Mitsubishi LANCER EVOLUTION 2003 Betriebsanleitung
GROUP INDEX
1
BODY CONSTRUCTION . . . . . . . . .
2
BODY DIMENSIONS . . . . . . . . . . . . .
3
WELDED PANEL REPLACEMENT. .
4
CORROSION PROTECTION . . . . . .
5
SYNTHETIC-RESIN PARTS . . . . . . .
6
BODY COLOR . . . . . . . . . . . . . . . . . .
7
WIRING AND PIPING DIAGRAM . . .
8
REFERENCE MATERIAL . . . . . . . . .
9
BASE OF BODY REPAIR . . . . . . . . .
2003
MITSUBISHI
LANCER
EVOLUTION VIII
BODY
REPAIR MANUAL
FOREWORD
This manual has been prepared for the use of all
service mechanics engaged in the body repair service.
Body dimensions, welded panel replacement
procedures, body sealing application instructions, and
all the other information required to provide quick and
accurate body repair service are contained herein.
One especially important point is the welding method.
All of the vehicle’s original strength and durability can
be maintained by following the welding procedures
contained in this manual.
Now that, in order to maximize the efficiency of the
repair work, first, both the extent of the damage and
the replacement parts that are needed must be
calculated accurately, and then the actual work must
be performed accurately and efficiently.
The publications shown on the following page are also
available, and should be used in conjunction with this
manual.
Mitsubishi Motors Corporation reserves the right to make changes in
design or to make additions to or improvements in its products without
imposing any obligations upon itself to install them on its products
previously manufactured.
ã2003 Mitsubishi MotorsCorporationPrinted inUSA MSSP-260B-2003
Technical Information
Return to Main Menu
1-1
GROUP 1
BODY
CONSTRUCTION
CONTENTS
BODY COMPONENTS. . . . . . . . . . . . 1-2
BODY MAIN CROSS-SECTIONAL
VIEWS . . . . . . . . . . . . . . . . . . . . . . . . 1-4
MAINTENANCE, SERVICEABILITY . 1-6
BODY CONSTRUCTION
CHARACTERISTICS . . . . . . . . . . . . . 1-8
FRONT BODY. . . . . . . . . . . . . . . . . . . . . . . 1-8
ROOF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
SIDE BODY. . . . . . . . . . . . . . . . . . . . . . . . . 1-14
REAR BODY. . . . . . . . . . . . . . . . . . . . . . . . 1-16
UNDER BODY. . . . . . . . . . . . . . . . . . . . . . . 1-17
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
SILENCER APPLICATION
LOCATIONS . . . . . . . . . . . . . . . . . . . . 1-21
LOCATIONS USING URETHANE FOAM
AND FOAM MATERIAL . . . . . . . . . . . 1-22
STIFFENER AND DAMP SHEET
APPLICATION LOCATIONS . . . . . . . 1-24
THEFT PROTECTION . . . . . . . . . . . . 1-25
BODY COMPONENTS
BODY CONSTRUCTION
1-2
BODY COMPONENTS
M4010001000102
AB202151AB
: Anti-corrosion steel panels
: High-tensile steel panels
1
62
64
69
70
19
2
3
16
17
28
47
29
48
49
81
41
14
15
25 55
38
37
21
18
4
5
6
78
9
10
71
2324
22
72 7374
75
76 77
26
27
31 32 33
30
46
35
36
34
11 12
20
13
65
78 79
66
39
40
42
44
43
56
57
83 82
61
67
68
58
59
60
63
45
5051
52 53 54
BODY COMPONENTS
BODY CONSTRUCTION 1-3
1. HEADLAMP SUPPORT PANEL
2. HOOD LOCK STAY
3. FRONT END CROSSMEMBER
4. FRONT END UPPER BAR
5. HEADLAMP SUPPORT PANEL SIDE
6. FRONT FENDER SHIELD
7. FRONT UPPER FRAME INNER
8. UPPER FRAME BULKHEAD FRONT
9. UPPER FRAME BULKHEAD
10. UPPER FRAME BULKHEAD REAR
11. FRONT SIDEMEMBER INNER
12. ENGINE MOUNT BRACKET
13. FRONT SIDEMEMBER REAR
14. FRONT SIDEMEMBER OUTER
15. SPRING HOUSE PANEL
16. DASH PANEL
17. DASH PANEL SILENCER
18. DASH PANEL REINFORCEMENT
19. UPPER FRAME TO FRONT PILLAR BRACE
20. UPPER FRAME EXTENSION OUTER
21. UPPER FRAME EXTENSION INNER
22. COWL TOP LOWER PANEL
23. COWL TOP INNER PANEL
24. COWL TOP UPPER PANEL
25. FRONT DECK CROSSMENBER
26. HOOD INNER PANEL
27. HOOD OUTER PANEL
28. FRONT ROOF RAIL
29. FRONT ROOF BOW
30. ROOF PANEL
31. ROOF BOW FRONT REINFORCEMENT
32. REAR ROOF BOW
33. REAR ROOF RAIL
34. SEAT BACK PLATE
35. REAR SEAT BACK PANEL
36. REAR SHELF PANEL
37. REAR SEAT BACK BRACE
38. TRUNK LID OUTER PANEL
39. TRUNK LID INNER PANEL
40. TRUNK LID HINGE
41. QUARTER INNER EXTENSION REAR
42. QUARTER CORNER PANEL
43. REAR COMBINATION LAMP HOUSING
44. SIDE ROOF RAIL INNER
45. ROOF SIDE RAIL REINFORCEMENT CENTER
46. FRONT PILLAR INNER UPPER
47. FRONT PILLAR INNER LOWER
48. CENTER PILLAR INNER
49. SIDE OUTER PANEL
50. REAR WHEEL HOUSE INNER PANEL
51. QUARTER INNER PANEL
52. REAR FLOOR SIDE BRACE
53. QUARTER OUTER EXTENSION LOWER
54. FUEL FILLER DOOR
55. REAR END PANEL OUTER
56. REAR END PANEL INNER
57. REAR DOOR OUTER PANEL
58. REAR DOOR SIDE DOOR BEAM LOWER
59. REAR DOOR SIDE DOOR BEAM UPPER
60. REAR DOOR INNER PANEL
61. FRONT DOOR OUTER PANEL
62. FRONT DOOR SIDE DOOR BEAM
63. FRONT DOOR INNER PANEL
64. FENDER PANEL
65. FRONT FLOOR CROSSMEMBER REAR
66. FRONT FLOOR CROSSMEMBER FRONT
67. FRONT FLOOR SIDE SILL INNER
68. FRONT FLOOR SIDEMEMBER
69. BACKBONE REINFORCEMENT
70. INSTRUMENT PANEL CENTER BRACKET
REINFORCEMENT
71. FRONT FLOOR PAN
72. FRONT FLOOR EXTENSION PANEL REAR
73. REAR FLOOR EXTENSION
74. REAR FLOOR PAN
75. SEAT BACK PLATE EXTENSION
76. JACK BRACKET
77. SPARE TIRE BRACKET
78. TOWING HOOK REINFORCEMENT
79. REAR FLOOR SIDEMEMBER EXTENSION
80. CROSSMEMBER CENTER SUPPORT
81. REAR FLOOR CROSSMEMBER
82. REAR FLOOR SIDEMEMBER
83. REAR SEAT BACK REINFORCEMENT
BODY MAIN CROSS-SECTIONAL VIEWS
BODY CONSTRUCTION
1-4
BODY MAIN CROSS-SECTIONAL VIEWS
M4010002000105
AB201974
AB
C
D
EF
AC
AB201984
A
ROOF PANEL
MAP LAMP
BRACKET
FRONT ROOF RAIL
AC
AB201886AB
SIDE ROOF
RAIL INNER
SIDE OUTER
PANEL
FRONT PILLAR INNER
REINFORCEMENT
FRONT PILLAR
REINFORCEMENT UPPER
FRONT
PILLAR
REINFORCE-
MENT
UPPER (B)
ROOF
PANEL
B
AB200255AC
C
COWL TOP
LOWER PANEL
COWL TOP
UPPER
PANEL
COWL TOP
INNER PANEL
AB200256AC
D
FRONT END CROSSMEMBER
REIFORCEMENT
FRONT
END
CROSS-
MENBER
INNER
FRONT END
CROSSMENBER
OUTER
AB201985AB
E
FRONT PILLAR REINFORCEMENT
LOWER FRONT PILLAR
INNER LOWER
SIDE OUTER PANEL
AB200258AC
F
FRONT
FLOOR
SIDE SILL
INNER
SIDE SILL
REINFORCEMENT
SUPPORT
SIDE SILL OUTER
REINFORCEMENT
CENTER
SIDE OUTER PANEL
BODY MAIN CROSS-SECTIONAL VIEWS
BODY CONSTRUCTION 1-5
AB201911AB
G
J
I
H
K
AB201887AB
G(STANDARD ROOF)
SIDE OUTER
PANEL
FRONT
PILLAR
INNER
UPPER
FRONT PILLAR
INNER REINFORCEMENT
UPPER
FRONT PILLAR INNER UPPER
REINFORCEMENT
FRONT
PILLAR
REINFORCE-
MENT UPPER
(B)
FRONT PILLAR
REINFORCEMENT
UPPER
AB202122AB
G(SUNROOF)
SIDE OUTER PANEL
FRONT PILLAR
INNER UPPER
FRONT PILLAR
REINFORCEMENT
UPPER
AB201986
H
CENTER PILLAR
REINFORCEMENT
CENTER PILLAR
SEATBELT
REINFORCEMENT
CENTER PILLAR
INNER
SIDE
OUTER
PANEL
AB
AB201988AB
SIDE OUTER
PANEL
REAR PILLAR
INNER
I
AB200264AC
SIDE OUTER
PANEL
QUARTER
INNER PANEL
REAR WHEEL
HOUSE INNER
PANEL
J
AB201989AB
REAR END
PANEL
OUTER
REAR END
PANEL
INNER
K
MAINTENANCE, SERVICEABILITY
BODY CONSTRUCTION
1-6
MAINTENANCE, SERVICEABILITY
M4010003000120
FENDER SHIELD
A positioning hole, marking and cut-out has been
added on the front fender shield, front upper frame
inner, front side member gusset rear and dash panel
to improve assembling workability when replacing
the panel.
AB202152AB
MAINTENANCE, SERVICEABILITY
BODY CONSTRUCTION 1-7
SIDE STRUCTURE
A panel positioning cut-out has been added on the
door opening to improve assembling workability
when replacing the panel.
SIDE OUTER PANEL
The extra parts are supplied in 4 different cut forms
as a result of employing the integrated side-frame
side outer panel.
AB200202AB
PANEL POSITIONING NOTCH
AB202025AB
AB202024
CENTER PILLAR OUTER
FRONT PILLAR OUTER
SIDE SILL OUTER
QUARTER OUTER
AB
BODY CONSTRUCTION CHARACTERISTICS
BODY CONSTRUCTION
1-8
BODY CONSTRUCTION CHARACTERISTICS
FRONT BODY M4010010000092
HEADLAMP SUPPORT
By adopting a steel sheet with variable thickness* for
the front end crossmember outer, the steel sheet
thickness on the right side of the vehicle has been
increased to improve safety in collision and body
rigidity.
NOTE: *: Steel sheets with different thickness
welded to form one steel sheet.
AB201017AB
10
1
4
2
5 3
6
7
8
9
11
1. FRONT END UPPER BAR
2. SENSOR BRACKET
3. HEADLAMP SUPPORT PANEL
4. HOOD LOCK STAY
5. FRONT END CROSSMEMBER INNER
REINFORCEMENT
6. A/C CONDENSER BRACKET
7. RADIATOR BRACKET
8. FRONT END CROSSMEMBER INNER
9. FRONT END CROSSMEMBER OUTER
10. SHIPPING HOOK
10. FRONT END CROSSMEMBER REINFORCEMENT
BODY CONSTRUCTION CHARACTERISTICS
BODY CONSTRUCTION 1-9
FENDER SHIELD
The cross section of the front sidemember has been
increased and a steel sheet with variable thickness*
has been adopted for the front sidemember inner to
increase the thickness of the cabinet side in the aim
to improve safety in collision, body rigidity, and real-
ize lightweight.
NOTE: *: Steel sheets with different thickness
welded to form one steel sheet.
The spring house panel has been designed to be
directly installed with the cowl top lower panel, and
the body rigidity of the suspension attachment holder
has been increased to improve operational stability
and quietness.
AB202153AB
9
10
8
7
6
4
3
5
2
RIGHT SIDE
LEFT SIDE9
1
11
8
10
5
764
2
12
11
1
A
1. HEADLAMP SUPPORT PANEL SIDE
2. FRONT FENDER SHIELD
3. ENGINE MOUNT REINFORCEMENT
4. UPPER FRAME BULKHEAD FRONT
5. FRONT UPPER FRAME INNER
6. UPPER FRAME BULKHEAD
7. UPPER FRAME BULKHEAD REAR
8. SPRING HOUSE BRACKET REINFORCEMENT
9. SPRING HOUSE BRACKET
10. SPRING HOUSE PANEL
11. FRONT SIDEMEMBER
12. TRANSMISSION MOUNT REINFORCEMENT
OUTER
AB200275AC
A
COWL TOP
LOWER PANEL
SPRING
HOUSE
BRACKET SPRING HOUSE
PANEL
Andere Handbücher für LANCER EVOLUTION 2003
1
Inhaltsverzeichnis
Andere Mitsubishi Automobil Handbücher
Mitsubishi
Mitsubishi 2016 OUTLANDER Benutzerhandbuch
Mitsubishi
Mitsubishi Mirage 1990 Konfigurationshandbuch
Mitsubishi
Mitsubishi Lancer Evolution IX 2006 Gebrauchsanweisung
Mitsubishi
Mitsubishi Outlander 2017 Bedienungsanleitung
Mitsubishi
Mitsubishi EVO VIII 260 Bedienungsanleitung
Mitsubishi
Mitsubishi 2010 RVR Bedienungsanleitung
Mitsubishi
Mitsubishi Outlander Sport 2014 Benutzerhandbuch
Mitsubishi
Mitsubishi OUTLANDER Bedienungsanleitung
Mitsubishi
Mitsubishi Stealth 1994 Bedienungsanleitung
Mitsubishi
Mitsubishi 3000gt 1997 Gebrauchsanweisung
Mitsubishi
Mitsubishi 3000GT Gebrauchsanweisung
Mitsubishi
Mitsubishi i-MiEV Bedienungsanleitung
Mitsubishi
Mitsubishi 3000GT 1994 Gebrauchsanweisung
Mitsubishi
Mitsubishi i-MiEV Bedienungsanleitung
Mitsubishi
Mitsubishi MIRAGE Bedienungsanleitung
Mitsubishi
Mitsubishi Carisma Bedienungsanleitung
Mitsubishi
Mitsubishi FUSO FE 2012 Bedienungsanleitung
Mitsubishi
Mitsubishi LANCER 2012 Bedienungsanleitung
Mitsubishi
Mitsubishi 1989-1993 GALANT Bedienungsanleitung
Mitsubishi
Mitsubishi Mirage 2015 Gebrauchsanweisung
