Mitsubishi Outlander XL. Manual - part 18

ZB600075

F

A

B

C

F

0000

A

REPAIR WELDS

Acoustic foam

(With the side outer panel removed)

Acoustic foam

 50 mm
(1.97 in)

 50 mm
(1.97 in)

260 mm

(10.2 in)

B

C

D

E

F

D

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

WELDED PANEL REPLACEMENT

3-21

SIDE SILL

NOTE ON REPAIR WORK

INSTALLATION

ZB6001260000

Center inner
pillar upper

Center inner
pillar lower

1.

Remove the center inner pillar upper and center inner pillar
lower from a new center pillar inner.

ZB6001270000

Side sill outer 
reinforcement rear

Side sill outer 
reinforcement front

2.

Remove  the  side  sill  outer  reinforcement  front  and  side  sill
outer reinforcement rear from a new side sill reinforcement.

ZB600169 0000

Side sill 
end plate

Quarter inner 
extension front

Cut position

3.

When installing a new side sill outer reinforcement rear, lift the
side sill end plate up to the point shown in the figure, cut the
quarter inner extension front at a position shown in the figure,
and remove it. Install the side sill outer reinforcement rear, and
next install and weld the quarter inner extension front.

ZB600136 0000

Urethane foam

4.

When  installing  the  new  floor  side  sill  outer,  affix  urethane
foam as shown in the figure as a temporary measure to fill the
inside of the center pillar.

3-22

WELDED PANEL REPLACEMENT

SIDE SILL

ZB600105 0000

5.

After installing the new floor side sill outer, seal the hole and
flange with bolt and aluminum tape, and then fill the hole with
foam materials as shown in the figure.

Foam: 3M™ AAD ULTRAPRO Panel foam-Yellow

ZB600112 0000

6.

Wait 2 hours after filling the foam materials to remove the bolt
and  aluminum  tape,  then  melt  the  foam  materials  with  a
soldering gun to ensure that a clip, etc. can be inserted in the
hole filled with foam materials.

QUARTER OUTER

M40300000080USA0000010000

ZB6001470000

(                                                              )

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 applications locations
(Use access holes to apply liberally to butt-welded joints.)

WELDED PANEL REPLACEMENT

3-23

QUARTER OUTER

ZB600076

A

F

A

E

0000

B

C

The same position as  
the new quarter outer panel

3 points
right side

REPAIR WELDS

3 points
left side

Right side

Acoustic foam 

B

C

D

D

190 ± 50 mm 
(7.5 ± 1.97 in)

40 ± 20 mm 
(1.57 ± 0.78 in)

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

3-24

WELDED PANEL REPLACEMENT

QUARTER OUTER