to pair MITSUBISHI LANCER EVOLUTION VIII 2004 Workshop Manual

Body RepairChassisElectricalTechnical Info

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

35CHANGING 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)
OperationAluminium alloy panelSheet steel
HammeringWood or plastic hammerSheet steel hammer
Washer weldingNot possiblePossible
Gas weldingWorkability is poor but possiblePossible
Spot weldingNot possiblePossible
MIG weldingPossible with welder using argon gas and equipment for
aluminium weldingPossible with CO2gas and normal 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 springback (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)
MaterialWelding temperature
Aluminium475˚C~660˚C (varies depending on alloy composition)
Sheet steel1500˚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 electrocorrosion 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.

36CHANGING WELDED PANELS – ALUMINIUM ALLOY PANELS
(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
CO
2MIG 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.

37CHANGING 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 bothaluminium 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

310CHANGING WELDED PANELS – ALUMINIUM ALLOY PANELS
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.

61BODY COLOUR GENERAL, BODY COLOUR LIST, DIFFERENT BODY COLOUR PAINT SECTIONS
SECTION 6
BODY COLOUR
CONTENTS
General ....................................................61
Body colour list.......................................61Body colour paint sections ...................61
Rear spoiler........................................................61
General
This specifies body colour and different body colour paint sections.
Body Colour List
Name of colour
(old colourname)Colour symbolColour codeColour (paint)
numberContent of paintRepair symbolPaint
manufacturer
Cool silver
metallicCLA31CMA10031AluminiumMKansai Paint
Medium Gun
Metal grey micaESA39CMA 10039Aluminium +
mica2PNippon Paint
Solid White
(Scotia White)2EW83AC10983SKansai Paint
Solid Red
(Parma Red)JWP85AC11185SKansai Paint
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
1Gun metal grey (CMA1002)
2Part material colour
RJYJ402022–22

MPI – Troubleshooting13A3
Connector inspection : B32
Change No.2 wastegate solenoid valve.
Check connector:B19X
Inspect, repair harness between No.2 wastegate
solenoid valve and engine control relay.
• Check for broken wire and shorting.
Check connector:C49
Replace engine ECU
Check harness between No.2 wastegate
solenoid valve and engine ECU.
• Check output wire to see if broken or shorting.
Check connector: C49
Replace engine ECU.
B32 No.2: measure at wastegate solenoid valve
connector
• Undo connector and take measurement on
solenoid valve side
• Resistance between 1 and 2
OK:29 35Ω(at 20˚C)
Measure at B32 No.2 waste gate solenoid valve
connector.
• Undo connector and take measurement on
harness side.
• Ignition switch ON:
• Resistance between 1 – earth
OK:battery voltage
Measurement at C49 engine ECU connector
•Engine ECU terminal voltage measurement
• Ignition switch: ON
• Voltage between 6 – Earth
OK:battery voltage
Check harness between No.2 wastegate
solenoid valve and engine ECU.
• Check for damage to output wire.
Check harness between No.2 wastegate
solenoid valve and engine control relay.
•Check for damage to power supply cable.
TROUBLESHOOTING
1.Inspection procedures for different types of malfunction
Inspection procedure 37
No.2 Wastegate solenoid valve system <6M/T>
The No.2 wastegate solenoid valve controls excess pressure
introduced via the turbocharger wastegate actuator.
Assumed cause of concern
• No.2 wastegate solenoid valve malfunction
• Engine ECU malfunction
Repair
Repair
Repair
Repair
OK
OK
OK
OK
OK
OK
OK
NG
NG
NG
NG
NG
NG
NG
NGRepair
NGRepair
Repair
OK OK OK

MANUAL TRANSMISSION TROUBLESHOOTING222
2. Check procedures by diagnosis code
Remarks
In cases where other diagnosis codes are output, please refer to the relevant item.
Code No.12 Power supply voltage (valve power supply) systemAssumed cause of concern
If the 4WDECU power supply voltage drops below 9V or rises
above 18V, Code No.12 is output, indicating either a broken wire in
the power supply circuit, a short, or a drop in the battery voltage.• battery malfunction
• harness, connector malfunction
• 4WDECU malfunction
Battery inspection
NG > replace
MUTII/III Service data
• No.10 Battery voltage
OK:battery voltage
OK > Intermittent malfunction
Measurement at C38 4WDECU connector
•ECU terminal voltage measurement
• Ignition switch: ON
OK:battery voltage
Connector check: C38
NG > repair
MUTII/III Service data
•No.10 battery voltage
OK:battery voltage
NG > replace 4WDECU
OK > intermittent malfunction
Connector check:C38, C133, C212, C210
NG > repair
Check harness between ignition switch – 4WDECU
• Check to see if power supply wire broken, short, or
damage
NG > repair
OK
OK
OK
OK
NG
NG