Mitsubishi Outlander. Body repair manual - part 19

SIDE SILL

WELDED PANEL REPLACEMENT

3-19

SIDE SILL

M4030007000403

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

AF

AB300040

A

D

E

G

B

C

F

A

B

C

D

E

F

G

REPAIR WELDS

160 mm

100 ± 20 mm

270 ± 20 mm

AB

Right 
side

Acoustic foam

Acoustic foam

Acoustic foam

CAUTION

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

SIDE SILL

WELDED PANEL REPLACEMENT

3-20

NOTE ON REPAIR WORK
REMOVAL

AB200598

70 mm

AD

Notch

To remove the side sill outer reinforcement, cut it 70 
mm behind the notch.

INSTALLATION

AB200599AD

50 mm

Side sill outer reinforcement centre

1. Cut only the side sill outer reinforcement centre 

on the body-side, 50 mm forward of the cut area 
and then remove.

AB200600

120 mm

AD

20 mm

Notch

2. Cut only the side sill outer reinforcement centre of 

the new side sill outer reinforcement parts from 
120 mm behind the notch, then cut from another 
20 mm behind the notch and remove. Re-use the 
parts removed.

AB200601AC

50 mm

Side sill reinforcement support

3. Cut the side sill reinforcement support 50 mm 

forward of the cut area of the side sill outer 
reinforcement centre.

AB200626

 : Adhesive

AC

4. Adhere in advance adhesives in the areas shown 

in the figure of the instructions when assembling 
the side sill outer reinforcement.

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

AB200602AD

5. After assembling the new parts to the body, weld 

the side sill reinforcement support, then weld the 
part cut from the side sill outer reinforcement 
centre.

AB300015

AB

Urethane foam

SIDE SILL

WELDED PANEL REPLACEMENT

3-21

6. After assembling the side sill outer reinforcement, 

it is not possible to fill it with foaming materials in 
the areas shown in the figure of the instructions. 
Therefore, adhere urethane foam to bury the front 
pillar.

AB300014

AB300014

AB

: Body sealant

7. Apply in advance body sealant in the areas shown 

in the figure of the instructions when assembling 
the side outer panel.

QUARTER OUTER

WELDED PANEL REPLACEMENT

3-22

QUARTER OUTER

M4030008000321

AB300043

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

AB300043

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

AB

AB200608AC

A

B

C

A

B

C

F

E

D

150 ± 30 mm

110 ± 50 mm

3 POINTS 
LEFT SIDE

AB200608

Acoustic foam

REPAIR WELDS

3 points left side

Acoustic foam

Acoustic foam

CAUTION

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