Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Mitsubishi Lancer Evolution 2003-2005 Approved Mitsubishi Lancer Evolution 2003 BM GR00000300-1
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1-1
GROUP 1
BODY
CONSTRUCTION
CONTENTS
BODY COMPONENTS. . . . . . . . . . . . 1-2 UNDER BODY. . . . . . . . . . . . . . . . . . . . . . . 1-17
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
BODY MAIN CROSS-SECTIONAL
VIEWS . . . . . . . . . . . . . . . . . . . . . . . . 1-4 SILENCER APPLICATION
LOCATIONS . . . . . . . . . . . . . . . . . . . . 1-21
MAINTENANCE, SERVICEABILITY . 1-6
LOCATIONS USING URETHANE FOAM
BODY CONSTRUCTION AND FOAM MATERIAL . . . . . . . . . . . 1-22
CHARACTERISTICS . . . . . . . . . . . . . 1-8
FRONT BODY. . . . . . . . . . . . . . . . . . . . . . . 1-8 STIFFENER AND DAMP SHEET
ROOF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 APPLICATION LOCATIONS . . . . . . . 1-24
SIDE BODY. . . . . . . . . . . . . . . . . . . . . . . . . 1-14
REAR BODY . . . . . . . . . . . . . . . . . . . . . . . . 1-16 THEFT PROTECTION . . . . . . . . . . . . 1-25
1-2 BODY CONSTRUCTION
BODY COMPONENTS
BODY COMPONENTS
M4010001000102
36
37
33 35 38
32
31 34
30
39
44 40
41
42
45
28 29 43
27 46
26
47 48 52 53 54
51
50 55
24 25 76 77
23 49 75
22
74 56
73 78
21 72 79
17 18 71
20 81
16
83
10 19 82
9 65
66
8 15 14
7 70
6
5 60
69
67 59
68
4 13 63
11 12 57
58
61
3 2 62
64
1
: Anti-corrosion steel panels
: High-tensile steel panels AB202151AB
BODY CONSTRUCTION
BODY COMPONENTS
1-3
1. HEADLAMP SUPPORT PANEL 43. REAR COMBINATION LAMP HOUSING
2. HOOD LOCK STAY 44. SIDE ROOF RAIL INNER
3. FRONT END CROSSMEMBER 45. ROOF SIDE RAIL REINFORCEMENT CENTER
4. FRONT END UPPER BAR 46. FRONT PILLAR INNER UPPER
5. HEADLAMP SUPPORT PANEL SIDE 47. FRONT PILLAR INNER LOWER
6. FRONT FENDER SHIELD 48. CENTER PILLAR INNER
7. FRONT UPPER FRAME INNER 49. SIDE OUTER PANEL
8. UPPER FRAME BULKHEAD FRONT 50. REAR WHEEL HOUSE INNER PANEL
9. UPPER FRAME BULKHEAD 51. QUARTER INNER PANEL
10. UPPER FRAME BULKHEAD REAR 52. REAR FLOOR SIDE BRACE
11. FRONT SIDEMEMBER INNER 53. QUARTER OUTER EXTENSION LOWER
12. ENGINE MOUNT BRACKET 54. FUEL FILLER DOOR
13. FRONT SIDEMEMBER REAR 55. REAR END PANEL OUTER
14. FRONT SIDEMEMBER OUTER 56. REAR END PANEL INNER
15. SPRING HOUSE PANEL 57. REAR DOOR OUTER PANEL
16. DASH PANEL 58. REAR DOOR SIDE DOOR BEAM LOWER
17. DASH PANEL SILENCER 59. REAR DOOR SIDE DOOR BEAM UPPER
18. DASH PANEL REINFORCEMENT 60. REAR DOOR INNER PANEL
19. UPPER FRAME TO FRONT PILLAR BRACE 61. FRONT DOOR OUTER PANEL
20. UPPER FRAME EXTENSION OUTER 62. FRONT DOOR SIDE DOOR BEAM
21. UPPER FRAME EXTENSION INNER 63. FRONT DOOR INNER PANEL
22. COWL TOP LOWER PANEL 64. FENDER PANEL
23. COWL TOP INNER PANEL 65. FRONT FLOOR CROSSMEMBER REAR
24. COWL TOP UPPER PANEL 66. FRONT FLOOR CROSSMEMBER FRONT
25. FRONT DECK CROSSMENBER 67. FRONT FLOOR SIDE SILL INNER
26. HOOD INNER PANEL 68. FRONT FLOOR SIDEMEMBER
27. HOOD OUTER PANEL 69. BACKBONE REINFORCEMENT
28. FRONT ROOF RAIL 70. INSTRUMENT PANEL CENTER BRACKET
29. FRONT ROOF BOW REINFORCEMENT
30. ROOF PANEL 71. FRONT FLOOR PAN
31. ROOF BOW FRONT REINFORCEMENT 72. FRONT FLOOR EXTENSION PANEL REAR
32. REAR ROOF BOW 73. REAR FLOOR EXTENSION
33. REAR ROOF RAIL 74. REAR FLOOR PAN
34. SEAT BACK PLATE 75. SEAT BACK PLATE EXTENSION
35. REAR SEAT BACK PANEL 76. JACK BRACKET
36. REAR SHELF PANEL 77. SPARE TIRE BRACKET
37. REAR SEAT BACK BRACE 78. TOWING HOOK REINFORCEMENT
38. TRUNK LID OUTER PANEL 79. REAR FLOOR SIDEMEMBER EXTENSION
39. TRUNK LID INNER PANEL 80. CROSSMEMBER CENTER SUPPORT
40. TRUNK LID HINGE 81. REAR FLOOR CROSSMEMBER
41. QUARTER INNER EXTENSION REAR 82. REAR FLOOR SIDEMEMBER
42. QUARTER CORNER PANEL 83. REAR SEAT BACK REINFORCEMENT
1-4 BODY CONSTRUCTION
BODY MAIN CROSS-SECTIONAL VIEWS
BODY MAIN CROSS-SECTIONAL VIEWS
M4010002000105
A B
C
E
F
D AB201974 AC
A B ROOF FRONT PILLAR
ROOF PANEL PANEL REINFORCEMENT UPPER
SIDE OUTER
PANEL
FRONT
MAP LAMP SIDE ROOF PILLAR
BRACKET RAIL INNER REINFORCE-
FRONT ROOF RAIL
MENT
AB201984 AC FRONT PILLAR INNER UPPER (B)
REINFORCEMENT
AB201886AB
C COWL TOP D FRONT END CROSSMEMBER
UPPER REIFORCEMENT
PANEL
FRONT
END
CROSS-
MENBER
INNER
COWL TOP
LOWER PANEL COWL TOP FRONT END
INNER PANEL CROSSMENBER
OUTER AB200256AC
AB200255AC
E FRONT PILLAR REINFORCEMENT F SIDE SILL OUTER
LOWER REINFORCEMENT
FRONT PILLAR FRONT CENTER
INNER LOWER FLOOR
SIDE SILL
INNER
SIDE SILL
REINFORCEMENT SIDE OUTER PANEL
SIDE OUTER PANEL
AB201985AB SUPPORT AB200258AC
BODY CONSTRUCTION
BODY MAIN CROSS-SECTIONAL VIEWS
1-5
G
H I
K
J
AB201911AB
G (STANDARD ROOF) FRONT G (SUNROOF) FRONT PILLAR
FRONT PILLAR INNER UPPER PILLAR INNER UPPER
REINFORCEMENT INNER FRONT PILLAR
UPPER REINFORCEMENT
FRONT UPPER
PILLAR
SIDE OUTER REINFORCE-
PANEL MENT UPPER
(B)
FRONT PILLAR
REINFORCEMENT FRONT PILLAR
UPPER INNER REINFORCEMENT
UPPER SIDE OUTER PANEL AB202122AB
AB201887AB
H CENTER PILLAR CENTER PILLAR I REAR PILLAR
INNER SEATBELT INNER
REINFORCEMENT
SIDE
OUTER
PANEL SIDE OUTER
CENTER PILLAR PANEL
REINFORCEMENT AB201986AB
AB201988AB
J K
SIDE OUTER REAR WHEEL
PANEL HOUSE INNER
PANEL
REAR END
PANEL
QUARTER REAR END OUTER
INNER PANEL PANEL
INNER
AB201989AB
AB200264AC
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
BODY CONSTRUCTION
MAINTENANCE, SERVICEABILITY
1-7
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 NOTE: *: Steel sheets with different thickness
By adopting a steel sheet with variable thickness* for welded to form one steel sheet.
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.
1
4
2
10
11 5 3
7 6
8 AB201017AB
9
1. FRONT END UPPER BAR 7. RADIATOR BRACKET
2. SENSOR BRACKET 8. FRONT END CROSSMEMBER INNER
3. HEADLAMP SUPPORT PANEL 9. FRONT END CROSSMEMBER OUTER
4. HOOD LOCK STAY 10. SHIPPING HOOK
5. FRONT END CROSSMEMBER INNER 10. FRONT END CROSSMEMBER REINFORCEMENT
REINFORCEMENT
6. A/C CONDENSER BRACKET
BODY CONSTRUCTION
BODY CONSTRUCTION CHARACTERISTICS
1-9
FENDER SHIELD NOTE: *: Steel sheets with different thickness
The cross section of the front sidemember has been welded to form one steel sheet.
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 real-
ize lightweight.
RIGHT SIDE
8 9
6 7
3 4
10
5
LEFT SIDE
2 8
9
A
7 6
4 12
5
1
10
11
2
1
11
AB202153AB
1. HEADLAMP SUPPORT PANEL SIDE 8. SPRING HOUSE BRACKET REINFORCEMENT
2. FRONT FENDER SHIELD 9. SPRING HOUSE BRACKET
3. ENGINE MOUNT REINFORCEMENT 10. SPRING HOUSE PANEL
4. UPPER FRAME BULKHEAD FRONT 11. FRONT SIDEMEMBER
5. FRONT UPPER FRAME INNER 12. TRANSMISSION MOUNT REINFORCEMENT
6. UPPER FRAME BULKHEAD OUTER
7. UPPER FRAME BULKHEAD REAR
The spring house panel has been designed to be
A COWL TOP directly installed with the cowl top lower panel, and
LOWER PANEL
the body rigidity of the suspension attachment holder
has been increased to improve operational stability
and quietness.
SPRING
HOUSE SPRING HOUSE
BRACKET PANEL AB200275AC
1-10 BODY CONSTRUCTION
BODY CONSTRUCTION CHARACTERISTICS
FRONT SIDEMEMBER REINFORCEMENT
RIGHT SIDE
7
6
8 9
5
4 10
11
3 2 12
19
18 15
17 14 13 AB201018AB
1
16
7
5 15
12
1 2 A B
AB202015AC
1. FRONT SIDEMEMBER INNER 10. PIPE SUPPORT REAR
2. FRONT SIDEMEMBER BULKHEAD A 11. PIPE NUT
3. FRONT SIDEMEMBER OUTER 12. FRONT SIDEMEMBER REAR
4. ENGINE MOUNT BRACKET 13. DASH CROSSMEMBER EXTENSION
5. FRONT SIDEMEMBER INNER REINFORCEMENT 14. SUSPENSION CROSSMEMBER SUPPORT
LOWER BRACKET
6. FRONT SIDEMEMBER GUSSET REAR 15. SUSPENSION CROSSMEMBER BRACKET INNER
7. FRONT SIDEMEMBER INNER REINFORCEMENT 16. PIPE
REAR 17. SQUARE HEAD BOLT
8. TIE DOWN REINFORCEMENT 18. RETAINER
9. DASH PANEL EXTENSION 19. PIPE SUPPORT FRONT
A B
2 3
3 1 5
7 AB200280AC
AB202019AB
BODY CONSTRUCTION
BODY CONSTRUCTION CHARACTERISTICS
1-11
LEFT SIDE
9 10
7 11
8
6
12
5 13
4
14
21
17 15
3
18
2 19
1 16
20
22
24 23 AB201019AB
7 9 21 12
14 15
3
12
B A 16
AB202017AC
1. SUSPENSION CROSSMEMBER SUPPORT 13. FRONT SIDEMEMBER INNER REINFORCEMENT
BRACKET 14. FRONT SIDEMEMBER REINFORCEMENT OUTER
2. DASH CROSSMEMBER EXTENSION 15. FRONT SIDEMEMBER BULKHEAD (A)
3. FRONT SIDEMEMBER REAR 16. FRONT SIDEMEMBER INNER
4. PIPE NUT 17. PIPE SUPPORT FRONT
5. PIPE SUPPORT REAR 18. RETAINER
6. DASH PANEL EXTENSION REINFORCEMENT 19. SQUARE HEAD BOLT
7. FRONT SIDEMEMBER REINFORCEMENT INNER 20. PIPE
UPPER 21. SUSPENSION CROSSMEMBER BRACKET INNER
8. TIE DOWN REINFORCEMENT 22. TRANSMISSION MOUNT REINFORCEMENT
9. FRONT SIDEMEMBER REINFORCEMENT INNER 23. TRANSMISSION MOUNT BRACKET
10. FRONT SIDEMEMBER GUSSET REAR 24. TRANSMISSION MOUNT REINFORCEMENT
11. FRONT SIDEMEMBER OUTER REAR
12. FRONT SIDEMEMBER BULKHEAD REAR
A B
11 11
16 14
15 16
13
AB200283AC 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
2 3
14 9 10
13
1
11
12 AB201020AB
1. STRUT TOWER BAR BRACKET 8. CLUTCH PEDAL SUPPORT BRACKET
2. COWL TOP LOWER PANEL 9. UPPER FRAME EXTENSION INNER
3. COWL TOP LOWER REINFORCEMENT 10. UPPER FRAME EXTENSION OUTER
4. COWL TOP UPPER REINFORCEMENT CENTER 11. UPPER FRAME TO FRONT PILLAR BRACE
5. COWL TOP INNER PANEL 12. STRUT HOUSE GUSSET
6. COWL TOP UPPER PANEL 13. COWL TOP LOWER BRACKET
7. PEDAL SUPPORT BRACKET 14. COWL TOP UPPER REINFORCEMENT
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