Mitsubishi Outlander (2013+). Manual - part 18

SIDE SILL

WELDED PANEL REPLACEMENT

3-17

NOTE ON REPAIR WORK

REMOVAL

When removing the side sill reinforcement outer rear, 
cut the centre pillar reinforcement 80 mm downward 
from the installation hole of the rear door hinge 
because the centre pillar reinforcement interferes 
with it. Remove the side sill end plate and the quarter 
inner front extension lower as the side sill reinforce-
ment outer rear interferes with them.

INSTALLATION

1. When installing the new centre inner pillar parts, 

remove the centre pillar inner upper from the 
centre inner pillar.

2. When installing the new side sill reinforcement 

parts, use only the side sill reinforcement outer 
rear and the side sill bulkhead A.

3. After installing the side sill reinforcement, install 

the side sill end plate and the quarter panel 
extension front.

ABB00917

D

AB

E

ABC00018

AB

Side sill end plate

Quarter inner 
front extension lower

80 mm

ABB00900 AB

Centre pillar 
inner lower

Centre pillar 
inner upper

AB501219

AD

Side sill bulkhead A

Side sill reinforcement outer rear

QUARTER OUTER

WELDED PANEL REPLACEMENT

3-18

4. When assembling the new front floor side sill 

outer parts, carry out the following procedure.

(1) Machine the body loose panel cushion 

(MR565301 or MR435765) for replacement as 
shown and apply it to the body side because 
the sound dampening foam material cannot be 
filled into the centre pillar.

(2) Apply body sealant in the area shown in the 

figure of the front floor side sill outer.

QUARTER OUTER

M4030008001391

CAUTION

When repairing the area using sound dampening foam material do not use firing tools since the 
sound dampening foam material may burn.

ABB00903

AB

A

A

60 mm

60 mm

25 mm

50 mm

450 mm

75 mm

20 mm

75 mm

50 mm

Side outer 
panel

Centre pillar 
reinforcement

 : Body loose panel cushion

NOTE:

ABC00046

AB

 : Body sealant

NOTE:

ABB00859 AB

Symbol

Operation description

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.)

(                                                               )

QUARTER OUTER

WELDED PANEL REPLACEMENT

3-19

ABB00865

REPAIR WELDS

AB

A

B

A

B

C

C

E

D

The same position as 
the new quarter 
panel outer parts.

4 points on 
left side

240 mm

Right side

Sound dampening 
foam material

20 mm

Centre of clip 
mounting hole

QUARTER OUTER

WELDED PANEL REPLACEMENT

3-20

NOTE: 

Partial replacement is possible depending on the 
range of damage.

NOTE ON REPAIR WORK

INSTALLATION

1. When installing the new quarter panel extension 

rear lower parts, apply the body sealant to the 
areas as shown in advance.

2. When assembling the new quarter panel outer 

parts, carry out the following procedure.

ABB00866AB

D

E

100 mm

Centre of tailgate 
gas spring assembly
mounting hole

ABB00867

AB

NOTE:         : Cuttable range

ABB00877

 : Body sealant

NOTE:

AB

ABB00870AB

15 mm

40 mm

Side outer 
panel

Quarter inner 
front extension

Rear pillar 
reinforcement 
lower

A

 : Body loose panel cushion

NOTE:

A

190 mm