2003 Mitsubishi Lancer Evolution 8 Evo VIII Service Repair Manual

1-1

GROUP 1

BODY CONSTRUCTION CONTENTS BODY COMPONENTS. . . . . . . . . . . .

1-2

BODY MAIN CROSS-SECTIONAL VIEWS . . . . . . . . . . . . . . . . . . . . . . . .

1-4

MAINTENANCE, SERVICEABILITY .

1-6

BODY CONSTRUCTION CHARACTERISTICS . . . . . . . . . . . . .

1-8

FRONT BODY. . . . . . . . . . . . . . . . . . . . . . .

1-8

ROOF . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-13

SIDE BODY. . . . . . . . . . . . . . . . . . . . . . . . .

1-14

REAR BODY . . . . . . . . . . . . . . . . . . . . . . . .

1-16

UNDER BODY. . . . . . . . . . . . . . . . . . . . . . .

1-17

DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-20

SILENCER APPLICATION LOCATIONS . . . . . . . . . . . . . . . . . . . .

1-21

LOCATIONS USING URETHANE FOAM AND FOAM MATERIAL . . . . . . . . . . .

1-22 STIFFENER AND DAMP SHEET APPLICATION LOCATIONS . . . . . . .

1-24

THEFT PROTECTION . . . . . . . . . . . .

1-25

1-2

BODY CONSTRUCTION BODY COMPONENTS

BODY COMPONENTS

32

31

30

M4010001000102

36 35

33

37 38

34 39 40

44 41

42

45 43

29

28 27

46

26 47

52 53 54

48 50

24

51

55

76 77

25

23

75

49

22

56

74 73 21 18

17 16

20

78

72

79

71 81 83

10 9 8 7 6 5

19 15 14

66 70

60

69 67

68 4

3

11

1

59

63

13

57

12

58 62

2

82

65

61

64

: Anti-corrosion steel panels : High-tensile steel panels

AB202151AB

BODY CONSTRUCTION BODY COMPONENTS 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

30.

31.

32.

33.

34.

35.

36.

37.

38.

39.

40.

41.

42.

HEADLAMP SUPPORT PANEL HOOD LOCK STAY FRONT END CROSSMEMBER FRONT END UPPER BAR HEADLAMP SUPPORT PANEL SIDE FRONT FENDER SHIELD FRONT UPPER FRAME INNER UPPER FRAME BULKHEAD FRONT UPPER FRAME BULKHEAD UPPER FRAME BULKHEAD REAR FRONT SIDEMEMBER INNER ENGINE MOUNT BRACKET FRONT SIDEMEMBER REAR FRONT SIDEMEMBER OUTER SPRING HOUSE PANEL DASH PANEL DASH PANEL SILENCER DASH PANEL REINFORCEMENT UPPER FRAME TO FRONT PILLAR BRACE UPPER FRAME EXTENSION OUTER UPPER FRAME EXTENSION INNER COWL TOP LOWER PANEL COWL TOP INNER PANEL COWL TOP UPPER PANEL FRONT DECK CROSSMENBER HOOD INNER PANEL HOOD OUTER PANEL FRONT ROOF RAIL FRONT ROOF BOW ROOF PANEL ROOF BOW FRONT REINFORCEMENT REAR ROOF BOW REAR ROOF RAIL SEAT BACK PLATE REAR SEAT BACK PANEL REAR SHELF PANEL REAR SEAT BACK BRACE TRUNK LID OUTER PANEL TRUNK LID INNER PANEL TRUNK LID HINGE QUARTER INNER EXTENSION REAR QUARTER CORNER PANEL

43.

44.

45.

46.

47.

48.

49.

50.

51.

52.

53.

54.

55.

56.

57.

58.

59.

60.

61.

62.

63.

64.

65.

66.

67.

68.

69.

70.

71.

72.

73.

74.

75.

76.

77.

78.

79.

80.

81.

82.

83.

1-3

REAR COMBINATION LAMP HOUSING SIDE ROOF RAIL INNER ROOF SIDE RAIL REINFORCEMENT CENTER FRONT PILLAR INNER UPPER FRONT PILLAR INNER LOWER CENTER PILLAR INNER SIDE OUTER PANEL REAR WHEEL HOUSE INNER PANEL QUARTER INNER PANEL REAR FLOOR SIDE BRACE QUARTER OUTER EXTENSION LOWER FUEL FILLER DOOR REAR END PANEL OUTER REAR END PANEL INNER REAR DOOR OUTER PANEL REAR DOOR SIDE DOOR BEAM LOWER REAR DOOR SIDE DOOR BEAM UPPER REAR DOOR INNER PANEL FRONT DOOR OUTER PANEL FRONT DOOR SIDE DOOR BEAM FRONT DOOR INNER PANEL FENDER PANEL FRONT FLOOR CROSSMEMBER REAR FRONT FLOOR CROSSMEMBER FRONT FRONT FLOOR SIDE SILL INNER FRONT FLOOR SIDEMEMBER BACKBONE REINFORCEMENT INSTRUMENT PANEL CENTER BRACKET REINFORCEMENT FRONT FLOOR PAN FRONT FLOOR EXTENSION PANEL REAR REAR FLOOR EXTENSION REAR FLOOR PAN SEAT BACK PLATE EXTENSION JACK BRACKET SPARE TIRE BRACKET TOWING HOOK REINFORCEMENT REAR FLOOR SIDEMEMBER EXTENSION CROSSMEMBER CENTER SUPPORT REAR FLOOR CROSSMEMBER REAR FLOOR SIDEMEMBER REAR SEAT BACK REINFORCEMENT

1-4

BODY CONSTRUCTION BODY MAIN CROSS-SECTIONAL VIEWS

BODY MAIN CROSS-SECTIONAL VIEWS

M4010002000105

B

A

C

E

F

D

AB201974 AC

A

B ROOF ROOF PANEL

PANEL

FRONT PILLAR REINFORCEMENT UPPER SIDE OUTER PANEL

FRONT ROOF RAIL

MAP LAMP BRACKET AB201984 AC

C

COWL TOP UPPER PANEL

COWL TOP LOWER PANEL

FRONT PILLAR INNER REINFORCEMENT

D

AB201886AB

FRONT END CROSSMEMBER REIFORCEMENT FRONT END CROSSMENBER INNER

COWL TOP INNER PANEL AB200255AC

E

SIDE ROOF RAIL INNER

FRONT PILLAR REINFORCEMENT UPPER (B)

FRONT PILLAR REINFORCEMENT LOWER FRONT PILLAR INNER LOWER

SIDE OUTER PANEL AB201985AB

FRONT END CROSSMENBER OUTER

F FRONT FLOOR SIDE SILL INNER

SIDE SILL REINFORCEMENT SUPPORT

AB200256AC

SIDE SILL OUTER REINFORCEMENT CENTER

SIDE OUTER PANEL AB200258AC

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1-5

BODY CONSTRUCTION BODY MAIN CROSS-SECTIONAL VIEWS

G H

I

K

J

AB201911AB

G (STANDARD ROOF) FRONT PILLAR INNER UPPER REINFORCEMENT

SIDE OUTER PANEL

FRONT PILLAR INNER UPPER FRONT PILLAR REINFORCEMENT UPPER (B)

G (SUNROOF) FRONT PILLAR REINFORCEMENT UPPER

FRONT PILLAR REINFORCEMENT FRONT PILLAR INNER REINFORCEMENT UPPER UPPER AB201887AB

H CENTER PILLAR INNER

CENTER PILLAR REINFORCEMENT

CENTER PILLAR SEATBELT REINFORCEMENT

FRONT PILLAR INNER UPPER

SIDE OUTER PANEL

I

AB202122AB

REAR PILLAR INNER

SIDE OUTER PANEL

SIDE OUTER PANEL

AB201986AB

AB201988AB

J SIDE OUTER PANEL

K REAR WHEEL HOUSE INNER PANEL

QUARTER INNER PANEL AB200264AC

REAR END PANEL INNER

REAR END PANEL OUTER

AB201989AB

1-6

BODY CONSTRUCTION MAINTENANCE, SERVICEABILITY

MAINTENANCE, SERVICEABILITY

M4010003000120

FENDER SHIELD A positioning hole, marking and cut-out has been added on the front fender shield, front upper frame inner, front side member gusset rear and dash panel to improve assembling workability when replacing the panel.

AB202152AB

1-7

BODY CONSTRUCTION MAINTENANCE, SERVICEABILITY

SIDE STRUCTURE A panel positioning cut-out has been added on the door opening to improve assembling workability when replacing the panel.

PANEL POSITIONING NOTCH AB200202AB

AB202025AB

SIDE OUTER PANEL The extra parts are supplied in 4 different cut forms as a result of employing the integrated side-frame side outer panel.

CENTER PILLAR OUTER

FRONT PILLAR OUTER

QUARTER OUTER

SIDE SILL OUTER

AB202024 AB

1-8

BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS

BODY CONSTRUCTION CHARACTERISTICS FRONT BODY

M4010010000092

HEADLAMP SUPPORT By adopting a steel sheet with variable thickness* for the front end crossmember outer, the steel sheet thickness on the right side of the vehicle has been increased to improve safety in collision and body rigidity.

NOTE: *: Steel sheets with different thickness welded to form one steel sheet.

1

4

2 10 11

5

3

8

7 6 AB201017AB

9 1.

2.

3.

4.

5.

6.

FRONT END UPPER BAR SENSOR BRACKET HEADLAMP SUPPORT PANEL HOOD LOCK STAY FRONT END CROSSMEMBER INNER REINFORCEMENT A/C CONDENSER BRACKET

7.

8.

9.

10.

10.

RADIATOR BRACKET FRONT END CROSSMEMBER INNER FRONT END CROSSMEMBER OUTER SHIPPING HOOK FRONT END CROSSMEMBER REINFORCEMENT

1-9

BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS

FENDER SHIELD The cross section of the front sidemember has been increased and a steel sheet with variable thickness* has been adopted for the front sidemember inner to increase the thickness of the cabinet side in the aim to improve safety in collision, body rigidity, and realize lightweight.

RIGHT SIDE

NOTE: *: Steel sheets with different thickness welded to form one steel sheet.

9

8 6 7

3 4

10

5

LEFT SIDE 9

2

8

A

7 6 5 1

4 12

10 11

2

1 11 AB202153AB

1.

2.

3.

4.

5.

6.

7.

HEADLAMP SUPPORT PANEL SIDE FRONT FENDER SHIELD ENGINE MOUNT REINFORCEMENT UPPER FRAME BULKHEAD FRONT FRONT UPPER FRAME INNER UPPER FRAME BULKHEAD UPPER FRAME BULKHEAD REAR

A

SPRING HOUSE BRACKET

SPRING HOUSE BRACKET REINFORCEMENT SPRING HOUSE BRACKET SPRING HOUSE PANEL FRONT SIDEMEMBER TRANSMISSION MOUNT REINFORCEMENT OUTER

The spring house panel has been designed to be directly installed with the cowl top lower panel, and the body rigidity of the suspension attachment holder has been increased to improve operational stability and quietness.

COWL TOP LOWER PANEL

SPRING HOUSE PANEL

8.

9.

10.

11.

12.

AB200275AC

1-10

BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS

FRONT SIDEMEMBER REINFORCEMENT RIGHT SIDE 6

7 9

8 5 4

10 11

3

2

12

19 18 17 16

1

15 14

13

AB201018AB

7

5

15

12 1

2

A

B

AB202015AC

1.

2.

3.

4.

5.

6.

7.

8.

9.

FRONT SIDEMEMBER INNER FRONT SIDEMEMBER BULKHEAD A FRONT SIDEMEMBER OUTER ENGINE MOUNT BRACKET FRONT SIDEMEMBER INNER REINFORCEMENT LOWER FRONT SIDEMEMBER GUSSET REAR FRONT SIDEMEMBER INNER REINFORCEMENT REAR TIE DOWN REINFORCEMENT DASH PANEL EXTENSION

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

PIPE SUPPORT REAR PIPE NUT FRONT SIDEMEMBER REAR DASH CROSSMEMBER EXTENSION SUSPENSION CROSSMEMBER SUPPORT BRACKET SUSPENSION CROSSMEMBER BRACKET INNER PIPE SQUARE HEAD BOLT RETAINER PIPE SUPPORT FRONT

B

A

3

2

3

5

1 AB202019AB

7

AB200280AC

1-11

BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS

LEFT SIDE 9

10

7

11 8

6 12 5

13

4

14

21

2

15

17 18 19

3 1

16

20

24

22

23

7

9

AB201019AB

21 12

15

14

3 12 A

B

16 AB202017AC

1.

SUSPENSION CROSSMEMBER SUPPORT BRACKET 2. DASH CROSSMEMBER EXTENSION 3. FRONT SIDEMEMBER REAR 4. PIPE NUT 5. PIPE SUPPORT REAR 6. DASH PANEL EXTENSION REINFORCEMENT 7. FRONT SIDEMEMBER REINFORCEMENT INNER UPPER 8. TIE DOWN REINFORCEMENT 9. FRONT SIDEMEMBER REINFORCEMENT INNER 10. FRONT SIDEMEMBER GUSSET REAR 11. FRONT SIDEMEMBER OUTER 12. FRONT SIDEMEMBER BULKHEAD REAR

A

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

FRONT SIDEMEMBER INNER REINFORCEMENT FRONT SIDEMEMBER REINFORCEMENT OUTER FRONT SIDEMEMBER BULKHEAD (A) FRONT SIDEMEMBER INNER PIPE SUPPORT FRONT RETAINER SQUARE HEAD BOLT PIPE SUSPENSION CROSSMEMBER BRACKET INNER TRANSMISSION MOUNT REINFORCEMENT TRANSMISSION MOUNT BRACKET TRANSMISSION MOUNT REINFORCEMENT REAR

B

11

16

15 AB200283AC

11

16

14 13 AB202018AB

1-12

BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS

FRONT DECK Strut house gusset and upper frame to front pillar brace have been added to improve body rigidity.

6 5 7

8

4 3

2

10

9

14 13

1

11

1.

2.

3.

4.

5.

6.

7.

STRUT TOWER BAR BRACKET COWL TOP LOWER PANEL COWL TOP LOWER REINFORCEMENT COWL TOP UPPER REINFORCEMENT CENTER COWL TOP INNER PANEL COWL TOP UPPER PANEL PEDAL SUPPORT BRACKET

DASH PANEL • A dash panel crossmember has been added and the thickness of the dash panel lower has been increased to improve collision stability.

12 8.

9.

10.

11.

12.

13.

14.

AB201020AB

CLUTCH PEDAL SUPPORT BRACKET UPPER FRAME EXTENSION INNER UPPER FRAME EXTENSION OUTER UPPER FRAME TO FRONT PILLAR BRACE STRUT HOUSE GUSSET COWL TOP LOWER BRACKET COWL TOP UPPER REINFORCEMENT

• A silencer (steel sheet biding type vibration damping material) has been added between the dash panel and dash panel silencer to control the penetrating sound and vibration from the engine.

5

4

3

6

7 2 9

1 1.

2.

3.

4.

5.

DASH PANEL CROSSMEMBER DASH PANEL DASH SILENCER CENTER DASH PANEL SILENCER ACCELERATOR PEDAL REINFORCEMENT

6.

7.

8.

9.

8

AB201021AB

DASH PANEL REINFORCEMENT ACCELERATOR STOPPER BRACKET DASH LOWER REINFORCEMENT DASH PANEL LOWER

1-13

BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS

ROOF

M4010013000091

The cross section of the roof bow has been made large to improve safety in collision.

STANDARD ROOF

1 2 4 5

6

3

7 AB202150AB

SUN ROOF

1 2 3 6

8 AB201928AB

7 1.

2.

3.

4.

ROOF PANEL REAR ROOF RAIL REAR ROOF BOW ROOF BOW FRONT REINFORCEMENT

5.

6.

7.

8.

FRONT ROOF BOW MAP LAMP BRACKET FRONT ROOF RAIL ROOF PANEL REINFORCEMENT

1-14

BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS

SIDE BODY

M4010011000095

SIDE STRUCTURE 15

14

16

17 18

13

19

50 48

21 57

10 9

12

5

41 4 3

23 24

26

56 55

38

31

39

40

27 29

36

2 1

25

54

37

8

6

53

44 45 43 46 42

7

22

52

47

11

20

51

49

32 35

28

34 33

30 AB201022AB

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

FRONT PILLAR REINFORCEMENT LOWER EXTENSION FRONT PILLAR INNER LOWER EXTENSION FRONT PILLAR REINFORCEMENT LOWER FRONT DOOR HINGE REINFORCEMENT LOWER FRONT DOOR CHECK REINFORCEMENT SIDE SILL TO FLOOR PLATE FRONT PILLAR INNER LOWER FRONT DOOR HINGE REINFORCEMENT UPPER DECK CROSSMEMBER BRACKET FRONT DECK CROSSMEMBER BRACKET FRONT PILLAR INNER UPPER FRONT PILLAR INNER UPPER REINFORCEMENT (VEHICLES WITH STANDARD ROOF) SIDE ROOF RAIL INNER REAR SEAT BACK BRACE REAR SHELF UPPER BRACE REAR SHELF LOWER BRACE REAR PILLAR INNER QUARTER INNER PANEL OIL TANK BRACKET REAR PILLAR REINFORCEMENT

21.

22.

23.

24.

25.

26.

27.

28.

29.

30.

31.

32.

33.

34.

35.

36.

37.

38.

39.

40.

41.

42.

REAR FLOOR SIDE BRACE REAR FLOOR BRACE REINFORCEMENT FUEL FILLER NECK BRACKET (LH only) QUARTER INNER EXTENSION REAR QUARTER CORNER PANEL REAR COMBINATION LAMP HOUSING REAR BUMPER BRACKET QUARTER OUTER EXTENSION LOWER STRIKER REINFORCEMENT SIDE OUTER PANEL SIDE SILL OUTER REINFORCEMENT REAR SIDE SILL OUTER REINFORCEMENT CENTER SIDE SILL OUTER REINFORCEMENT FRONT SIDE SILL BULKHEAD FRONT SIDE SILL REINFORCEMENT SUPPORT SIDE SILL (B) BULKHEAD SIDE SILL (C) BULKHEAD SIDE SILL (D) BULKHEAD SIDE SILL (E) BULKHEAD CENTER PILLAR REINFORCEMENT CENTER PILLAR INNER LOWER REAR DOOR HINGE REINFORCEMENT LOWER

1-15

BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS 43.

44.

45.

46.

47.

48.

49.

50.

51.

52.

53.

54.

55.

56.

57.

REAR DOOR HINGE REINFORCEMENT UPPER CENTER PILLAR SEATBELT REINFORCEMENT CENTER PILLAR INNER FRONT PILLAR REINFORCEMENT UPPER (B) (VEHICLES WITH STANDARD ROOF) FRONT PILLAR INNER REINFORCEMENT (VEHICLES WITH STANDARD ROOF) FRONT PILLAR REINFORCEMENT UPPER ROOF SIDE RAIL REINFORCEMENT CENTER REAR SPRING HOUSE BRACE REAR WHEEL HOUSE INNER REINFORCEMENT REAR WHEEL HOUSE INNER PANEL SPRING HOUSE PANEL SPRING HOUSE BRACKET SIDE SILL END PLATE REAR SEATBELT WHEEL HOUSE REINFORCEMENT SPRING HOUSE BRACE

SIDE STRUCTURE REINFORCEMENT 1. The thickness of the reinforcements of the front pillar and center pillar has been increased to improve collision safety.

2. The front pillar reinforcement upper, side outer panel, and front roof rail have been joined to improve twisting rigidity.

3. The side sill has been made thin by employing a variable thickness steel sheet* for the center pillar reinforcement to improve safety in collision and realize lightweight.

4. The cross section of the side sill outer reinforcement has been made large to improve safety in collision and body rigidity.

5. A rear pillar reinforcement has been added, and the rear shelf and rear wheel house have been joined to improve the twisting rigidity of the suspension attaching portion.

NOTE: *: Steel sheets with different thickness welded to form one steel sheet.

2

5 1, 3

1

4

AB202030AB

1-16

BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS

REAR BODY

M4010012000087

REAR END CROSSMEMBER A rear shelf extension has been added to form closed structure. Then, the rear shelf and the rear floor have been joined to improve the torsion rigidity of the seat back plate.

5

6

4

3 7

2

1

8

AB201022AB

1.

2.

3.

4.

5.

SEAT BACK PLATE REAR SEAT BACK PANEL REAR SHELF EXTENSION REAR SHELF PANEL

6.

7.

8.

REAR SHELF CHILD SEAT BELT REINFORCEMENT REAR SHELF REINFORCEMENT TRUNK LID HINGE REINFORCEMENT SEAT BELT REINFORCEMENT

REAR END PANEL

2

4 3 1

AB201024AB

1.

2.

REAR END PANEL INNER REAR END PANEL OUTER

3.

4.

TRUNK LID LOCK BRACKET SUPPORT TRUNK LID LOCK BRACKET

1-17

BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS

UNDER BODY

M4010014000094

FRONT FLOOR The cross section of the front floor sidemember has been made large to improve safety in collision.

3

2

4

1

5

6 11 7 13

8

12 10 9 AB202031AB

1.

2.

3.

4.

5.

6.

7.

INSTRUMENT PANEL CENTER BRACKET REINFORCEMENT FRONT FLOOR CROSSMEMBER FRONT FRONT FLOOR CROSSMEMBER REAR FRONT FLOOR EXTENSION PANEL REAR FRONT FLOOR PAN FRONT FLOOR SIDE SILL INNER FRONT FLOOR SIDEMEMBER REINFORCEMENT REAR

8.

9.

10.

11.

12.

13.

FRONT FLOOR SIDEMEMBER FRONT FLOOR SIDEMEMBER REINFORCEMENT FRONT FRONT FLOOR SIDEMEMBER REINFORCEMENT BACKBONE CROSSMEMBER REAR BACKBONE CROSSMEMBER FRONT BACKBONE REINFORCEMENT

1-18

BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS

REAR FLOOR 3 4

5 6

2 1 7

8 9

10

15

11

12 13 14 16 17

1.

2.

3.

4.

5.

6.

7.

8.

9.

REAR FLOOR PAN SEAT BACK PLATE EXTENSION JACK BRACKET SPARE TIRE BRACKET REAR SEAT BACK REINFORCEMENT TOWING HOOK REINFORCEMENT CROSSMEMBER CENTER SUPPORT REAR FLOOR CROSSMEMBER REAR FLOOR SEAT BELT REINFORCEMENT

AB201025AB

10. DIFFERENTIAL / FUEL SUPPORT BRACKET REAR 11. REAR FLOOR SIDEMEMBER 12. DIFFERENTIAL / FUEL SUPPORT BRACKET FRONT 13. REAR SEAT CROSSMEMBER 14. SEAT CROSSMEMBER REINFORCEMENT 15. FUEL TANK FRONT REINFORCEMENT 16. REAR FLOOR EXTENSION 17. FRONT FLOOR SIDEMEMBER EXTENSION

1-19

BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS

REAR FLOOR SIDEMEMBER REINFORCEMENT 10

14

12

15

11 9

16

13

8 7

17 6 19

18

5 20 21 3

4 2

22

1

15

11 13

4

AB202032AB

16

22 A

20 1

2 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

TRAILING ARM OUTER BRACKET REAR FLOOR SIDEMEMBER SUPPORT TRAILING ARM INNER BRACKET REAR FLOOR SIDEMEMBER REAR FLOOR CROSSMEMBER EXTENSION DIFFERENTIAL MOUNT BULKHEAD DIFFERENTIAL MOUNT REINFORCEMENT PIPE SQUARE HEAD BOLT RETAINER REAR SUSPENSION BRACKET MUFFLER HANGER CENTER

17

B

21

AB202033AB

13. REAR FLOOR SIDEMEMBER REINFORCEMENT FRONT 14. MUFFLER HANGER REAR 15. REAR FLOOR SIDEMEMBER REINFORCEMENT REAR 16. BUMPER STAY REINFORCEMENT 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

B

A

13

4 13 11

AB202034AB

15

17 AB202035AB

1-20

BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS

DOOR

M4010015000086

The front and back of side door beam has been made large to cope with the force from the front and sides during collision.

RONT DOOR 7

5

6 8 2

4

9

3

10

1

AB201026AB

15 16

EAR DOOR

17

18

19 20

21 14

13

12 AB201027AB

11 1.

2.

3.

4.

5.

FRONT DOOR HINGE PANEL FRONT DOOR HINGE REINFORCEMENT UPPER FRONT DOOR SIDE DOOR BEAM FRONT DOOR OUTER PANEL 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 PANEL

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21

REAR DOOR HINGE PANEL REAR DOOR SIDE DOOR BEAM LOWER REAR DOOR SIDE DOOR BEAM UPPER REAR DOOR OUTER PANEL REAR DOOR BELT LINE REINFORCEMENT OUTER REAR DOOR BELT LINE BRACKET REAR DOOR ENERGY ABSORBER REAR DOOR WINDOW SASH REAR DOOR BELTLINE REINFORCEMENT INNER REAR DOOR LATCH REINFORCEMENT REAR DOOR INNER PANEL

BODY CONSTRUCTION SILENCER APPLICATION LOCATIONS

SILENCER APPLICATION LOCATIONS A silencer (MD-12 and melting sheet) has been adhered on the top part of the floor to improve antivibration performance and to shut-out exhaust gas heat.

1-21 M4010005000115

NOTE: . • MD-12 is a high performance sheet composed of asphalt applied with mica and thermosetting resin for improving anti-vibration performance.

AB202009AB

: 1.6 mm (0.063 in) thick melting sheet : 3.2 mm (0.126 in) thick melting sheet [Place two 1.6 mm (0.063 in) melting sheet one on top of another.] : 4.0 mm (0.157 in) thick MD-12 [Place three 1.6 mm (0.063 in) melting sheet one on top of another.]

NOTE: When you use melting sheet(s) in place of MD-12 during serving, follow the instructions enclosed by [ ].

1-22

BODY CONSTRUCTION LOCATIONS USING URETHANE FOAM AND FOAM MATERIAL

LOCATIONS USING URETHANE FOAM AND FOAM MATERIAL

M4010007000092

• Introduction of noise was prevented by inserting urethane foam inside the center pillar.

• Introduction of noise was prevented by adding foam noise absorbing materials inside each pillar, side roof rail and wheel house arch interior.

• High rigidity foam materials were added inside the side roof rail and the side sill to heighten panel rigidity.

• Never use a gas burner or burn the areas using foam materials.

• When cutting the parts using foam materials, ensure to use tools (air saw, etc.) that do not generate fire.

• If there is residual foam materials remaining on the cut section (body side) then weld after removing the foam materials from periphery of the welding area.

CAUTION Precautions upon sheet metal processing the areas using foam materials.

The foam materials may burn when heated.

Always observe the following instructions.

A

D

B C AB202185AB

A

FRONT PILLAR INNER REINFORCEMENT

C

FRONT PILLAR REINFORCEMENT UPPER (B)

FOAM ACOUSTIC MATERIAL AB201973AB

HIGH RIGIDITY FOAM MATERIAL

B FOAM ACOUSTIC MATERIAL

FRONT PILLAR REINFORCEMENT LOWER

FRONT PILLAR INNER LOWER

AB202038AB

D SIDE OUTER PANEL

SIDE SILL OUTER REINFORCEMENT CENTER

AB201057

FOAM ACOUSTIC MATERIAL

QUARTER INNER PANEL SIDE OUTER PANEL AB201975AB

AB201976AB

1-23

BODY CONSTRUCTION LOCATIONS USING URETHANE FOAM AND FOAM MATERIAL

E

F

G H

I

AB201918 AB

AB100698

E

F

FOAM ACOUSTIC MATERIAL

HIGH RIGIDITY FOAM MATERIAL

SIDE OUTER PANEL

FRONT PILLAR REINFORCEMENT UPPER

SIDE OUTER PANEL

SIDE ROOF RAIL INNER AB201980AB

AB201977AB

G

H FOAM ACOUSTIC MATERIAL CENTER PILLAR INNER

REAR PILLAR INNER

FOAM ACOUSTIC MATERIAL SIDE OUTER PANEL

I CENTER PILLAR REINFORCEMENT

SIDE SILL OUTER REINFORCEMENT CENTER

AB201981AB

URETHANE FOAM

AB201983AB

SIDE OUTER PANEL REAR DOOR HINGE REINFORCEMENT UPPER

AB201982AB

1-24

BODY CONSTRUCTION STIFFENER AND DAMP SHEET APPLICATION LOCATIONS

STIFFENER AND DAMP SHEET APPLICATION LOCATIONS Sound insulation was improved with anti-vibration effects and heightening surface rigidity with a stiffener on the inner side of the side outer panel, and roof panel, as well as a damping sheet adhered to the inner side of the front door.

M4010008000103

NOTE: The main contents of a stiffener are epoxy resin. It comes in a sheet form and contains a mixture of glass fiber and filler, and cures (stiffens) when heated. It is used to improve the rigidity of the outer plate.

STIFFENER (VHIECLES WITH SUNROOF) STIFFENER

DAMP SHEET

STIFFENER

AB201919AB

AB201920AB

DAMP SHEET

BODY CONSTRUCTION THEFT PROTECTION

THEFT PROTECTION

1-25 M4010017000037

In order to protect against theft, a Vehicle Identification Number (VIN) is attached as a plate or label to the following major parts of the engine and transaxle, as well as main outer panels: Engine cylinder block, Transaxle housing, Fender, Doors, Trunk lid, Quarter panel, Hood, Bumpers In addition, a theft-protection label is attached to replacement parts for the body outer panel main components, and the same data is stamped into replacement parts for the engine and the transaxle.

THEFT PROTECTION LABEL

FOR ORIGINAL PARTS

FOR REPLACEMENT PARTS

AC101015 AB

CAUTION Cautions regarding panel repairs: 1. When repainting original parts, do so after first masking the theft-protection label. After painting, be sure to peel off the masking tape.

2. The theft-protection label for replacement parts is covered by masking tape, so such parts can be painted as is. The masking tape should be removed after painting is finished.

3. The theft-protection label should not be removed from original parts or replacement parts.

1-26

BODY CONSTRUCTION THEFT PROTECTION

LOCATIONS LABEL AREA (A: FOR ORIGINAL EQUIPMENT PARTS, B: FOR REPLACEMENT PARTS) ENGINE

MANUAL TRANSAXLE

A

B A B

AC211574 AB

AC211575 AB

QUARTER PANEL OUTER

FENDER B

B A

A

AC101605AB

THE ILLUSTRATION INDICATES LEFT OUTER SIDE. RIGHT SIDE IS SYMMETRICALLY OPPOSITE.

AC101606 AB

THE ILLUSTRATION INDICATES LEFT OUTER SIDE. RIGHT SIDE IS SYMMETRICALLY OPPOSITE.

1-27

BODY CONSTRUCTION THEFT PROTECTION

LABEL AREA (A: FOR ORIGINAL EQUIPMENT PARTS, B: FOR REPLACEMENT PARTS)

FRONT DOOR REAR DOOR

A B

B

A

THE ILLUSTRATION INDICATES LEFT INNER SIDE. RIGHT SIDE IS SYMMETRICALLY OPPOSITE.

THE ILLUSTRATION INDICATES LEFT INNER SIDE. RIGHT SIDE IS SYMMETRICALLY OPPOSITE.

AC101607AB

HOOD

AC101608AB

TRUNK LID

B

A

B

A

AC211576 AB

AC212032 AB

FRONT BUMPER REAR BUMPER

A A B B

AC211577 AB

AC211578 AB

NOTES

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