Mitsubishi Outlander. Body repair manual - part 22

REAR END CROSSMEMBER

WELDED PANEL REPLACEMENT

3-31

NOTE ON REPAIR WORK
REMOVAL

AB300007

AB

Quarter inner 
extension lower

1. If the rear end crossmember outer comes in 

contact with the quarter inner extension lower, 
distance the welding points from the specifications 
of the figure (instructions) and leave a slight 
clearance, then pull forward the dotted line of the 
rear end crossmember outer.

AB300008

AB

2. Turn the bottom portion of the rear end 

crossmember upward and remove, as shown in 
the figure of the instructions.

QUARTER, INNER

WELDED PANEL REPLACEMENT

3-32

QUARTER, INNER

M4030012000324

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

AE

AB300141

AB202207

E

A

C

D

B

AB

REPAIR WELDS

(With the quarter outer removed)

Acoustic foam 

9 points 
on left side

6 points 
on right 
side

A

CAUTION

When repairing the area using foam materials do not use firing tools since the foaming materials may 
burn.
NOTE: Refer to the Quarter Outer section on 

P.3-22

 for the welding points with the quarter outer. 

AB200593AC

B

C

D

E

(With the sill outer reinforcement rear removed)

QUARTER, INNER

WELDED PANEL REPLACEMENT

3-33

NOTE ON REPAIR WORK
REMOVAL

AB300005AB

After assembling the quarter inner panel it is not pos-
sible to fill the inside of the rear pillar with foam mate-
rials. Thus, push in urethane foam (L45 mm x W60 
mm x H60 mm) from the hole up to the dotted line to 
bury the inside of the rear pillar, as shown in the fig-
ure of the instructions.

FRONT DOOR OUTER PANEL

WELDED PANEL REPLACEMENT

3-34

FRONT DOOR OUTER PANEL

M4030013000327

AB300033

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

AB202413

B

C

A

B

D

C

D

REPAIR WELDS

A

AB

: Adhesive

50 mm

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

NOTE: After hemming the front door outer panel, 
MIG spot weld the flange overlap section at a pitch of 
50 mm.

NOTE ON REPAIR WORK
REMOVAL

Since it is difficult to replace the sash due to a 
pressed door structure, cut the outer panel from the 
bottom of the sash.