2004 MITSUBISHI LANCER EVOLUTION VIII roof

32CHANGING WELDED PANELS – ROOF
SymbolOperation details
Spot welding
MIG plug welding ( : two layers : three layers)
+ + + +MIG spot welding
MIG arc welding (continuous)
Rivet
Areas where rust inhibitor is applied. (Applied using
holes in butt welded locations)
Front pillar
upper supportCentre pillar
upper supportRear pillar upper
support
Note
: these welding points are done by manufacturer (not necessary during repairs).
:
black shading indicates areas where structural adhesive is applied.
AdhesiveTypeProduct name
Epoxy structural adhesiveSumitomo 3M Auto Mix Panel Bond 8115
SERVICE JOINTS

33CHANGING WELDED PANELS – ROOF
(Front pillar upper support (Rear pillar upper support
removed condition) removed condition)
IMPORTANT POINTS TO OBSERVE WHEN DOING THE
WORK
REMOVAL
1.When removing the roof, use a support to prevent the side
panels opening out or leaning in.
2. To cut weld the front or rear roof rail, remove the front pillar
upper support and rear pillar upper support.
3. Using a drill (
5mm), make a hole in through the centre of the
rivet, crack it, and remove. Normally, selfpiercing rivets are
used, but blind rivets may also be used.
For areas where there is adhesive, use a cold chisel or similar
tool to free and remove the roof.Selfpiercing rivetBlind rivet
Drill
Rivet
Roof panel

34CHANGING WELDED PANELS – ROOF
Fitting
1.Temporarily set the new roof to the body, and drill holes for
rivets with drill (
5mm).
2. Remove the roof, smooth off any burring around the holes,
then clean the body.
3. Apply structural adhesive to the body side, then fit the roof.
4. Using the appropriate tool, set the rivets as follows:
Rivets: POP rivet SD62HR
(1) Insert the rivet into the hole in the base material (roof).
(2) Insert the appropriate tool into Part A of the rivet.
(3) Using the appropriate tool, use the tool handle to press therivet flange surface down.
(4) Secure the rivet, snapping at the thin part of A.
Note
In places where setting rivets so that flange makes good
contact is difficult, it is OK to set from inside the vehicle.
Reference:
Appropriate tool (use rivet
4.8mm)
Lobster Tools Ltd
Hand riveter: HR003B
5.When adhesive is dry, remove any excess adhesive then, to
prevent water ingress, apply body sealant to cover entire rivet
area and roof edge.
:black shading indicates body sealant
Product name:Sun Star Penguin Seal 353 (white)
Adhesive TypeProduct name
Epoxy structural
adhesiveSumitomo 3M Auto Mix
Panel Bond 8115
appropriate tool
part A appropriate
tool
flange
rivet
Roof panel
Body sealant
Rivet

GENERAL INFORMATION - DETAILS OF CHANGES0-3
Main circuit Name of circuit Page Details of change
J/C - p.3-2• Partial changes to circuit and
destination system names in J/C(1) —
(6)
-• With the introduction of manual air
conditioning, the circuit used by the
fusible link No.2 has been changed.
• Wastegate solenoid valve 2 added to
load of special fuse No.3.
• Rating of special fuse No.10 changed
from 15A to 20A.
Power supply - p.3-10• Partial changes to destination system
names.
• Earth No.13 added.
• Rating of special fuse No.10 changed
from 15A to 20A.
• Partial changes to circuit details, due
to removal of sunroof.
Engine control - p.3-16• Rating of special fuse No.10 changed
from 15A to 20A.
• Earth No.13 added.
• Some changes to circuit, due to
addition of wastegate solenoid valve
2 (B-32).
• Partial changes, due to removal of
DVD-MMCS
Lighting Interior lights, boot interior
light, ignition key cylinder
illumination light, door not
closed indicator light-• Change to terminal number in J/C(2)
(C-119) on line linking ETACS and
diagnosis connector. (No.1 " No.5)
Reversing lights -• Change to terminal number in J/C(2)
(C-119) on line linking reversing light
and rear combination light (LH).
(No.18 " No.19)Signal
Stop lights p.3-24• Spare connector (F-28) added, and
circuit partially changed.
Meters / Gauges -Meters
Remaining fuel warning
light, oil pressure warning
light, brake warning light,
seatbelt warning light-• Change to terminal number in J/C(1)
(C-07) on line inking J/B (general fuse
No.18) and combination meter. (No.4
" No.8)
• Change to terminal number in J/C(4)
(C-110) on line linking combination
meter and fuel gauge unit (sub).
(No.20 " No.21)
Door opening
controlElectric windows -• Change to terminal number in J/C(2)
(C-119) on line linking power window
main switch and diagnosis connector.
(No.12 " No.14)
Fully automatic air
conditioning-• Change to terminal number in J/C(1)
(C-07) on line linking J/B (general
fuse No. 18) and A/C-ECU. (No.6 "
No.4)
• Change to terminal number in J/C(5)
(C-06) on line linking A/C-ECU and
diagnosis connector. (No.8 " No.9)Air
conditioning
Manual air conditioning p.3-26• With the adoption of manual air
conditioning, a new circuit has been
installed.
Windscreen wipers and
washers-Safety and
visibility
Electric retractable remote
control door mirrors-• Change to terminal number in J/C(2)
(C-119) on line linking ETACS and
diagnosis connector. (No.1 " No.5)
Circuit diagrams
M3000004500157

GENERAL INFORMATION - LIST OF CIRCUIT DIAGRAMS0-6
Main circuit Name of Circuit Circuit Diagram
Windscreen wipers, washers *2!
Rear wiper, washer!
Demister (vehicle not fitted with fully automatic A/C)!
Demister, door mirror heating elements (vehicle fitted with
fully automatic A/C)!
Safety / Visibility
Electric retractable remote control door mirrors *2
!
Spare Audio connectors *1,2!
DVD-MMCS X
Clock *1,2!
Accessories
Cigar lighter, ashtray illumination light
!
ABS#
ACD (vehicle not fitted with AYC)#
ACD, AYC#
SRS airbags, seatbelt pre-tensioners (vehicle not fitted
with side airbags)!
SRS airbags, seatbelt pre-tensioners (vehicle fitted with
side airbags)!
Sun roof X
Ignition key reminder buzzer!
Intercooler water spray *2!
Engine immobiliser system#
Security alarm!
Spare connectors for fog lights!
Special Equipment
Spare general connectors *2
!