Mitsubishi Lancer. Manual — part 23

FRONT PILLAR

WELDED PANEL REPLACEMENT

3-10

FRONT PILLAR

M4030005000548

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

AB300993AB

AB301047AB

C

3 points
Right side

<Driver's side>

<Passenger's side>

B

B

A

REPAIR WELDS

C

A

180 mm

(With the upper frame extension outer removed)

Acoustic foam

High-rigidity foam

B

50 mm

FRONT PILLAR

WELDED PANEL REPLACEMENT

3-11

CAUTION

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

P.3-4

for the welding points with the upper frame extension

outer.

NOTE ON REPAIR WORK
INSTALLATION <DRIVER’S SIDE>

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 reinforcement upper B.

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

cut the side outer panel 145 mm behind the side
sill cut area, then cut the side sill outer
reinforcement centre 60 mm behind the side sill
cut area.

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

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

4. When assembling Part A, weld the areas shown

in the figure of the instructions from the outside
and inside.

CAUTION

Weld and repair the front pillar reinforcement
upper B if it is damaged.
5. Cut Part B in alignment with the front pillar

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

AB301054

120 mm

160 mm

80 mm

AB

Front pillar
reinforcement upper B

Front pillar
reinforcement
upper

Side outer
panel

AB301055AB

Side outer panel

145 mm

60 mm

Side sill outer
reinforcement
centre

AB200369AB

A

B

AB202039 AC

A

AB301056AB

Front pillar
reinforcement
upper B

Cover

Front pillar
reinforcement
upper

80 mm

40 mm

FRONT PILLAR

WELDED PANEL REPLACEMENT

3-12

6. To assemble Part B, weld the front pillar

reinforcement upper B then weld the cover of the
front pillar reinforcement upper.

CAUTION

Weld and repair if the side sill reinforcement sup-
port is damaged.
7. Remove the side outer panel from the new front

pillar outer parts. Cut the front pillar outer by
aligning it with the side sill outer reinforcement
centre on the body-side. Next, cut only the side sill
outer reinforcement centre 100 mm forward from
the cut area to create a cover, then cut the side sill
reinforcement support 40 mm behind the cut area
of the side sill outer reinforcement centre.

8. When assembling a new front pillar outer parts,

apply a front pillar silencer protector in advance,
bury the clearance with butyl tape then apply
structural adhesives in the areas shown in the
figure of the instructions.

Adhesive: Epoxyayresin adhesive
Brand: 3M ATD Part No.8115 or equivalent

9. Weld the side sill reinforcement support then weld

the cover of the side sill outer reinforcement
centre.

AB200372AB

Cover

AB301057AB

Cover

100 mm

Side sill outer
reinforcement centre

Side sill reinforcement
support

40 mm

AB200375

AB200375AB

Front pillar
silencer protector

: Adhesive

AB200374AB

Cover

FRONT PILLAR

WELDED PANEL REPLACEMENT

3-13

10.Apply in advance body sealant in the areas

shown in the figure of the instructions when
assembling the side outer panel.

11.Assemble the side outer panel, then cover the

hole and flange with bolt and aluminium tape and
fill the hole with foam materials as shown in the
figure of the instructions.

• FOAM (Hole A): 3M ATD ULTRAPRO

Panel foam-Yellow

• FOAM (Hole B): 3M ATD Super panel filler

12.Wait 2 hours after filling the foam materials to

remove the bolt and aluminium tape, then melt the
foam materials with a soldering gun so a clip, etc.
can thoroughly be inserted in the hole filled with
foam materials.

INSTALLATION <PASSENGER’S SIDE>

1. To reinforce the strength of the front pillar cut

area, cut the side outer panel 50 mm above the
front pillar cut area, 100 mm above the front pillar
inner upper.

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

cut the side outer panel 145 mm behind the side
sill cut area, then cut the side sill outer
reinforcement centre 60 mm behind the side sill
cut area.

3. Divide the new front pillar inner upper parts into

the front pillar inner upper and the front pillar
reinforcement upper.

AB200475AB

: Body sealant

AB202041

A

B

AC

AB100787

AB301021

100 mm

50 mm

AB

Front pillar
inner upper

Side outer panel

AB301022 AB

Side outer panel

145 mm

60 mm

Side sill outer
reinforcement
centre

AB301023AB

Front pillar
inner upper

Front pillar
reinforcement upper