Mitsubishi Outlander. Body repair manual - part 20

AB300009

AB202183

AB202182

F

E

D

AB

260 ± 30 mm

QUARTER OUTER

WELDED PANEL REPLACEMENT

3-23

NOTE ON REPAIR WORK
INSTALLATION

AB300012

AB

50 mm

1. Cut only the side outer panel from 50 mm above 

the cut area of the gate pillar.

AB300013

AB

Urethane
foam

2. Since it is not possible to fill the rear pillar with 

foam materials, apply urethane foam to bury the 
inside of the rear pillar.

AB200612

AC

: Body sealant

Urethane 
foam

QUARTER OUTER

WELDED PANEL REPLACEMENT

3-24

3. To prevent the foam materials from dripping, apply 

urethane foam to bury the inside of the wheel 
house arch.

4. When assembling the quarter outer panel, apply 

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

AB300011

AB

5. Assemble the quarter outer panel, bolt and tape 

the hole and flange with aluminium tape, then fill 
the hole with foam materials as shown in the 
figure of the instructions.
Foam: 3M ULTRAPRO Panel foam-Yellow

AB100787AC

6. 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 that 
was clogged with foam materials, to bore open 
the hole.

AB300010AB

7. After assembling the quarter outer panel it is not 

possible to fill the inside of the gate pillar with 
foam materials. Thus, push in urethane foam 
(L130 mm x W65 mm x H60 mm) from the hole up 
to the dotted line to bury the inside of the gate 
pillar, as shown in the figure of the instructions.

QUARTER OUTER

WELDED PANEL REPLACEMENT

3-25

NOTES

ROOF

WELDED PANEL REPLACEMENT

3-26

ROOF

M4030011000343

AB300048

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

AB300048

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

AH

AB300125

AB300098

AB300099

A

B

C

A

C

AB

D

Standard roof

Repair welds

 : Adhesive 1

Vehicles with
roof rail

Vehicles with
roof rail

Vehicles with
roof rail

Vehicles with
roof rail

Vehicles with
roof rail

Vehicles with
roof rail

Vehicles with
roof rail

Vehicles with
roof rail

D

Sunroof 
and roof window glass

 : Adhesive 2

Adhesive 1 : Urethane body sealer
Brand : 3M ATD Part No.8542 or equivalent

Adhesive 2 : Epoxyayresin adhesive
Brand : 3M ATD Part No.8115 or equivalent