Mitsubishi Outlander XL. Manual - part 13

GROUP 3

WELDED PANEL REPLACEMENT

CONTENTS

ULTRA HIGH STRENGTH STEEL PLATE
.................................

3-2

FRONT END CROSSMEMBER............

3-3

FENDER SHIELD....................

3-4

FRONT SIDEMEMBER (PARTIAL
REPLACEMENT).....................

3-8

FRONT PILLAR....................

3-10

FRONT PILLAR (PARTIAL REPLACEMENT)
................................

3-14

CENTER PILLAR...................

3-17

SIDE SILL.......................

3-20

QUARTER OUTER...................

3-23

ROOF (ALUMINUM ROOF)............

3-26

REAR END CROSSMEMBER............

3-31

REAR FLOOR......................

3-34

QUARTER INNER...................

3-36

QUARTER INNER (PARTIAL REPLACEMENT)
................................

3-40

FRONT DOOR OUTER PANEL (WELDED TYPE)
................................

3-43

FRONT DOOR OUTER PANEL (ADHESION
TYPE)...........................

3-45

REAR DOOR OUTER PANEL (WELDED TYPE)
................................

3-46

REAR DOOR OUTER PANEL (ADHESION
TYPE)...........................

3-48

ALUMINUM PANEL.................

.3-49

ALUMINUM PANEL CHARACTERISTICS. .

3-49

ALUMINUM PANEL LOCATIONS........

3-50

ALUMINUM PANEL REPAIR...........

3-50

ALUMINUM PANEL PAINT............

3-56

3-1

ULTRA HIGH STRENGTH STEEL PLATE

M40300000151USA0000010000

ULTRA HIGH STRENGTH STEEL PLATE APPLICATION

ZB600358

 : High-tensile steel panel in 590Mpa-class

 : Ultra-high-tensile steel panel in 980MPa-class

0000

ADVANTAGES OF ULTRA HIGH

STRENGTH STEEL PLATE

The ultra high strength steel plate has the following
advantages  as  compared  with  conventional  high
strength steel plate.

｠

It  has  tensile  strength  approximately  1.7  times
higher  than  the  conventional  high  strength  steel
sheet.

｠

It  has  a  higher  yielding  point  and  yielding  ratio
(yielding point/tensile strength).

These advantages allow thinner and lighter plates and
better fuel efficiency than the high strength steel plate.

PRECAUTION UPON MAINTENANCE OF

ULTRA HIGH STRENGTH STEEL PLATE

｠

Use a spot cutter for ultra high strength steel plate
to ensure that the spot-welded area is cut off.

｠

For the part in which the ultra high strength steel
plate is used, do not repair it by cutting and bonding
to avoid the reduction in strength by heat. Instead,
replace the whole assembly including the part.

3-2

WELDED PANEL REPLACEMENT

ULTRA HIGH STRENGTH STEEL PLATE

｠

Be careful with rough extending work, because the
ultra  high  strength  steel  plate  has  higher  tensile
strength  and  a  higher  yielding  point  than  high
strength  steel  plate  and  general  steel  plate.
Careless  work  will  cause  symptom  such  as  over-
pulling and springback. Do not extend it completely

at  a  time.  Do  it  gradually  while  removing  the
distortion by sheet metal processing with a hammer.

｠

Plug welding of Φ 8 mm (0.31 inches) diameter plug
for  repair  ensures  the  strength  equivalent  to  spot
welding  for  2  steel  sheets.  For  3  sheets,  weld  2
sheets each time instead of welding from one side
to give sufficient welding strength.

FRONT END CROSSMEMBER

M40300000152USA0000010000

ZB6001650000

(                                                              )

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

3-3

FRONT END CROSSMEMBER

ZB600068

A

A

B

0000

B

REPAIR WELDS

FENDER SHIELD

M40300000040USA0000010000

AB501088

ZB6001440000

(                                                              )

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.)

3-4

WELDED PANEL REPLACEMENT

FENDER SHIELD