and the strength of the individual nuggets will be insuf ficient Make the spot welds at the center of the flanges to provide sufficient adhesion When welding at an edge make the spot welds at least 5 mm 0 2 inch from the edge of the flange The number of spot weld points should be the same as or slightly more than the number of original repair wel...

Page 66: ...d points should therefore be ten or eleven If however a pitch of 26 mm 1 02 inch or more cannot be maintained the plug welding method eight weld points should be used Panel thickness mm in Number of repair weld percentage of factory weld Safety equipment area 1 0 0 04 or less 100 Same number as factory welds 1 2 0 047 150 Maintain pitch of at least 22 mm 0 87 inch if not possible plug weld 1 4 0 0...

Page 67: ...rection indi cated by the arrows in the illustration and determine the strength of the weld 1 Good The welded part remains at one side 2 and 3 The weld conditions are unsatisfactory adjust the welding current the current application time and or the applied pressure Panel thickness mm in Number of repair weld percentage of factory weld Safety equipment area 0 9 0 035 or less 100 Same number as fact...

Page 68: ...43 Gas shielded arc welding is one method of arc weld ing In this method while the area to be welded is shielded from the air by a layer of inert gas such as argon or carbon dioxide gas the filler metal wire is fed from the torch nozzle at a constant rate and an electric arc is generated between the tip of the wire and the area being welded thus generating heat to fuse the area There are two types...

Page 69: ...zed and will stop automatically when the weld is complete FEATURES OF MIG SPOT WELDING In comparison to resistance spot welding MIG spot welding has the following advantages and disadvan tages AB200036 Gas cup Gas outlet Wire AE Item Mig spot welding Electric resistance spot welding Working characteristics Light weight Welding possible at various positions no limit upon welding positions Although ...

Page 70: ...2 0 24 inch in diameter in one of the panels to be welded together position ing the torch at a right angle to the holes and then filling in the holes one at a time Welding strength Depends on strength of welding wire itself Same as base material Little oxidation Uniform welding quality Weld traces Button head slightly convex Slight concave Almost no indentation if swivel tip used Re repairability ...

Page 71: ...at a distance of 6 10 mm 0 24 0 39 inch from the surface being welded Preventing warping 1 Backhand technique Because the direction for each weld pass and that for the fusion progression are opposite the residual stress is evenly distributed 2 Symmetrical technique Because the welds are made in symmetrical positions in relation to the center of the joint the residual stress is also symmetrical 3 S...

Page 72: ...panels Note that if two panels of dif ferent kinds of metal are brazed the electrolysis gen erated between the two metals will cause moisture to from which will result in corrosion Panels should not be connected together by brazing at any place except those places indicated The fol lowing materials filler metals are usually used for brazing 1 Brass filler metal brass solder Brass filler metal is a...

Page 73: ...rbon in the acetylene is burned completely resulting in the maximum obtainable temperature This is the flame most commonly used for weld ing 3 Peroxide flame oxygen rich flame This flame has an excess of oxygen or a defi ciency of acetylene The flame core is shorter and sharper and the entire flame has a black ish purplish color The combustion is unstable and the flame flickers continuously Notes ...

Page 74: ... which are not be replaced or any other such parts There are harnesses hoses and other such parts routed inside the front pillar the rear pillar the fender shield the side sill etc perform the repair work only after any such material has been removed For overlap cutting allow an overlap of approximately 30 50 mm 1 18 1 97 inches when performing the cutting operation 1 Rough cutting of panels First...

Page 75: ...ng of brazing and arc welds Heat only the brazed or arc welded portion such as the upper portion of pillars etc and then separate by using a screwdriver while melting occurs 5 Finishing work of spot welding Grind and smooth any weld traces which might be left on the body surface by using an air grinder or similar tool being careful not to damage any of the panels which is not to be replaced When p...

Page 76: ...r tool 9 Rough cutting of new parts Cut off the unnecessary portions of new parts Allow an overlap of approximately 30 50 mm 1 18 1 97 inches when performing overlap cutting of the pillars side sills or other locations CAUTION Carefully select the location for cutting taking care not to cut a reinforcement at the inner side of a pillar etc or a panel that is not to be replaced 10 Overlap cutting o...

Page 77: ...in order to obtain maximum strength Three layer construction When cutting a front pillar or center pillar which has a three layer including a reinforcement construction dou ble box construction cut the outer panel and the reinforce ment at the same position and don t forget to butt weld the reinforcement If the inner panel is an assembly replace ment part cut it at two places in order to provide a...

Page 78: ...ctions necessary in order to obtain agreement with the measurements 2 In addition make temporary welds and then check to confirm that the closing and fit of the doors fenders etc are correct For parts which should be symmetrical to the body center measure the distances from the body center point to both the left part and the right part and confirm that the distances are the same CAUTION Weld compl...

Page 79: ...or plug welding in the new parts and then MIG weld Because the quality of the fusion varies according to the size of the holes they should be about 5 6 mm 0 2 0 24 inch in diameter In addition be sure the two surfaces are in complete contact with each other by using vise grip pliers to securely hold them NOTE Depending on the working conditions it might also be necessary to make holes in the panel...

Page 80: ...he outer panel be sure to apply an anticorrosion agent 19 Finishing work for butt welding and plug welding Do the finishing work to smooth the protruding weld traces However the butt joints of reinforcements and other internal parts will be stronger if the weld traces are not finished 20 Application of body sealant Apply a coating of sealant carefully without breaks as described in the section of ...

Page 81: ...m which the paint coat was removed The paint coat of welded areas will have been damaged by the heat be sure to apply an anticorrosion agent to surfaces to be repaired Use an aerosol type anticorrosion agent for application to the side sills the pillars and other similar parts which have a hollow construction by utilizing the trim mounting holes etc 22 Application of undercoating If the underbody ...

Page 82: ... parts Fuel pipe Brakes Fuel tank installation parts etc 2 Because seat belts are directly related to driver and passenger safety any welds of seat belt anchor points or reinforcements must be done with particular care in order to maintain strength PREVENTION OF CORROSION AND OF WATER OR DUST ENTRY 1 After any work is completed it is important to completely remove any welding residue particles or ...

Page 83: ...praying In addition remember to peel off the masking tape after completion of the respray 2 Because theft protection labels on the supplementary parts are covered with masking tape already they can be resprayed just as they are 3 Take care not to peel off the theft protection labels from either the original or the supplementary parts HOW TO PEEL OFF THE SURFACE MASKING FILM FROM THE THEFT PROTECTI...

Page 84: ...peeled off in the course of replacement or repair of a welded panel cut and attach replacement material in the shape shown in the figure For detailed infor mation concerning the locations where silencers are to be attached for individual models refer to the manual for that model 1 Heat the silencer layer petroleum asphalt sheet with a blow drier to soften it AB200097 AD Dash panel interior side Th...

Page 85: ... to heat both the silencer layer and the body panels be sure to wear gloves POSITIONING DIMENSIONS FOR OPENINGS M4090010000045 When replacing the panel of the opening of the front pillar center pillar and other openings make a point to securely bite the poltapower etc so the position of the opening is not off center Upon assembling adjust the opening dimensions to the standard speci fications and ...

Page 86: ...el surface If so clean it away CAUTION The surface of the hammer and dolly must be free of scars etc 2 Select the appropriate hammer and dolly to be used according to the panel shape CAUTION Care should be taken as far as possible not to permit the panel plates to become elongated 3 Use the hammer and dolly to repair the dents and other uneven surfaces of the panel 1 First repair the larger areas ...

Page 87: ...upon the method of repair especially regarding the initial overall repair by following the steps below OVERALL ROUGH REPAIRS 1 First analyze the impact This means analysis and consideration of the point of collision the speed at the time of collision and the strength weight and shape of the object hit 2 Then get a complete understanding of the condition of the existing damage In particular if the ...

Page 88: ... high tensile steel that the pulling not be all done at one time pull gradually while using a hammer to repair distorted areas as the pulling is done FRAME REPAIR PROCEDURES M4090014000047 The frame is subjected to the following types of loads Vertical loads Vertical loads may occur either while stopped or during travel Lateral horizontal loads This type of loads occurs during turning start off an...

Page 89: ...hing be careful not to grind the frame excessively 5 Using a grinder for finishing after welding CAUTION The reinforcement plate should completely cover the cracked part The reinforcement plate should be the same thickness and material as the frame 6 To avoid a concentration of stress prepare a reinforcement plate that has been cut to 30 45 degree angle at both ends AB301469 Crack stop hole Crack ...

Page 90: ...rder to avoid a concentration of stress at the time weld the reinforcement plate at points about 10 mm 0 39 inch from its edges NOTE If the crack is at the upper side of the frame attach the reinforcement plate facing downward as shown in 1 If the crack is at the lower side attach the reinforcement plate to face upward as shown in 2 8 Finally apply a coating of chassis black to the repaired area a...

Page 91: ...ning labels must be heeded when servicing or handling SRS components 4 Always use the designated special tools and test equipment 5 Store components removed from the SRS in a clean and dry place The air bag module should be stored on a flat surface and placed so that the pad surface is facing upward 6 Never attempt to disassemble or repair the SRS components SRS ECU air bag module and clock spring...

Page 92: ...ment having a memory function will be cleared when the battery cable is disconnected NOTE Vehicles today include a great many electronic parts and components and these are in general very susceptible to adverse effects caused by overcurrent reverse current elec tromagnetic waves high temperature high humidity impacts etc In particular such electronic components can be damaged if there is a large c...

Page 93: ... exposure to the skin of adhe sives organic solvents etc If an unavoidable exposure occurs the exposed area should be immediately washed with clean water VEHICLE PROTECTION Vehicle covers fender covers seat covers etc and tape if there is the possibility of damage by tools equipment etc should be used to protect painted surfaces interior exterior parts and components etc from staining and damage F...

Page 94: ...e terephthalate PBT 120 248 Dome light lens Headlight lens Polyethylene PE 100 212 Heater duct Fender liner Washer tank High density polyethylene PE HD HDPE 70 90 158 194 Fuel tank Splash shield Phenole formaldehyde PF 170 190 338 374 Ashtray Polymethyl methacrylate PMMA 80 100 176 212 Light lens Polyacetal POM 120 248 Door regulator handle Ball joint seat Polypropylene PP 80 176 Glove compartment...

Page 95: ...tate E VAC EVA 60 140 Mud guard Talc filled polypropylene PP E P TD HMPP 80 100 176 212 Bumper face Side air dam Side protector molding Polyvinyl chloride Polyurethane PVC PUR E 2 Instrument panel pad Thermoplastic elastomer styrene Talc filled polypropylene TES PP TD 100 120 212 248 Side splash Polycarbonate Acrylonitrile butadiene PC ABS 120 125 248 257 Door outside handle Polycarbonate Polyethy...

Page 96: ...l piece where the scar can t be seen and burning it to judge by the way it burns etc The following is an outline of the burning method which is a relatively simple method Plastic name Abbreviation Flame color Combustion Conditions Self extinguishing Odor Polyvinyl chloride PVC Yellow flame top Blue flame bottom Burns to black residue Yes Irritating acid odor Polyethylene PE Yellow flame top Blue f...

Page 97: ...s used in areas which have a high possibility of painting deficiency ZINC PHOSPHATE COATING In order to improve the adhesive properties of the paint coat on the steel plate and also to improve the finish of the paint coat the entire body is coated with a film of zinc phosphate prior to undergoing the electrodeposition undercoating process 1 Final coat 2 Intermediate coat 3 Anticorrosion primer 4 U...

Page 98: ...ined are much better than those from conventional anionic electrodeposition BODY SEALING Sealant has been applied to all body panel joints and seams in order to provide resistance to water dust and corrosion UNDERBODY COATING An underbody coating has been applied to the underside of the floor pans the inside of the doors etc in order to provide resistance to vibration corrosion and wear AB200110AD...

Page 99: ...ect ANTICORROSION PRIMER Anticorrosion primer is used at the side sill outer pan els in order to prevent corrosion and to suppress vibration SEALING TAPE Sealing tape is attached at unused holes at the inner side of the panel for waterproofing and anticorrosion protection AB200113 AB701034 1 Rocker panel primer application AB 1 1 A A AB701034 AB301463AF AB301463 Locations for attachment of sealing...

Page 100: ...ides of hollow parts such as the side sill pillars etc which have been welded are more susceptible to corrosion Spray an aerosol type anticorrosion agent into these parts by using the trim mounting holes and other openings ANTICORROSION TREATMENT OF ROUGH CUTS An anticorrosion agent should be applied to rough cuts made in the course of welding because the surface film has been dam aged by the heat...

Page 101: ...of sealant is not applied to each of the panel joints and seams Insufficient sealant will result in water leakage corrosion etc NOTE Use a piece of clean cloth dampened in lead free gaso line or a similar material to clean parts and areas where sealant is applied When applying sealant to areas at which the external appearance is important areas which can be seen or where the condition of the paint...

Page 102: ...he area around the place where undercoating is to be applied before applying it Be sure not to apply the undercoating to tires or to the drive shaft and other drive components If the undercoating application inside the wheel housing on the under body etc is insufficient it can result in corrosion Be sure therefore to apply a good coating of undercoating to such parts after repairs are completed AB...

Page 103: ...aller Crack tear length 200 mm 7 8 in or smaller Scratch length 200 mm x width 120 mm 7 8 x 4 7 in or smaller 1 Cleaning 2 Reshaping of damaged area 3 Fixing of glass cloth backing 5 Base surface preparation surface grinding 6 Rough grinding 7 Filling putty application 8 Surface grinding 9 Surface preparation for primer surfacer 12 Primer surfacer coating 13 Primer surfacer grinding 10 Cleaning an...

Page 104: ...nches or smaller UNREPAIRABLE COMPONENTS Black base area is raw urethane base and repairable however its color does not match in color of the repair agent ash gray In this case the replacement of the bumper is preferable BUMPER REMOVAL AND CLEANING The damage of holes cracks and tears requires a repair work from the rear surface Remove the bumper to clean the whole surface degrease the front and r...

Page 105: ...hesive fix the repair area For PP apply PP primer Apply the adhesive to the glass cloth fixing area of the repair part in order to adhere the glass cloth TAPE Glass cloth tape BRAND 3M Glass Cloth Tape 6400 or equivalent ADHESIVE Urethane adhesive BRAND 3M Duramix Plastic Repair Semi rigid 4040 or equivalent 4 ADHESIVE APPLICATION Apply a resin adhesive to cover the fixing glass cloth and its surr...

Page 106: ... repair area and then remove the wax and oil completely 2 For scrape apply putty to the repair area PUTTY Epoxy resin putty BRAND 3M Automix EZ Sond Flexble Parts 5887 or equivalent PUTTY Epoxy resin putty BRAND 3M Resin Putty No 1 8120 or equivalent NOTE The amount to be applied at a time is approximately 1 5 mm 0 059 inches Therefore recoat it as needed For tear and scratch apply putty after san...

Page 107: ...y 11 MASKING To avoid splashing of primer surfacer during the coating apply masking MASKING Masking paper tape BRAND 3M Scotch Block Masking Paper or equiva lent 12 PRIMER SURFACER COATING CAUTION If an excessive amount is applied at a time or force dried in a short time the coating film may crack For color separation use masking tape While taking flash off time apply 1 to 3 times of double coatin...

Page 108: ...RIMER BRAND 3M Automix Polyolefin Adhesion Promoter 5907 or equivalent CAUTION If an excessive amount is applied at a time or force dried in a short time the coating film may crack 4 While taking flash off time apply 1 to 3 times of double coating using a spray gun 5 Dry sand with a sandpaper 240 to 300 or finer Then as a surface preparation for painting grind lightly so as not to expose the base ...

Page 109: ...9 SIDE SILL 3 23 QUARTER OUTER 3 29 REAR END PANEL 3 33 ROOF 3 34 REAR FLOOR 3 37 QUARTER INNER 3 39 QUARTER INNER PARTIAL REPLACEMENT 3 44 FRONT DOOR OUTER PANEL WELDED TYPE 3 46 FRONT DOOR OUTER PANEL ADHESION TYPE 3 47 REAR DOOR OUTER PANEL WELDED TYPE 3 48 REAR DOOR OUTER PANEL ADHESION TYPE 3 49 ALUMINUM PANEL 3 50 ALUMINUM PANEL CHARACTERISTICS 3 50 ALUMINUM PANEL LOCATIONS 3 50 ALUMINUM PAN...

Page 110: ...ngth steel plate to ensure that the spot welded area is cut off For the part in which the ultra high strength steel plate is used do not repair it by cutting and bond ing to avoid the reduction in strength by heat Instead replace the whole assembly including the part Be careful with rough extending work because the ultra high strength steel plate has higher ten sile strength and a higher yielding ...

Page 111: ...bol Operation description Spot welding MIG plug welding indicates two panels to be welded indicates three panels to be welded MIG spot welding MIG arc welding continuous Braze welding Anti corrosion agent application locations Use access holes to apply liberally to butt welded joints AB601317 A A B AB B REPAIR WELDS ...

Page 112: ...int with front end crossmem ber AB700421AB Symbol Operation description Spot welding MIG plug welding indicates two panels to be welded indicates three panels to be welded MIG spot welding MIG arc welding continuous Braze welding Anti corrosion agent application locations Use access holes to apply liberally to butt welded joints AB700993 A AB A I REPAIR WELDS ...

Page 113: ...FENDER SHIELD TSB Revision WELDED PANEL REPLACEMENT 3 5 AB700994 J E C F B AB B G C H D ...

Page 114: ...LD TSB Revision WELDED PANEL REPLACEMENT 3 6 AB700933 E F G H I AB Right side only D J With the upper frame to front pillar brace Fender shield frame upper outer and front deck frame upper outer removed Right side ...

Page 115: ... the front sidemember inner and the front body frame to side sill brace INSTALLATION When installing the new front sidemember align the hole of the front sidemember brace lower with the front sidemember outer to make a hole because the front sidemember outer prevents the front sidemember inner and front sidemember brace lower from being welded Then weld the front sidemember outer front sidemember ...

Page 116: ...ding points with the front fender Shield front AB700422 Symbol Operation description Spot welding MIG plug welding indicates two panels to be welded indicates three panels to be welded MIG spot welding MIG arc welding continuous Braze welding Anti corrosion agent application locations Use access holes to apply liberally to butt welded joints AB AB700444AB 135 mm 5 3 in REPAIR WELDS A B 275 mm 10 8...

Page 117: ...ug welding indicates two panels to be welded indicates three panels to be welded MIG spot welding MIG arc welding continuous Braze welding Anti corrosion agent application locations Use access holes to apply liberally to butt welded joints AB700449 A B C C AB B E D A F G REPAIR WELDS 40 mm 1 57 in 230 mm 9 05 in Cutting position Cutting position Sound dampening foam material Sound dampening foam m...

Page 118: ...nd dampening foam material do not use firing tools since the sound dampening foam material may burn AB700978 AB601219 AB700381 AB E F D G Cutting position Sound dampening foam material Cutting position Sound dampening foam material With the side outer panel removed With the side outer panel removed ...

Page 119: ...mm 3 9 inches above the cut area 2 Assemble the new front pillar inner lower parts 3 Assemble the new front upper inner pillar part 4 Assemble the new side sill reinforcement front parts After that cover the hole with aluminum tape to prevent the sound dampening foam material from dropping when the material is filled into the front pillar in the next process AB601206 Front pillar inner lower Side ...

Page 120: ...r 7 When installing the new front outer pillar parts machine the body loose panel cushion MR535301 or MR435765 as shown and apply it to the body side to prevent the sound dampening foam material from dropping when the material is filled into the front pillar upper in the next process for front pillar upper AB601297 AB601297AB Body loose panel cushion A A Front pillar reinforcement lower Front pill...

Page 121: ...body side because the sound dampening foam material is filled into the front pillar for front pillar lower 9 When installing the new front outer pillar parts apply the body sealant to the areas as shown in advance AB700451AB A A Body loose panel cushion 35 mm 1 37 in 30 mm 1 18 in 10 mm 0 39 in 80 mm 3 14 in 90 mm 3 54 in 110 mm 4 33 in Front pillar reinforcement lower Side outer panel AB601221AB ...

Page 122: ...und dampening foam material 3M AAD ULTRA PRO Panel foam Yellow 11 Wait 2 hours after filling the sound dampening foam material to remove the bolt and aluminum tape then melt the sound dampening foam material with a soldering gun so a clip etc can thoroughly be inserted in the hole filled with sound dampening foam material AB700452 AB601214 AC A A Front pillar reinforcement lower Front pillar inner...

Page 123: ... deck frame upper outer AB700945 Symbol Operation description Spot welding MIG plug welding indicates two panels to be welded indicates three panels to be welded MIG spot welding MIG arc welding continuous Braze welding Anti corrosion agent application locations Use access holes to apply liberally to butt welded joints AB AB700938 REPAIR WELDS B C A C AB 230 mm 9 05 in Cutting position E D A G 110...

Page 124: ...ront inner pillar lower remaining on the body side INSTALLATION 1 To reinforce the strength in the front pillar cut area cut the side outer panel 50 mm 1 97 inches above the cut area 2 Assemble the new front lower inner pillar parts AB700941 AB601219 AB D E With the side outer panel removed Cutting position AB601206 Front pillar inner lower Side outer panel 140 mm 5 51 in AD Side sill reinforcemen...

Page 125: ...the new front outer pillar machine the body loose panel cushion MR535301 or MR435765 for replacement as shown and apply it to the body side because the sound dampening foam material cannot be filled into the front pillar 6 When installing the new front outer pillar apply the body sealant to the areas as shown in advance AB601208 Side sill reinforcement front Aluminum tape AB AB700451AB A A Body lo...

Page 126: ...instructions Sound dampening foam materiaL 3M AAD ULTRA PRO Panel foam Yellow 8 Wait 2 hours after filling the sound dampening foam material to remove the bolt and aluminum tape then melt the sound dampening foam material with a soldering gun so a clip etc can thoroughly be inserted in the hole filled with sound dampening foam material AB700943AB Front pillar reinforcement lower A A Front inner pi...

Page 127: ...g MIG plug welding indicates two panels to be welded indicates three panels to be welded MIG spot welding MIG arc welding continuous Braze welding Anti corrosion agent application locations Use access holes to apply liberally to butt welded joints AB AB700944 REPAIR WELDS A B C A C B AB The same position as the new center outer part The same position as the new center outer part D D Cutting positi...

Page 128: ...he strength in the center pillar cut area cut the side outer panel 100 mm 3 94 inches above the cut area and cut the center pillar reinforcement 50 mm 1 97 inches above the cut area 2 Remove the center pillar inner lower from the new center inner pillar and install the center inner pillar to the body AB601418AB Center pillar reinforcement Side sill reinforcement outer rear Side outer panel AB60124...

Page 129: ...forcement then weld the cover of the center pillar reinforcement 5 When installing the new center outer pillar machine the body loose panel cushion MR535301 or MR435765 for replacement as shown and apply it to the body side because the sound dampening foam material cannot be filled into the front pillar AB601250AB Center pillar reinforcement 100 mm 3 94 in 50 mm 1 97 in Rear door hinge reinforceme...

Page 130: ... Sound dampening foam material 3M AAD ULTRA PRO Panel foam Yellow 7 Wait 2 hours after filling the sound dampening foam material to remove the bolt and aluminum tape then melt the sound dampening foam material with a soldering gun so a clip etc can thoroughly be inserted in the hole filled with sound dampening foam material AB601255AB A A Center pillar reinforcement Side sill reinforcement outer r...

Page 131: ... be welded indicates three panels to be welded MIG spot welding MIG arc welding continuous Braze welding Anti corrosion agent application locations Use access holes to apply liberally to butt welded joints AB700454 A AC B C A B C REPAIR WELDS 50 mm 1 97 in 65 mm 2 56 in 40 mm 1 57 in Sound dampening foam material Sound dampening foam material Sound dampening foam material ...

Page 132: ...aterial may burn NOTE Partial replacement is possible depending on the range of damage Cut the side sill reinforcement outer rear 50 mm 1 97 inches away from the cut area of the side outer panel AB700455 AB601437 D AB D With the side outer panel removed Sound dampening foam material AB601311 Cuttable range AB With the side outer panel removed Side sill reinforcement outer rear ...

Page 133: ...eres with it For the rear wheel house remove the rear wheel house panel front lower outer and quarter panel extension inner because the quarter panel extension inner interferes with the rear wheel house panel front lower outer 2 After removing the side sill reinforcement outer rear remove the center pillar inner lower AB700456 AB601296 AB601302 AB 80 mm 3 15 in Quarter panel extension inner Rear w...

Page 134: ... the body 3 When installing the new front floor side sill outer machine the body loose panel cushion MR535301 or MR435765 for replacement as shown and apply it to the body side because the sound dampening foam material cannot be filled into the front pillar AB601249AC Center pillar inner upper AB601309AB Side sill reinforcement outer front AB700451AD A A Body loose panel cushion 35 mm 1 37 in 30 m...

Page 135: ...ill outer bolt and tape the hole and flange with aluminum tape then fill the hole with sound dampening foam material as shown in the figure of the instructions Sound dampening foam material 3M AAD ULTRA PRO Panel foam Yellow AB601310AB A Side outer panel Body loose panel cushion Center pillar reinforcement A 20 mm 0 8 in 35 mm 1 4 in 50 mm 2 0 in 50 mm 2 0 in 50 mm 2 0 in 75 mm 3 0 in 75 mm 3 0 in...

Page 136: ...2 hours after filling the sound dampening foam material to remove the bolt and aluminum tape then melt the sound dampening foam material with a soldering gun so a clip etc can thoroughly be inserted in the hole filled with sound dampening foam material AB100787 ...

Page 137: ...ree panels to be welded MIG spot welding MIG arc welding continuous Braze welding r Anti corrosion agent application locations Use access holes to apply liberally to butt welded joints Symbol Operation description AB AB700483 A E D AB B C A B C REPAIR WELDS 320 mm 12 6 in 35 mm 1 38 in 3 points on left side only Sound dampening foam material Sound dampening foam material ...

Page 138: ...ER OUTER TSB Revision WELDED PANEL REPLACEMENT 3 30 CAUTION When repairing the area using sound dampening foam material do not use firing tools since the sound dampening foam material may burn AB602342AD D E ...

Page 139: ...n installing the new quarter panel outer machine the body loose panel cushion MR535301 or MR435765 for replacement as shown and apply it to the body side because the sound dampening foam material cannot be filled into the wheel arch AB601738AB Body loose panel cushion A A Side outer panel Roof side rail reinforcement rear 40 mm 1 57 in 25 mm 0 984 in 185 mm 7 28 in AB700900AC A A Body loose panel ...

Page 140: ...CEMENT 3 32 3 When installing the new quarter panel outer apply the body sealant in advance to the areas as shown 4 Partial replacement is possible depending on the range of damage AB700619 Left side only AB Body sealant AB700356 Cuttable range AB ...

Page 141: ...ng MIG plug welding indicates two panels to be welded indicates three panels to be welded MIG spot welding MIG arc welding continuous Braze welding Anti corrosion agent application locations Use access holes to apply liberally to butt welded joints Symbol Operation description AB AB601442 REPAIR WELDS A A AB ...

Page 142: ...ent AB700285AB Spot welding MIG plug welding indicates two panels to be welded indicates three panels to be welded MIG spot welding MIG arc welding continuous Anti corrosion agent application locations Use access holes to apply liberally to butt welded joints Symbol Operation description Rivet AB700919AB Vehicles with sunroof steel panel Vehicles without sunroof aluminum panel Adhesive 1 Adhesive ...

Page 143: ...y install the new roof panel to the body and drill holes at riveting positions with a drill 5 mm 0 19 inch in diameter 2 Remove the roof remove burrs at the drilled holes and clean the body 3 Apply structural adhesive to the body and install the roof Adhesive Epoxyayresin adhesive Brand 3M AAD Part No 8115 or equivalent 4 Use the recommended tool to tighten the roof lid rivet by the following proc...

Page 144: ...t by the recommended tool 4 Part A of the rivet is cut and the rivet is tightened 5 After the adhesive is dried remove the excessive residues and apply body sealant to the whole rivets and the roof edge in order to prevent water leakage AB302218 AC205918 AB501314 Recommended tool Roof lid rivet A Flange surface Recommended tool 1 2 3 4 AC Roof panel AB501313 AB302189 AB302205 AC A A Body sealing R...

Page 145: ...d panel AB700429 Spot welding MIG plug welding indicates two panels to be welded indicates three panels to be welded MIG spot welding MIG arc welding continuous Braze welding Anti corrosion agent application locations Use access holes to apply liberally to butt welded joints Symbol Operation description AB AB700939AB A A D E C B REPAIR WELDS With the rear floor removed ...

Page 146: ...CEMENT 3 38 NOTE ON REPAIR WORK REMOVAL When removing the rear floor side panel cut it 290 mm 11 4 inches behind the installation hole of the child restraint bracket AB700940 C B AB E D AB700599AB 290 mm 11 4 in With the rear floor rear removed ...

Page 147: ...rter outer AB700430 Spot welding MIG plug welding indicates two panels to be welded indicates three panels to be welded MIG spot welding MIG arc welding continuous Braze welding Anti corrosion agent application locations Use access holes to apply liberally to butt welded joints Symbol Operation description AB AB700999 A AB A F B G B REPAIR WELDS With the quarter outer removed Left side only Sound ...

Page 148: ...T 3 40 AB701000AB E C D Right side C E D Right side only Right side only Right side only Right side only Right side only Right side only Right side Right side Right side With the rear pillar reinforcement and the rear pillar reinforcement lower removed ...

Page 149: ...QUARTER INNER TSB Revision WELDED PANEL REPLACEMENT 3 41 AB700546 AB G F H F Left side Right side H With the rear wheel house panel front lower outer removed ...

Page 150: ...s 2 When installing the new rear pillar reinforcement lower parts machine the body loose panel cushion MR535301 or MR435765 for replacement as shown and apply it to the body side because the sound dampening foam material cannot be filled into the rear pillar reinforcement lower AB601339AB A A Quarter panel inner Body loose panel cushion Roof side rail reinforcement rear 125 mm 4 92 in 70 mm 2 75 i...

Page 151: ...material as shown in the figure of the instructions Sound dampening foam material 3M AAD ULTRA PRO Panel foam Yellow 4 Wait 2 hours after filling the sound dampening foam material to remove the bolt and aluminum tape then melt the sound dampening foam material with a soldering gun so a clip etc can thoroughly be inserted in the hole filled with sound dampening foam material AB601338AB AB100787 ...

Page 152: ...lar reinforcement lower AB700946 Spot welding MIG plug welding indicates two panels to be welded indicates three panels to be welded MIG spot welding MIG arc welding continuous Braze welding Anti corrosion agent application locations Use access holes to apply liberally to butt welded joints Symbol Operation description AB AB700972 C A B REPAIR WELDS A B C AB With the rear wheel house panel front l...

Page 153: ...flange remains then cut and remove INSTALLATION 1 For the new quarter panel inner parts cut the wheel arch end are so that it overlaps with the flange on the body side 2 Overlap assemble and weld the quarter panel inner with the body side flange Weld at a pitch of 40 mm 1 57 inches 3 Weld the quarter panel inner then apply a body sealing in the area shown in the figure of the instructions AB700987...

Page 154: ...outer panel MIG spot weld the flange overlap section at a pitch of 50 mm 1 97 inches AB601289 AC Symbol Operation description Spot welding MIG plug welding indicates two panels to be welded indicates three panels to be welded MIG spot welding MIG arc welding continuous Braze welding Anti corrosion agent application locations Use access holes to apply liberally to butt welded joints AB700976 A REPA...

Page 155: ...ind and remove the paint from the bonded surface of the outer panel to ensure the bonding strength After the removal degrease it 2 Install the outer panel and hem it Wipe off the excessive adhesive and finish it AB601288AD Symbol Operation description Spot welding MIG plug welding indicates two panels to be welded indicates three panels to be welded MIG spot welding MIG arc welding continuous Braz...

Page 156: ...uter panel MIG spot weld the flange overlap section at a pitch of 50 mm 1 97 inches AB700852AB Symbol Operation description Spot welding MIG plug welding indicates two panels to be welded indicates three panels to be welded MIG spot welding MIG arc welding continuous Braze welding Anti corrosion agent application locations Use access holes to apply liberally to butt welded joints AB700542 A A AB R...

Page 157: ... and remove the paint etc from the bonded surface of the outer panel to ensure the bonding strength After the removal degrease it 2 Install the outer panel and hem it Wipe off the excessive adhesive and finish it AB700853AB Spot welding MIG plug welding indicates two panels to be welded indicates three panels to be welded MIG spot welding MIG arc welding continuous Braze welding Anti corrosion age...

Page 158: ...requires 1 4 times in thickness to obtain the same rigidity as the steel panel resulting in one half in weight 2 More durable Aluminum has the property of creating oxide coating on its surface when it contacts with the air This coating prevents it from being corroded 3 More heat conductive The heat conductivity of aluminum is twice as high as that of iron This means that aluminum absorbs and dispe...

Page 159: ...the material is soft choose an abrasive carefully Wear a dustproof mask and safety glasses because ground particle is light and tends to float in the air 7 If a disk sander is strongly pressed against the aluminum plate friction heat is generated resulting in exfoliation of the aluminum alloy and clogging of the disk sander with the exfoliated particles 8 Because the clogged disk sander will damag...

Page 160: ...ally the same as the steel panel However give a consid eration to the aluminum alloy characteristics 1 Repair of sheet metal 1 Heat with a burner CAUTION Heat up the panel until you feel heat with a keplar work glove on the reverse side of the panel Keep moving the burner evenly to prevent heat from concentrating in one point 2 Because hammering may stretch the panel use a mallet or plastic hammer...

Page 161: ...an appropriate abrasive to prevent the surface from deeply scratched The heating temperature should be approximately 250 C 482 F Correction of cuts and cracks If cuts cracks or holes occur in a steel sheet panel MIG weld ing with CO2 is used for repair However for an aluminum panel use MIG or TIG welding with argon gas inert gas as shielding gas for repair DEGREE OF DISTORTION CAUSED BY WELDING Ga...

Page 162: ...oat is removed CAUTION Do not over grind the base of the panel 3 Refinish the welding area by a 100 grit disk sander and then check for any faulty welding by the visible dye penetrate testing 4 Check for distortion Grind the surface with 80 to 120 grit sandpaper and then check for distortion CAUTION The heating temperature should be approximately 250 C 482 F Pay particular attention to heating bec...

Page 163: ... MIG welding however it uses a welding rod instead of electrode wire Wire diameter 1 6 mm 0 063 inch CAUTION Be careful to avoid excessive stretch of or damage to the panel Minimize the gap of the butt joint GAS WELDING OXIDE ACETYLENE If gas welding is allowed the welding can be conducted using a welding rod and flux oxide coat remover However before the welding work do sufficient practice to avo...

Page 164: ...s steel wire brush Finish with putty 1 Grind the putty applied area with a 150 to 180 grit double action sander 2 Degrease and clean the putty applied area 3 Apply 2 liquid type epoxy primer or a pretreatment agent for aluminum 4 Grind with a 180 grit double action sander for cutting action 5 Degrease and clean the putty applied area 6 Apply putty for metal sheets and dry it naturally CAUTION Do n...

Page 165: ...off of paint film 2 Cleaning and degreasing CAUTION Apply 2 liquid type epoxy primer or a pretreatment agent for aluminum to the aluminum base surface 3 Application of wash primer 4 Drying 60 C 140 F or lower 5 Application of primer surfacer 6 Drying 60 C 140 F or lower 7 Grinding 8 Cleaning and degreasing 9 Finish coating 10 Drying 60 C 140 F or lower NOTE Refer to paint manufacturers paint speci...

Page 166: ...NOTES ...

Page 167: ...4 1 GROUP 4 CORROSION PROTECTION CONTENTS BODY SEALING LOCATIONS 4 2 UNDERCOAT APPLICATION LOCATIONS 4 10 ...

Page 168: ...appearance quality of the application in areas such as the drip rail pillar clinch and so on then apply the sealant so that it is flat or wipe off any excess mounding after the application Be careful not to obstruct the water draining hole NOTE The bold dotted line indicates the application area on the underside FLOOR UPPER BODY AB701023AB 4 5 7 3 1 2 6 AB701024AB 10 9 8 11 12 ...

Page 169: ...BODY SEALING LOCATIONS TSB Revision CORROSION PROTECTION 4 3 SIDE BODY AB701025AB 19 13 14 15 18 16 20 17 Left side only AB701017 1 AB AB701001 2 AB ...

Page 170: ...BODY SEALING LOCATIONS TSB Revision CORROSION PROTECTION 4 4 AB701002 3 AB AB701005 4 AB AB701018 5 AB AB701004 6 AB ...

Page 171: ...BODY SEALING LOCATIONS TSB Revision CORROSION PROTECTION 4 5 AB700615 7 AC AB701006AB 8 AB701007AB 9 AB701008AB 10 ...

Page 172: ...BODY SEALING LOCATIONS TSB Revision CORROSION PROTECTION 4 6 AB701003AB 11 AB701009AB 12 AB701010AB Left side only Right side only 13 AB701011AB 14 ...

Page 173: ...BODY SEALING LOCATIONS TSB Revision CORROSION PROTECTION 4 7 AB701012AB 15 AB701013AB 16 AB700340AD 17 AB701019AB 18 ...

Page 174: ...BODY SEALING LOCATIONS TSB Revision CORROSION PROTECTION 4 8 AB701015AB 19 AB701016 20 AB AB701020AB Hood AB601134AC Front door ...

Page 175: ...BODY SEALING LOCATIONS TSB Revision CORROSION PROTECTION 4 9 AB601135AC Rear door AB601136AC Trunk lid outer AB700344AB Trunk lid inner ...

Page 176: ...undercoated for anti corrosive anti rust anti chipping and anti vibration performance After correcting the body restore as shown in the instructions of the figure if necessary Tape the areas marked with an asterisks to pro tect those areas from getting any undercoating on those areas AB701026AB Undercoat film thickness is at least 0 5 mm 0 0197 inch ...

Page 177: ...5 1 GROUP 5 SYNTHETIC RESIN PARTS CONTENTS LOCATION OF SYNTHETIC RESIN PARTS 5 2 ...

Page 178: ... SYNTHETIC RESIN PARTS M4050001001433 The location and material of each of the principal synthetic resin parts are shown below AB700997AB 29 33 6 11 28 1 13 10 4 9 5 30 35 17 31 16 32 18 15 14 7 8 2 3 15 40 48 AB700998AB 42 23 24 12 36 37 19 34 26 25 27 21 20 22 38 43 39 41 46 44 45 47 ...

Page 179: ...r outside handle Polycarbonate Polyethylene terephthalate PC PET 120 248 11 Front door outside handle 12 Front splash shield Low density Polyethylene PE LD LLDPE 80 176 13 High mounted stoplight Polymethyl methacrylate PMMA 80 176 14 Front bumper air guide center duct Polypropylene PP 80 176 15 Front bumper core 16 Rear bumper core lower 17 Rear bumper core upper Vehicles for Canada 18 Rear bumper...

Page 180: ... 15 PP E P TD15 80 176 35 Side air dam Talc filled rubber modified polypropylene 20 PP E P TD20 110 230 36 Rear wheel splash shield rear Talc filled polypropylene PP TD PPF 100 212 37 Front door trim upper Talc filled polypropylene 10 PP TD10 PPF 110 120 230 248 38 Center pillar trim lower 39 Rear door trim upper 40 Front deck garnish Talc filled polypropylene 20 PP TD20 PPF 120 130 248 266 41 Ins...

Page 181: ...6 1 GROUP 6 BODY COLOR CONTENTS BODY COLOR CODE 6 2 BODY COLOR CHARTS 6 2 BODY COLORING 6 3 RADIATOR GRILLE 6 3 GARNISH 6 4 BUMPER NET 6 5 WHEEL HOUSE 6 5 ...

Page 182: ...ainting inner panel colors should be similar to the outer panel colors AB601277 Body color code AB Color Color code Color number Color name Coating film structure Composition of film SILVER A31 CMA10031 Cool Silver Metallic 2M Metallic MEDIUM PURPLISH GRAY A39 CMA10039 Medium Purplish Gray Mica 2P Metallic Interferenced Pearl BLUE D06 CMD10006 Lightning Blue Mica 2P Interferenced Pearl DARK GRAY U...

Page 183: ...DY COLOR 6 3 BODY COLORING RADIATOR GRILLE M4060007000967 AB700597AB A A 1 2 2 2 1 2 Dark warm gray AC10895 GSR MR Gray CMH18036 2 2 6 mm 0 24 in B B C C 3 3 3 3 3 Material color Chrome plating Chrome plating Dark warm gray AC10895 ...

Page 184: ...n BODY COLOR 6 4 GARNISH M4060001300034 HOOD AIR SCOOP AB700800AB 1 A A 1 2 1 2 1 2 Cool Silver Metallic CMA10031 White CMW10037 Except Cool Silver Metallic CMA10031 Gray CMH18036 Body Color Body Color White CMW10037 Body Color ...

Page 185: ...B Revision BODY COLOR 6 5 BUMPER NET M4060001400020 WHEEL HOUSE M4060012000598 AB701086 1 1 GSR MR 1 2 AB 2 Black AC10657 LH Black AC10657 Black AC10657 Gray CMH18038 Material color RH AB601150 AB700926AC Black AC10657 ...

Page 186: ...NOTES ...

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Summary of Contents for Lancer Evolution 2008

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Mitsubishi MOTORS Lancer Evolution 2008, Body Repair Manual, Page: 144 / 186

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Summary of Contents for Lancer Evolution 2008

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