Mitsubishi Lancer. Manual — part 24

FRONT PILLAR

WELDED PANEL REPLACEMENT

3-14

CAUTION

Weld and repair if the side sill reinforcement sup-
port is damaged.
4. 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 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.

5. 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

6. Weld the side sill reinforcement support then weld

the cover of the side sill outer reinforcement
centre.

7. Apply in advance body sealant in the areas shown

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

8. 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

AB201024AB

Cover

100 mm

Side sill outer
reinforcement
centre

Side sill reinforcement
support

40 mm

AB301117AB

Front pillar
silencer protector

: Adhesive

AB301117

AB301118AB

Cover

AB301119AB

: Body sealant

AB301120

A

B

AB

FRONT PILLAR

WELDED PANEL REPLACEMENT

3-15

9. 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.

AB100787

CENTRE PILLAR

WELDED PANEL REPLACEMENT

3-16

CENTRE PILLAR

M4030006000176

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

AB300994AB

AB301062AB

A

B

D

A

E

C

REPAIR WELDS

Acoustic foam

290 ± 10 mm

C

High-rigidity foam

125 ± 10 mm

D

E

125 ± 10 mm

B

CENTRE PILLAR

WELDED PANEL REPLACEMENT

3-17

CAUTION

Do not use heat at areas using foam material as the foam material may burn.

NOTE ON REPAIR WORK
REMOVAL

1. Since the centre pillar reinforcement and side sill

outer reinforcement centre of the side sill is
adhered together, cut the side outer panel in a
place where the reinforcement joint is visible, as
shown in the figure of the instructions, to remove
the centre pillar reinforcement.

2. To detach the welding of the centre pillar seat belt

reinforcement and centre pillar reinforcement, cut
the lower part of the side roof rail inner as shown
in the figure of the instructions.
NOTE: Hold the side roof rail inner (A) that was
cut since it will be re-used.

INSTALLATION

1. Remove the side outer panel, side sill outer

reinforcement centre, side sill bulkhead, and side
sill reinforcement support from the new centre
pillar.

2. To ensure the strength of the cut area at the top of

the centre pillar, cut the side outer panel 30 mm
above the cut area.
Cut the new centre pillar at the same positions.

CAUTION

If the centre pillar seat belt reinforcement has
been damaged, repair by welding.
3. Cut only the centre pillar reinforcement, aligned

with the body-side, of the new centre pillar
reinforcement parts so the centre pillar seat belt
reinforcement is not damaged.

4. When assembling the centre pillar reinforcement,

apply adhesives in the areas shown in the figure
of the instructions.

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

AB201265

AD

Side sill outer
reinforcement centre

Centre pillar
reinforcement

Adhesive points

Adhesive points

AB301065AB

(A)

Centre pillar
seat belt
reinforcement

AB200422AB

30 mm

AB301067AB

Centre pillar seat
belt reinforcement

Centre pillar
reinforcement

AB300021

: Adhesive

AB