2007 MITSUBISHI LANCER EVOLUTION Service Repair Manual

WELDED PANEL REPLACEMENT -Side SillC-13
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 the side sill outer
reinforcement.
2. When attaching the side sill outer reinforcement, apply
adhesive to the areas indicated in the illustration.
: Adhesive
Adhe-
sive
TypeBRAND
siveEpoxyayresin
adhesive3M DP-460, 3M DP-420 or
equivalent
3. When attaching the side outer panel, apply body sealant
to the areas indicated in the illustration.
: Body sealant
Reference
Depending on the damaged range, it is advisable to replace
the side outer panel and side sill outer reinforcement parts.
:Cuttable range
Caution
Cut the side sill outer reinforcement 50 mm away from
the cut area of the side outer panel.
Center pillar Front pillar

WELDED PANEL REPLACEMENT -Quarter, OuterC-14
QUARTER, OUTER
SymbolOperation description
Spot welding
MIG plug welding (J: indicates two panels to be
welded
Y: 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.)
B
D
C
A
B
160±50mm
A
E
500±50mm
C
REPAIR WELDS
Foam acoustic material

Foam acoustic material
3 pointsLeft side

Caution
Do not use heat at areas using foam material as the foam material may burn.

WELDED PANEL REPLACEMENT -Quarter, OuterC-15
D
E
F
F
NOTE ON REPAIR WORK
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.
: Body sealant
Rear pillar
silencer protector
Left side only

WELDED PANEL REPLACEMENT -Quarter, OuterC-16
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 materialTypeBrand Used
Foam acoustic
materialTwo-part expanded
wretane3M ULTRAPRO
Panel foam - Yellow
3. After two hours after filling the foam material, remove
the bolts and plate tape, and solder the sealed holes
until a clip, etc. can be inserted completely.
Reference
Parts replacement is advised. depending on the damaged
range.
: Cuttable range
Caution
Avoid the fuel filler bracket (left side).

WELDED PANEL REPLACEMENT -RoofC-17
ROOF
SymbolOperation description
Spot welding
MIG plug welding (J: indicates two panels to be
welded
Y: 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
A
C
C
AB
BD
D
: Adhesive
AdhesiveType
Chloroprene-base drying sealant

WELDED PANEL REPLACEMENT -Rear End PanelC-18
REAR END PANEL
SymbolOperation description
Spot welding
MIG plug welding (J: indicates two panels to be
welded
Y: 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

WELDED PANEL REPLACEMENT -Rear FloorC-19
REAR FLOOR
SymbolOperation description
Spot welding
MIG plug welding (J: indicates two panels to be
welded
Y: 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.)
AD
C
B
AB
EF
REPAIR WELDS

WELDED PANEL REPLACEMENT -Rear FloorC-20
CD
EF
(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
REMOVAL
1. Cut the rear floor panel 320±10 mm from the back
of the rear seat back reinforcement.
Cut the rear floor pan 200±50 mm from the back of
the rear seat back reinforcement as shown in the
illustration.
Rear seat back
reinforcement
200±50 mm