2011-2014 Mitsubishi Outlander Sport/RVR/ASX OEM Service & Repair Manual

1-1 GROUP 1 BODY CONSTRUCTION CONTENTS BODY COMPONENTS. . . . . . . . . . . . 1-2 BODY MAIN CROSS-SECTIONAL VIEWS . . . . . . . . . . . . . . . . . . . . . . . . 1-4 MAINTENANCE, SERVICEABILITY . . . . . . . . . . . . . . . 1-6 BODY CONSTRUCTION CHARACTERISTICS . . . . . . . . . . . . . 1-8 FRONT BODY. . . . . . . . . . . . . . . . . . . . . . . 1-8 SIDE BODY. . . . . . . . . . . . . . . . . . . . . . . . . 1-14 REAR BODY . . . . . . . . . . . . . . . . . . . . . . . . 1-16 ROOF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17 UNDER BODY. . . . . . . . . . . . . . . . . . . . . . . 1-18 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21 SILENCER APPLICATION LOCATIONS . . . . . . . . . . . . . . . . . . . . 1-22 FOAMING MATERIAL USAGE LOCATIONS . . . . . . . . . . . . . . . . . . . . 1-23 STIFFENER AND DAMP SHEET APPLICATION LOCATIONS . . . . . . . 1-24

BODY COMPONENTS TSB Revision BODY CONSTRUCTION 1-2 BODY COMPONENTS M4010001002056 ABA00162 AB 1 2 3 4* 56 90 5 7 9* 11 16* 17 21 28 22 63** 87 88 68 18 31 32 34 27 24 67 66 72 71** 84* 85 79 78* 8 6 19 65 81** 82 30 29 36* 33 39 69 42 45 46 70 47 49 50 51 91 92 48 89 38 40 41 20 10 62 12 13 14 15 64* 49 52 54 80 83 35 44 55 86 37 43 53 58 61 57 59 60* 73 74** 75* 76* 77** 23 25 26 : Anti-corrosion steel panels : High-tensile steel panels (*: Indicates 590MPa-high-tensile steel panels.) (**: Indicates 980MPa-ultra-high-tensile steel panels.) NOTE:

BODY COMPONENTS TSB Revision BODY CONSTRUCTION 1-3 1. Front bumper reinforcement 2. Headlight support panel upper 3. Front body frame to side sill brace 4. Front sidemember rear 5. Front inner sidemember 6. Headlight support panel 7. Front sidemember plate 8. Front outer sidemember 9. Front sidemember extension 10. Front fender gusset 11. Headlight support panel upper 12. Front fender shield 13. Engine mounting gusset 14. Fender shield frame upper inner 15. Spring house panel 16. Dash panel crossmember upper 17. Dash panel crossmember lower 18. Upper frame to front pillar brace 19. Front deck frame upper outer 20. Dash panel 21. Cowl top panel 22. Front deck crossmember 23. Front lower inner pillar 24. Hood panel inner 25. Hood panel outer 26. Front door side door beam 27. Front door panel inner 28. Front door panel outer 29. Rear door side door beam 30. Rear door side door beam lower 31. Rear door panel inner 32. Rear door panel outer 33. Roof rail front upper <Vehicles with panorama glass roof> 34. Roof side rail <Vehicles with panorama glass roof> 35. Roof rail front 36. Roof bow center 37. Roof rail rear 38. Roof panel 39. Liftgate panel outer 40. Liftgate panel inner 41. Gate pillar reinforcement 42. Quarter panel extension outer 43. Quarter panel extension lower rear 44. Side outer panel 45. Fuel filler door panel (Left side) 46. Rear bumper reinforcement 47. Rear bumper reinforcement 48. Rear end panel outer 49. Rear end panel inner 50. Rear end inner crossmember 51. Rear floor crossmember 52. Rear floor crossmember 53. Rear floor 54. Second seat anchor reinforcement 55. Rear floor under stringer 56. Rear floor side panel 57. Rear floor sidemember extension 58. Rear floor sidemember lower 59. Rear floor extension 60. Rear floor rear seat under crossmember 61. Front floor 62. Front floor reinforcement 63. Front floor side sill inner 64. Front floor sidemember 65. Front floor crossmember rear center 66. Front floor crossmember front 67. Battery tray stay rear (Left side) 68. Battery tray stay front (Left side) 69. Radiator bracket lower 70. Headlight support panel lower 71. Front floor crossmember front 72 Front floor crossmember rear 73. Front floor backbone reinforcement 74. Side sill reinforcement 75. Front pillar reinforcement lower inner 76. Center pillar reinforcement 77. Front pillar reinforcement upper 78. Roof side rail reinforcement center 79. Roof side rail reinforcement rear 80. Center inner pillar 81. Front upper inner pillar 82. Roof rail extension front inner 83. Roof rail extension rear inner <Vehicles without panorama glass roof> 84. Roof side rail inner 85. Rear wheel house panel inner 86. Rear pillar brace 87. Second seat anchor reinforcement 88. Quarter panel extension lower inner 89. Rear pillar inner 90. Quarter panel inner 91. Quarter panel extension inner 92. Rear pillar reinforcement lower

BODY MAIN CROSS-SECTIONAL VIEWS TSB Revision BODY CONSTRUCTION 1-4 BODY MAIN CROSS-SECTIONAL VIEWS M4010002001283 AB900379 AB A B D C E F AB900400AB A Roof panel Roof rail front ABA00121AB B Roof side rail reinforcement center Side outer panel Roof side rail inner Roof side reinforcement support AB900749AB Center pillar reinforcement Center pillar inner upper Rear door hinge reinforcement Side outer panel C AB900399 D AB Front end crossmember upper Front end crossmember lower Front end crossmember bulkhead AB900724AB E Front pillar reinforcement lower inner Front pillar inner lower Side outer panel ABA00122 F AB Side sill reinforcement outer rear Side outer panel Front floor side sill inner Side sill reinforcement support center

BODY MAIN CROSS-SECTIONAL VIEWS TSB Revision BODY CONSTRUCTION 1-5 AB900380 AB G I J K H L AB900586AB G Side outer panel Front upper inner pillar Front pillar reinforcement upper AB900401AB H Roof panel Roof rail rear inner Roof rail rear outer AB900648 AB I Quarter panel inner Side outer panel AB900649 J AB Gate pillar reinforcement upper Quarter outer panel extension upper Second seat belt reinforcement upper (Left side) Quarter panel inner Side outer panel AB900725AB K Rear pillar reinforcement lower Rear wheel house panel inner Quarter panel extension front Side sill end plate Side outer panel AB900398 AB L Rear end panel outer Rear end inner crossmember Tailgate striker reinforcement

MAINTENANCE, SERVICEABILITY TSB Revision BODY CONSTRUCTION 1-6 MAINTENANCE, SERVICEABILITY M4010003001112 FENDER SHIELD A positioning hole, lug, and notch have been added on the front end upper bar side, front upper frame inner, upper frame extension inner, front side member brace upper and dash panel to improve assembling workability during panel replacement. ABA00008 AB

MAINTENANCE, SERVICEABILITY TSB Revision BODY CONSTRUCTION 1-7 SIDE STRUCTURE A panel positioning notch has been added on the door opening to improve assembling workability when replacing the panel. AB201388 AB Panel positioning notch AB900484 AB

BODY CONSTRUCTION CHARACTERISTICS TSB Revision BODY CONSTRUCTION 1-8 BODY CONSTRUCTION CHARACTERISTICS FRONT BODY M4010010001608 HEADLIGHT SUPPORT • The crush box structure, which has an octagonal cross-section at the front end of the front sidemember, has been adopted. This structure can effectively absorb energy upon frontal impact and reduces the vehicle repair cost caused by a light collision. • The bolt-on headlight support panel upper is used to improve maintainability. The crush box structure has been changed to straight type with an octagon cross-section so that the structure can effectively absorb energy from the impact at the time of collision. AB900381 3 1 4 7 5 6 2 AB 9 8 9 8 3 A 10 5 7 9.0 ± 2.0 N·m 80 ± 17 in-lb 9.0 ± 2.0 N·m 80 ± 17 in-lb 20 ± 5 N·m 15 ± 3 ft-lb 1. Front bumper reinforcement 2. Headlight support panel upper 3. Front end crossmember gusset 4. Front end crossmember upper 5. Radiator bracket lower A 6. Front end crossmember bulkhead 7. Radiator bracket lower B 8. Shipping hook front 9. Shipping reinforcement front 10. Front end crossmember lower AB900384AB A Crush box

BODY CONSTRUCTION CHARACTERISTICS TSB Revision BODY CONSTRUCTION 1-9 FENDER SHIELD • The front frame structure is supported in three directions by the dash crossmember center, dash crossmember lower and front sidemember rear in order to improve the frontal collision characteristics, and increase the vehicle body rigidity. • The padding structure of the front fender bracket upper front and the front fender bracket rear has been adopted to have a crushable structure in order to efficiently absorb energy upon impact, improving the pedestrian protection capability. AB602313 AB900390 1 15 21 7 AB 20 19 4 3 2 18 17 16 14 9 12 10 11 6 5 8 13 (Right side) AB900741AB 22 24 23 1 25 2 6 5 7 8 14 9 12 13 10 15 19 21 (Left side) 26 1. Front fender gusset 2. Front fender shield 3. Condense tank reinforcement 4. Engine mounting gusset 5. Front end upper bar side 6. Front fender bracket upper front 7. Upper frame bulkhead front 8. Front fender bracket rear 9. Upper frame bulkhead rear 10. Front upper frame inner 11. Horn bracket 12. Spring house bracket reinforcement 13. Spring house corner gusset 14. Spring house bracket front 15. Spring house panel rear 16. Grand strap bracket 17. Suction hose bracket 18. Spring house harness bracket 19. Spring house panel 20. Engine mounting bracket upper

BODY CONSTRUCTION CHARACTERISTICS TSB Revision BODY CONSTRUCTION 1-10 FRONT SIDEMEMBER REINFORCEMENT The 590-MPa class high tensile strength steel panels have been adopted for the front sidemember extension, front sidemember rear bulkhead and front sidemember rear to improve the frontal collision characteristics. 21. Front sidemember 22. Engine control module bracket 23. Relay box bracket 24. Relay box bracket rear 25. Transmission mounting gusset 26. Clutch tube bracket <M/T> ABA00123 3 13 2 9 8 12 11 10 19 16 6* 18 14 1* AB 17 5* 20 4 15 7 21 22 (Right side) NOTE: *: Indicates 590MPa-high-tensile steel panels. 23 ABA00125 AB 22 12 5 6 15 16 17 A B 21 21 11 4 10 14 1. Front sidemember extension 2. Front sidemember outer 3. Front brake hose bracket 4. Front sidemember reinforcement rear lower 5. Front sidemember rear bulkhead 6. Front sidemember rear 7. Height sensor bracket 8. Dash crossmember extension lower 9. Front body frame to side sill brace 10. Tie down reinforcement front 11. Front suspension crossmember bracket front 12. Front sidemember inner 13. Front sidemember plate 14. Front sidemember support front 15. Front sidemember bulkhead front 16. Engine mounting bulkhead 17. Front suspension crossmember bulkhead 18. Headlight bracket lower 19. Headlight support panel 20. Engine mounting reinforcement 21. Engine mounting bracket 22. Front sidemember brace upper 23. Front sidemember reinforcement rear

2011-2014 Mitsubishi Outlander Sport/RVR/ASX OEM Service & Repair Manual

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