Mitsubishi Outlander. Body repair manual - part 17

FRONT SIDEMEMBER (PARTIAL REPLACEMENT)

WELDED PANEL REPLACEMENT

3-11

NOTES

FRONT PILLAR

WELDED PANEL REPLACEMENT

3-12

FRONT PILLAR

M4030005000537

AB300048

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

AB300048

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

AE

AB200556

REPAIR WELDS

A

B

E

A

B

C

Upper frame extension outer

D

130 mm

90 ± 20 mm

AB

(With the upper frame extension outer removed)

F

Acoustic foam

Right 
side

Acoustic foam

CAUTION

When repairing the area using foam materials do not use firing tools since the foaming materials may 
burn.

AB200566

C

D

E

F

AB

FRONT PILLAR

WELDED PANEL REPLACEMENT

3-13

FRONT PILLAR

WELDED PANEL REPLACEMENT

3-14

NOTE ON REPAIR WORK
INSTALLATION

AB200367

120 mm

160 mm

80 mm

AB

Front pillar support

Front pillar 
reinforcement 
upper

Side outer 
panel

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 support.

AB200368 AE

Side outer panel

100 mm

50 mm

Side sill outer 
reinforcement 
centre

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

cut the side outer panel 100 mm behind the side 
sill cut area and 50 mm behind the side sill outer 
reinforcement centre.

AB100231AC

Aluminium
tape

3. When assembling a new front pillar inner lower 

parts, cover the front pillar inner lower hole with 
aluminium tape since it is not possible to fill the 
area shown in the figure of the instructions with 
foam materials.

AB200369AB

A

B

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

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

AB200370AB

Urethane foam

5. When assembling Part A, weld the areas shown 

in the figure of the instructions from the outside 
and inside. After assembling, to prevent the 
foaming materials from dripping in the area shown 
in the figure of the instructions, adhere urethane 
foam to fill (bury) the front pillar interior.

AB200371AB

Front pillar
support

Cover

Front pillar 
reinforcement 
upper

80 mm

40 mm

6. Cut Part B in alignment with the front pillar 

reinforcement 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 
support 40 mm above the front pillar 
reinforcement upper cut area.