Mitsubishi Lancer Evolution 2003 Body Repair Manual
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Mitsubishi Lancer Evolution 2003 Body Repair Manual

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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
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 Motors Corporation
GROUP INDEX
BODY CONSTRUCTION . . . . . . . . .
BODY DIMENSIONS . . . . . . . . . . . . .
WELDED PANEL REPLACEMENT. .
CORROSION PROTECTION . . . . . .
SYNTHETIC-RESIN PARTS . . . . . . .
BODY COLOR . . . . . . . . . . . . . . . . . .
panel
replacement
WIRING AND PIPING DIAGRAM . . .
REFERENCE MATERIAL . . . . . . . . .
BASE OF BODY REPAIR . . . . . . . . .
Printed in USA
Technical Information
Return to Main Menu
MSSP-260B-2003
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  • Page 1 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.

  • Page 2: Table Of Contents

    GROUP 1 BODY CONSTRUCTION CONTENTS BODY COMPONENTS... . UNDER BODY..... . . 1-17 DOOR .

  • Page 3: Body Components

    BODY CONSTRUCTION BODY COMPONENTS BODY COMPONENTS M4010001000102 52 53 54 76 77 : Anti-corrosion steel panels : High-tensile steel panels AB202151AB...
  • Page 4 BODY CONSTRUCTION BODY COMPONENTS 43. REAR COMBINATION LAMP HOUSING HEADLAMP SUPPORT PANEL 44. SIDE ROOF RAIL INNER HOOD LOCK STAY 45. ROOF SIDE RAIL REINFORCEMENT CENTER FRONT END CROSSMEMBER 46. FRONT PILLAR INNER UPPER FRONT END UPPER BAR 47. FRONT PILLAR INNER LOWER HEADLAMP SUPPORT PANEL SIDE 48.

  • Page 5: Body Main Cross-Sectional Views

    BODY CONSTRUCTION BODY MAIN CROSS-SECTIONAL VIEWS BODY MAIN CROSS-SECTIONAL VIEWS M4010002000105 AB201974 FRONT PILLAR ROOF REINFORCEMENT UPPER ROOF PANEL PANEL SIDE OUTER PANEL FRONT MAP LAMP PILLAR SIDE ROOF BRACKET REINFORCE- FRONT ROOF RAIL RAIL INNER MENT UPPER (B) FRONT PILLAR INNER AB201984 REINFORCEMENT AB201886AB...
  • Page 6 BODY CONSTRUCTION BODY MAIN CROSS-SECTIONAL VIEWS AB201911AB (SUNROOF) (STANDARD ROOF) FRONT FRONT PILLAR PILLAR INNER UPPER FRONT PILLAR INNER UPPER INNER FRONT PILLAR REINFORCEMENT UPPER REINFORCEMENT UPPER FRONT PILLAR SIDE OUTER REINFORCE- PANEL MENT UPPER FRONT PILLAR FRONT PILLAR REINFORCEMENT INNER REINFORCEMENT UPPER SIDE OUTER PANEL...

  • Page 7: Maintenance, Serviceability

    BODY CONSTRUCTION MAINTENANCE, SERVICEABILITY 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.
  • Page 8 BODY CONSTRUCTION MAINTENANCE, SERVICEABILITY SIDE STRUCTURE A panel positioning cut-out has been added on the door opening to improve assembling workability when replacing the panel. PANEL POSITIONING NOTCH AB200202AB AB202025AB 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.

  • Page 9: Body Construction Characteristics

    BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS BODY CONSTRUCTION CHARACTERISTICS FRONT BODY M4010010000092 HEADLAMP SUPPORT NOTE: *: Steel sheets with different thickness welded to form one steel sheet. 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.
  • Page 10 BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS FENDER SHIELD NOTE: *: Steel sheets with different thickness welded to form one steel sheet. 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.
  • Page 11 1-10 BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS FRONT SIDEMEMBER REINFORCEMENT RIGHT SIDE AB201018AB AB202015AC 10. PIPE SUPPORT REAR FRONT SIDEMEMBER INNER 11. PIPE NUT FRONT SIDEMEMBER BULKHEAD A 12. FRONT SIDEMEMBER REAR FRONT SIDEMEMBER OUTER 13. DASH CROSSMEMBER EXTENSION ENGINE MOUNT BRACKET 14.
  • Page 12 1-11 BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS LEFT SIDE AB201019AB AB202017AC 13. FRONT SIDEMEMBER INNER REINFORCEMENT SUSPENSION CROSSMEMBER SUPPORT 14. FRONT SIDEMEMBER REINFORCEMENT OUTER BRACKET 15. FRONT SIDEMEMBER BULKHEAD (A) DASH CROSSMEMBER EXTENSION 16. FRONT SIDEMEMBER INNER FRONT SIDEMEMBER REAR 17. PIPE SUPPORT FRONT PIPE NUT 18.
  • Page 13 1-12 BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS FRONT DECK Strut house gusset and upper frame to front pillar brace have been added to improve body rigidity. AB201020AB CLUTCH PEDAL SUPPORT BRACKET STRUT TOWER BAR BRACKET UPPER FRAME EXTENSION INNER COWL TOP LOWER PANEL 10.

  • Page 14: Roof

    1-13 BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS ROOF M4010013000091 The cross section of the roof bow has been made large to improve safety in collision. STANDARD ROOF AB202150AB SUN ROOF AB201928AB FRONT ROOF BOW ROOF PANEL MAP LAMP BRACKET REAR ROOF RAIL FRONT ROOF RAIL REAR ROOF BOW ROOF PANEL REINFORCEMENT...

  • Page 15: Side Body

    1-14 BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS SIDE BODY M4010011000095 SIDE STRUCTURE 23 24 AB201022AB 21. REAR FLOOR SIDE BRACE FRONT PILLAR REINFORCEMENT LOWER 22. REAR FLOOR BRACE REINFORCEMENT EXTENSION 23. FUEL FILLER NECK BRACKET (LH only) FRONT PILLAR INNER LOWER EXTENSION 24.
  • Page 16 1-15 BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS 43. REAR DOOR HINGE REINFORCEMENT UPPER 44. CENTER PILLAR SEATBELT REINFORCEMENT 45. CENTER PILLAR INNER 46. FRONT PILLAR REINFORCEMENT UPPER (B) (VEHICLES WITH STANDARD ROOF) 47. FRONT PILLAR INNER REINFORCEMENT (VEHICLES WITH STANDARD ROOF) 48.

  • Page 17: Rear Body

    1-16 BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS REAR BODY M4010012000087 REAR END CROSSMEMBER A rear shelf extension has been added to form closed structure. Then, the rear shelf and the rear floor have been joined to improve the torsion rigidity of the seat back plate. AB201022AB REAR SHELF CHILD SEAT BELT SEAT BACK PLATE...

  • Page 18: Under Body

    1-17 BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS UNDER BODY M4010014000094 FRONT FLOOR The cross section of the front floor sidemember has been made large to improve safety in collision. AB202031AB FRONT FLOOR SIDEMEMBER INSTRUMENT PANEL CENTER BRACKET FRONT FLOOR SIDEMEMBER REINFORCEMENT REINFORCEMENT FRONT FRONT FLOOR CROSSMEMBER FRONT...
  • Page 19 1-18 BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS REAR FLOOR AB201025AB 10. DIFFERENTIAL / FUEL SUPPORT BRACKET REAR FLOOR PAN REAR SEAT BACK PLATE EXTENSION 11. REAR FLOOR SIDEMEMBER JACK BRACKET 12. DIFFERENTIAL / FUEL SUPPORT BRACKET SPARE TIRE BRACKET FRONT REAR SEAT BACK REINFORCEMENT 13.
  • Page 20 1-19 BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS REAR FLOOR SIDEMEMBER REINFORCEMENT AB202032AB AB202033AB 13. REAR FLOOR SIDEMEMBER REINFORCEMENT TRAILING ARM OUTER BRACKET FRONT REAR FLOOR SIDEMEMBER SUPPORT 14. MUFFLER HANGER REAR TRAILING ARM INNER BRACKET 15. REAR FLOOR SIDEMEMBER REINFORCEMENT REAR FLOOR SIDEMEMBER REAR REAR FLOOR CROSSMEMBER EXTENSION 16.

  • Page 21: Door

    1-20 BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS DOOR M4010015000086 The front and back of side door beam has been made large to cope with the force from the front and sides during collision. RONT DOOR AB201026AB 15 16 EAR DOOR AB201027AB 11.

  • Page 22: Silencer Application Locations

    1-21 BODY CONSTRUCTION SILENCER APPLICATION LOCATIONS SILENCER APPLICATION LOCATIONS M4010005000115 A silencer (MD-12 and melting sheet) has been NOTE: • MD-12 is a high performance sheet composed of adhered on the top part of the floor to improve anti- vibration performance and to shut-out exhaust gas asphalt applied with mica and thermosetting resin heat.

  • Page 23: Locations Using Urethane Foam And Foam Material

    1-22 BODY CONSTRUCTION LOCATIONS USING URETHANE FOAM AND FOAM MATERIAL LOCATIONS USING URETHANE FOAM AND FOAM MATERIAL M4010007000092 • Introduction of noise was prevented by inserting • Never use a gas burner or burn the areas urethane foam inside the center pillar. using foam materials.
  • Page 24 1-23 BODY CONSTRUCTION LOCATIONS USING URETHANE FOAM AND FOAM MATERIAL AB201918 AB100698 FOAM ACOUSTIC MATERIAL HIGH RIGIDITY FOAM MATERIAL FRONT PILLAR SIDE ROOF REINFORCEMENT SIDE OUTER PANEL RAIL INNER UPPER SIDE OUTER PANEL AB201980AB AB201977AB FOAM ACOUSTIC MATERIAL CENTER PILLAR REAR PILLAR INNER INNER SIDE OUTER...

  • Page 25: Stiffener And Damp Sheet Application Locations

    1-24 BODY CONSTRUCTION STIFFENER AND DAMP SHEET APPLICATION LOCATIONS STIFFENER AND DAMP SHEET APPLICATION LOCATIONS M4010008000103 Sound insulation was improved with anti-vibration NOTE: The main contents of a stiffener are epoxy effects and heightening surface rigidity with a stiff- resin. It comes in a sheet form and contains a mix- ener on the inner side of the side outer panel, and ture of glass fiber and filler, and cures (stiffens) when roof panel, as well as a damping sheet adhered to...

  • Page 26: Theft Protection

    1-25 BODY CONSTRUCTION THEFT PROTECTION THEFT PROTECTION M4010017000037 In order to protect against theft, a Vehicle Identification Number (VIN) is attached as a plate or label to the following major parts THEFT PROTECTION LABEL of the engine and transaxle, as well as main outer panels: Engine cylinder block, Transaxle housing, Fender, Doors, Trunk lid, Quarter panel, Hood, Bumpers In addition, a theft-protection label is attached to replacement...
  • Page 27 1-26 BODY CONSTRUCTION THEFT PROTECTION LOCATIONS LABEL AREA (A: FOR ORIGINAL EQUIPMENT PARTS, B: FOR REPLACEMENT PARTS) ENGINE MANUAL TRANSAXLE AC211574 AB AC211575 QUARTER PANEL OUTER FENDER AC101605 AB THE ILLUSTRATION INDICATES LEFT OUTER SIDE. AC101606 AB RIGHT SIDE IS SYMMETRICALLY OPPOSITE. THE ILLUSTRATION INDICATES LEFT OUTER SIDE.
  • Page 28 1-27 BODY CONSTRUCTION THEFT PROTECTION LABEL AREA (A: FOR ORIGINAL EQUIPMENT PARTS, B: FOR REPLACEMENT PARTS) FRONT DOOR REAR DOOR THE ILLUSTRATION INDICATES LEFT INNER SIDE. THE ILLUSTRATION INDICATES LEFT INNER SIDE. RIGHT SIDE IS SYMMETRICALLY OPPOSITE. RIGHT SIDE IS SYMMETRICALLY OPPOSITE. AC101607AB AC101608 AB HOOD...
  • Page 29 NOTES...
  • Page 30 GROUP 2 BODY DIMENSIONS CONTENTS BODY DIMENSIONS AND MEASUREMENT TYPE B (ACTUAL-MEASUREMENT METHODS ..... DIMENSIONS)....UNDER BODY.
  • Page 31 BODY DIMENSIONS BODY DIMENSIONS AND MEASUREMENT METHODS BODY DIMENSIONS AND MEASUREMENT METHODS M4020001000095 1. Type A (projected dimensions) PROJECTED DIMENSION Indicates the dimension when a measurement location is projected onto the plane. The difference in height of the measurement points should HEIGHT be taken into consideration when measuring.

  • Page 32: Body Dimensions And Measurement

    BODY DIMENSIONS BODY DIMENSIONS AND MEASUREMENT METHODS 6. When measuring the suspension mounting arm, or link BOLT mounting position, use the suspension mounting bolt, etc. (Type B only) 7. The body center points are shown for the purpose of check- ing the position of the left and right symmetry location.

  • Page 33: Under Body

    BODY DIMENSIONS TYPE A (PROJECTED DIMENSIONS) TYPE A (PROJECTED DIMENSIONS) UNDER BODY M4020005000150 mm (in) Y0620AV 1,239 (48.8) (38.7) (13.4) 1,010 (39.8) (28.1) (31.9) (6.0) 1,232 (29.5) (28.1) (48.5) (37.0) (6.3) (13.3) (30.9) (21.4) (28.4) (9.7) AB201748AB Y0620AV (29.8) 1,232 1,157 (48.5) (45.6)
  • Page 34 BODY DIMENSIONS TYPE A (PROJECTED DIMENSIONS) mm (in) (19.6) (13.4) (10.0) (13.3) (8.0) (13.6) (13 .0) (7.3) (8.0) (7.1) (6.4) (5.6) (3.9) (4.5) (22.2) (9.8) (19.8) (27.2) 1,230 1,335 (48.4) (52.6) (13.3) 1,545 (60.8) AB201750AB AB202159 AB201817AB AB201728 AC 5, 6, 7, 8 AB201808AB AB201809 AB202160AB...
  • Page 35 BODY DIMENSIONS TYPE A (PROJECTED DIMENSIONS) SUSPENSION INSTALLATION DIMENSIONS M4020013000133 mm (in) (28.4) (14.6) (32.6) (11.4) (18.5) (7.5) 1,110 1,186 (18.9) (43.7) (28.1) (46.7) (27.6) (33.8) (39.3) (31.9) (35.7) (28.1) (33.5) (35.5) (3.9) (16.4) (3.4) (11.3) (14.8) 18 19 (12.7) (14.6) AB201751AB (30.1)
  • Page 36 BODY DIMENSIONS TYPE A (PROJECTED DIMENSIONS) mm (in) VEHICLE CENTER VEHICLE CENTER 11˚36´ 4˚24´ (20.8) (34.0) (17.3) (14.1) 3 12´ (13.2) 14 15 (29.6) (24.7) (13.0) (9.4) (13.3) (13.7) (8.5) (6.4) (4.1) (3.9) (6.9) (7.8) (7.5) (13.6) 1,257 (49.5) (18.8) (15.8) (22.2) (20.6)

  • Page 37: Under Body

    BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS) TYPE B (ACTUAL-MEASUREMENT DIMENSIONS) UNDER BODY M4020005000161 AB201748 mm (in) 1,250 (49.2) (13.4) (38.7) 1,010 (39.8) 1,232 (7.0) (28.1) (28.1) (48.5) (31.9) (37.0) (29.5) (6.8) (31.7) (21.4) (13.4) (29.0) (11.5) AB201754AB (29.8) 1,170 1,241 (46.1) (34.4) (48.9)
  • Page 38 BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS) AB202159 AB201817AB AB201728 AC 5, 6, 7, 8 AB201808AB AB201809 AB202160AB AB201818AB AB201811AB...

  • Page 39: Suspension Installation

    2-10 BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS) SUSPENSION INSTALLATION DIMENSIONS M4020013000144 mm (in) (15.3) (29.2) (7.5) (11.6) (18.5) (19.6) 1,186 (46.7) (35.7) (28.1) (28.1) (27.6) (31.9) (35.5) (4.4) (33.5) (17.2) (4.1) (11.5) (15.2) (15.0) (14.1) AB201756AB 1,137 1,075 (35.0) (33.8) (44.8) (42.3) (30.6)
  • Page 40 2-11 BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS) 3, 16 10, 22 AB201820 AB201821AB AB201819AB 18, 20 AB201822AB AB201823AB AB201824 AB201825...

  • Page 41: Front Body

    2-12 BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS) FRONT BODY M4020006000078 mm (in) 1,091 (43.0) (34.3) 1,508 (59.4) BODY CENTER POINT 1,390 1,437 (54.7) (56.6) (26.2) 1,558 (61.3) (28.7) (21.4) (34.8) (12.9) (34.4) (34.3) 1,382 1,040 (29.5) (54.4) (40.9) (29.6) (27.2) (35.2) AB201758AB (28.8)
  • Page 42 2-13 BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS) STANDARD HOLE SHAPE− STANDARD HOLE SHAPE− MEASUREMENT POINT SIZE mm (in) MEASUREMENT POINT SIZE mm (in) Center of hood hinge Round−9 (0.4) Center of front bumper Round−9 (0.4) mounting hole reinforcement mounting hole Corner of roof panel −...

  • Page 43: Side Body

    2-14 BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS) SIDE BODY M4020007000071 mm (in) (32.6) (27.1) (34.4) (31.8) (18.2) (28.2) (22.9) 1,127 (44.4) 1,084 1,174 (42.7) (35.5) (46.2) (34.0) (37.8) AB201760AB 1,100 (28.8) (43.3) 1,067 (42.0) (33.0) 1,124 1,094 (44.3) (43.1) (14.0) (13.3) (35.5) 1,041...
  • Page 44 2-15 BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS) 38, 48 42, 50 46, 51 AB201836 AB202191 AB201838...

  • Page 45: Rear Body

    2-16 BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS) REAR BODY M4020008000085 mm (in.) (39.0) (25.7) 1,271 (50.0) BODY CENTER POINT 1,200 (47.2) 1,269 (21.0) (50.0) (22.3) (27.9) 1,104 (43.5) (18.0) 1,562 1,018 (61.5) (40.1) (29.5) AB201762 AB STANDARD HOLE SHAPE− STANDARD HOLE SHAPE−...
  • Page 46 2-17 BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS) AB201840AB AB201841AB AB201839AB 55, 56 AB201842 AB201843AB AB201844AB...
  • Page 47 2-18 BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS) INTERIOR M4020009000088 mm (in) 1,112 1,145 (43.8) (45.1) 1,235 1,297 (48.6) 1,289 (51.1) (50.7) 1,379 1,395 (54.3) (54.9) 1,407 1,368 (55.4) (53.9) 1,388 (54.6) AB201763AB 1,072 1,100 (42.2) (43.3) 1,016 1,085 (40.0) (42.7) 1,136 (44.7) (33.4)
  • Page 48 2-19 BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS) mm (in) (38.8) (31.8) 1,106 (43.5) (22.8) (37.0) AB201765AB STANDARD HOLE SHAPE− STANDARD HOLE SHAPE− MEASUREMENT POINT SIZE mm (in) MEASUREMENT POINT SIZE mm (in) Center of rear end trim Round−8.5 (0.3) Front pillar positioning −...
  • Page 49 2-20 BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS) AB202195 AB202195 AB201843AB AB201845AB AB201846AB AB201849AB 62, 63 AB201848AB AB201850AB AB201847AB...
  • Page 50 GROUP 3 WELDED PANEL REPLACEMENT CONTENTS HEADLAMP SUPPORT ... ROOF ......3-28 FENDER SHIELD.

  • Page 51: Headlamp Support

    WELDED PANEL REPLACEMENT HEADLAMP SUPPORT HEADLAMP SUPPORT M4030003000100 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.) AB201903...
  • Page 52 WELDED PANEL REPLACEMENT HEADLAMP SUPPORT NOTE: Partial replacement is okay depending on the range of damage. : CUTTABLE RANGE AB201968...

  • Page 53: Fender Shield

    WELDED PANEL REPLACEMENT FENDER SHIELD FENDER SHIELD M4030004000095 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.) AB201904...
  • Page 54 WELDED PANEL REPLACEMENT FENDER SHIELD (WITH THE UPPER FRAME EXTENSION OUTER REMOVED) AB202219...
  • Page 55 WELDED PANEL REPLACEMENT FENDER SHIELD 17 POINTS, LEFT SIDE ONLY 6 POINTS, LEFT SIDE ONLY 9 POINTS, LEFT SIDE ONLY 5 POINTS, LEFT SIDE ONLY AB202220...
  • Page 56 WELDED PANEL REPLACEMENT FENDER SHIELD NOTES...

  • Page 57: Front Sidemember (Partial Replacement)

    WELDED PANEL REPLACEMENT FRONT SIDEMEMBER (PARTIAL REPLACEMENT) FRONT SIDEMEMBER (PARTIAL REPLACEMENT) M4030000100045 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.)
  • Page 58 WELDED PANEL REPLACEMENT FRONT SIDEMEMBER (PARTIAL REPLACEMENT) LEFT SIDE 45 mm (1.77 in) CENTER OF SPLASH 83 mm (3.27 in) CENTER OF FRONT SHIELD MOUNTING SIDEMEMBER INNER HOLE POSITIONING HOLE AB202222AB NOTE: Refer to the Headlamp Support Section on P.3-2 for the welding point with headlamp support.

  • Page 59: Front Pillar

    3-10 WELDED PANEL REPLACEMENT FRONT PILLAR FRONT PILLAR M4030005000139 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.) AB201906...
  • Page 60 3-11 WELDED PANEL REPLACEMENT FRONT PILLAR RIGHT SIDE <VEHICLES WITH STANDARD ROOF> <VEHICLES WITH SUNROOF> AB202203 NOTE ON REPAIR WORK INSTALLATION <Vehicles with standard roof> 1. To reinforce the strength of the front pillar cut area, cut the FRONT PILLAR side outer panel 160 mm (6.3 in) above the front pillar cut REINFORCEMENT UPPER B...
  • Page 61 3-12 WELDED PANEL REPLACEMENT FRONT PILLAR 3. Divide the new front pillar inner upper parts into A (front pillar inner reinforcement and front pillar inner upper) and B (front pillar reinforcement upper and front pillar reinforcement upper B). AB200369AB 4. When assembling Part A, weld the areas shown in the figure of the instructions from the outside and inside.
  • Page 62 3-13 WELDED PANEL REPLACEMENT FRONT PILLAR 8. When assembling a new front pillar outer parts, apply a front pillar silencer protector in advance, bury the clearance with butyl tape then apply structural adhesives in the areas shown in the figure of the instructions. ADHESIVE TYPE BRAND Epoxyayresin...
  • Page 63 3-14 WELDED PANEL REPLACEMENT FRONT PILLAR 12.Wait 2 hours after filling the foam materials to remove the bolt and aluminum tape, then melt the foam materials with a soldering gun so a clip, etc. can thoroughly be inserted in the hole filled with foam materials. AB100787 INSTALLATION <Vehicles with sunroof>...
  • Page 64 3-15 WELDED PANEL REPLACEMENT FRONT PILLAR CAUTION Weld and repair if the side sill reinforcement support is SIDE SILL REINFORCEMENT damaged. SUPPORT 4. Remove the side outer panel from the new front pillar outer parts. Cut the front pillar outer by aligning it with the side sill outer reinforcement center on the body-side.
  • Page 65 3-16 WELDED PANEL REPLACEMENT FRONT PILLAR 7. Apply in advance body sealant in the areas shown in the figure of the instructions when assembling the side outer panel. : BODY SEALANT AB200475 AB 8. Assemble the side outer panel, then bolt and tape the hole and flange with aluminum tape and fill the hole with foam materials as shown in the figure of the instructions.

  • Page 66: Center Pillar

    3-17 WELDED PANEL REPLACEMENT CENTER PILLAR CENTER PILLAR M4030006000091 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.) AB201907...
  • Page 67 3-18 WELDED PANEL REPLACEMENT CENTER PILLAR NOTE ON REPAIR WORK REMOVAL 1. Since the center pillar reinforcement and side sill outer CENTER PILLAR reinforcement center of the side sill is adhered together, cut REINFORCEMENT the side outer panel in a place where the reinforcement joint is visible, as shown in the figure of the instructions, to remove the center pillar reinforcement.
  • Page 68 3-19 WELDED PANEL REPLACEMENT CENTER PILLAR 4. When assembling the center pillar reinforcement, apply adhesives in the areas shown in the figure of the instructions. ADHESIVE TYPE BRAND Epoxyayresin 3Mä Part No.8115 or adhesive equivalent : ADHESIVE AB100796AC 5. When attaching the center pillar inner, attach the center pillar silencer protector to the center pillar inner, and seal the holes of the center pillar silencer protector with butyl tape.

  • Page 69: Side Sill

    3-20 WELDED PANEL REPLACEMENT SIDE SILL SIDE SILL M4030007000102 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.) AB201908...
  • Page 70 3-21 WELDED PANEL REPLACEMENT SIDE SILL AB202327AB NOTE ON REPAIR WORK REMOVAL To remove the side sill outer reinforcement, cut it 60mm (2.36 in) behind the cut-out part. 60 mm (2.36 in) SIDE SILL OUTER REINFORCEMENT CENTER AB200598AC INSTALLATION 1. Cut only the side sill outer reinforcement center on the body- 50 mm (1.97 in) side, 50mm (1.97 in) forward of the cut area and then remove.
  • Page 71 3-22 WELDED PANEL REPLACEMENT SIDE SILL 3. Cut the side sill reinforcement support 50mm (1.97 in) forward of the cut area of the side sill outer reinforcement 50 mm (1.97 in) center. SIDE SILL REINFORCEMENT SUPPORT AB200601AB 4. Adhere in advance adhesives in the areas shown in the figure of the instructions when assembling the side sill outer reinforcement.
  • Page 72 3-23 WELDED PANEL REPLACEMENT SIDE SILL 8. Wait 2 hours after filling the foam materials to remove the bolt and aluminum tape, then melt the foam materials with a soldering gun so a clip, etc. can thoroughly be inserted in the hole filled with foam materials.

  • Page 73: Quarter Outer

    3-24 WELDED PANEL REPLACEMENT QUARTER OUTER QUARTER OUTER M4030008000097 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.) AB201912...
  • Page 74 3-25 WELDED PANEL REPLACEMENT QUARTER OUTER AB202224 CAUTION Avoid the fuel filler bracket (left side). NOTE: Parts replacement is advised.Depending on the dam- aged range. : CUTTABLE RANGE AB201967AB...
  • Page 75 3-26 WELDED PANEL REPLACEMENT QUARTER OUTER NOTE ON REPAIR WORK INSTALLATION 1. Attach the rear pillar silencer protector, and fill the gaps with Y0249AV REAR PILLAR butyl tape. When attaching the quarter outer, apply sealant SILENCER PROTECTER to the areas indicated in the illustration. LEFT SIDE ONLY : BODY SEALANT AB202225AB...
  • Page 76 3-27 WELDED PANEL REPLACEMENT QUARTER OUTER 3. Wait 2 hours after filling the foam materials to remove the bolt and aluminum tape. Then melt the foam materials with a soldering gun so a clip, etc. can thoroughly be inserted in the hole that was clogged with foam materials, to bore open the hole.
  • Page 77 3-28 WELDED PANEL REPLACEMENT ROOF ROOF M4030011000097 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.) AB201909 REPAIR WELDS...

  • Page 78: Rear End Panel

    3-29 WELDED PANEL REPLACEMENT REAR END PANEL REAR END PANEL M4030009000067 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.)

  • Page 79: Rear Floor

    3-30 WELDED PANEL REPLACEMENT REAR FLOOR REAR FLOOR M4030010000094 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.) AB201915...
  • Page 80 3-31 WELDED PANEL REPLACEMENT REAR FLOOR LEFT SIDE ONLY RIGHT SIDE ONLY AB202229AB NOTE ON REPAIR WORK REMOVAL Cut the rear floor pan 200 ± 50 mm (7.9 ± 1.97 in) from the REAR SEAT BACK back of the rear seat back reinforcement as shown in the illus- REINFORCEMENT tration.

  • Page 81: Quarter Inner

    3-32 WELDED PANEL REPLACEMENT QUARTER INNER QUARTER INNER M4030012000090 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.) AB201913...
  • Page 82 3-33 WELDED PANEL REPLACEMENT QUARTER INNER LEFT SIDE ONLY (WITH THE SIDE SILL OUTER REINFORCEMENT REAR REMOVED) AB202231AB...

  • Page 83: Quarter Inner (Partial Replacement)

    3-34 WELDED PANEL REPLACEMENT QUARTER INNER (PARTIAL REPLACEMENT) QUARTER INNER (PARTIAL REPLACEMENT) M4030000200031 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.)
  • Page 84 3-35 WELDED PANEL REPLACEMENT QUARTER INNER (PARTIAL REPLACEMENT) NOTE ON REPAIR WORK REMOVAL 1. Since there is a rear pillar reinforcement in the quarter inner panel cut area, remove the rear pillar reinforcement. REAR PILLAR REINFORCE- MENT AB202008 2. Adhere tape along the wheel arch of the quarter inner panel as shown in the figure of the instructions, use the tape as a guide so about 20mm (0.79 in) of the flange remains, then cut and remove.
  • Page 85 3-36 WELDED PANEL REPLACEMENT QUARTER INNER (PARTIAL REPLACEMENT) 3. Weld the quarter inner panel then apply a body sealing in the area shown in the figure of the instructions. BODY SEALING AB202293AC...

  • Page 86: Front Door Outer Panel

    3-37 WELDED PANEL REPLACEMENT FRONT DOOR OUTER PANEL FRONT DOOR OUTER PANEL M4030013000093 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 AB201894...

  • Page 87: Rear Door Outer Panel

    3-38 WELDED PANEL REPLACEMENT REAR DOOR OUTER PANEL REAR DOOR OUTER PANEL M4030014000096 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 AB201893...

  • Page 88: Aluminum Panel

    3-39 WELDED PANEL REPLACEMENT ALUMINUM PANEL ALUMINUM PANEL ALUMINUM PANEL CHARACTERISTICS M4030000500010 Description of aluminum panel 2. More durable: Aluminum has the property of creating oxide coating on its surface when it A new aluminum panel with higher strength and bet- contacts with the air.

  • Page 89: Aluminum Panel Repair

    3-40 WELDED PANEL REPLACEMENT ALUMINUM PANEL ALUMINUM PANEL REPAIR M4030000700014 Items to be noted when working on sheet metal 1. Main differences of sheet metal work WORK ALUMINUM STEEL SHEET DESCRIPTION PANEL Hammering Mallet or plastic Sheet metal hammer hammer Washer welding Not possible Possible...
  • Page 90 3-41 WELDED PANEL REPLACEMENT ALUMINUM PANEL Correction of uneven surface Basically, the same as the steel panel. Work with consideration of characteristics of the aluminum panel. 1. Correction of metal sheet: CAUTION • Heat-up the panel until you feel heat with a keplar work glove on the reverse side of the panel.
  • Page 91 3-42 WELDED PANEL REPLACEMENT ALUMINUM PANEL CAUTION Aluminum plates are softer than steel sheets, therefore select an appropriate abrasive to prevent the surface from deep scratch. 4. Sanding: Grind the surface by a disk sander or a double- action sander. •...
  • Page 92 3-43 WELDED PANEL REPLACEMENT ALUMINUM PANEL 4. Check for distortion: Grind the surface with 80 to 120-grit sandpaper and then check for distortion. AB202113 CAUTION • The surface shall be heated to approximately 250°C (482°F) when correcting distortion. • Care must be taken when heating the panel because it can melt without discoloration.

  • Page 93: Aluminum Panel Paint

    3-44 WELDED PANEL REPLACEMENT ALUMINUM PANEL 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.
  • Page 94 GROUP 4 CORROSION PROTECTION CONTENTS BODY SEALING LOCATIONS ..UNDERBODY ANTICORROSION AGENT LOCATIONS ... . . UNDERCOAT APPLICATION LOCATIONS ....
  • Page 95 CORROSION PROTECTION BODY SEALING LOCATIONS BODY SEALING LOCATIONS M4040001000138 If the sealant application is directly visible on the NOTE: The bold dotted line indicates the application outer plate and requires appearance quality of the area on the rear. 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.
  • Page 96 CORROSION PROTECTION BODY SEALING LOCATIONS SIDE BODY AB202134 AB202136AB AB202135 AB202138AB AB202137 TSB Revision...
  • Page 97 CORROSION PROTECTION BODY SEALING LOCATIONS AB202139AB AB202140AB AB202141AB AB202142AB AB202143AB AB202144 AB202145AB AB202146AB TSB Revision...
  • Page 98 CORROSION PROTECTION BODY SEALING LOCATIONS HOOD FRONT DOOR AB202131 AB202147 REAR DOOR TRUNK LID AB202148 AB202149AB TSB Revision...
  • Page 99 CORROSION PROTECTION UNDERCOAT APPLICATION LOCATIONS UNDERCOAT APPLICATION LOCATIONS M4040003000112 The under parts of the body is undercoated for anti- Tape the areas marked with an asterisks to protect corrosive, anti-rust, anti-chipping, and anti-vibration those areas from getting any undercoating on those performance.
  • Page 100 CORROSION PROTECTION UNDERBODY ANTICORROSION AGENT LOCATIONS UNDERBODY ANTICORROSION AGENT LOCATIONS M4040009000024 In order to provide a greater corrosion resistance, NOTE: • underbody corrosion prevention treatment should be Take care not to permit the anticorrosion agent to performed after undercoat application. After complet- come in contact with body painting, brake parts, ing body repairs, restore this underbody corrosion exhaust pipes, bearing seals for rear axle and...
  • Page 101 NOTES...
  • Page 102 GROUP 5 SYNTHETIC-RESIN PARTS CONTENTS LOCATION OF SYNTHETIC-RESIN PARTS ......
  • Page 103 SYNTHETIC-RESIN PARTS LOCATION OF SYNTHETIC-RESIN PARTS LOCATION OF SYNTHETIC-RESIN PARTS M4050001000117 The location and material of each of the principal synthetic-resin parts are shown below. 2, 5 AB202186AB AB202187AB NO PART NAME NAME OF RESIN ABBREVIATION HEAT- WITHSTAND TEMP [°C (°F)] Door mirror Acrylonitrile butadiene styrene 80 (176)
  • Page 104 SYNTHETIC-RESIN PARTS LOCATION OF SYNTHETIC-RESIN PARTS NO PART NAME NAME OF RESIN ABBREVIATION HEAT- WITHSTAND TEMP [°C (°F)] Splash shield Polyethylene 100 (212) 10 Front bumper side cover Polypropylene 80 (176) 11 Oil cooler duct 12 Front bumper side core 13 Front bumper center core 14 Rear bumper core 15 Instrument panel...
  • Page 105 NOTES...
  • Page 106 GROUP 6 BODY COLOR CONTENTS BODY COLOR CODE ... . BODY COLORING ....HEADLAMP SUPPORT ....BODY COLOR CHARTS .
  • Page 107 BODY COLOR BODY COLOR CODE BODY COLOR CODE M4060001000118 1. The body color code is imprinted on the vehicle information code plate, which is mounted on the front deck. VEHICLE INFORMATION CODE PLATE AC211608AB 2. The information is contained in the body color charts. BODY COLOR CODE AB202021AD BODY COLOR CHARTS...
  • Page 108 BODY COLOR BODY COLORING BODY COLORING HEADLAMP SUPPORT M4060009000071 (Except color code X42) :BLACK (AC10657) AB202124 DOOR SASH, WHEELHOUSE M4060000100048 (Except color code X42) 1 LUSTROUS BLACK (AC10790) 2 BLACK (AC10657) AB202125...
  • Page 109 NOTES...
  • Page 110 GROUP 8 REFERENCE MATERIAL CONTENTS BOLTED PANEL FIT AND ADJUSTMENT ADJUSTMENT OF OTHER PARTS ........

  • Page 111: Bolted Panel Fit And Adjustment

    REFERENCE MATERIAL BOLTED PANEL FIT AND ADJUSTMENT BOLTED PANEL FIT AND ADJUSTMENT HOOD M4080005000060 ADJUSTMENT OF HOOD FIT 1. If the clearance between the hood and body is uneven, loosen the hood hinge assembling nut and hood hinge assembling bolt, move the hood to and fro, and left and right to adjust the hood so the clearance around the hood is even.

  • Page 112: Door

    REFERENCE MATERIAL BOLTED PANEL FIT AND ADJUSTMENT DOOR M4080006000085 ADJUSMENT OF DOOR FIT CAUTION • Attach protection tape to the fender and door edges where the hinge is installed. • Do not rotate special tool MB991164 with a torque of over 98 N⋅m (72 ft-lb) 1.

  • Page 113: Trunk Lid

    REFERENCE MATERIAL BOLTED PANEL FIT AND ADJUSTMENT (3) Adjustment by using shims (forward and rearward) Increase or decrease the number of shims so that the SHIM striker engages with the door latch properly. STRIKER Door striker assembling bolt tightening torque: 11 ±...

  • Page 114: Installation And Removal Of Adhesive Components

    REFERENCE MATERIAL INSTALLATION AND REMOVAL OF ADHESIVE COMPONENTS INSTALLATION AND REMOVAL OF ADHESIVE COMPONENTS AERO PARTS M4080015000038 SIDE AIR DAM REAR SPOILER <TYPE A> REAR SPOILER <TYPE B> AB202317...
  • Page 115 REFERENCE MATERIAL INSTALLATION AND REMOVAL OF ADHESIVE COMPONENTS ADHESIVE TAPE POSITION DOUBLE-SIDED TAPE SIDE AIR DAM AB202318AB ADHESIVE TAPE: DOUBLE-SIDED TAPE [ 5 mm (0.20 in) WIDTH AND 1.2 mm (0.05 in) THICKNESS ] DOUBLE-SIDED TAPE REAR SPOILER <TYPE A> AB202335AB ADHESIVE TAPE: DOUBLE-SIDED TAPE A: [5 mm ( 0.2 in ) WIDTH AND 0.8 mm ( 0.03 in ) THICKNESS ]...
  • Page 116 REFERENCE MATERIAL INSTALLATION AND REMOVAL OF ADHESIVE COMPONENTS 1. Attach protection tape all the way along the edges of the double-sided tape which is still adhering to the body. DOUBLE-SIDED TAPE PROTECTION TAPE AC200049 2. Scrape off the double-sided tape with a resin spatura as possible.

  • Page 117: Adjustment Of Other Parts

    REFERENCE MATERIAL ADJUSTMENT OF OTHER PARTS ADJUSTMENT OF OTHER PARTS FRONT WHEEL ALIGNMENT M4080009000062 Measure wheel alignment with alignment equipment on a level surface. The front suspension, steering system, wheels, and tires should be serviced to normal condition before measuring wheel alignment.

  • Page 118: Rear Wheel Alignment

    REFERENCE MATERIAL ADJUSTMENT OF OTHER PARTS REAR WHEEL ALIGNMENT M4080010000066 1. The rear suspension, wheels and tyres should be serviced to normal condition prior to measurement of wheel alignment. 2. Measure the wheel alignment with the vehicle parked on a level surface.

  • Page 119: Headlight Aiming

    8-10 REFERENCE MATERIAL ADJUSTMENT OF OTHER PARTS HEADLIGHT AIMING M4080011000069 PRE-AIMING INSTRUCTIONS 1. Inspect for badly rusted or faulty headlight assemblies. 2. These conditions must be corrected before a satisfactory adjustment can be made. 3. Inspect tire inflation, and adjust if it is necessary. 4.

  • Page 120: Fog Light Aiming

    8-11 REFERENCE MATERIAL ADJUSTMENT OF OTHER PARTS HEADLIGHT ADJUSTMENT 1. The low beam headlight should project on the screen upper edge of the beam (cut-off). 2. If not the case, turn the adjusting screws to achieve the specified low-beam cut-off location on the aiming screen. VERTICAL ADJUSTING VERTICAL...
  • Page 121 8-12 REFERENCE MATERIAL ADJUSTMENT OF OTHER PARTS 6. Thoroughly clean fog light lenses. 7. Place the vehicle on a level floor, perpendicular to a flat screen 7.62m (25.0 feet) away from the bulb center-marks on the fog light lens. 8. Rock vehicle sideways to allow vehicle to assume its normal position.

  • Page 122: Supplemental Restraint

    MITSUBISHI dealer. Before beginning service or maintenance • of any SRS air bag components or related components, MITSUBISHI dealer person- nel must thoroughly review the Service Manual (especially GROUP 52B - SRS AIR BAG).
  • Page 123 NOTES...
  • Page 124 GROUP 9 BASE OF BODY REPAIR CONTENTS WELDING..... . STANDARD PROCEDURES FOR SHEET METAL WORK ..... . 9-25 WELDING .

  • Page 125: Welding

    BASE OF BODY REPAIR WELDING WELDING WELDING M4090001000025 Welding is the partial joining of two or more metals by deposition; the welding methods used for body maintenance and repair can be classified into the fol- lowing methods. Fusion methods Shielded arc welding Temperature: 1,130˚C - 1,550˚C gas arc welding (2,066˚F - 2,822˚F)
  • Page 126 BASE OF BODY REPAIR WELDING 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.
  • Page 127 BASE OF BODY REPAIR WELDING NUGGET FORMATION COOLING WATER MORE THAN ELECT- 1.6 mm RODE (0.06 in) MELTING POINT STEEL PANEL 1.6 mm (0.06 in) OR LESS NUGGET ELECT- C IS THE SCATTER POINT RODE SMALL ← WELDING CURRENT → LARGE WATER 1,095 1,650˚C...
  • Page 128 BASE OF BODY REPAIR WELDING NOTES REGARDING WELDING 90˚ - 120˚ DIAMETER OF THE ELECTRODE TIP THICKNESS OF THE PANEL AB200030AB • The overall strength will increase as the pitch 1. Selection of the electrode tips decreases; however, if the pitch decreases •...
  • Page 129 BASE OF BODY REPAIR WELDING WELDING REQUIREMENTS Example Standard steel plate (SPCC, etc.) • Center pillar (outer): plate thickness 1.4 mm (0.06 inch), material SPCC CAUTION • Center pillar (inner): plate thickness 1.5 mm (0.06 If the total thickness of the plates at the weld inch), material SPCC places is 3 mm (0.12 inch) or more, use plug The number of weld points are as below when the...
  • Page 130 BASE OF BODY REPAIR WELDING Galvanized steel plate (SECC) CAUTION If the total thickness of the plates at the weld places is 3 mm (0.1 inch) or more, use plug weld- ing, because spot welding will not provide suffi- cient welded strength. PANEL NUMBER OF REPAIR WELD (PERCENTAGE OF FACTORY WELD) THICKNESS*...

  • Page 131: Gas Shield Arc Welding

    BASE OF BODY REPAIR WELDING GAS SHIELD ARC WELDING M4090003000010 WIRE NOZZLE CONTACT TIP METAL VAPOR SHIELD GAS AB200035 Gas shielded arc welding is one method of arc weld- fuse the area. There are two types of gas shielded ing. In this method, while the area to be welded is arc welding, classified according to the gas they use shielded from the air by a layer of inert gas (such as as the shield gas: carbon dioxide (CO2) gas shielded...
  • Page 132 BASE OF BODY REPAIR WELDING FEATURES OF MIG SPOT WELDING In comparison to resistance spot welding, MIG spot welding has the following advantages and disadvan- tages. ITEM MIG SPOT WELDING ELECTRIC RESISTANCE SPOT WELDING • Light weight • Although the torch with separate Working •...
  • Page 133 9-10 BASE OF BODY REPAIR WELDING The MIG welding done around the doors, wheelhouse arches, etc., to prevent the flanges from coming undone after hemming work is also called MIG spot welding. AB200038 AB PLUG WELDING CAUTION In order to prevent the formation of blowholes, fill in each 5 TO 6 mm hole completely in one pass.Be sure that the two panels (0.2 in)

  • Page 134: Other Types Of Welding

    9-11 BASE OF BODY REPAIR WELDING The angle of the torch should be 15 degree angle to 30 degree angle for either technique, and the tip should be maintained at a distance of 6 to 10 mm (0.2 to 0.4 inch) from the surface 15˚...
  • Page 135 9-12 BASE OF BODY REPAIR WELDING This filler metal is most applicable for the brazing 2. Silver alloy filler metal (silver solder) of steel and non-ferrous alloy other than alumin- Silver alloy filler metal consists of silver, copper, ium, magnesium, and others with low melting zinc or cadmium, nickel, and tin, or other metals.
  • Page 136 9-13 BASE OF BODY REPAIR WELDING 1. Carburizing flame (acetylene-rich flame) Notes with regard to gas welding This flame has an excess of acetylene or a defi- 1. Handle the oxygen and acetylene tanks carefully. ciency of oxygen. The incomplete combustion 2.

  • Page 137: Body Repair

    9-14 BASE OF BODY REPAIR BODY REPAIR BODY REPAIR STANDARD BODY REPAIR PROCEDURES M4090006000031 STANDARD PROCEDURES FOR The following is an explanation of the standard repair procedures for the monocoque body and the frame- REPLACEMENT OF WELDED PANELS type body. Furthermore, please refer to the replace- In order to maintain the proper levels of strength, ment of welded panels for the applicable model for rigidity, and precision when making welded panel...
  • Page 138 9-15 BASE OF BODY REPAIR BODY REPAIR NOTE: If a replacement panel is to be mounted by doing plug welding from the side of the panel remaining on the body, either a hole can be made in the panel on the body, or a hole can be made right through both the panel which is to remain on the body and the panel to be replaced.
  • Page 139 9-16 BASE OF BODY REPAIR BODY REPAIR 7. Flange correction for spot weld traces Correct any flanges that become bent or deformed when spot welds are broken or during other work. AB200058 CAUTION Do not use a flame for paint coat removal because doing so might damage the paint coat of panels which are not to be replaced, thus causing corrosion.
  • Page 140 9-17 BASE OF BODY REPAIR BODY REPAIR CAUTION Perform the operations carefully so that the cut ends fit TWO-LAYER together properly. CONSTRUCTION 11.Cutting of new parts by using a measurement marking If overlap cutting is not possible in a place where butt OUTER PANEL welding is to be done, make a measurement marking on the APPROX.
  • Page 141 9-18 BASE OF BODY REPAIR BODY REPAIR CAUTION During temporary mounting, it is extremely important to obtain accurate measurements for each component. The mounting positions for the front and rear suspensions are especially crucial with regard to safety; therefore, it is nec- essary that all work concerning these areas be done care- fully and correctly.
  • Page 142 9-19 BASE OF BODY REPAIR BODY REPAIR 15.Spot welding When doing spot welding, it is not only important to correctly position the electrode tips, but also to hold the two panels securely together with vise-grip pliers or some other type of clamps, being sure that they are in perfect contact with each other.
  • Page 143 9-20 BASE OF BODY REPAIR BODY REPAIR (2) After completing the hemming work, make MIG spot welds at 50 to 60 mm (2.0 to 2.4 inches) intervals on the inside. AB200073 CAUTION Be sure not to grind the panel down too much. Before welding the outer panel, be sure to apply an anticorrosion agent.
  • Page 144 9-21 BASE OF BODY REPAIR BODY REPAIR CAUTION Wipe off any anticorrosion agent which oozes out onto surfaces to be painted later; the presence of such anticor- rosion agent would prevent correct adhesion of the paint coat. 20.Application of an anticorrosion agent Apply an ample amount of anticorrosion agent to any welded areas and to all surfaces from which the paint coat was removed.

  • Page 145: Theft Protection

    9-22 BASE OF BODY REPAIR BODY REPAIR • At the outer and inner side of any place sub- SAFETY jected to heat. 1. Procedures related to the installation of any com- ponent related to safety must be done with partic- 3.
  • Page 146 9-23 BASE OF BODY REPAIR BODY REPAIR PANEL REPAIR CAUTION 1. Take care when respraying the original part to cover the theft protection label with masking tape prior to respraying. In addition, remember to peel off the masking tape after completion of the respray.

  • Page 147: Attachment Of Silencers

    9-24 BASE OF BODY REPAIR BODY REPAIR ATTACHMENT OF SILENCERS M4090009000018 DASH PANEL INTERIOR SIDE Thickness: 1.6 mm (0.06 in) AB200097 Thickness: 3.2 mm (0.13 in) (two 1.6 mm (0.06 in) silencers overlapped) Silencers (petroleum-asphalt sheets) are attached to welded panel, cut and attach replacement material the upper surface of the floor and at the interior side (in the shape shown in the figure).

  • Page 148: Positioning Dimensions For Openings

    9-25 BASE OF BODY REPAIR BODY REPAIR POSITIONING DIMENSIONS FOR OPENINGS M4090010000012 PORTA POWER AB200100 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.
  • Page 149 9-26 BASE OF BODY REPAIR BODY REPAIR 3. Use the hammer and dolly to repair the dents and other uneven surfaces of the panel. (1) First repair the larger areas of damage so that they are as close as possible to the original condition before the damage occurred.

  • Page 150: Using A Frame Straightener

    9-27 BASE OF BODY REPAIR BODY REPAIR USING A FRAME STRAIGHTENER M4090013000011 For serious and extensive damage, when for exam- 3. Finally, determine what repair methods should be ple the damage extends to the frame of members, it used. is necessary to first use a frame straightener to make •...

  • Page 151: Frame Repair Procedures

    9-28 BASE OF BODY REPAIR BODY REPAIR FRAME REPAIR PROCEDURES M4090014000014 The frame is subjected to the following types of These various types of loads are compounded under loads. various conditions, and are applied to the frame. • Vertical loads... Vertical loads may occur either As a result, it is important, before attempting to repair while stopped or during travel.
  • Page 152 9-29 BASE OF BODY REPAIR BODY REPAIR 4. Use a chisel or gouging tool to open up the crack and holes, and then fill the crack and holes by MIG welding. CRACK CRACK-STOP HOLE APPROX. APPROX. APPROX. 8 mm (0.3 in) 1 mm 90˚...

  • Page 153: Notes Regarding Repair Work

    9-30 BASE OF BODY REPAIR BODY REPAIR 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).
  • Page 154 9-31 BASE OF BODY REPAIR BODY REPAIR • SRS-ECU, air bag module, clock spring, front (2) If heat damage may occur during paint work, impact sensor, the side impact sensor: 93 °C remove the SRS-ECU, the air bag module, (200 °F) or more clock spring, the front impact sensor, the side •...

  • Page 155: Heat-Withstand Temperatures Of Resin-Plastic Parts

    9-32 BASE OF BODY REPAIR BODY REPAIR Only the amounts of paint to be used for the day's work should be in the work area; do not keep excessive amounts of paint, or paint which is not going to be used, in the work area. HEALTH AND SANITATION PROCEDURES The following points should be noted for employee health and sanitation.
  • Page 156 9-33 BASE OF BODY REPAIR BODY REPAIR MATERIAL NAME ABBREVIATION HEAT-DEFORMATION WHERE MAINLY USED TEMPERATURE °C (°F) Cellulose acetate 60 to 100 (140 to 212) Door trim molding butyrate Polyamide 140 to 160 (284 to 320) Harness connector, Wheel cover, Cooling fan, Fuel strainer Talc filled PA-TD...
  • Page 157 9-34 BASE OF BODY REPAIR BODY REPAIR MATERIAL NAME ABBREVIATION HEAT-DEFORMATION WHERE MAINLY USED TEMPERATURE °C (°F) Thermoplastic TPO (TEO) 80 (176) Mud guard, Side airdam elastomer (olefine) Urea formaldehyde UF 120 to 145 (248 to 293) Glass fiber UP-(GT + TD) 200 (392) Rear air spoiler reinforced...

  • Page 158: How To Distinguish Types Of Plastics

    9-35 BASE OF BODY REPAIR BODY REPAIR HOW TO DISTINGUISH TYPES OF PLASTICS M4090017000013 There are various methods that can be employed to determine types of plastics, among them (1) using a chemical solvent, etc., to check it chemically, (2) scratching the material to determine its make-up, (3) cutting of a small piece (where the scar can't be seen) and burning it to judge by the way it burns, etc.

  • Page 159: Corrosion Protection

    9-36 BASE OF BODY REPAIR CORROSION PROTECTION CORROSION PROTECTION ANTICORROSION TREATMENT AT THE FACTORY M4090019000019 Anticorrosion treatment at the time of production includes the following measures. THE USE OF GALVANIZED STEEL PLATE : locations where galvanized steel plate is used. AB200136 AB Because galvanized steel plate has excellent corro- sion resistance, it is used in areas which have a high...
  • Page 160 9-37 BASE OF BODY REPAIR CORROSION PROTECTION CATIONIC ELECTRODEPOSITION UNDERCOATING CATIONIC ANIONIC COATING COATING ALKALI COUNTERAGENT COUNTERAGENT SOLUTION ANIONIC ELECTRODEPOSITION CATIONIC ELECTRODEPOSITION AB200110AB In the cationic electrodeposition method, the car body is the negative pole, thus preventing damage to the zinc plating of the galvanized body panels or to the chemically formed phosphate crystals.
  • Page 161 9-38 BASE OF BODY REPAIR CORROSION PROTECTION WAX INJECTION Wax injection is used at the lower part of the frame, side sill and hollow panels, etc., in order to obtain a better anticorrosion effect. AB200113 ANTICORROSION PRIMER 1. ROCKER PANEL PRIMER APPLICATION AB200114 AB200114 Anticorrosion primer is used at the side sill outer pan-...

  • Page 162: Anticorrosion Treatment At The Time Of Body Repair Work

    9-39 BASE OF BODY REPAIR CORROSION PROTECTION ANTICORROSION TREATMENT AT THE TIME OF BODY REPAIR WORK M4090020000013 The following procedures should be followed for anticorrosion protection when making repairs. AB200116 CORROSION PROTECTION FOR HOLLOW PARTS CAUTION • Wipe away any excess anticorrosion agent on the coated surface, because it can adversely affect the coating.
  • Page 163 9-40 BASE OF BODY REPAIR CORROSION PROTECTION 2. Use a brush to apply spot sealer to the contact surfaces of the panels (both the new panel and the panel remaining on the body) to be spot welded. AB200119 3. Do not spot welding. NOTE: The spot welding can be done as the spot sealer is dry to the touch.
  • Page 164 9-41 BASE OF BODY REPAIR CORROSION PROTECTION • After applying sealant to the door-stop, etc., clean away any excess so as to be sure that there is no interference with installed parts, etc. AB200123 UNDERCOATING : Undercoating application locations AB200124 •...
  • Page 165 NOTES...
  • Page 166 GROUP 7 WIRING AND PIPING DIAGRAM CONTENTS PIPING DIAGRAM ....
  • Page 167 WIRING AND PIPING DIAGRAM PIPING DIAGRAM PIPING DIAGRAM M4070002000026 Drain hose is equipped routed in some parts of These drain hose must be removed before body pan- closed-section structures of the body construction. els in these areas can be replaced. DRAIN HOSE (VHICLES WITH SUNROOF) DRAIN HOSE...

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