SERVICE MANUAL

BODY

Supplement
 LANCER
EVOLUTION VIII
MR
FOREWORD CONTENTS
This manual contains details of the main changes to
the 2004 model Lancer Evolution VIII MR. Only
differences to the current Lancer Evolution VIII are
included, so please use this manual in conjunction with
the related information specified on the next page.
General.......................................... 0
This information relates to the current vehicle (February
2004). Since specifications will change, some of the
information contained here will inevitably be
superseded. Body construction ....................... 1
Note that SI units are used in this manual. Old units are
not shown alongside them.
(However, old units are used for some figures we have
taken from existing documents). Standard measurements ............. 2
Any opinions, requests, or questions concerning this
manual, should be written on the ‘Servicing
Comments Form’ at the end, and sent to us by fax.
Changing welded panels............. 3
February 2004

MITSUBISHI MOTOR CORPORATION

Rust treatment.............................. 4

Plastics parts................................ 5

Body colour .................................. 6

Wiring layout and diagrams ........ 7

Reference materials ..................... 8

There are no changes to the shaded chapters,
so they are not included at all in this manual.

This manual is printed on recycled paper.

Related information

Title No. Issue date Title No. Issue date

New model manuals Body Service Manuals
• Mirage, Lancer 1036F30 10/1995 • Mirage, Lancer 1036F52 8/1996
(supplement)
• Mirage, Lancer 1036F31 1/1996 • Lancer Sedia 1036K50 5/2000
• Mirage, Lancer 1036F32 8/1996 • Lancer Sedia 1036K51 7/2000
(supplement)
• Mirage, Lancer 1036F33 7/1997 • Lancer Evolution VII 1036K52 5/2001
(supplement)
• Lancer 1036F34 1/1998 • Lancer Sedia 1036K53 10/2001
(supplement)
• Mirage, Lancer 1036F35 10/1998
• Lancer 1036F36 1/1999
• Lancer 1036F37 12/1999
• Lancer Sedia 1036K30 5/2000
• Lancer Sedia 1036K31 7/2000
• Lancer Evolution VII 1036K32 1/2001 Wiring layout diagram
Service Manuals
• Lancer Sedia 1036K33 5/2001 • Lancer Evolution VIII 1036K77 1/2003
• Lancer Sedia 1036K34 5/2001 • Lancer Evolution VII 1036K80 2/2004
MR (Supplement)
• Lancer Evolution VII 1036K35 1/2001
• Lancer Sedia 1036K36 5/2002
• Lancer Evolution VIII 1036K37 1/2003
• Lancer 1036K38 2/2003
• Lancer 1036K39 12/2003
• Lancer Evolution VIII MR 1036K40 2/2004
Service Manuals Engine Service Manuals
• Lancer Sedia 1036K00 5/2000 • 4G6 Engine 1039G46 1/2001
• Lancer Sedia 1036K01 7/2000 • 4G6 Engine 1039G63 1/2003
• Lancer Evolution VII 1036K02 1/2001
(supplement)
• Lancer Sedia (supplement) 1036K03 5/2001
• Lancer Sedia (supplement) 1036K04 10/2001 Transmission Service
Manuals
• Lancer Evolution VII 1036K05 1/2002 • W5M51 Manual 1039M17 1/2001
(supplement) Transmission
• Lancer Sedia (supplement) 1036K06 5/2002 • W5M51Manual 1039M22 1/2003
transmission
(Supplement)
• Lancer Evolution VII 1036K07 1/2003 • W6MAA Manual 1039M23 1/2003
(supplement) transmission
• Lancer (supplement) 1036K08 2/2003
• Lancer (supplement) 1036K09 12/2003
• Lancer Evolution VIII MR 1036K10 2/2004

Precautions to be taken when servicing vehicles with seatbelts fitted with SRS Airbag and Pretensioners
Precautions
1. Incorrect inspection or servicing of SRS airbag and pretensioner fitted seatbelt parts, as well as any related
components, could lead to major damage or non-operation as a result of sudden, unintentional operation of SRS
airbag and pretensioner fitted seatbelts (incorrect deployment).
2. In cases where heating from painting processes occurs, the SRS-ECU, driver side airbag module, passenger side
airbag module, pre-tensioner fitted seatbelts, and cross springs, should be removed.
• 93°C and above: SRS-ECU, driver side airbag module, passenger side airbag module, cross springs
• 90°C and above: pretensioner fitted seatbelts
3. Inspections and servicing of SRS airbag and pretensioner fitted seatbelt parts and any related components must,
without fail, be done by a Mitsubishi Motors authorized dealer.
4. Inspections and servicing of SRS airbag and pretensioner fitted seatbelt parts and any related components must be
done paying scrupulous attention to the relevant service manual (particularly in the case of Group 52B – SRS
airbags).
 GENERAL - MODEL LINE-UP, APPLIED VEHICLES 0-1

SECTION 0

GENERAL
CONTENTS
Model line-up...........................................0-1 Main specifications.................................0-2
Applied vehicle numbers .......................0-1

Model line-up

Model Version ’04 Model Grade Engine Model Transmission Fuel System
GH-CT9A SNDFZ ¡ RS 4G63 W5M51 (4WD, 5M/T) MPI
(2 000 DOHC 16 valve
intercooler turbo)

SJDFZ ¡ RS W6MAA (4WD, 6 M/T)

SJGFZ ¡ GSR

Note
¡ = Continued model

Applied vehicles
GH-CT9A: CT9A-0300001 ~
0-2 GENERAL - MAIN SPECIFICATIONS

MAIN SPECIFICATIONS

ITEM GH-CT9A
SNDFZ SJDFZ SJGFZ
Class Ordinary
Use Passenger
vehicle
Body Saloon
shape
Dimensions Vehicle length mm 4490
Vehicle width mm 1770
Vehicle height mm 1450
Distance between axles mm 2625
Distance between Front 1515*1, 1515*1
2
wheels mm 1500*
Rear 1515*1, 1515*1
2
1500*
Minimum ground clearance mm 140
Interior dimensions Length 1880
mm Width 1425
Height 1185
Body overhang mm Front 825
Rear 875
Driving Front Toe-in mm 0±2
devices wheels Camber *3 -1º 00´ ±30´ or -2º 00´ ±30´
Castor 3º 55´ ±30´
King pin angle 13º 45´
Rear Toe-in mm 3 ±2
wheels Camber -1º 00´ ±30´
Tyre size 205/65R15 94H 235/45ZR17
235/45ZR17

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.
 BODY CONSTRUCTION – GENERAL, BODY CONSTRUCTION SPECIAL FEATURES 1-1

SECTION 1

BODY CONSTRUCTION
CONTENTS

Summary .................................................1-1 Roof..........................................................1-1

Body construction ..................................1-1 Doors........................................................1-2

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.

Roof panel

Rear pillar upper support

Centre pillar upper support

Front pillar upper support

a : shaded areas indicate parts that are the same as those used on current vehicle.
1-2 BODY 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

Rear door side door beam

a : shaded areas indicate parts that are the same as those used on current vehicle.
 STANDARD DIMENSIONS – GENERAL, B TYPE (straight line measurements) 2-1

SECTION 2

STANDARD DIMENSIONS
CONTENTS
General ....................................................2-1 Roof..........................................................2-2
B type (straight line measurements) ....2-2

General
Together with the changes relating to roof panel replacement, dimensions without the roof in place are specified.

B Type (straight line measurements)

ROOF units mm

Diagram shows roof assembly removed condition.

Number Measurement points Hole shapes – Sizes (mm) Number Measurement points Hole shapes – Sizes (mm)

90 Side roof rail inner corner - 91 Side roof rail inner corner -
3-1 CHANGING WELDED PANELS - GENERAL

SECTION 3

CHANGING WELDED PANELS

CONTENTS
Summary .................................................3-1 Repairing aluminium alloy panels ........3-5
Body construction ..................................3-2 Painting aluminium alloy panels .........3-10
Aluminium alloy panels..........................3-5

General
Along with the change to an aluminium roof, important roof replacement details have been specified.
 CHANGING WELDED PANELS – ROOF 3-2

Symbol Operation 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)

SERVICE JOINTS

Rear pillar upper

Centre pillar support
Front pillar
upper support
upper support

Note
❉: these welding points are done by manufacturer (not necessary during repairs).

: black shading indicates areas where structural adhesive is applied.

Adhesive Type Product name

Epoxy structural adhesive Sumitomo 3M Auto Mix Panel Bond 8115

3-3 CHANGING 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.

Self-piercing rivet Blind rivet 3. Using a drill (∅5mm), make a hole in through the centre of the
rivet, crack it, and remove. Normally, self-piercing rivets are
Drill 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.
Rivet

Roof panel
 CHANGING WELDED PANELS – ROOF 3-4
Fitting
appropriate tool 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.

Adhesive Type Product name

Epoxy structural Sumitomo 3M Auto Mix
adhesive Panel Bond 8115
appropriate
part A tool 4. Using the appropriate tool, set the rivets as follows:
Rivets: POP rivet SD-62-HR
flange (1) Insert the rivet into the hole in the base material (roof).
(2) Insert the appropriate tool into Part A of the rivet.
rivet
(3) Using the appropriate tool, use the tool handle to press the
rivet 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: HR-003B

5. When adhesive is dry, remove any excess adhesive then, to

Roof panel 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)

Body sealant

Rivet
3-5 CHANGING WELDED PANELS – ALUMINIUM ALLOY PANELS

ALUMINIUM ALLOY PANELS

Repairing Aluminium Alloy Panels

Precautions when working on sheet metal

1. The main differences to working with sheet steel. (Assuming an ordinary body shop)

Operation Aluminium alloy panel Sheet steel

Hammering Wood or plastic hammer Sheet steel hammer
Washer welding Not possible Possible
Gas welding Workability is poor but possible Possible
Spot welding Not possible Possible
MIG welding Possible with welder using argon gas and equipment for Possible with CO2 gas and normal welding
aluminium welding equipment

2. At low temperatures, if subjected to a major impact, strength will deteriorate and it will crack.
3. Coefficient of elasticity is high, so spring-back (force acting to make material regain original form) is high.
4. Rate of heat transmission is high, and this can cause local thermal expansion.
5. If overheated, it becomes brittle, and strength deteriorates. If heated further, it will melt without discolouration.
(Heat treatment temperature: approx. 250˚C)
Material Welding temperature
Aluminium 475˚C~660˚C (varies depending on alloy composition)
Sheet steel 1500˚C~2500˚C

6. Material is soft, so be careful when selecting polish to use.

Also, since polishing powder is light and easily airborne, wear dust mask and goggles.
7. If strong pressure is used when using a disk sander on the alloy, the friction could cause the aluminium alloy to peel off,
and cause clogging.
8. Disk sanders that become clogged will cause deep scratching on aluminium alloy panels, so replace promptly.
9. Do not use general tools or sanders for sanding sheet steel.
(steel fragments or dust will remain on the sander, causing electro-corrosion with other metal)
10. With MIG welding, shield the local area. Sparks, often difficult to see, can be generated and dispersed over a wide area.

Repairing unevenness
This is basically the same as for sheet steel. However, bear in mind
aluminium alloy characteristics when carrying out this work.
1. Repairing sheet metal
(1) Heat with a torch

Note
a. Heat to the point where heat can be felt on the rear side
of panel with hand wearing a glove.
b. Keep torch moving so as not to overheat one area.
CHANGING WELDED PANELS – ALUMINIUM ALLOY PANELS 3-6
(2) When hammering, note that the panels stretch easily, so use a
wooden or plastic hammer.
Note
Reduce stretching and process hardening, and do not
leave hammer marks.

2. Check for distortion

Polish with #80 ~ #120 grade sandpaper, checking for any
distortion.

3. Removing distortions
Remove any distortions Using a levelling hammer and a torch,
correct any distortions.
Note
(1) Heat to about 250˚C to do this work.
(2) Be careful when heating so as not to cause
discolouration when welding.
(3) Use a damp cloth to prevent heat increases which
could result in heat affecting heated area (distortion
etc.)
(4) Do not use drawing hammers which are used for
sheet steel, as this could result in cracking.

4. Polishing
Polish with a disk or a double action sander.
• Disk sander: #100 ~ #120
• Double action sander: #150 ~ #180
Note
Since the material is softer than sheet steel, choose a
polishing material that does not scour the surface deeply.

Repairing cuts and tears

When sheet steel panels are cut, torn, or have holes, repair using
CO2 MIG welding. However, with aluminium alloy panels, use MIG
or TIG welder and use argon gas (inert gas) as shield gas.

Extent of distortion from welding

Gas welding (large distortion) > TIG welding > MIG welding (little
distortion).
Here we explain the MIG welding process, where distortion
resulting from welding is small.
3-7 CHANGING WELDED PANELS – ALUMINIUM ALLOY PANELS

MIG welding procedure

1. Repairing sheet metal
These should be repaired by heating the damaged part gently,
and lightly hammering. The areas stretched by hammering out
should be cut away using an air saw.
Note
(1) Take care not to overstretch or damage the panel.
(2) The gaps at the joint areas should be as narrow as
possible.

2. Welding
This work should be done using equipment designed for
aluminium welding or equipment that can be used for both
aluminium and steel plate welding.
• Welding wire: 5356, 5556, 5183 (JIS classifications)
• Wire dia.: 0.8 or 1.0mm
(1) Remove any grease from welding areas using white spirit
or similar.
(2) Immediately prior to welding, remove any oxidation film
with a stainless steel wire brush (including the rear side), and
carry out the work immediately after cleaning.
Note
To minimize distortion and material melting and coming
away, weld a little at a time, rather than welding long
stretches.

3. Inspecting welded areas

After finishing off areas sanded with #100 disk sander, check
that there are no inadequately welded parts (red check).
Note
The panel surface should not be excessively sanded away.

4. Checking for distortions

Polish with #80 ~ #120 sandpaper, and check for distortion.
5. Removing distortions
Remove any distortions by pressing out using a levelling
hammer and a torch.
Note
(1) Heat to approx. 250˚C to do this work
(2) Take care when heating so that welding can be done
without heating causing any discolouration
CHANGING WELDED PANELS – ALUMINIUM ALLOY PANELS 3-8
(3) Use a damp cloth to prevent temperature rising and
causing distortion or other effects in the area being
heated.
(4) Do not use levelling hammers which are used for sheet
steel as they can cause cracking.

6. Finishing
Finish off with #100~#120 grade disk sander.

Note
As spark marks and carbon adhesion can have an
adverse effect during painting, remove completely using a
stainless steel wire brush.

Other welding
1. TIG welding
The process is basically the same as MIG welding, using the
same arc welder, but instead of using an electrode wire, a rod
coated with flux is used.
To help prevent distortion from the heat generated in welding,
and poor quality welding, this job should be done by someone
with suitable training and practice.
• Welding rod: 5356, 5556, 5183 (JIS classification)
• Diameter: 1.6mm

2. Gas welding (oxyacetylene)

In essence, if gas welding can be done, then a welding rod
and flux (for cleaning and reducing oxide inclusions) can be
used.
To help prevent distortion from the heat generated in welding,
and poor quality welding, this job should be done by someone
with suitable training and practice.

• Welding rod: 5356, 5556, 5183 (JIS classification)

• Diameter: 1.6mm

(1) Flux is made to adhere by heating the welding rod.

3-9 CHANGING WELDED PANELS – ALUMINIUM ALLOY PANELS

(2) Melt the flux with the torch, and weld, removing oxide film.

Note
The molten welding rod flows easily, so as far as possible
keep the surface being welded flat.
(3) Flux left on the panel should be removed using a stainless
steel wire brush or similar.

Finishing filler
1. Polish areas filled with filler using #150 ~ #180 (double action
sander).
2. Clean away any grease on the surfaces where there is filler.
3. Apply 2 part epoxy primer or, for a primer pre-treatment
designed for use with aluminium.
4. Flatten down with # 180 (double action sander)
5. Remove grease and clean surface areas where there is filler.
6. Paint filler in sheet metal, and allow to dry naturally.

Note
Do not speed up by drying at 60˚C or over.

7. Polish with #180.

 CHANGING WELDED PANELS – ALUMINIUM ALLOY PANELS 3-10
Painting aluminium panels

Painting on the production line

Same as for painting ordinary steel plate.

Painting for repairs

The main points for repairs in general are as follows.
Paint adhesion to aluminium alloy panels is not quite as good as ordinary steel plate, so pay careful attention to precautionary
notes.

1. Peeling of paint film

Caution: avoid harsh polishing, and try not to generate heat during polishing.

2. Clean and remove any grease

3. Apply wash primer

4. Dry

5. Apply primer surfacer

6. Dry
Note: do not speed up by drying at over 60˚C.

7. Polish

8. Clean, remove any grease

9. Overcoat

10. Dry
Note: do not speed up by drying at over 60˚C.

Remarks:
1. Please refer to paint manufacturer’s instructions for details.
2. Same as for paint repair jobs done on stainless steel plate.
6-1 BODY COLOUR GENERAL, BODY COLOUR LIST, DIFFERENT BODY COLOUR PAINT SECTIONS

SECTION 6

BODY COLOUR
CONTENTS
General ....................................................6-1 Body colour paint sections ...................6-1
Body colour list.......................................6-1 Rear spoiler........................................................6-1

General
This specifies body colour and different body colour paint sections.

Body Colour List

Name of colour Colour symbol Colour code Colour (paint) Content of paint Repair symbol Paint
(old colour number manufacturer
name)
Cool silver CL A31 CMA10031 Aluminium M Kansai Paint
metallic
Medium Gun- ES A39 CMA 10039 Aluminium + 2P Nippon Paint
Metal grey mica mica
Solid White 2E W83 AC10983 - S Kansai Paint
(Scotia White)
Solid Red JW P85 AC11185 - S Kansai Paint
(Parma Red)

Remarks
1. Repair symbols show only overcoat S: solid M: Metallic 2P: 2 coat pearl.
2. The paint manufacturer’s names are the names used at time of manufacturing.

Different Body Colour Paint Sections

The different rear spoiler paint sections are specified below.

Rear Spoiler

1 Gun metal grey (CMA1002)

2 Part material colour

RJYJ402022–22