2004 MITSUBISHI LANCER EVOLUTION VIII Workshop Manual

01
GENERAL MODEL LINEUP , APPLIED VEHICLES
SECTION 0
GENERAL
CONTENTS
Model lineup
Note
= Continued model
Applied vehicles
GHCT9A: CT9A0300001 ~
Model lineup...........................................01
Applied vehicle numbers .......................01Main specifications.................................02
ModelVersion’04 ModelGradeEngine ModelTransmissionFuel System
GHCT9ASNDFZ
SJDFZ
SJGFZ

RS
RS
GSR4G63
(2 000 DOHC 16 valve
intercooler turbo)W5M51 (4WD, 5M/T)
W6MAA (4WD, 6 M/T)MPI

02GENERAL MAIN SPECIFICATIONS
ITEMGHCT9A
SNDFZSJDFZSJGFZ
ClassOrdinary
UsePassenger
vehicle
Body
shapeSaloon
4490
1770
1450
Vehicle length mm
Vehicle width mmVehicle height mm
Distance between axles mm
2625
Front1515*1,
1500*21515*1Distance between
wheels mm
Rear1515*1,
1500*21515*1
Minimum ground clearance mm140
Length1880
Width1425
Interior dimensions
mm
Height1185
Front825
Dimensions
Body overhang mm
Rear875
Toein mm0±2
Camber *31º 00´ ±30´ or 2º 00´ ±30´
Castor3º 55´ ±30´
Front
wheels
King pin angle13º 45´
Toein mm3 ±2Rear
wheels
Camber1º 00´ ±30´
Driving
devices
Tyre size205/65R15 94H
235/45ZR17235/45ZR17
MAIN SPECIFICATIONS
Notes
1. *1 in the case of vehicles fitted with 17 inch tyres *2 in the case of vehicles fitted with 15 inch tyres
2.*3 it is possible to select from 3 types of camber. This is be set to 1˚ 00´ ±30´ when shipped from the factory.

11BODY CONSTRUCTION – GENERAL, BODY CONSTRUCTION SPECIAL FEATURES
SECTION 1
BODY CONSTRUCTION
CONTENTS
Summary .................................................11
Body construction ..................................11Roof..........................................................11
Doors........................................................12
Summary
• The roof and side door beams have been changed from steel to aluminium.
Body Construction Special Features
ROOF
Body is now lighter as a result of changing the roof panels to aluminium.
The body is also more rigid now as a result of additional support in pillar areas.
:shaded areas indicate parts that are the same as those used on current vehicle.
a
Roof panel
Rear pillar upper support
Centre pillar upper support
Front pillar upper support

12BODY CONSTRUCTION – BODY CONSTRUCTION SPECIAL FEATURES
DOORS
The body has been lightened as a result of using aluminium for the side door beams.
FRONT DOOR
Front door side door beam
Rear door side door beam
REAR DOOR
:shaded areas indicate parts that are the same as those used on current vehicle.a

21STANDARD DIMENSIONS – GENERAL, B TYPE (straight line measurements)
SECTION 2
STANDARD DIMENSIONS
CONTENTS
General ....................................................21
B type (straight line measurements) ....22Roof..........................................................22
General
Together with the changes relating to roof panel replacement, dimensions without the roof in place are specified.
B Type (straight line measurements)
ROOFunits mm
Diagram shows roof assembly removed condition.
NumberMeasurement pointsHole shapes – Sizes (mm)NumberMeasurement pointsHole shapes – Sizes (mm)
90Side roof rail inner corner91Side roof rail inner corner

31CHANGING WELDED PANELS GENERAL
SECTION 3
CHANGING WELDED PANELS
CONTENTS
Summary .................................................31
Body construction ..................................32
Aluminium alloy panels..........................35Repairing aluminium alloy panels ........35
Painting aluminium alloy panels .........310
General
Along with the change to an aluminium roof, important roof replacement details have been specified.

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