2011-2014 Mitsubishi Outlander Sport RVR ASX Service & Repair Manual
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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
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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
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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
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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
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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
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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 mem-
ber brace upper and dash panel to improve assem-
bling workability during panel replacement.
ABA00008 AB
MAINTENANCE, SERVICEABILITY
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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
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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 side-
member, 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
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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 characteris-
tics, 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
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BODY CONSTRUCTION
1-10
FRONT SIDEMEMBER REINFORCEMENT
The 590-MPa class high tensile strength steel panels
have been adopted for the front sidemember exten-
sion, front sidemember rear bulkhead and front side-
member 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
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What's Included?
Lifetime Access
Fast Download Speeds
Offline Viewing
Access Contents & Bookmarks
Full Search Facility
Print one or all pages of your manual
$31.99
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