Mitsubishi Outlander. Body repair manual - part 3

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

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

1-14

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

1-16

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

1-17

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

1-18

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

1-21

SILENCER APPLICATION 

 

LOCATIONS . . . . . . . . . . . . . . . . . . . .

1-22

LOCATIONS USING URETHANE FOAM 

 

AND FOAM MATERIAL . . . . . . . . . . .

1-23

STIFFENER AND DAMP SHEET 
APPLICATION LOCATIONS  . . . . . . .

1-26

BODY COMPONENTS

BODY CONSTRUCTION

1-2

BODY COMPONENTS

M4010001000306

AB400049

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

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

AD

 : High-tensile steel panels

 : Anti-corrosion steel panels

1.

Front bumper reinforcement

2.

Headlamp support panel

3.

Hood lock stay

4.

Front end crossmember

5.

Front end upper bar

6.

Headlamp support panel side

7.

Front upper frame inner 

8.

Upper frame bulkhead front

9.

Upper frame bulkhead

10. Dash panel
11. Dash panel silencer
12. Dash panel reinforcement
13. Cowl top panel
14. Front deck crossmember
15. Hood inner panel
16. Hood outer panel
17. Front door inner panel
18. Front door side door beam
19. Front door outer panel
20. Rear door side door beam
21. Rear door outer panel
22. Rear door inner panel
23. Roof panel
24. Tailgate inner panel
25. Tailgate outer panel
26. Gate pillar reinforcement
27. Quarter outer extension upper
28. Quarter inner extension
29. Rear lamp housing upper
30. Rear lamp housing lower
31. Quarter outer extension lower
32. Rear end crossmember
33. Rear bumper bracket
34. Rear floor sidemember extension
35. Rear floor pan
36. Rear floor sidemember
37. Upper arm crossmember
38. Rear floor extension

39. Front floor crossmember rear
40. Front floor crossmember front
41. Front floor side sill inner
42. Front floor sidemember
43. Backbone reinforcement
44. Fender panel
45. Front sidemember rear
46. Front sidemember inner
47. Front sidemember outer
48. Front fender shield
49. Spring house panel
50. Instrument panel centre reinforcement bracket
51. Front floor pan
52. Front upper frame extension outer
53. Upper frame to front pillar brace
54. Front pillar inner lower
55. Front pillar inner upper
56. Roof rail front 
57. Roof bow front
58. Roof bow centre
59. Roof bow A
60. Roof bow B
61. Roof bow C
62. Roof rail rear
63. Side roof rail inner
64. Rear pillar reinforcement
65. Quarter inner panel
66. Quarter inner extension lower
67. Fuel filler door
68. Quarter inner extension front
69. Heat protector bracket
70. Spare tyre bracket
71. Rear floor crossmember upper
72. Child anchor bracket lower
73. Side outer panel
74. Centre pillar inner
75. Rear wheel house inner panel

BODY COMPONENTS

BODY CONSTRUCTION

1-3

BODY MAIN CROSS-SECTIONAL VIEWS

BODY CONSTRUCTION

1-4

BODY MAIN CROSS-SECTIONAL VIEWS

M4010002000183

AB200199

AC

A

B

C

D

E

F

AB200024

A

Side roof 
rail inner

Side roof 
support

Side outer panel

Front pillar inner 
upper reinforcement 

Front pillar upper 
reinforcement

AE

AB200194AB 

Side roof rail inner

Side outer panel

B

AB200200AD

C

Front end crossmember
reinforcement

Front end 
crossmember outer

Front end 
crossmember inner

AB100242 AJ

Front pillar
inner lower

Front pillar inner 
lower reinforcement 

Front pillar
reinforcement lower

D

AB200023 AF

E

Front floor 
side sill inner

Side sill 
reinforcement
support

Side sill outer
reinforcement centre

Side outer panel

AB200023

F

AC

Front floor 
side sill inner

Side sill 
reinforcement
support rear

Side sill outer
reinforcement rear

Side outer panel