Mitsubishi Galant (2004+). Manual - part 19

SIDE SILL

TSB Revision

WELDED PANEL REPLACEMENT

3-23

4. Weld the side sill outer reinforcement inner, then weld the 

side outer reinforcement.

5. Assemble the side sill reinforcement rear by inserting it to 

the side outer reinforcement from backward.

6. Adhere in advance body sealant in the areas of the body 

side shown in the figure when assembling the front floor side 
sill outer. 

AB301524 AB

REAR SIDE

FRONT SIDE

SIDE SILL OUTER 
REINFORCEMENT INNER

AB301403

SIDE SILL REINFORCEMENT 
REAR

AB

AB301404

: BODY SEALANT

AB

QUARTER OUTER

TSB Revision

WELDED PANEL REPLACEMENT

3-24

QUARTER OUTER

M4030008000150

AB301458

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.)

(                                                               )

AB301527

AB

A

B

C

A

B

C

E

FOAM ACOUSTIC 
MATERIAL

4 POINTS 
LEFT SIDE

REPAIR WELDS

620 mm

(24.4 in)

200 mm

(7.9 in)

D

FOAM ACOUSTIC 
MATERIAL

QUARTER OUTER

TSB Revision

WELDED PANEL REPLACEMENT

3-25

CAUTION

When repairing the area using foam materials do not use firing tools since the foaming materials may 
burn.

NOTE ON REPAIR WORK

.

INSTALLATION
1. Adhere in advance adhesives in the areas shown in the 

figure of the instructions when assembling the rear quarter 
outer panel extension.

2. When filling the foam materials, to prevent the foam 

materials from dripping, apply urethane foam to bury the 
inside of the rear pillar and the wheel arch.

AB301528

E

D

AB

ADHESIVE TYPE

BRAND

Epoxyayresin 
adhesive

3M

ä AAD Part No.8115 or 

equivalent

AB301426

: ADHESIVE

AB

AB301444 AB

URETHANE 
FOAM

QUARTER OUTER

TSB Revision

WELDED PANEL REPLACEMENT

3-26

3. When assembling the new rear quarter outer panel parts, 

apply in advance body sealant and adhesive to the areas 
shown in the figure of the instructions.

4. Assemble the rear quarter outer panel, bolt and tape the 

hole and flange with aluminum tape, then fill the hole with 
foam materials as shown in the figure of the instructions.
FOAM: 3M

ä AAD ULTRAPRO Panel foam-Yellow

5. Wait 2 hours after filling the foam materials to remove the 

bolt and aluminum tape. Then melt the foam materials with a 
soldering gun so a clip, etc. can thoroughly be inserted in 
the hole that was clogged with foam materials, to bore open 
the hole.

ADHESIVE TYPE

BRAND

Epoxyayresin 
adhesive

3M

ä AAD Part No.8115 or 

equivalent

AB301530AB

: ADHESIVE

: BODY SEALANT

LEFT SIDE ONLY

AB301531AB

AB100787