Mitsubishi Outlander. Body repair manual - part 8

BODY CONSTRUCTION CHARACTERISTICS

BODY CONSTRUCTION

1-21

DOOR

M4010015000161

A one-piece top-bottom pressed door structure was 
employed for the door outer panel and door inner 
panel to improve door panel rigidity.

AB200222

AB200221

AB202356

Front Door

Rear Door

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5

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8

9

10

11

12

13

14

15

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18

19

20

21

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BT

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1.

Front door hinge reinforcement 

2.

Front door sash front 

3.

Front door side door beam

4.

Front door outer panel

5.

Front door belt line reinforcement

6.

Front door weather strip hold upper

7.

Front door hinge reinforcement upper

8.

Front door sash upper 

9.

Front door sash rear

10. Front door belt line reinforcement inner
11. Front door latch reinforcement
12. Front door inner panel

13. Rear door hinge reinforcement 
14. Rear door sash front
15. Rear door side door beam
16. Rear door outer panel
17. Rear door belt line reinforcement 
18. Rear door weather strip holder
19. Rear door sash upper 
20. Rear door belt line reinforcement inner
21 Rear door sash rear 
22. Rear door latch reinforcement
23. Rear door inner panel

SILENCER APPLICATION LOCATIONS

BODY CONSTRUCTION

1-22

SILENCER APPLICATION LOCATIONS

M4010005000193

A silencer (MD-12, RSS and melting sheet) has been 
adhered on the top part of the floor to improve 
anti-vibration performance and to shut-out exhaust 
gas heat.

NOTE: 

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

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AB301591

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 : 3.0 mm thick melting sheet [Place two 1.6 mm melting sheet one on top of another.]

 : 1.6 mm thick melting sheet

 : 4.0 mm thick MD-12 [Place three 1.6 mm melting sheet one on top of another.]

 : 1.6 mm thick MD-12 [Place a 1.6 mm melting sheet.]

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 : 3.6 mm thick melting sheet and RSS [Place three 1.6 mm melting sheet one on top of another.]

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AB

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 : 6.0 mm thick MD-12 [Place three 1.6 mm melting sheet one on top of another.]

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RSS (Rubber Special Sheet) is a product name 
of Nihon Tokushu Toryo Co., Ltd. The product 
features the same performance as a steel sheet 
sandwich type and refers to a heat cured resin 
sheet that is moulded into a sheet with a uniform 
thickness (2.0mm). It contains degenerating resin 
and filler with asphalt and rubber as the main 
contents. 

LOCATIONS USING URETHANE FOAM AND FOAM MATERIAL

BODY CONSTRUCTION

1-23

LOCATIONS USING URETHANE FOAM AND FOAM 

MATERIAL

M4010007000144

• Introduction of noise was prevented by inserting 

urethane foam inside the centre 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 front sidemember (right side) and rear floor 
sidemember to heighten panel rigidity.

CAUTION

The foam materials may burn when heated. 
Always observe the following instructions.

• 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.

•

AB200011

AB200011

A

B

C

D

E

F

AC

AB200229

A

Side roof
support

Front pillar inner 
upper reinforcement

AB

Acoustic form 

AB202333

AB202333

Centre pillar inner 

Rear door hinge

reinforcement upper

Acoustic Foam

AC

B

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.

AB200230

AB

C

Front pillar support 

Front pillar inner
upper reinforcement

Acoustic

foam

AB200228

D

Front 
sidemember 
inner

AC

High rigidity 
foam

Front sidemember 
outer
reinforcement
rear (B)

AB200231

E

AC

Front pillar
inner lower

Front pillar inner 
lower reinforcement 

Front pillar 
reinforcement lower

Acoustic foam

AB202332AB

Side outer

panel

Quarter inner

extension front

Acoustic foam

F

AB202011

AB300068AC

G

H

I

J

K

L

AB202340AB

Side roof 
rail inner

Side outer panel

G

Acoustic foam

AB100031

Side outer panel

H

Acoustic

Foam

Quarter inner
panel

Rear pillar
reinforcement
upper

AF

LOCATIONS USING URETHANE FOAM AND FOAM MATERIAL

BODY CONSTRUCTION

1-24