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WORKSHOP MANUAL
EVOLUTION-VII
Pub. No. S0105CT9A

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Summary of Contents for Mitsubishi Electric Lancer Evolution-VII

  • Page 1 WORKSHOP MANUAL EVOLUTION-VII Pub. No. S0105CT9A...
  • Page 2 WIRING AND PIPING DIAGRAM CONTENTS WIRING AND PIPING DIAGRAM ..
  • Page 3: Wiring And Piping Diagram

    WIRING AND PIPING DIAGRAM - Wiring and Piping Diagram WIRING AND PIPING DIAGRAM Pole antennas are routed in some parts of closed-section structures of the body construction. These pole antennas must be removed before body panels in these areas can be replaced. Pole antenna (Vehicles with pole antennas) Antenna feeder-line...
  • Page 4 BODY COLOUR CONTENTS BODY COLOUR CODE ....BODY COLOURING ..... . BUMPER .
  • Page 5 BODY COLOUR - Body Colour Code/Body Colour Charts BODY COLOUR CODE 1. The body colour code is imprinted on the plate, which is mounted on the front deck. 2. The body colour code is imprinted at the areas indicated in the illustration. Body colour code BODY COLOUR CHARTS Check the vehicle’s body colour code, and then use this body colour chart to determine the refinishing...
  • Page 6: New Colour Numbers

    BODY COLOUR - Body Colour Charts NEW COLOUR NUMBERS Example (Body colour code T10) Item Content Identification code C: The colour number is indicated. Manufacture center code M: Japan (Automobile Engineering Center) T: Japan (Truck and Bus Engineering Center) System colour code W (N): White H (A, U): Silver/Gray X (J): Black...
  • Page 7 BODY COLOUR - Body Colouring BLACK PAINT Headlamp support : Black (AC10657) Door sash Front door Rear door : Black (AC10790) Wheel house : Black (AC10657)
  • Page 8 SYNTHETIC-RESIN PARTS CONTENTS LOCATION OF SYNTHETIC-RESIN PARTS...
  • Page 9 SYNTHETIC-RESIN PARTS - Location of Synthetic-resin Parts LOCATION OF SYNTHETIC-RESIN PARTS The following shows the main locations of synthetic-resin parts.
  • Page 10: Location Of Synthetic-Resin Parts

    SYNTHETIC-RESIN PARTS - Location of Synthetic-resin Parts Part number Material Abbreviation of Heat-resistant material temperature (_C) Outside mirror Acrylonitrile Rear spoiler Butadiene styrene Roof antenna Acrylonitrile Ethylene butadiene Headlamp Polycarbonate Front bumper bezel Polycarbonate + PC + ABS 125 - 135 Rear door outside handle Acrylonitrile butadiene styrene Front door outside handle...
  • Page 11 NOTES...
  • Page 12 CORROSION PROTECTION CONTENTS BODY SEALING LOCATIONS ... . UNDERCOAT APPLICATION LOCATIONS . . . FLOOR ........UPPER BODY .
  • Page 13: Upper Body

    CORROSION PROTECTION - Body Sealing Locations BODY SEALING LOCATIONS NOTES REGARDING REPAIR WORK In places where the sealant can be directly seen on surfaces such as the drip rails, pillars, or clinch, and where the appearance of the paint surface is important, apply sealant or wipe away sealant after ▄...
  • Page 14 CORROSION PROTECTION - Body Sealing Locations...
  • Page 15 CORROSION PROTECTION - Body Sealing Locations Front door Hood Rear door Trunk lid...
  • Page 16 CORROSION PROTECTION - Undercoat Application Locations UNDERCOAT APPLICATION LOCATIONS In order to provide resistance to rust, corrosion, chipping, and vibration, an undercoat is applied to certain areas of the underbody. After completing body repairs, restore this undercoat if necessary. * Mark the areas indicated with asterisks to make sure no undercoat adheres to these areas. : Undercoat (Film thickness of at least 0.5 mm)
  • Page 17 NOTES...
  • Page 18 WELDED PANEL REPLACEMENT CONTENTS HEADLAMP SUPPORT ....ROOF ........FENDER SHIELD .
  • Page 19 NOTES...
  • Page 20: Headlamp Support

    WELDED PANEL REPLACEMENT - Headlamp Support HEADLAMP SUPPORT 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 21: Fender Shield

    WELDED PANEL REPLACEMENT - Fender Shield FENDER SHIELD 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 22 WELDED PANEL REPLACEMENT - Fender Shield (With the upper frame extension outer removed)
  • Page 23 WELDED PANEL REPLACEMENT - Fender Shield 17 points, left side only 5 points, left side only <LHD> 4 points, left side only <RHD(Right side)> <RHD>...
  • Page 24: Front Pillar

    WELDED PANEL REPLACEMENT - Front Pillar FRONT PILLAR 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 25: Center Pillar

    WELDED PANEL REPLACEMENT - Front Pillar NOTE ON REPAIR WORK REMOVAL Weld points As the front pillar reinforcement lower and side sill outer Front pillar reinforce- reinforcement front are welded at the side sill, cut the side ment lower outer panel at the position shown in the illustration where the weld points of the reinforcement can be seen, remove, and then remove the weld points of the front pillar reinforcement lower.
  • Page 26: Center Pillar

    WELDED PANEL REPLACEMENT - Center Pillar CENTER PILLAR 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 27 C-10 WELDED PANEL REPLACEMENT - Center Pillar NOTE ON REPAIR WORK Weld Center pillar points reinforcement REMOVAL 1. As the center pillar reinforcement and side sill outer reinforcement center are welded at the side sill, cut the side outer panel at the position shown in the illustration where the weld points of the reinforcement can be seen, remove, and then remove the weld points of the center pillar reinforcement.
  • Page 28 C-11 WELDED PANEL REPLACEMENT - Center Pillar <The following service procedures are only applied to RS-II.> 5. When attaching the center pillar inner, attach the center Center pillar silencer pillar silencer protector to the center pillar inner, and seal protector the holes of the center pillar silencer protector with butyl tape.
  • Page 29 C-12 WELDED PANEL REPLACEMENT - Side Sill SIDE SILL 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 30 C-13 WELDED PANEL REPLACEMENT - Side Sill NOTE ON REPAIR WORK INSTALLATION 1. Release the side outer panel from the new parts and remove unnecessary front pillar reinforcement lower, front pillar reinforcement lower extension, and center pillar reinforcement from side sill outer reinforcement.
  • Page 31: Quarter, Outer

    C-14 WELDED PANEL REPLACEMENT - Quarter, Outer QUARTER, OUTER 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 32 C-15 WELDED PANEL REPLACEMENT - Quarter, Outer NOTE ON REPAIR WORK Left side only INSTALLATION 1. When attaching the quarter outer, apply sealant to the areas indicated in the illustration. For RS-II, attach the rear pillar silencer protector, and fill the gaps with butly tape.
  • Page 33 C-16 WELDED PANEL REPLACEMENT - Quarter, Outer <The following service procedures are only applied to RS-II.> 2. After attaching the quarter outer, seal the holes and flanges with bolts and plate tape, and fill foam material from hole shown in the illustration. Foam material Type Brand Used...
  • Page 34 C-17 WELDED PANEL REPLACEMENT - Roof ROOF 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.) REPAIR WELDS...
  • Page 35: Rear End Panel

    C-18 WELDED PANEL REPLACEMENT - Rear End Panel REAR END PANEL 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...
  • Page 36: Rear Floor

    C-19 WELDED PANEL REPLACEMENT - Rear Floor REAR FLOOR 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 37 C-20 WELDED PANEL REPLACEMENT - Rear Floor (Vehicles with ACD) Right side only NOTE For details on the weld points with the rear end panel refer to REAR END PANEL on P.C-18. NOTE ON REPAIR WORK Rear seat back REMOVAL reinforcement 1.
  • Page 38: Quarter, Inner

    C-21 WELDED PANEL REPLACEMENT - Quarter, Inner QUARTER, INNER 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 39 C-22 WELDED PANEL REPLACEMENT - Quarter, Inner Left side (Vehicles with ACD) (With the side sill outer reinforcement rear removed.)
  • Page 40: Front Door Outer Panel

    C-23 WELDED PANEL REPLACEMENT - Front Door Outer Panel FRONT DOOR OUTER PANEL 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...
  • Page 41: Rear Door Outer Panel

    C-24 WELDED PANEL REPLACEMENT - Rear Door Outer Panel REAR DOOR OUTER PANEL 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...
  • Page 42 BODY DIMENSIONS CONTENTS BODY DIMENSIONS AND MEASUREMENT TYPE B (ACTUAL-MEASUREMENT METHODS ......DIMENSIONS) .
  • Page 43 BODY DIMENSIONS - Body Dimensions and Measurement Methods BODY DIMENSIONS AND MEASUREMENT METHODS Projecteddimension 1. Type A (projected dimensions) Height Indicates the dimension when a measurement location Probe is projected onto a plane. The difference in height of the measurement points should be taken into consideration when measuring.
  • Page 44 BODY DIMENSIONS - Body Dimensions and Measurement Methods NOTES...
  • Page 45 BODY DIMENSIONS - Type A (Projected Dimensions) <EVOLUTION- > TYPE A (PROJECTED DIMENSIONS) UNDER BODY 1,239 1,010 1,232 1,225 1,461 1,232 1,157 1,028 1,641...
  • Page 46 BODY DIMENSIONS - Type A (Projected Dimensions) 1,335 1,230 1,545 Standard measurement point Hole Size Standard measurement point Hole Size shape shape Centre of under cover mounting hole Front edge of center bearing mounting bolt Notch of front sidemember inner Front edge of center bearing mounting bolt Centre of crossmember mounting hole - 18...
  • Page 47 BODY DIMENSIONS - Type A (Projected Dimensions) INSTALLATION OF SUSPENSION 1,110 1,186 18 19 1,127 1,073 1,025...
  • Page 48 BODY DIMENSIONS - Type A (Projected Dimensions) Centre of vehicle ° ′ 4°24′ Centre of vehicle 3°12′ 1° 22 23 14 15 1,257 Standard measurement point Hole Size Standard measurement point Hole Size shape shape Centre of crossmember mounting hole - 18 Trailing arm mounting position Centre of front fioor sidemember positioning hole...
  • Page 49 BODY DIMENSIONS - Type B (Actual-measurement Dimensions) TYPE B (ACTUAL-MEASUREMENT DIMENSIONS) UNDER BODY 1,250 1,010 1,232 1,463 1,170 1,241 1,225 1,028 1,649...
  • Page 50 BODY DIMENSIONS - Type B (Actual-measurement Dimensions) Standard measurement point Hole Size Standard measurement point Hole Size shape shape Centre of under cover mounting hole Front edge of center bearing mounting bolt Notch of front sidemember inner Front edge of center bearing mounting bolt Centre of crossmember mounting hole - 18 Centre of rear seat crossmember positioning hole...
  • Page 51 B-10 BODY DIMENSIONS - Type B (Actual-measurement Dimensions) INSTALLATION OF SUSPENSION 1,186 1,137 1,075 1,025...
  • Page 52 B-11 BODY DIMENSIONS - Type B (Actual-measurement Dimensions) Standard measurement point Hole Size Standard measurement point Hole Size shape shape Centre of crossmember mounting hole - 18 Trailing arm mounting position Centre of crossmember mounting hole - 14 Control link mounting position Front edge of crossmember mounting bolt (Left Front edge of differential support mounting bolt side)
  • Page 53 B-12 BODY DIMENSIONS - Type B (Actual-measurement Dimensions) FRONT BODY 1,091 1,508 Body centre point 1,390 1,437 1,532 1,040 1,382 1,050...
  • Page 54 B-13 BODY DIMENSIONS - Type B (Actual-measurement Dimensions) Standard measurement point Hole Size Standard measurement point Hole Size shape shape Centre of front end crossmember upper drain hole Centre of hood hinge mounting hole Centre of harness clip mounting hole Corner of roof panel Centre of intercooler pipe mounting hole Centre of front end crossmember outer positioning...
  • Page 55 B-14 BODY DIMENSIONS - Type B (Actual-measurement Dimensions) SIDE BODY 1,127 1,174 1,084 1,100 1,067 1,094 1,124 1,041 Standard measurement point Hole Size Standard measurement point Hole Size shape shape Front pillar positioning notch (