Mitsubishi Evolution X. Manual — part 35

FRONT PILLAR

TSB Revision

WELDED PANEL REPLACEMENT

3-10

CAUTION

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

AB700978

AB601219

AB700381

AB

E

F

D

G

Cutting position

Sound dampening
foam material

Cutting position

Sound dampening
foam material

(With the side outer panel removed)

(With the side outer panel removed)

FRONT PILLAR

TSB Revision

WELDED PANEL REPLACEMENT

3-11

NOTE ON REPAIR WORK

.

REMOVAL

After removing the front pillar, cut the side outer panel 140 mm
(5.5 inches) behind the positioning notch to remove the side sill
reinforcement outer front, side sill inner support front, and front
pillar inner lower remaining on the body side.

.

INSTALLATION

1. To reinforce the strength in the front pillar cut area, cut the

side outer panel 50 mm (1.97 inches) above the cut area
and cut the front upper inner pillar 100 mm (3.9 inches)
above the cut area.

2. Assemble the new front pillar inner lower parts.
3. Assemble the new front upper inner pillar part.

4. Assemble the new side sill reinforcement front parts. After

that, cover the hole with aluminum tape to prevent the sound
dampening foam material from dropping when the material
is filled into the front pillar in the next process.

AB601206

Front pillar inner lower

Side outer panel

140 mm
(5.51 in)

AD

Side sill reinforcement outer front

Side sill inner
support front

AB601206

AB601213

100 mm
(3.93 in)

50 mm
(1.97 in)

AB

Front upper
inner pillar

Side outer
panel

Roof side rail
front reinforcement

Front pillar
support

AB601208

Side sill reinforcement front

Aluminum tape

AB

FRONT PILLAR

TSB Revision

WELDED PANEL REPLACEMENT

3-12

5. Align the new roof side rail reinforcement parts to the body

side to cut and install. After that, machine the body loose
panel cushion (MR535301 or MR435765) as shown and
apply it to the body side to prevent the sound dampening
foam material from dropping when the material is filled into
the front pillar in the next process.

6. Assemble the new front pillar reinforcement lower.

7. When installing the new front outer pillar parts, machine the

body loose panel cushion (MR535301 or MR435765) as
shown and apply it to the body side to prevent the sound
dampening foam material from dropping when the material
is filled into the front pillar upper in the next process (for front
pillar upper).

AB601297

AB601297

AB

: Body loose panel cushion

A

A

Front pillar reinforcement lower

Front pillar
inner upper

50 mm

(1.97 in)

20 mm

(0.78 in)

40 mm

(1.57 in)

AB700912

A

A

AB

: Body loose panel cushion

Front pillar
reinforcement lower

Side outer panel

65 mm

(2.55 in)

20 mm

(0.78 in)

15 mm

(0.59 in)

35 mm

(1.37 in)

25 mm

(0.98 in)

20 mm

(0.78 in)

FRONT PILLAR

TSB Revision

WELDED PANEL REPLACEMENT

3-13

8. When installing the new front outer pillar parts, machine the

body loose panel cushion (MR535301 or MR435765) for
replacement as shown and apply it to the body side because
the sound dampening foam material is filled into the front
pillar (for front pillar lower).

9. When installing the new front outer pillar parts, apply the

body sealant to the areas as shown in advance.

AB700451

AB

A

A

: Body loose panel cushion

35 mm

(1.37 in)

30 mm

(1.18 in)

10 mm

(0.39 in)

80 mm

(3.14 in)

90 mm

(3.54 in)

110 mm

(4.33 in)

Front pillar reinforcement lower

Side outer
panel

AB601221AB

: Body sealant