Mitsubishi Outlander XL. Manual - part 40

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16.

Plug welding
If spot welds cannot be made, make holes for plug welding
in the new parts, and then MIG weld. Because the quality of
the fusion varies according to the size of the holes, they
should be about 5 - 6 mm (0.2 inch) in diameter. In addition,
be sure the two surfaces are in complete contact with each
other by using vise-grip pliers to securely hold them.

NOTE:

Depending on the working conditions, it might also

be necessary to make holes in the panel remaining on the
body

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Section

A – A

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Hemming tool

17.

Hemming (Adhesion type)

(1)

Apply an adhesive to the area to be hemmed of the door
outer panel.

(2)

For the area to be hemmed of the door outer panel, apply
an adhesive and smooth the panel with a hammer and a
dolly. Then, hem the panel with a hemming tool.

ZB6002320000

Hemming tool

18.

Hemming (Welded type)

(1)

For the area to be hemmed of the door outer panel, etc.,
smooth the panel with a hammer and a dolly, and hem it
with a hemming tool.

(2)

After completing the hemming work, make MIG spot
welds at 50 - 60 mm (2.0 - 2.4 inches) intervals on the
inside.

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Be sure not to grind the panel down too much. Before
welding the outer panel, be sure to apply an anticorrosion
agent.

19.

Finishing work for butt welding and plug welding
Do the finishing work to smooth the protruding weld traces.
However, the butt joints of reinforcements and other internal
parts will be stronger if the weld traces are not finished.

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20.

Application of body sealant
Apply a coating of sealant carefully, without breaks, as
described in the section (of the manual corresponding to that
model).

NOTE:

After application has been made to any external

surfaces, perform smooth-finishing work.

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Wipe off any anticorrosion agent which oozes out onto
surfaces to be painted later; the presence of such
anticorrosion agent would prevent correct adhesion of the
paint coat.

21.

Application of an anticorrosion agent
Apply an ample amount of anticorrosion agent to any welded
areas and to all surfaces from which the paint coat was
removed.
The paint coat of welded areas will have been damaged by
the heat; be sure to apply an anticorrosion agent to surfaces
to be repaired.
Use an aerosol-type anticorrosion agent for application to the
side sills, the pillars, and other similar parts which have a
hollow construction, by utilizing the trim mounting holes, etc.

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BODY REPAIR

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22.

Application of undercoating
If the underbody is repaired or replaced, carefully apply a
coating of undercoating as described in the section (of the
manual corresponding to that model).

CAUTIONS REGARDING BODY REPAIR

Because  each  component  part  of  a  single-unit
construction body makes some contribution, more or
less,  to  the  overall  strength  of  that  body,  it  is
necessary  to  sufficiently  understand  the  actual
function of any part to be repaired before attempting
any repair or welding procedure.

STRENGTH AND RIGIDITY

The  suspension  installation  part  plays  an
important role, determining the wheel alignment.
Wheel misalignment is of course potentially very
dangerous  because  it  can  lead  to  driving
instability, one-sided braking, abnormal tire wear,
abnormal vibration, etc.
At the time of repair, it is particularly necessary to
take  measurements  at  the  components  noted
below, and to make all welds and installations with
special care.

｠

Front sidemember

｠

Rear floor sidemember

｠

Front wheelhouse (inner)

｠

Rear wheelhouse (inner) (Independent rear
suspension type)

Because the places where the floor panel and
sidemember parts are joined have an important
effect upon the rigidity of the entire body, welds in
these places must be done with particular care.

After repairs have been completed, the wheel
alignment, wheel base, tread, etc., must be

carefully checked to be sure that there is no
deviation.

SAFETY

Procedures related to the installation of any
component related to safety must be done with
particular care in order to assure full maintenance
of safety.

｠

Suspension installation parts

｠

Fuel pipe

｠

Brakes

｠

Fuel tank installation parts, etc.

Because seat belts are directly related to driver
and passenger safety, any welds of seat belt
anchor points or reinforcements must be done with
particular care in order to maintain strength.

PREVENTION OF CORROSION AND OF WATER
OR DUST ENTRY

After any work is completed, it is important to
completely remove any welding residue, particles
or residue from cutting, and any other dirt, etc.

Corrosion-prevention material must without fail be
applied at the following places:

｠

At any place where paint has flaked off or
peeled away.

｠

At any surfaces that have been cut.

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BODY REPAIR

｠

At the outer and inner side of every welded
place.

｠

Within any semi-enclosed structure or
component (aerosol-type rust inhibitors are
effective for difficult-to-reach places).

｠

At the outer and inner side of any place
subjected to heat.

Apply a coating of undercoating if the underbody
is repaired.

Use spot sealer if spot welds are made.

Repair any scratches to panels made by moldings,
sashes, etc.

Carefully apply body sealant to panel connection
joints and other fitting places.

Tape over any unused holes in the panel inner side
by using sealing tape.

VIBRATION AND NOISE

Prevent any decrease of tensional rigidity caused
by welding distortion.

Carefully apply body sealant to panel connection
joints and other fitting places.

Tape over any unused holes in the panel inner side
by using sealing tape.

CONTACT AND ALIGNMENT

In order to maintain the precision of openings,
make careful measurements as repairs are being
made.

Make contact/alignment adjustments of door
hinge, lid, and hood hinge installation parts.

THEFT PROTECTION

M40900000070USA0000010000

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Theft protection label
For original parts

For replacement parts

0000

In order to prevent theft, following Vehicle Identification Number
(VIN) has been engraved and attached, in the form of a label to
the engine, transaxle, and main of the outer body:

Engine cylinder block, Transaxle housing, Fender,
Doors, Quarter panel, Hood, Liftgate, Trunk lid,
Bumpers

Furthermore, supplementary parts for the main portions of the
outer body have theft protection labels attached and the
supplementary parts for the engine and the transaxle are
engraved with the same details.

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BODY REPAIR

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