MITSUBISHI LANCER EVOLUTION VIII 2004 Service Manual

34CHANGING WELDED PANELS – ROOF
Fitting
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.
4. Using the appropriate tool, set the rivets as follows:
Rivets: POP rivet SD62HR
(1) Insert the rivet into the hole in the base material (roof).
(2) Insert the appropriate tool into Part A of the rivet.
(3) Using the appropriate tool, use the tool handle to press therivet 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: HR003B
5.When adhesive is dry, remove any excess adhesive then, to
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)
Adhesive TypeProduct name
Epoxy structural
adhesiveSumitomo 3M Auto Mix
Panel Bond 8115
appropriate tool
part A appropriate
tool
flange
rivet
Roof panel
Body sealant
Rivet

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

38CHANGING WELDED PANELS – ALUMINIUM ALLOY PANELS
(3) Use a damp cloth to prevent temperature rising and
causing distortion or other effects in the area beingheated.
(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 rodcoated 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 beused.
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.

39CHANGING 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 pretreatment
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.

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

SERVICE MANUAL
Supplement

SERVICE MANUAL
LANCER
EVOLUTION VIII
MR
FOREWORD
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.
Please ensure that proper servicing is carried out
promptly, and that the information contained in the
relevant manuals is carefully read and understood
before doing any servicing work.
This information relates to the current vehicle (February2004).Since specifications will change, some of the
information contained here will inevitably besuperseded.
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).
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.
February 2004
MITSUBISHI MOTOR CORPORATION
This manual is printed on recycled paper.
CONTENTS
General ..........................................
Fuel ................................................
Intake, Exhaust .............................
Manual Transmission ...................
Front Suspension.........................
Rear Suspension ..........................
Exterior..........................................
00
13
15
22
33
34
51