Mitsubishi Lancer. Manual - part 23

FRONT PILLAR

WELDED PANEL REPLACEMENT

3-10

 FRONT PILLAR

M4030005000548

Spot welding

MIG plug welding      : indicates two panels to be welded
                                  : indicates three panels to be welded

MIG spot welding

MIG arc welding (continuous)

Braze welding

Anti-corrosion agent application locations
(Use access holes to apply liberally to butt-welded joints.)

(                                                               )

Symbol

Operation description

AB300993AB

AB301047AB

C

3 points
Right side

<Driver's side>

<Passenger's side>

B

B

A

REPAIR WELDS

C

A

180 mm

(With the upper frame extension outer removed)

Acoustic foam

High-rigidity foam

B

50 mm

FRONT PILLAR

WELDED PANEL REPLACEMENT

3-11

CAUTION

When repairing the area using foam materials do not use firing tools since the foaming materials may 
burn.
NOTE: Refer to the Fender Shield section on 

P.3-4

 for the welding points with the upper frame extension 

outer.

NOTE ON REPAIR WORK
INSTALLATION <DRIVER’S SIDE>

1. To reinforce the strength of the front pillar cut 

area, cut the side outer panel 160 mm above the 
front pillar cut area, 120 mm above the front pillar 
reinforcement upper and 80 mm above the front 
pillar reinforcement upper B.

2. To reinforce the strength in the side sill cut area, 

cut the side outer panel 145 mm behind the side 
sill cut area, then cut the side sill outer 
reinforcement centre 60 mm behind the side sill 
cut area.

3. Divide the new front pillar inner upper parts into A 

(front pillar inner reinforcement and front pillar 
inner upper) and B (front pillar reinforcement 
upper and front pillar reinforcement upper B).

4. When assembling Part A, weld the areas shown 

in the figure of the instructions from the outside 
and inside.

CAUTION

Weld and repair the front pillar reinforcement 
upper B if it is damaged.
5. Cut Part B in alignment with the front pillar 

reinforcement upper on the body-side. Next, cut 
only the front pillar reinforcement upper 80 mm 
from the cut area to create a cover, then cut the 
front pillar reinforcement upper B 40 mm above 
the front pillar reinforcement upper cut area.

AB301054

120 mm

160 mm

80 mm

AB

Front pillar 
reinforcement upper B

Front pillar 
reinforcement 
upper

Side outer 
panel

AB301055AB

Side outer panel

145 mm

60 mm

Side sill outer 
reinforcement  
centre

AB200369AB

A

B

AB202039 AC

A

AB301056AB

Front pillar
reinforcement 
upper B

Cover

Front pillar 
reinforcement 
upper

80 mm

40 mm

FRONT PILLAR

WELDED PANEL REPLACEMENT

3-12

6. To assemble Part B, weld the front pillar 

reinforcement upper B then weld the cover of the 
front pillar reinforcement upper.

CAUTION

Weld and repair if the side sill reinforcement sup-
port is damaged.
7. Remove the side outer panel from the new front 

pillar outer parts. Cut the front pillar outer by 
aligning it with the side sill outer reinforcement 
centre on the body-side. Next, cut only the side sill 
outer reinforcement centre 100 mm forward from 
the cut area to create a cover, then cut the side sill 
reinforcement support 40 mm behind the cut area 
of the side sill outer reinforcement centre.

8. When assembling a new front pillar outer parts, 

apply a front pillar silencer protector in advance, 
bury the clearance with butyl tape then apply 
structural adhesives in the areas shown in the 
figure of the instructions.

Adhesive: Epoxyayresin adhesive
Brand: 3M ATD Part No.8115 or equivalent

9. Weld the side sill reinforcement support then weld 

the cover of the side sill outer reinforcement 
centre.

AB200372AB

Cover

AB301057AB

Cover

100 mm

Side sill outer  
reinforcement  centre

Side sill reinforcement 
support

 40 mm

AB200375

AB200375AB

Front pillar 
silencer protector

: Adhesive

AB200374AB

Cover

FRONT PILLAR

WELDED PANEL REPLACEMENT

3-13

10.Apply in advance body sealant in the areas 

shown in the figure of the instructions when 
assembling the side outer panel.

11.Assemble the side outer panel, then cover the 

hole and flange with bolt and aluminium tape and 
fill the hole with foam materials as shown in the 
figure of the instructions.

• FOAM (Hole A): 3M ATD ULTRAPRO 

Panel foam-Yellow

• FOAM (Hole B): 3M ATD Super panel filler

12.Wait 2 hours after filling the foam materials to 

remove the bolt and aluminium tape, then melt the 
foam materials with a soldering gun so a clip, etc. 
can thoroughly be inserted in the hole filled with 
foam materials.

INSTALLATION <PASSENGER’S SIDE>

1. To reinforce the strength of the front pillar cut 

area, cut the side outer panel 50 mm above the 
front pillar cut area, 100 mm above the front pillar 
inner upper.

2. To reinforce the strength in the side sill cut area, 

cut the side outer panel 145 mm behind the side 
sill cut area, then cut the side sill outer 
reinforcement centre 60 mm behind the side sill 
cut area.

3. Divide the new front pillar inner upper parts into 

the front pillar inner upper and the front pillar 
reinforcement upper.

AB200475AB

: Body sealant

AB202041

A

B

AC

AB100787

AB301021

100 mm

 50 mm

AB

Front pillar 
inner upper

Side outer panel

AB301022 AB

Side outer panel

145 mm

60 mm

Side sill outer 
reinforcement  
centre

AB301023AB

Front pillar 
inner upper

Front pillar 
reinforcement upper