Mitsubishi Evolution X. Manual — part 36

FRONT PILLAR

TSB Revision

WELDED PANEL REPLACEMENT

3-14

10.Assemble the front outer pillar, bolt and tape the hole and

flange with aluminum tape, then fill the hole with sound
dampening foam material as shown in the figure of the
instructions.

Sound dampening foam material: 3M

™ AAD ULTRA-

PRO Panel foam-Yellow

11.Wait 2 hours after filling the sound dampening foam material

to remove the bolt and aluminum tape, then melt the sound
dampening foam material with a soldering gun so a clip, etc.
can thoroughly be inserted in the hole filled with sound
dampening foam material.

AB700452

AB601214

AC

A

A

Front pillar reinforcement lower

Front pillar
inner lower

: Sound dampening foam material

AB100787

FRONT PILLAR (PARTIAL REPLACEMENT)

TSB Revision

WELDED PANEL REPLACEMENT

3-15

FRONT PILLAR (PARTIAL REPLACEMENT)

M4030001200089

CAUTION

When repairing the area using sound dampening foam material do not use firing tools since the
sound dampening foam material may burn.
NOTE: Refer to the Fender Shield section on

P.3-4

for the welding points with the upper frame to front pillar

brace and front deck frame upper outer.

AB700945

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.)

( )

AB

AB700938

REPAIR WELDS

B

C

A

C

AB

230 mm

(9.05 in)

Cutting position

E

D

A

G

110 mm

(4.33 in)

Cutting position

Cutting position

B

Sound dampening
foam material

Sound dampening
foam material

(With the upper frame to front pillar brace
and front deck frame upper outer removed)

FRONT PILLAR (PARTIAL REPLACEMENT)

TSB Revision

WELDED PANEL REPLACEMENT

3-16

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
inner pillar 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.

2. Assemble the new front lower inner pillar parts.

AB700941

AB601219

AB

D

E

(With the side outer panel removed)

Cutting position

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

AB601207

Side outer
panel

50 mm
(1.97 in)

AB

FRONT PILLAR (PARTIAL REPLACEMENT)

TSB Revision

WELDED PANEL REPLACEMENT

3-17

3. 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.

4. Assemble the new front pillar reinforcement lower.

5. When installing the new front outer pillar, 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 cannot be filled into the
front pillar.

6. When installing the new front outer pillar, apply the body

sealant to the areas as shown in advance.

AB601208

Side sill reinforcement front

Aluminum tape

AB

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

AB700989

: Body sealant

AB