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