MITSUBISHI LANCER EVOLUTION 2007 Service Owner's Manual

BODY CONSTRUCTION -Body Construction Characteristics
A
114 13B
13
1517
A-19
Rear Floor Sidemember Reinforcement
1 2 3 4 5 6 7810
912
1314
14
AB
111516
17
18 19
20
21
22
2 22
20
211113
1516
17
1. Trailing arm outer bracket
2. Rear floor sidemember support
3. Trailing arm inner bracket
4. Rear floor sidemember
5. Rear floor crossmember extension
6. Differential mount bulkhead
7. Differential mount reinforcement
8. Pipe
9. Square head bolt
10. Retainer
11. Rear suspension bracket12. Muffler hanger center
13. Rear floor sidemember reinforcement front
14. Muffler hanger rear
15. Rear floor sidemember reinforcement rear
16. Bumper stay reinforcement (RS)
17. Rear floor sidemember extension
18. Rear floor sidemember reinforcement
19. Upper link bracket
20. Toe-control link side reinforcement
21. Toe-control link bracket
22. Rear floor side sill

BODY CONSTRUCTION -Body Construction CharacteristicsA-20
DOOR
The front and back of the side door beam has been made large to cope with the force from the front
and sides during collision.
Front door
1 2 3 4567
8
9
10
11 12 1314
1516
17
18
19
Rear door
1. Front door hinge panel
2. Front door hinge reinforcement upper
3. Front door side door beam
4. Front door outer panel
5. Front door outside handle reinforcement
6. Front door beltline reinforcement outer
7. Front door window sash
8. Front door beltline reinforcement inner
9. Front door latch reinforcement
10. Front door inner panel11. Rear door hinge panel
12. Rear door side door beam upper
13. Rear door outer panel
14. Rear door beltline reinforcement outer
15. Rear door beltline bracket
16. Rear door window sash
17. Rear door beltline reinforcement inner
18. Rear door latch reinforcement
19. Rear door inner panel

BODY CONSTRUCTION -Silencer Application LocationsA-21
SILENCER APPLICATION LOCATIONS
Silencers (MD - 12 and melting sheets) are attached to the top of the floor to reduce vibration and insulate
against the heat from exhaust gas.
NOTE
MD - 12 is a high performance sheet composed of asphalt applied with mica and thermosetting resin for
improving anti-vibration performance.
: 1.6 mm thick melting sheet
: 3.2 mm thick melting sheet (Place two 1.6 mm melting sheets one on top of another.)
: 4.0 mm thick MD - 12 (Place three 1.6 mm melting sheets one on top of another.)
<RS>
<RS-II>
NOTE
The number in the parentheses indicates the number of melting sheet
used for repair.

BODY CONSTRUCTION -Locations Using Urethane Foam and Foam MaterialA-22
LOCATIONS USING URETHANE FOAM AND FOAM MATERIAL
1. Urethane foam is inserted into the center pillar to prevent the penetration of noise.
2. By filling the top of the front pillar, bottom of the front pillar, center pillar, side roof rail, rear pillar
and inside the wheel house arch with foam acoustic material, penetration of noise is prevented.
Precautions on performing work involving sheet metal at locations using foam material
As foam may burn when heated, observe the following precautions.
1. Do not perform heating work using gas burners at locations using foam material.
2. When cutting locations using foam material, use tools (air saw, etc.) which do not generate
heat.
3. If leftover foam material is present at the area to be cut (body side), remove the foam around
the area to be welded before proceeding with welding.
AB
C
A
B
C
Front pillar
inner lower
Foam
acoustic
material
Quarter
inner panel
Roof panel
Side roof rail inner
Rear wheel
house inner
panel
Front pillar
reinforcement
lower Side
outer panel
Front pillar
reinforcement
upper
Side outer
panel
Side
outer panelFoam acoustic
material
Foam
acoustic
material <RS-II>
<RS-II><RS-II>

BODY CONSTRUCTION -Locations Using Urethane Foam and Foam MaterialA-23
E
F
G
E
F
Side outer panel
Rear pillar inner
Side outer
panel
Rear door hinge
reinforcement
upperSide sill outer
reinforcement
center Center pillar
reinforcement
Front floor
side sill
inner Center
pillar inner
Side
outer panel
G
Foam acoustic
material
Foam
acoustic
material
Urethane
foam Rear door hinge
reinforcement
lower
D
D
Roof panel
Side roof rail inner
Foam
acoustic
material
<RS-II> <RS-II>
<RS-II>
<RS-II>

BODY CONSTRUCTION -Stiffener and Dump Sheet Application LocationsA-24
STIFFENER AND DUMP SHEET APPLICATION LOCATIONS
Stiffener is pasted to the inside of the side outer panel, and dump sheets are pasted on the inside
of the front doors to increase surface rigidity, thus improving soundproof qualities with the anti-vibration
effects.
NOTE
The stiffener comes in sheet form and is composed mainly of epoxy resin, glass fibers, and fillers. It hardens
when heated. It is used to improve the rigidity of outer panels.
Stiffener
Dump sheet
<Right side(RS-II)>

B-1
BODY
DIMENSIONS
CONTENTS
BODY DIMENSIONS AND MEASUREMENT
METHODS 2..............................
TYPE A (PROJECTED DIMENSIONS) 4.....
UNDER BODY 4............................
INSTALLATION OF SUSPENSION 6..........
TYPE B (ACTUAL-MEASUREMENT
DIMENSIONS) 8...........................
UNDER BODY 8............................
INSTALLATION OF SUSPENSION 10.........
FRONT BODY 12...........................
SIDE BODY 14.............................
REAR BODY 15............................
INTERIOR 16...............................

BODY DIMENSIONS -Body Dimensions and Measurement MethodsB-2
BODY DIMENSIONS AND
MEASUREMENT METHODS
1. Type A (projected dimensions)
Indicates the dimension when a measurement location
is projected onto a plane.
The difference in height of the measurement points should
be taken into consideration when measuring.
2. Type B (actual-measurement dimensions)
Indicates the actual distance between the measurement
points.
Measure using a tracking gauge or a measuring tape,
etc.
NOTE
DMake the lengths of the tracking gauge probes the
same (A=A’).
DDo not bend or twist the measuring tape.
3. Insert the tracking gauge probes securely into the
measurement holes
4. When the standard dimensions in the illustration are
enclosed by, this indicates that the symmetrical left and
right positions have the same dimensions.
5. When using a notch for dimension measurement, set
the measuring point at the centre of the notch.
6. When measuring the suspension mounting arm, or link
mounting position, use the suspension mounting bolt,
etc..
7. The body centre points are shown for the purpose of
checking the position of the left and right symmetry
locations.Height
Probe
Projecteddimension
A’
Actually-measured
dimension
A
Centre
of hole
Bolt
Measuring point

BODY DIMENSIONS -Body Dimensions and Measurement MethodsB-3
NOTES

BODY DIMENSIONS -Type A (Projected Dimensions)B-4
<EVOLUTION->
TYPE A (PROJECTED DIMENSIONS)
UNDER BODYmm
750713810
1,2321,010940
247
982
1,641
1,028
786
722
1,2321,461905909
1,157
1,225
544
1,239
340
338
153
161
715
756
848
872
1
2
34
5
6
7
8
9
1011
1234
5
67
8
9
1011
714